Attention! Wait until the engine has completely cooled down before starting work.
Withdrawal
1. Bring the piston of the first cylinder to the TDC position of the end of the compression stroke (see Bringing the piston of the first cylinder to the top dead center position (TDC)).
2. Disconnect the negative cable from the battery.
Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!
3. Empty the cooling system and remove the spark plugs (see chapter Current service).
4. Remove the air cleaner with air intake sleeve (see chapter Power and exhaust systems).
5. Remove accessory drive belts (see chapter Current service). Loosen the steering pump and move it aside without disconnecting the hydraulic lines, then remove the steering pump bracket (see chapter Suspension and steering).
6. Disconnect the accelerator cable and release the pressure in the power system (see chapter Power and exhaust systems).
7. Disconnect the following hoses and lines (see chapters Power and exhaust systems and Engine management systems):
- a) Fuel supply hose;
- b) evaporative emission hose (EVAP);
- c) ventilation hose (breather pipe);
- d) PCV hose.
8. Disconnect the coolant bypass hose, heater hose and upper radiator hose (see chapter Cooling and heating systems).
9. Disconnect the electrical wiring from the following components:
- a) fuel injection injectors;
- b) coolant temperature sensor (CTS);
- c) Coolant temperature sensor-switch;
- d) Temperature sensor;
- e) Throttle position sensor (TPS);
- f) Absolute pressure sensor in the pipeline (IDA);
- g) Oxygen sensor (and secondary oxygen sensor on models with D16Y7 engine);
- h) EGR valve sensor (D16Y5);
- i) VTEC solenoid valve (D16Y5 and D16Y8);
- j) VTEC pressure switch (D16Y5 and D16Y8);
- k) Idle speed control valve (IAC).
10. Support the engine with a jack (in order to distribute the load between the head of the jack and the oil pan, lay a block of wood). Remove upper engine mount bracket (see Checking the condition and replacing the suspension bearings of the power unit).
11. Remove the mounting bracket supporting the intake manifold and remove the exhaust manifold flange bolts.
Note. Optionally, the intake piping and/or exhaust manifold can be separated from the engine (see Removal and installation of the inlet pipeline and Removal and installation of a final collector), to facilitate further manipulation of the head.
12. Remove the cylinder head cover (see Removal and installation of a cover of a head of cylinders).
13. Remove the ignition distributor (see chapter Engine electrical equipment) together with the cover and the BB wires connected to it.
14. Remove the timing belt (see Removing, checking the condition and installing the gas distribution belt and timing gears), rocker arm assembly (see Removal, condition check and installation of rocker arm assembly) and camshaft (see Removal, condition check and installation of a camshaft).
15. Proceeding in the reverse order shown in the illustration (see below), in several steps (1/4 turn per approach) loosen the head bolts just enough to be able to turn them out by hand. Try to remember the location of each of the mounting bolts - during assembly, they must be screwed strictly into their original places.
16. Remove the cylinder head from the engine. If the head does not separate from the block, you can use the lever, which should be wound between the steering pump bracket and the block (never pry the head under the mating surface). Place the head removed from the engine on a couple of wooden blocks to avoid damaging the gasket surfaces.
17. A description of the procedures for disassembling the head and checking the condition of its internal components is given in Part General and overhaul of the engine of this Chapter. At this stage, evaluate only the flatness of the mating surface.
Installation
1. The mating surfaces of the head and cylinder block must be absolutely clean and dry.
2. Thoroughly clean the mating surfaces of the head and cylinder block. After scraping off the remnants of the gasket material and carbon deposits, wipe the surfaces with a rag soaked in acetone. The presence of an old gasket on the mating surfaces of the material at the time of installation can lead to a violation of the tightness of the gasket fit and, as a result, the development of leaks. When processing the block, plug the cylinder bores with rags to prevent small debris and various foreign objects from getting into them (as a last resort, vacuum the cylinders thoroughly). Since the cylinder head and cylinder block are made of soft aluminum alloy, proceed with extreme care, trying not to leave scratches and burrs on the mating surfaces (use only copper or plastic tools to scrape deposits).
3. Check the mating surfaces of the head and block for deep scratches, nicks and other damage. Light defects can be removed with fine-grained sandpaper. In more severe cases, the only alternative is to remake the components.
4. With a tap of the appropriate size, drive the threaded holes for the head mounting bolts. Alternately clamping the bolts in a vise by the head, go through their threads with a lerka. The presence of old sealant, dirt and corrosion products in the threads leads to a discrepancy between the actual fastener tightening force and the indications of the torque wrench indicator.
5. Lay a new gasket on the cylinder block (type marking "TOR" up). Lubricate the edges of the timing belt cover mating with the block with sealant. Carefully install the cylinder head on the block.
6. Lubricate the threads and the bottom surface of the heads of the mounting bolts with clean engine oil and screw the fasteners into place. Acting in order (see accompanying illustration), tighten the cylinder head bolts to the required torque in four steps (see Specifications). Due to the critical nature of the purpose of bolts, the compilers of this Guide recommend the following precautions when tightening bolts:
- a) It is preferable to use a torque wrench equipped with a ratchet drive with a force limiter. Otherwise, proceed very carefully, trying not to accidentally break the thread.
- b) If, when screwing in, the bolt starts to make any sounds (squealing, creaking, clicking, etc.), unscrew it completely and try again. 7. Put the gear wheel on the camshaft pin, then install the timing belt (see Removing, checking the condition and installing the gas distribution belt and timing gears).
8. Install the remaining components in the reverse order of their dismantling.
9. Manually slowly turn the crankshaft counterclockwise two full turns.
Attention! If there is resistance when turning the shaft, stop immediately to prevent damage to the valves if they come into contact with the piston crowns.
10. Start the engine and check the correct ignition timing (see chapter Current service).
11. Warm up the engine to normal operating temperature and check it for signs of leaks. Make sure the engine is working properly.