Honda - Accord Prelude 1996 2000

Cylinder Head

Print

REMOVAL & INSTALLATION




WARNING
To avoid damaging the cylinder head, allow the coolant temperature to drop below 100°F (38°C) before removing the head bolts.

Carefully thought and a clean work environment should be a priority when removing a cylinder head. Have plenty of cardboard boxes and a good marker handy to label and organize the parts as they are removed.

Be sure to have an ample supply of sealable clear plastic bags that can be labeled for the removed fasteners. Make sure to investigate whether or not certain fasteners can be reused or must be replaced.

Have sealable containers available for the used coolant and engine oil which must be drained during the procedure. Have a pencil and note pad handy to make drawings and make notes of cable routing , wire and bracket locations.

Follow the installation procedures carefully to know whether certain fasteners should be lubricated or not when being installed.

Read the procedures before starting to get a thorough understanding of the tools and equipment needed. Many of the components of the cylinder head are precision machined pieces that need to be thoroughly cleaned and inspected before reinstalling. For specific details on the basics of the cylinder head, refer to the ENGINE RECONDITIONING information located further along in this section.

When machined components are removed NEVER:



Allow two machined pieces to rest or contact one another
 
Lay the component directly on the ground or garage floor
 
Mix up the location from which they were removed
 

Use wood or cardboard to protect a machined component, especially items such as a cylinder head.

The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery. After connecting the battery, turn the steering wheel lock-to-lock to reset the steering control unit.

2.2L Engines
F22B1 AND F22B2 ENGINES


Click image to see an enlarged view

Fig. Exploded view of the cylinder head and related components-2.2L engines (except F22B1 & F22B2)



Click image to see an enlarged view

Fig. The cylinder head and valve train components can easily be seen with the valve cover removed



Click image to see an enlarged view

Fig. Use a breaker bar to break the cylinder head bolts loose



Click image to see an enlarged view

Fig. Once the head bolts have been broken loose with a breaker bar, you may use a ratchet to speed up the removal process.



Click image to see an enlarged view

Fig. Noting their installed location, remove the bolts from the cylinder head . . .



Click image to see an enlarged view

Fig. . . . and use a piece of cardboard as a holder to keep them in the proper order



Click image to see an enlarged view

Fig. Marking the position of each head bolt is extremely important because they are of unequal length



Click image to see an enlarged view

Fig. Firmly grasp the cylinder head and slowly and carefully lift it off the block



Click image to see an enlarged view

Fig. You may want to leave the intake manifold attached to the head until it has been removed from the block. This will speed up the removal process



Click image to see an enlarged view

Fig. Once the head has been removed, the cylinders can easily be inspected for wear



Click image to see an enlarged view

Fig. Always replace the head gasket with a new one that meets or exceeds the factory specifications



Click image to see an enlarged view

Fig. View of the head gasket alignment dowel



Click image to see an enlarged view

Fig. It is easier to remove the intake manifold from the cylinder head once the head has been removed from the block

  1. Disconnect the negative battery cable.
  2.  
  3. Bring the No. 1 cylinder to TDC.
  4.  
  5. Drain the engine coolant into a sealable container.
  6.  
  7. Relieve the fuel pressure, as outlined in Fuel System .
  8.  
  9. Remove the vacuum hose, breather hose and air intake duct.
  10.  
  11. Remove the water bypass hose from the cylinder head.
  12.  
  13. Disconnect the fuel feed and return hose from the fuel rail.
  14.  
  15. Remove the EVAP control canister hose from the intake manifold.
  16.  
  17. Remove the brake booster vacuum hose from the intake manifold. If equipped with an automatic transaxle, remove the vacuum hose mount.
  18.  
  19. Remove the throttle cable from the throttle body. If equipped with an automatic transaxle, remove the throttle control cable at the throttle body.
  20.  

Be careful not to bend the cable when removing. Do not use pliers to remove the cable from the linkage. Always replace a kinked cable with a new one.

  1. Remove the ignition coil.
  2.  
  3. Label, then detach the electrical connectors from the distributor and the spark plug wires from the spark plugs. Mark the position of the distributor and remove it from the cylinder head. Disconnect the ignition coil wire from the distributor.
  4.  
  5. Remove the connector and the terminal from the alternator, then remove the engine wiring harness from the valve cover.
  6.  
  7. Label and detach the following engine wiring harness connectors:
    1. Fuel injector connectors
    2.  
    3. IAT sensor connector, if equipped
    4.  
    5. IAC valve connector
    6.  
    7. TP sensor connector
    8.  
    9. EGR valve lift sensor
    10.  
    11. Ground cable terminals
    12.  
    13. ECT switch B connector, if equipped
    14.  
    15. HO 2 S connector
    16.  
    17. ECT sensor
    18.  
    19. ECT gauge sending unit connector
    20.  
    21. CKP/CYP sensor connector, if equipped
    22.  
    23. VSS connector
    24.  
    25. ECT switch A connector
    26.  

  8.  
  9. Remove the upper radiator hose and the heater inlet hose from the cylinder head.
  10.  
  11. Remove the lower radiator hose and heater outlet hose from the intake manifold.
  12.  
  13. Remove the bypass hose from the thermostat housing and intake manifold.
  14.  
  15. Remove the thermostat housing mounting bolts. Remove the thermostat housing from the intake manifold and the connecting pipe by pulling and twisting the housing. Discard the O-rings.
  16.  
  17. Tag, then disconnect the emissions vacuum hoses from the intake manifold assembly.
  18.  
  19. Disconnect the cruise control actuator electrical connector and the vacuum tube, then remove the cruise control actuator.
  20.  
  21. Remove the engine ground cable from the body.
  22.  
  23. Remove the mounting bolts and drive belt from the power steering pump. Pull the pump away from the mounting bracket without disconnecting the hoses. Support the pump out of the way.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. Remove the front wheel and tire assemblies.
  28.  
  29. Remove the splash shield.
  30.  

You can also leave the intake manifold attached to the cylinder head, then separate the two components once they are removed from the engine.

  1. Remove the intake manifold bracket bolts.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Disconnect the exhaust pipe from the exhaust manifold.
  6.  
  7. Remove the exhaust manifold and the exhaust manifold heat insulator.
  8.  
  9. Remove the power steering pump mounting bracket.
  10.  
  11. Remove the PCV hose, then remove the rocker arm (valve) cover. Replace the rubber seals if damages or deteriorated.
  12.  
  13. Remove the timing belt. Refer to the procedure located in this section.
  14.  
  15. Remove the cylinder head bolts in the reverse order of installation.
  16.  

To prevent warpage, unscrew the bolts in sequence 1 / 3 turn at a time. Repeat the sequence until all bolts are loosened.

  1. Separate the cylinder head from the engine block with a suitable flat-bladed prytool.
  2.  

To install:

  1. Be sure all cylinder head and block gasket surfaces are clean. Check the cylinder head for warpage. If warpage is less than 0.002 in. (0.05mm), cylinder head resurfacing is not required. Maximum resurface limit is 0.008 in. (0.2mm) based on a cylinder head height of 3.94 in. (100mm). Refer to engine rebuilding at the end of this section for more information.
  2.  
  3. Always use a new head gasket.
  4.  
  5. The UP mark on the camshaft pulley should be at the top.
  6.  
  7. Be sure the No. 1 cylinder is at TDC.
  8.  
  9. Clean the oil control orifice and install a new O-ring. Install and align the cylinder head dowel pins and oil control jet.
  10.  
  11. Install the bolts that secure the intake manifold to its bracket but do not tighten them.
  12.  
  13. Install the cylinder head, then tighten the cylinder head bolts sequentially in 3 steps:

    Step 1: 29 ft. lbs. (40 Nm).
     
    Step 2: 51 ft. lbs. (70 Nm).
     
    Step 3: 72 ft. lbs. (100 Nm).
     

  14.  
  15. Install the intake manifold and tighten the nuts in a crisscross pattern, in 2 or 3 steps, beginning with the inner nuts. Final torque should be 16 ft. lbs. (22 Nm). Always use a new intake manifold gasket.
  16.  
  17. Connect the intake manifold bracket to the intake manifold. Tighten the bolt to 16 ft. lbs. (22 Nm).
  18.  
  19. Install the heat insulator to the cylinder head and the block.
  20.  
  21. Install the power steering pump mounting bracket to the cylinder head. Tighten the 2 10mm bolts to 36 ft. lbs. (50 Nm). Torque the 8mm bolt to 16 ft. lbs. (22 Nm).
  22.  
  23. Install the exhaust manifold and tighten the nuts in a crisscross pattern in 2 or 3 steps, beginning with the inner nut. Final torque should be 23 ft. lbs. (32 Nm). Always use a new exhaust manifold gasket.
  24.  
  25. Install the exhaust manifold bracket, then install the exhaust pipe, bracket and upper shroud.
  26.  
  27. Be sure the camshaft sprocket and the crankshaft pulleys are aligned to TDC. Install the timing belt. Refer to the procedure located in this section.
  28.  
  29. Install the splash shield and the front wheels.
  30.  
  31. Lower the vehicle.
  32.  
  33. Check and adjust the valves, as necessary.
  34.  
  35. Tighten the crankshaft pulley bolt to 181 ft. lbs. (250 Nm).
  36.  
  37. Installation of the remaining components is the reverse of the removal procedure.
  38.  
  39. Fill the cooling system.
  40.  
  41. Connect the negative battery cable and enter the radio security code.
  42.  
  43. Start the engine and check carefully for any leaks.
  44.  
  45. Check the ignition timing and tighten the distributor bolts to 13 ft. lbs. (18 Nm).
  46.  

F22B1 AND F22B2 ENGINES


Click image to see an enlarged view

Fig. Exploded view of the cylinder head assembly-2.2L (F22B1) engine



Click image to see an enlarged view

Fig. Exploded view of cylinder head and related components-2.2L (F22B2) engine

  1. Disconnect the negative battery cable, then the positive battery cable.
  2.  
  3. Turn the engine to align the timing marks and set cylinder No.1 to TDC. The white mark on the crankshaft pulley should align with the pointer on the timing belt cover.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the engine coolant into a sealable container.
  8.  
  9. Remove the front wheel and tire assemblies.
  10.  
  11. Remove the splash shield.
  12.  
  13. Disconnect the exhaust pipe from the exhaust manifold.
  14.  
  15. Remove the intake manifold bracket bolts.
  16.  
  17. Lower the vehicle to a working level without placing it on the floor.
  18.  
  19. Remove the throttle cable from the throttle body. On automatic transaxle equipped vehicles, remove the throttle control cable. If equipped with cruise control, remove the cruise control cable.
  20.  

Be careful not to bend the cable when removing it. Always replace a kinked cable with a new one. Do not use pliers to remove the cable from the linkage.

  1. Remove the intake air duct.
  2.  
  3. Remove the breather hose, PCV hose, and EVAP control canister hose.
  4.  
  5. Relieve the fuel pressure, as outlined in Fuel System .
  6.  
  7. Remove the fuel feed and return hose from the fuel rail.
  8.  
  9. Disconnect the vacuum hoses attached to the engine located near the fuel feed and return hoses.
  10.  
  11. Remove the brake booster vacuum hose from the intake manifold. Label and remove the other vacuum hoses from the intake manifold.
  12.  
  13. Remove the clamp holding the power steering hose to the strut tower.
  14.  
  15. Remove the wiring harness clamp and the ground cable from the intake manifold.
  16.  
  17. Remove the connector and the terminal from the alternator, then remove the engine wiring harness from the valve cover.
  18.  
  19. Remove the mounting bolts and drive belt from the power steering pump. Pull the pump away from the mounting bracket without disconnecting the hoses. Support the pump out of the way.
  20.  
  21. Loosen the adjusting and mounting bolts for the alternator and remove the drive belt.
  22.  
  23. Remove the engine wiring harness and bypass hose from the lower side of the intake manifold.
  24.  
  25. Label and detach the following engine wiring harness connectors:

    Fuel injector connectors
     
    IAT sensor connector
     
    IAC valve connector
     
    TP sensor connector
     
    MAP sensor connector
     
    HO 2 S connector
     
    ECT sensor connector
     
    ECT switch connector
     
    ECT gauge sending unit connector
     
    VTEC solenoid valve connector
     
    VTEC pressure switch connector
     
    EGR valve lift sensor
     
    CKP/CYP sensor connector
     
    Ignition coil connector (Non VTEC engine)
     
    Fuel Injection Air (FIA) control solenoid valve connector (VTEC engine)
     

  26.  
  27. Label, then detach the electrical connectors from the distributor and the spark plug wires from the spark plugs. Mark the position of the distributor and remove it from the cylinder head. Disconnect the ignition coil wire from the distributor.
  28.  
  29. Remove the upper radiator hose and the heater inlet hose from the cylinder head.
  30.  
  31. Remove the lower radiator hose from the thermostat housing.
  32.  
  33. Remove the coolant bypass hoses.
  34.  
  35. Use a jack to support the engine. Be sure to place a cushion between the oil pan and the jack. Remove the through-bolt from the side engine mount and remove the mount.
  36.  
  37. Remove the rocker arm (valve) cover. Replace the rubber seals if damaged or deteriorated.
  38.  
  39. Remove the timing belt covers and the timing belt. Refer to the procedure located in this section.
  40.  
  41. Remove the camshaft sprocket and the back cover. Do not lose the sprocket key.
  42.  
  43. Remove the exhaust manifold heat insulator and the exhaust manifold.
  44.  
  45. Remove the thermostat housing mounting bolts. Remove the thermostat housing from the intake manifold and the connecting pipe, by pulling and twisting the housing. Discard the O-rings.
  46.  
  47. Remove the fuel rail and fuel injectors.
  48.  
  49. Remove the intake manifold.
  50.  
  51. Remove the cylinder head bolts in the reverse order proper sequence, then remove the cylinder head.
  52.  

To prevent warpage, unscrew the bolts in sequence 1 / 3 turn at a time. Repeat the sequence until all bolts are loosened.

To install:

  1. Be sure all cylinder head and block gasket surfaces are clean. Check the cylinder head for warpage. If warpage is less than 0.002 in. (0.05mm), cylinder head resurfacing is not required. Maximum resurface limit is 0.008 in. (0.2mm) based on a cylinder head height of 3.94 in. (100mm). Refer to engine rebuilding, at the end of this section for more information.
  2.  
  3. Always use a new head gasket.
  4.  
  5. Be sure the No. 1 cylinder is at TDC.
  6.  
  7. Clean the oil control orifice and install a new O-ring (VTEC engine only).
  8.  
  9. Install the dowel pins to the engine block.
  10.  
  11. Install the bolts that secure the intake manifold to its bracket but do not tighten them.
  12.  
  13. Position the camshaft correctly.
  14.  
  15. Install the cylinder head, then tighten the cylinder head bolts sequentially in 3 steps:

    Step 1: 29 ft. lbs. (39 Nm).
     
    Step 2: 51 ft. lbs. (69 Nm).
     
    Step 3: 72 ft. lbs. (98 Nm).
     

  16.  



Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.2L (F22B1 and F22B2) engines

  1. Install the intake manifold with a new gasket.
  2.  
  3. Connect the intake manifold bracket to the intake manifold and tighten the bolt to 16 ft. lbs. (22 Nm).
  4.  
  5. Install the fuel rail with the fuel injectors.
  6.  
  7. Install the exhaust manifold with a new gasket.
  8.  
  9. Install the exhaust manifold bracket.
  10.  
  11. Install the timing belt back cover to the cylinder head. Tighten the cover bolt on the non VTEC engine to 108 inch lbs. (12 Nm). On the VTEC engine tighten the bolt on the intake side of the head to 108 inch lbs. (12 Nm) and tighten the bolt on the exhaust side of the head to 84 inch lbs. (10 Nm).
  12.  
  13. Install the key to the camshaft, then install the camshaft sprocket. Tighten the sprocket bolt to 27 ft. lbs. (37 Nm).
  14.  
  15. Be sure the camshaft sprocket and the crankshaft pulleys are aligned to TDC and install the timing belt. Refer to the procedure located in this section.
  16.  
  17. Install the lower timing belt cover and tighten the bolts to 108 inch lbs. (12 Nm).
  18.  
  19. Install a new seal around the adjusting nut. Do not loosen the adjusting nut.
  20.  
  21. Install the crankshaft pulley. Coat the threads and seating face of the pulley bolt with engine oil. Install and tighten the bolt to 181 ft. lbs. (250 Nm).
  22.  
  23. Install the side engine mount. Tighten the bolt and nut attaching the mount to the engine to 40 ft. lbs. (55 Nm). Tighten the through nut and bolt to 47 ft. lbs. (65 Nm), remove the jack from under the center beam.
  24.  
  25. Adjust the valves.
  26.  
  27. Install the upper timing belt cover. Tighten the bolt on the intake side of the head to 108 inch lbs. (12 Nm) and tighten the bolt on the exhaust side of the head to 84 inch lbs. (10 Nm).
  28.  
  29. Raise and safely support the vehicle.
  30.  
  31. Connect the exhaust pipe to the exhaust manifold with new gaskets. Tighten the nuts 40 ft. lbs. (54 Nm).
  32.  
  33. Install the splash shield and the front wheels.
  34.  
  35. Lower the vehicle.
  36.  
  37. Install the rocker arm (valve) cover gasket cover to the groove of the rocker arm (valve) cover. Before installing the gasket thoroughly clean the seal and the groove. Seat the recesses for the camshaft first, then work it into the groove around the outside edges. Be sure the gasket is seated securely in the corners of the recesses.
  38.  
  39. Apply liquid gasket to the 4 corners of the recesses of the rocker arm (valve) cover gasket. Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. After assembly, wait at least 20 minutes before filling the engine with oil.
  40.  
  41. If equipped with a VTEC engine, install the spark plug seals on the spark plug pipes. Take care not to damage the spark plug seals when installing the rocker arm (valve) cover.
  42.  
  43. Clean the rocker arm (valve) cover contacting surface with a shop towel. Install the rocker arm (valve) cover and tighten the rocker arm (valve) cover bolts in 2 or 3 steps. Tighten the cap nuts in the proper sequence to 84 inch lbs. (10 Nm).
  44.  



Click image to see an enlarged view

Fig. Non-VTEC engine rocker arm (valve) cover torque sequence



Click image to see an enlarged view

Fig. VTEC engine rocker arm (valve) cover torque sequence

  1. Install the remaining components in the reverse order of removal.
  2.  
  3. Fill the crankcase to the proper level with clean oil.
  4.  
  5. Fill and bleed the air from the cooling system.
  6.  
  7. Connect the positive, then the negative battery cable. Enter the radio security code.
  8.  
  9. Start the engine and check carefully for any leaks.
  10.  
  11. Check the ignition timing, as outlined in Section 1.
  12.  

2.3L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Turn the crankshaft so the No. 1 piston is at TDC.
  4.  

The No. 1 piston is at TDC when the pointer on the block aligns with the white painted mark on the flywheel (manual transaxle) or driveplate (automatic transaxle).

  1. Drain the engine coolant into a sealable container.
  2.  
  3. Relieve the fuel pressure, as outlined in Fuel System .
  4.  
  5. Remove the air intake duct.
  6.  
  7. Remove the EVAP control canister hose from the intake manifold.
  8.  
  9. Remove the throttle cable from the throttle body. If equipped with an automatic transaxle, remove the throttle control cable from the throttle body.
  10.  

Be careful not to bend the cable when removing. Always replace a kinked cable with a new one.

  1. Disconnect the fuel feed and return hose.
  2.  
  3. Remove the brake booster vacuum hose from the intake manifold.
  4.  
  5. Tag and detach the following engine wiring harness connectors:

    Fuel injector connectors
     
    IAT sensor connector
     
    IAC valve connector
     
    TP sensor connector
     
    EGR valve lift sensor
     
    Ground cable terminals
     
    ECT switch B connector
     
    Heated Oxygen sensor (HO 2 S) connector
     
    ECT sensor
     
    ECT gauge sending unit connector
     
    ICM connector
     
    CKP/CYP sensor connector
     
    VSS connector
     
    Ignition coil connector
     
    Intake air bypass solenoid valve connector
     
    ECT switch A connector
     
    Knock sensor connector
     

  6.  
  7. Remove the engine ground cable from the rocker arm (valve) cover.
  8.  
  9. Remove the connector and the terminal from the alternator, then remove the engine wiring harness from the valve cover.
  10.  
  11. Remove the mounting bolts and drive belt from the power steering pump. Pull the pump away from the mounting bracket, without disconnecting the hoses. Support the pump out of the way.
  12.  
  13. Remove the ignition coil.
  14.  
  15. Tag, then disconnect the emissions vacuum hoses from the intake manifold assembly.
  16.  
  17. Remove the bypass hose from the intake manifold.
  18.  
  19. Remove the upper radiator hose and the heater hose from the cylinder head.
  20.  
  21. Remove the lower radiator hose and bypass hose from the thermostat housing.
  22.  
  23. Remove the thermostat housing mounting bolts. Remove the thermostat housing from the intake manifold and the connecting pipe, by pulling and twisting the housing. Discard the O-rings.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. Remove the front wheel and tire assemblies.
  28.  
  29. Remove the splash shield.
  30.  
  31. Remove the intake manifold bracket bolts.
  32.  
  33. Remove the intake manifold.
  34.  
  35. Disconnect the exhaust pipe from the exhaust manifold.
  36.  
  37. Remove the exhaust manifold and the exhaust manifold heat insulator.
  38.  
  39. Label, then detach the electrical connectors from the distributor and the spark plug wires from the spark plugs. Mark the position of the distributor and remove it from the cylinder head. Disconnect the ignition coil wire from the distributor.
  40.  
  41. Remove the PCV hose, then remove the rocker arm (valve) cover. Replace the rubber seals if damaged or deteriorated.
  42.  
  43. Remove the timing belt. Refer to the procedure located in this section.
  44.  
  45. Insert a 5.0mm pin punch in each of the camshaft caps, nearest to the sprockets, through the holes provided. Remove the camshaft sprocket attaching bolts, then remove the sprockets. Do not lose the sprocket keys.
  46.  
  47. Loosen all of the rocker arm adjusting screws, then remove the pin punches from the camshaft caps.
  48.  
  49. Remove the camshaft holders, note the holders locations for ease of installation.
  50.  
  51. Remove the rubber cap from the head, located at the end of the intake camshaft.
  52.  
  53. Remove the rocker arms from the cylinder head. Note the locations of the rocker arms.
  54.  

The rocker arms have to be installed to their original locations if being reused.

  1. Remove the side engine mount bracket B, then the back cover from behind the camshaft sprockets.
  2.  
  3. Remove the cylinder head bolts in the proper sequence.
  4.  

To prevent warpage, unscrew the bolts in sequence 1 / 3 turn at a time. Repeat the sequence until all bolts are loosened.



Click image to see an enlarged view

Fig. Cylinder head bolt removal sequence-2.3L engine

  1. Separate the cylinder head from the engine block with a suitable flat-bladed prytool.
  2.  

To install:

  1. Be sure all cylinder head and block gasket surfaces are clean. Check the cylinder head for warpage. If warpage is less than 0.002 in. (0.05mm), cylinder head resurfacing is not required. Maximum resurface limit is 0.008 in. (0.2mm) based on a cylinder head height of 5.20 in. (132.0mm). Refer to engine rebuilding, at the end of this section for more information.
  2.  
  3. Always use a new head gasket.
  4.  
  5. Be sure the No. 1 cylinder is at TDC.
  6.  
  7. Clean the oil control orifice and install a new O-ring. The cylinder head dowel pins and oil control jet must be aligned.
  8.  
  9. Install the bolts that secure the intake manifold to its bracket but do not tighten them.
  10.  
  11. Install the cylinder head, then tighten the cylinder head bolts sequentially in 3 steps:

    Step 1: 29 ft. lbs. (40 Nm).
     
    Step 2: 51 ft. lbs. (70 Nm).
     
    Step 3: 72 ft. lbs. (100 Nm).
     

  12.  



Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.3L engine

A beam type torque wrench is recommended. If a bolt makes any noise while being tightened, loosen the bolt and retighten it.

  1. Install the intake manifold with a new gasket.
  2.  
  3. Install the exhaust manifold with a new gasket.
  4.  
  5. Install the exhaust manifold bracket, then install the exhaust pipe, bracket, and upper shroud.
  6.  
  7. Install the camshafts and rocker arms.
  8.  
  9. Install the timing belt back cover.
  10.  
  11. Install the side engine mount bracket B. Tighten the bolt attaching the bracket to the cylinder head to 33 ft. lbs. (45 Nm). Tighten the bolts attaching the bracket to the side engine mount to 16 ft. lbs. (22 Nm).
  12.  
  13. Install the camshaft sprockets onto the camshafts.
  14.  
  15. Install the timing belt. Refer to the procedure located in this section.
  16.  
  17. Adjust the valves, as outlined in Section 1.
  18.  
  19. Tighten the crankshaft pulley bolt to 181 ft. lbs. (250 Nm).
  20.  
  21. Install the splash shield and the front wheels.
  22.  
  23. Lower the vehicle.
  24.  
  25. Install the remaining components in the reverse order of removal.
  26.  
  27. Drain the oil from the engine into a sealable container. Install the drain plug and refill the engine with clean oil.
  28.  
  29. Fill and bleed the air from the cooling system.
  30.  
  31. Connect the negative battery cable and enter the radio security code.
  32.  
  33. Start the engine and check carefully for any leaks.
  34.  
  35. Check and adjust the ignition timing. Tighten the distributor bolts to 13 ft. lbs. (18 Nm).
  36.  

2.7L Engines


Click image to see an enlarged view

Fig. Exploded view of the cylinder heads, gasket and block-2.7L engines



Click image to see an enlarged view

Fig. Exploded view of the cylinder head and related components-2.7L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Turn the engine to align the timing marks and set cylinder No.1 to Top Dead Center (TDC). Remove the inspection caps on the upper timing belt covers to check the alignment of the timing marks. The white mark on the crankshaft pulley should align with the pointer on the timing belt cover. The pointers for the camshafts should align with the green marks on the camshaft pulleys.
  4.  
  5. Drain the engine coolant into a sealable container.
  6.  
  7. Remove the intake air duct.
  8.  
  9. Remove intake manifold cover B , then disconnect the throttle cable and cruise control cables from the throttle linkage. Take care to not bend the cables. Always replaced a kinked cable.
  10.  
  11. Remove the starter cable from the strut brace, then remove the strut brace.
  12.  
  13. Relieve the pressure from the fuel system, as outlined in Fuel System .
  14.  


CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Disconnect the fuel feed hose from the fuel filter. Disconnect the fuel return hose from the regulator.
  2.  
  3. Disconnect the brake booster vacuum hose and the evaporative emissions (EVAP) control canister hose.
  4.  
  5. Label and disconnect all vacuum hoses from the throttle body, intake manifold, and cylinder head.
  6.  
  7. Disconnect the coolant hoses from the Idle Air Control (IAC) valve, the fast idle thermo valve, and the water passage.
  8.  
  9. Remove the intake manifold cover.
  10.  
  11. Disconnect the breather hose from the rocker arm (valve) cover.
  12.  
  13. Remove the PCV hose from the rocker arm (valve) cover.
  14.  
  15. Loosen the idler pulley center nut and adjusting bolt, then remove the air conditioning compressor belt.
  16.  
  17. Disconnect the engine ground cable from the body, located near the drive belts.
  18.  
  19. Remove the vacuum pipe assembly.
  20.  
  21. Loosen the alternator mounting bolt, nut, and adjusting bolt, then remove the alternator drive belt.
  22.  
  23. Support the engine with a floor jack on the oil pan (use a cushion between the jack and pan). Tension the jack so that it is just supporting the engine but not lifting it.
  24.  
  25. Remove the 3 bolts from the side engine mount, then loosen the through-bolt. Pivot the side engine mount out of the way.
  26.  
  27. Loosen the power steering pump mounting nuts and adjusting nut, then remove the power steering drive belt.
  28.  
  29. Disconnect the inlet hose from the power steering pump, then plug the hose and pump. Remove the power steering pump and place it out of the way.
  30.  
  31. Remove the wiring harness cover and the ground cable from the water passage inlet.
  32.  
  33. Label and detach the following engine harness connectors from the cylinder head and the intake manifold:

    Six injector connectors
     
    IAT sensor connector
     
    TDC/CYP sensor connector
     
    IAC valve connector
     
    MAP sensor connector
     
    ECT sensor connector
     
    ECT gauge sending unit connector
     
    ECT switch connector
     
    EGR valve lift sensor connector
     
    TP sensor connector
     
    IAB control solenoid valve connector
     
    Engine oil temperature sensor connector
     
    EVAP purge control solenoid valve connector
     
    Alternator connector
     

  34.  
  35. Label, then disconnect the electrical connectors from the distributor and the spark plug wires from the spark plugs. Remove the distributor from the cylinder head.
  36.  
  37. Remove the upper and lower radiator hoses, then disconnect the heater hoses from the engine.
  38.  
  39. Remove the intake air bypass vacuum tank.
  40.  
  41. Remove the bolts attaching the water passage to the cylinder heads, then remove it from the engine. Discard the O-rings.
  42.  
  43. Remove the engine wiring harness covers from the intake manifold.
  44.  
  45. Remove the nuts attaching the EGR pipe to the intake manifold and discard the gasket. Loosen the nut attaching the EGR pipe to the exhaust manifold and remove the pipe from the vehicle.
  46.  
  47. Remove the intake manifold.
  48.  
  49. Remove the exhaust manifolds from the engine.
  50.  
  51. Remove the rocker arm (valve) covers and the side covers.
  52.  
  53. Remove the timing belt covers and the timing belt. Refer to the procedure located in this section.
  54.  
  55. Remove the camshaft sprockets and the timing belt back covers.
  56.  
  57. Remove the bolts attaching the camshaft holder plates and camshaft holders in the reverse order of installation.
  58.  
  59. Remove the camshaft holder plates, camshaft holders, and the dowel pins from the cylinder head.
  60.  
  61. Remove the camshafts from the cylinder heads and the rubber cap from the rear cylinder head. Discard the camshaft seals.
  62.  
  63. Remove the intake rocker arms, exhaust inside rocker arms and the pushrods. Identify the location of the parts as they are removed to ensure reinstallation to the original locations.
  64.  
  65. Remove the cylinder head bolts in the proper sequence.
  66.  

To prevent warpage, loosen the bolts in sequence 1 / 3 turn at a time. Repeat the sequence until all bolts are removed.



Click image to see an enlarged view

Fig. Cylinder head bolt removal sequence-2.7L engine

  1. Remove the cylinder heads from the engine block.
  2.  
  3. Remove and clean the oil control orifices, then install new O-rings to the orifices.
  4.  

To install:

  1. Be sure all cylinder head and block gasket surfaces are clean. Check the cylinder head for warpage. If warpage is less than 0.002 in. (0.05mm), cylinder head resurfacing is not required. Maximum resurface limit is 0.008 in. (0.2mm) based on a cylinder head height of 5.24 in. (133mm). Refer to engine rebuilding, at the end of this section for more information.
  2.  
  3. Install new head gaskets.
  4.  
  5. Be sure the No. 1 cylinder is at TDC.
  6.  
  7. Install and align the cylinder head dowel pins and oil control orifices.
  8.  
  9. Install the cylinder heads. Apply clean oil to the threads of the cylinder head bolts and washers, then install and tighten the cylinder head bolts sequentially in 2 steps:

    Step 1: 29 ft. lbs. (39 Nm).
     
    Step 2: 56 ft. lbs. (76 Nm).
     

  10.  



Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.7L engine

  1. Fill the hydraulic tappet mounting hole and the oil fillers with clean engine oil.
  2.  
  3. Install the hydraulic tappets.
  4.  


WARNING
Do not rotate the hydraulic tappets while installing them.

  1. Apply clean engine oil to the rocker arms, pushrods, and the camshafts.
  2.  
  3. Loosen the exhaust rocker arm adjusting screws and locknuts, then install the pushrods, exhaust inside rocker arms, and the intake rocker arms. Install the parts to their original locations.
  4.  
  5. Be sure the rocker arms are properly positioned on the valve stems. Advance the crankshaft 30° from TDC to prevent interference between the pistons and valves, then install the camshafts. Position the rear camshaft on the cylinder head so the cam is not pushing on any valves.
  6.  
  7. Install the timing belt back covers and tighten the attaching bolts to 108 inch lbs. (12 Nm).
  8.  
  9. Install the camshaft sprockets and tighten the attaching bolts to 23 ft. lbs. (31 Nm).
  10.  
  11. Set the camshaft sprockets so that the No. 1 piston is at TDC. Align the TDC marks (green mark) on the camshaft pulleys to the pointers on the back covers.
  12.  
  13. Turn the crankshaft counterclockwise to set it at TDC. Align the TDC mark on the tooth of the timing belt drive pulley with the pointer on the oil pump.
  14.  
  15. Install the timing belt and timing belt covers. Refer to the procedure located in this section.
  16.  
  17. Set No. 1 cylinder to TDC.
  18.  
  19. Tighten the adjusting screws for No. 1, No. 2, and No. 4 cylinders. Tighten the screw until it contacts the valve, then tighten the screw 1 1 / 8 turns. Hold the screw in place and tighten the locknut to 14 ft. lbs. (20 Nm).
  20.  
  21. Rotate the crankshaft pulley 1 turn clockwise, then tighten the adjusting screws for No. 3, No. 5 and No. 6 cylinders. Tighten the screw until it contacts the valve, then tighten the screw 1 1 / 8 turns. Hold the screw in place and tighten the locknut to 14 ft. lbs. (20 Nm).
  22.  
  23. Install the rocker arm (valve) cover gasket into the groove of the rocker arm (valve) cover. Seat the recesses for the camshaft first, then work it into the groove around the outside edges.
  24.  

Before installing the rocker arm (valve) cover gasket, thoroughly clean the seal groove.

  1. Apply liquid gasket to the rocker arm (valve) cover gasket at the 4 corners of the recesses. Use a shop towel and wipe the cylinder heads where the rocker arm (valve) covers will come in contact.
  2.  
  3. Install the rocker arm (valve) covers, hold the gasket in the groove by placing your fingers on the camshaft contacting surfaces. With the rocker arm (valve) cover on the cylinder heads, slide the covers slightly back and forth to seat the rocker arm (valve) cover gaskets. Replace the washers if damaged or deteriorated.
  4.  
  5. Tighten the rocker arm (valve) cover bolts in 2 or 3 steps. In the final step, tighten all the bolts, in sequence, to 11 ft. lbs. (15 Nm).
  6.  
  7. Install the cylinder head side covers with new O-rings and tighten the bolts to 108 inch lbs. (12 Nm).
  8.  
  9. Install the intake manifold.
  10.  
  11. Install the exhaust manifolds.
  12.  
  13. Install new O-rings to the water passage and install the water passage to the engine and tighten the mounting bolts to 16 ft. lbs. (22 Nm).
  14.  
  15. Install the EGR pipe with a new gasket at the intake manifold. Tighten the nuts attaching the pipe to the intake manifold to 108 inch lbs. (12 Nm) and tighten the exhaust manifold fitting to 43 ft. lbs. (59 Nm).
  16.  
  17. Install the side engine mount. Use 3 new bolts to attach the mount to the engine and tighten the bolts to 40 ft. lbs. (54 Nm).
  18.  
  19. Tighten the side engine mount through-bolt to 47 ft. lbs. (64 Nm).
  20.  
  21. Install the remaining components in the reverse of removal.
  22.  
  23. Drain the engine oil into a sealable container, then refill the engine with clean oil.
  24.  
  25. Connect the negative battery cable and enter the radio security code.
  26.  
  27. Fill and bleed the air from the cooling system.
  28.  
  29. Switch the ignition ON but do not engage the starter. The fuel pump should run for approximately 2 seconds, building pressure within the lines. Switch the ignition OFF , then ON 2 or 3 more times to build full system pressure. Check for fuel leaks.
  30.  
  31. Start the engine, allow it to idle and check for any signs of leakage.
  32.  

3.0L Engine


Click image to see an enlarged view

Fig. Exploded view of the cylinder head and valve train components-3.0L engine

  1. Obtain the security code for the radio.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the coolant into a suitable container.
  6.  
  7. Remove the EVAP canister hose from the throttle body.
  8.  
  9. Remove the air intake duct.
  10.  
  11. Remove the upper engine covers.
  12.  
  13. Disconnect the accelerator and cruise control cables from the throttle body.
  14.  
  15. Remove the spark plug wire holder, cover, and intake manifold covers.
  16.  
  17. Properly relieve the fuel system pressure, as outlined in Fuel System .
  18.  
  19. Disconnect the fuel hoses from the supply rail.
  20.  
  21. Tag and disconnect the following hoses and lines:

    Brake booster vacuum hose
     
    PCV hose
     
    Breather hose
     
    Water bypass hose
     
    Vacuum hose from the throttle body
     

  22.  
  23. Remove the ground cable from the engine.
  24.  
  25. Remove the alternator belt.
  26.  
  27. Support the engine with a jack and a block of wood and remove the side engine mounting bracket.
  28.  
  29. Remove the power steering pump without disconnecting the hoses.
  30.  
  31. Remove the alternator.
  32.  
  33. Detach the wiring harness connectors from the components on the engine that may interfere with removing the cylinder head.
  34.  
  35. Remove the distributor and spark plug wires.
  36.  
  37. Remove the intake manifold.
  38.  
  39. Detach the connectors from the fuel injectors.
  40.  
  41. Remove the fuel supply rails.
  42.  
  43. Remove the vacuum hoses from the fuel control valve.
  44.  
  45. Set the engine to TDC by aligning the marks on the crankshaft and camshaft pulleys.
  46.  
  47. Remove the timing belt. Refer to the procedure located in this section.
  48.  
  49. Remove the upper and lower radiator hoses.
  50.  
  51. Disconnect the heater hoses.
  52.  
  53. Remove both exhaust manifolds.
  54.  
  55. Remove the water passage assembly.
  56.  
  57. Remove the camshaft pulleys and rear timing belt covers.
  58.  
  59. Loosen each cylinder head bolt 1 / 3 turn at a time in the correct sequence. This will take several passes.
  60.  
  61. Remove the cylinder heads.
  62.  



Click image to see an enlarged view

Fig. Loosen the cylinder head bolts in the sequence shown to prevent damage to the head-3.0L engine

To install:

  1. Clean the cylinder head and the surface of the cylinder block.
  2.  
  3. Install the oil control orifices and install them using new o-rings.
  4.  
  5. If removed, install the dowel pins.
  6.  
  7. Position new cylinder head gaskets on the cylinder block.
  8.  
  9. If moved, set the crankshaft and camshaft pulleys to TDC by aligning the marks on the pulley and oil pump.
  10.  
  11. Carefully position the cylinder heads on the engine.
  12.  
  13. Lubricate the cylinder head bolts with clean engine oil.
  14.  



Click image to see an enlarged view

Fig. Tighten the cylinder head bolts in the sequence shown to prevent damage to the head-3.0L engine

If any cylinder head bolt makes noise while being tightened, loosen the bolts and begin the tightening sequence again.

  1. Tighten the cylinder head bolts in sequence, in 3 separate steps. First tighten each bolt in sequence to 29 ft. lbs. (39 Nm).
  2.  
  3. Tighten each bolt in sequence to 51 ft. lbs. (69 Nm).
  4.  
  5. Tighten each bolt a third time in sequence to a final torque of 72 ft. lbs. (98 Nm).
  6.  
  7. Install the exhaust manifolds.
  8.  
  9. Install the timing belt. Refer to the procedure located in this section.
  10.  
  11. Check and adjust the valve clearance if necessary.
  12.  
  13. Install the rocker arm (valve) cover. Tighten the bolts in sequence to 108 inch lbs. (12 Nm).
  14.  



Click image to see an enlarged view

Fig. Tighten the rocker arm (valve) cover bolts in the sequence shown-3.0L engine

  1. Install the water passage. Be sure to use new gaskets and o-rings. Tighten the bolts to 16 ft. lbs. (22 Nm).
  2.  
  3. Install the intake manifold.
  4.  
  5. Install all of the remaining hoses, tubes, and connectors are installed correctly.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Enter the security code for the radio.
  10.  

 
label.common.footer.alt.autozoneLogo