Cylinder Head

REMOVAL & INSTALLATION

1.5L and 1.8L (BP) Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Disconnect the negative battery cable.
4. Drain the cooling system.
5. Remove or disconnect the following:
   • Right front wheel and splash shield
   • Water pump pulley bolts, loosen them
   • Power steering belt shield
   • Power steering belt
   • Alternator belt

     Fig. 1: Exploded view of the cylinder head assembly — 1.5L engine

     Fig. 2: Exploded view of the cylinder head assembly for the 1.8L (BP) engine

   • Water pump pulley
   • Crankshaft pulley bolt
   • Crankshaft pulley using a puller
   • Guide plate
   • Power steering hose brackets from the cylinder head cover
   • Spark plug wires and wire clips
   • Breather tube and PCV valve from the cylinder head cover
   • Cylinder head cover bolts, in 2 steps, by reversing the tightening sequence
   • Cylinder head cover
   • Oil dipstick and bracket
   • Timing belt upper cover
6. Install a suitable engine support tool.
7. No. 3 engine mount bracket
8. Timing belt middle and lower covers
9. Rotate the crankshaft, in the normal direction of rotation, until the No. 1 cylinder piston is at Top Dead Center (TDC) on the compression stroke. Be sure the timing marks on the crankshaft and camshaft sprocket(s) are properly aligned and mark the direction of rotation of the belt.
10. Remove or disconnect the following:
    • Timing belt tensioner, loosen it
    • Timing belt.

    NOTE: Do not rotate the crankshaft until the timing belt is reinstalled.

    • AIr cleaner assembly and front pipe
    • Exhaust manifold
    • Accelerator and throttle cables
    • Distributor/coil
    • Engine coolant temperature sensor
    • Cooling fan coolant temperature sensor
    • Temperature gauge sensor
    • Spark plug wires from the spark plugs
    • Spark plugs
    • Distributor cap and wires assembly
    • Distributor
    • Heater hoses
    • Brake vacuum hose
    • Purge hose
    • Fuel hoses
    • Water hose
    • Upper radiator hose
    • Camshaft sprockets and the camshaft
11. On the 1.5L engine, remove the tappets. Identify each tappet as it is removed so it can be reinstalled in the same position.
12. On the 1.8L engine, remove the hydraulic lifters. Identify each lifter as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in an oil-filled sealed container.
13. Remove or disconnect the following:
    • Intake manifold bracket
    • Intake manifold
    • Cylinder head bolts, in 2–3 steps, in sequence
    • Cylinder head

    To install:

14. Thoroughly, clean the cylinder head and the block contact surfaces. Examine the head gasket and check the cylinder head for cracks. Check the cylinder head for warpage using a feeler gauge and straightedge. The maximum allowable distortion is 0.004 in. (0.10mm).
15. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
16. Install new head gasket on the engine block.
17. Be sure the camshaft sprocket timing marks are still aligned, as set during the removal procedure.
18. Install the cylinder head.

    NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the torque specification chart.

19. Lubricate the bolt threads and seat surfaces with clean engine oil and install them as follows:
    1. On the 1.5L engines, tighten the bolts in 2–3 steps to 13–16 ft. lbs. (17–22 Nm) in the proper sequence. Paint a reference mark on each bolt head and turn the bolts, in sequence, 90 degrees, then an additional 90 degrees.
    2. On the 1.8L (BP) engines, tighten the bolts in 2–3 steps to 56–60 ft. lbs. (75–81 Nm) in the proper sequence.
20. Install or connect the following:
    • Intake manifolds. Tighten the bolts/nuts to 19 ft. lbs. (25 Nm).
    • Intake manifold bracket
    • Exhaust manifold using a new gasket. Tighten the nuts to 34 ft. lbs. (46 Nm).
    • Exhaust pipe using a new gasket. Tighten the nuts to 34 ft. lbs. (46 Nm).
    • Tappets in their original positions lubricated with engine oil
    • Camshaft and sprockets
21. Be sure the crankshaft and camshaft sprocket timing marks are aligned.
22. Install or connect the following:
    • Timing belt and set the tension. Carefully rotate the crankshaft 2 turns to be sure the timing marks still aligned.
    • Timing belt middle and lower covers. Tighten the cover bolts to 70–95 inch lbs. (8–11 Nm).
    • No. 3 engine mount bracket. Tighten the nut to 70–95 inch lbs. (8–11 Nm) and the bolt to 14–16 ft. lbs. (19–22 Nm).
23. Remove the engine support tool.
24. Install or connect the following:
    • Upper timing belt cover. Tighten the bolts to 70–95 inch lbs. (8–11 Nm).
    • Oil dipstick and bracket
25. Apply silicone sealant to the cylinder surface in the area adjacent to the front camshaft bearing caps.
26. Install the cylinder head cover using a new gasket and sealant.
27. Tighten the cylinder head cover bolts, in 5–6 steps, in sequence, to:
    1. 1.5L (Z5D) engines: 61–95 inch lbs. (7–11 Nm)
    2. 1.8L (BP) engines: 44–78 inch lbs. (5–9 Nm)
28. Install or connect the following:
    • Power steering hose brackets. Tighten the bolts to 70–95 inch lbs. (7–11 Nm).
    • Spark plug wires and wire clips
    • Breather tube and PCV valve
    • Guide plate
    • Crankshaft pulley. Tighten the bolt to 116–122 ft. lbs. (157–166 Nm).
    • Water pump pulley
    • Alternator belt and adjust the tension
    • Power steering belt and adjust the tension
29. Tighten the through-bolt to 32–44 ft. lbs. (44–60 Nm) and the lockbolt to 24–33 ft. lbs. (32–46 Nm).
30. Install or connect the following:
    • Power steering belt shield. Tighten the bolts to 86 inch lbs. (9 Nm).
    • Splash shield and wheel
    • Electrical engine harness connectors
    • Heater hose
    • Brake vacuum hose
    • Purge hose
    • Fuel hoses
    • Water hose
    • Upper radiator hoses
    • Distributor
    • Spark plugs
    • Distributor cap and wires
    • Accelerator and throttle cables, adjust if necessary
    • Air cleaner assembly
    • Negative battery cable
31. Fill the cooling system.
32. Adjust the ignition timing.
33. Start the engine and check for leaks.

1.6L and 1.8L (FP) Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Properly relieve the fuel system pressure.
3. Drain the engine coolant.
4. Remove or disconnect the following:
   • Negative battery cable
   • Timing belt
   • Front exhaust pipe
   • Exhaust manifold insulator and the Exhaust Gas Recirculation (EGR) pipe
   • Fresh air duct and air cleaner assembly
   • Power steering pump and bracket, if necessary, and move it aside leaving the hoses attached
   • Accelerator cable and bracket
   • All vacuum hoses
   • Engine wiring harness connectors
   • Fuel supply and return hoses
   • Intake manifold support bracket
   • Heater hoses
   • Camshaft pulleys by holding the them with a wrench
   • Camshafts
   • Cylinder head bolts in the order
   • Cylinder head

   To install:

   Fig. 3: Cylinder head bolt removal sequence — 1.6L and 1.8L (FP) engines

   Fig. 4: Replace any bolts that exceed the maximum length — 1.6L and 1.8L engines

5. Thoroughly, clean the cylinder head and the block contact surfaces.
6. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
7. Measure the length of the cylinder head bolts, as shown, maximum bolt length is 3.957 in. (100.5mm) for 1.6L engine or 4.154 in. (105.5mm) for 1.8L (FP) engine.
8. Install or connect the following:
   • New head gasket
   • Cylinder head

   NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

9. Tighten the cylinder head bolts, in sequence, as follows.
   1. Step 1: 13–16 ft. lbs. (17–22 Nm)
   2. Step 2: Turn 85–95 degrees
   3. Step 3: Turn an additional 85–95 degrees
10. Install or connect the following:
    • Camshafts.
    • Camshaft pulleys. Tighten the bolts to 37–44 ft. lbs. (50–20 Nm).
    • Heater hoses
    • Intake manifold support bracket
    • Fuel hoses
    • Engine wiring harness connector
    • Any vacuum hoses that were removed
    • Accelerator cable and bracket
    • Power steering pump and bracket, if removed
    • Air cleaner assembly and fresh air duct
    • EGR system
    • Exhaust manifold insulator and front exhaust pipe
    • Timing belt
    • Negative battery cable
11. Refill the engine coolant.
12. Start the vehicle and check for leaks.

    Fig. 5: Cylinder head gasket positioning — 6-cylinder engines

2.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Disconnect the negative battery cable.
4. Drain the cooling system.
5. Remove or disconnect the following:
   • Splash shield, fresh air duct and air cleaner assembly

     Fig. 6: Exploded view of the cylinder head assembly — 2.0L engine

   • Accelerator cable
   • The following hoses: heater, brake vacuum, purge, fuel, water and upper radiator
   • All accessory drive belts
   • Power steering pump and move it aside, leaving the hoses attached
   • Alternator bracket and move aside
   • Exhaust pipe from the manifold
   • Spark plug wires
   • Power steering hose brackets from the cylinder head cover
   • The following electrical connectors: distributor/coil, engine coolant temperature sensor, cooling fan coolant temperature sensor and temperature gauge sensor
   • All hoses from the cylinder head cover
6. Loosen the cover bolts in 5–6 steps, in the reverse order of the tightening sequence.
7. Remove or disconnect the following:
   • Cylinder head cover
   • Timing belt cover and the timing belt
   • Coolant temperature sensor housing from the cylinder head
   • Distributor
   • Camshaft sprockets and the camshaft
   • Hydraulic lifters
8. Identify each lifter as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in an oil-filled sealed container.
9. Remove or disconnect the following:
   • Cylinder head bolts by loosening them, in 2–3 steps, in sequence
   • Cylinder head
10. Clean all gasket mating surfaces. Inspect the cylinder head for damage, cracks and water and oil leakage. Check the head gasket surface for distortion using a straightedge and feeler gauge. Maximum allowable distortion is 0.004 in. (0.10mm).

    To install:

11. Install or connect the following:
    • New cylinder head gasket
    • Cylinder head

    NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the torque specification chart.

12. Apply clean engine oil to the bolt threads and seating faces.
13. Install new cylinder head bolts and tighten in 2–3 steps, in sequence, to 13–16 ft. lbs. (17–22 Nm).
14. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 90 degrees. Again, turn each bolt, in sequence, an additional 90 degrees.
15. Apply clean engine oil to the hydraulic lifters and install them in their original positions. Be sure they move freely in the bores.
16. Install or connect the following:
    • Camshafts and sprockets
    • Distributor
    • Distributor/coil electrical connectors
    • Timing belt and cover
    • New cylinder head cover gasket with sealant on the cylinder head cover; apply sealant to the cylinder head surface in the area adjacent to the front camshaft caps
    • Cylinder head cover. Tighten the bolts in 5–6 steps, in sequence, to 61–95 inch lbs. (7–11 Nm).
    • Hoses to the cylinder head cover
    • Spark plug wires
    • Exhaust manifold
    • Alternator bracket. Tighten the nut/bolt to 19 ft. lbs. (25 Nm).
    • Alternator belt and adjust the tension
    • Power steering pump through and lockbolts
    • Pump pressure switch connector
    • Power steering pump belt and adjust the tension. Tighten the through-bolt to 45 ft. lbs. (61 Nm) and the lockbolt to 34 ft. lbs. (46 Nm).
    • Power steering pump belt shield. Tighten the shield bolts to 86 inch lbs. (9 Nm).
    • Power steering hose brackets to the cylinder head cover. Tighten the bolts to 88 inch lbs. (10 Nm).
    • Coolant temperature sensor housing using a new gasket. Tighten the bolts to 19 ft. lbs. (25 Nm).
    • Electrical connectors at the housing
    • Accelerator cable, adjust as necessary
    • Heater, brake vacuum, purge, fuel, water and upper radiator hoses
    • Air cleaner assembly, fresh air duct and splash shield
    • Negative battery cable
17. Fill and bleed the cooling system.
18. Run the engine and check for proper operation.

2.3L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Drain the engine coolant.
4. Remove or disconnect the following:
   • Negative battery cable.
   • Oxygen (O2S) sensor connectors
   • Exhaust pipe-to-manifold nuts and lower the exhaust pipes
   • Right-hand 3-way catalytic converter
   • Compressor (supercharger)
   • Intake manifold
   • Timing belt covers and timing belt
   • Spacer and O-ring from the front of the camshaft
   • Ignition coils
   • Cylinder head cover mounting bolts, in 5–6 steps, using the reverse of the tightening sequence
   • Cylinder head cover
   • Camshaft sprockets
5. Turn the camshafts so the knock pins are aligned with the marks on the camshaft caps. This will reduce the pressure on the adjustment shims.
6. Note the markings on the camshaft caps prior to removal, so they can be reinstalled in the same positions. The right-hand (rear) caps are marked with numbers and the left-hand (front) caps are marked with letters.
7. Loosen the front camshaft cap bolts in sequence, in 5–6 steps. Remove the front camshaft caps. Remove the remaining camshaft cap bolts in the proper sequence. Remove the caps, being sure to remove the thrust caps last. Do not damage the cylinder head thrust bearing support.
8. Remove or disconnect the following:
   • Camshafts and oil seals
   • Lifters and adjustment shims
9. Identify and mark each lifter as it is removed so it can be reinstalled in the same position.
10. Remove or disconnect the following:
    • Lower radiator hose
    • Water inlet pipe
    • Compressor bracket
    • Alternator bracket bolt to gain additional clearance
    • Rubber insulator from the left-hand cylinder head
11. Temporarily install the No. 3 engine mount, which was removed with the timing belt, to support the engine.
12. Remove or disconnect the following:
    • Engine support device
    • Cylinder head bolts, in 2–3 steps, by the reversing order of the torque sequence
    • Cylinder heads
    • Oil control plug O-rings
13. Clean all gasket mating surfaces. Inspect the cylinder head for damage, cracks, and water and oil leakage. Check the head gasket surface for distortion using a straightedge and feeler gauge. Maximum allowable distortion is 0.004 in. (0.10mm).

    To install:

14. Apply clean engine oil to the O-rings, and install them onto the oil control plugs.
15. Position new head gaskets on the cylinder block. The gaskets cannot be interchanged between sides and are marked R and L for right and left side.
16. Install the cylinder heads.

    NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

17. Apply clean engine oil to the threads of new cylinder head bolts and install. Tighten the cylinder head bolts in 2–3 steps, in sequence, to 17–19 ft. lbs. (23–26 Nm).
18. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 90 degrees. Again, turn each bolt, in sequence, an additional 90 degrees.
19. Install the rubber insulator onto the left-hand cylinder head.
20. Fit the knock sensor harness into the drill hole on the cylinder block. Pass the harness under the rubber insulator.
21. Install or connect the following:
    • Engine support device and remove the No. 3 engine mount
    • Alternator bracket bolt. Tighten the bolt to 12–16 ft. lbs. (16–22 Nm).
    • Compressor bracket. Tighten the bolts to 14–18 ft. lbs. (19–25 Nm).
    • Water inlet pipe. Tighten the bolts to 14–18 ft. lbs. (19–25 Nm).
    • Lower radiator hose
    • Lifters in their original positions by lubricating them with engine oil. Verify that they move smoothly in their bore.
    • New oil seals on the camshafts
22. Apply clean engine oil to the camshaft lobes, journals and supports.
23. Install or connect the following:
    • Camshafts so the gear marks align
    • Thrust caps. Tighten the bolts, in 5–6 steps, until they are fully seated on the cylinder head.
24. Apply silicone sealant, at a thickness of 0.06–0.09 in. (1.5–2.5mm), to the cylinder head surface in the area forward of the camshaft gear cavity.
25. Install or connect the following:
    • Remaining camshaft caps in their original positions. Tighten the caps, in sequence, in 5 equal steps, with the final step being 100–125 inch lbs. (11–14 Nm).
    • New camshaft oil seal lubricated with engine oil. Tap the seal in evenly with a Seal Installer tool 49 F401 337A with a final protrusion of 0–0.02 in. (0–0.5mm). Tap in a new blind cap.
    • Camshaft sprockets. Tighten the bolts to 91–103 ft. lbs. (123–140 Nm).
26. Measure and adjust the valve clearances.
27. Remove any sealant and gasket material from the cylinder head cover contact surfaces.
28. Apply silicone sealant to the cylinder head in the area adjacent to the front and rear camshaft caps.
29. Install or connect the following:
    • Cylinder head cover using a new gasket. Tighten the bolts in 5–6 steps, in sequence, to 44–78 inch lbs. (5–9 Nm).
    • Distributor using a new O-ring
    • Ignition coils
    • Spacer using a new O-ring. Tighten the bolt to 14–18 ft. lbs. (19–25 Nm).
    • Timing belt and timing belt cover
    • Intake manifold
    • Compressor (supercharger)
    • Right-hand 3-way catalytic converter
    • Exhaust pipes to the manifolds. Tighten the nuts to 28–38 ft. lbs. (38–51 Nm).
    • O2S connectors
    • Negative battery cable
30. Fill and bleed the coolant system.
31. Run the engine and check for leaks.

    Fig. 7: Exploded view of the cylinder head and related components — 2.3L engine

2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Disconnect the negative battery cable.
4. Drain the cooling system.
5. Remove or disconnect the following:
   • Fresh air duct and the air cleaner assembly
   • Battery, if additional clearance space is needed.
   • Accelerator cable
   • Wiring harness from the cylinder heads
   • Fuel, heater and vacuum hoses

     Fig. 8: Exploded view of the cylinder head assemblies — 2.5L engine

   • Intake manifold
   • Distributor
   • Ventilation pipe from the left cylinder head cover
   • Cylinder head covers
   • Timing belt covers and the timing belt
   • Camshafts
   • 3 bolts and the seal plate from the front of the engine
   • Upper radiator hose
   • Oxygen (O2S) sensor connectors
   • Exhaust pipe-to-manifold nuts and lower the pipes
   • Hydraulic lifters

   NOTE: Identify each lifter as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in an oil-filled, sealed container.

   • Cylinder head bolts, in 2–3 steps, in the reverse order of the torque sequence
   • Cylinder heads
6. Clean all gasket mating surfaces. Inspect the cylinder head for damage, cracks, and water and oil leakage. Check the head gasket surface for distortion using a straightedge and feeler gauge. Maximum allowable distortion is 0.004 in. (0.10mm).

   To install:

7. Position new head gaskets on the cylinder block. The gaskets cannot be interchanged between sides and are marked R and L for right and left side.
8. Install the cylinder heads.

   NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

9. Apply clean engine oil to the threads of new cylinder head bolts and install. Tighten the cylinder head bolts in 2–3 steps, in sequence, to 17–19 ft. lbs. (23–26 Nm).
10. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 90 degrees. Again, turn each bolt, in sequence, an additional 90 degrees.
11. Install or connect the following:
    • Lifters in their original positions lubricated with engine oil. Be sure they move freely in the bores.
    • Camshafts
    • Exhaust pipes to the manifolds. Tighten the nuts to 41 ft. lbs. (55 Nm).
    • O2S connectors
    • Timing belt and timing belt covers
12. Apply sealant to the cylinder head surface in the area of the front and rear camshaft caps.
13. Install or connect the following:
    • Cylinder head covers using new gaskets. Tighten the bolts in 5–6 steps, in sequence, to 44–78 inch lbs. (5–9 Nm).
    • Intake manifold using new gaskets. Tighten the bolts to 14–18 ft. lbs. (19–25 Nm).
    • Distributor using a new O-ring lubricated with engine oil. Hand-tighten the mounting bolts.
    • Vacuum, heater and fuel hoses
    • Wiring harness to the cylinder heads
    • Accelerator cable, adjust as necessary
    • Battery, if removed
    • Air cleaner assembly and the fresh air duct
    • Negative battery cable
14. Fill and bleed the cooling system.
15. Adjust the ignition timing and idle speed.
16. Run the engine and check for proper operation.