Mazda Car 2002-04

Cylinder Head 1

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing chain.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Disconnect the following components:

    Warm Up-Three Way Converter (WU-TWC)
     
    Upper radiator hose
     
    Water and heater hose
     
    Wiring harness
     

  10.  
  11. Support the engine using an engine jack and attachment as shown in the illustration.

    Click image to see an enlarged view

    Fig. Support the engine using an engine jack and attachment as shown-Mazda 3 models

  12.  
  13. Remove the camshafts.
    NOTE
    The cylinder head and camshaft caps are numbered and must be reassembled in their original locations. When removing a when removed, keep the caps with the cylinder head they were removed from, do not switch the caps.

  14.  
  15. Loosen the cylinder head bolts using 2-3 passes in the sequence illustrated.
  16.  
  17. Once all the bolts have been removed, remove the cylinder head and gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-Mazda 3 models

  18.  

To install:

  1. )If reusing old bolts, which is not recommended; measure the length of each head bolt at the locations illustrated. If any bolt exceeds 5.717-5.740 inch (145.2-145.8mm) replace the bolt.

    Click image to see an enlarged view

    Fig. Measure the length of each head bolt at the locations illustrated, if reusing the old bolts. If any bolt exceeds 5.717-5.740 inch (145.2-145.8mm) replace the bolt-Mazda 3 models



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-Mazda 3 models

  2.  
  3. Install a new cylinder head gasket.
  4.  
  5. Install the cylinder head.
  6.  
  7. Apply clean engine oil to the bolt threads and seating faces.
  8.  
  9. Install new cylinder head bolts and torque in 2-3 steps, in sequence as follows:
    1. Step 1: Tighten the bolts in sequence to 27-97 inch lbs. (3-11 Nm).
    2.  
    3. Step 2: Tighten the bolts in sequence to 9.5-12.5 ft. lbs. (13-17 Nm).
    4.  
    5. Step 3: Tighten the bolts in sequence to 32-34.5 ft. lbs. (43-47 Nm).
    6.  
    7. Step 4: Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 88-92 degrees.
    8.  
    9. Step 5: Turn each bolt, in sequence, 88-92 degrees.
    10.  

  10.  
  11. Install the camshafts and caps in their original positions.
  12.  
  13. Install the remaining components in the reverse order of removal.
  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Change the oil and filter.
  18.  
  19. Run the engine and check for proper operation.
  20.  

1.5L & 1.8L (BP) Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Right front wheel and splash shield
     
    Water pump pulley bolts, loosen them
     
    Power steering belt shield
     
    Power steering belt
     
    Alternator belt

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head assembly-1.5L engine



    Click image to see an enlarged view

    Fig. 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 and install a suitable engine support tool
     
    No. 3 engine mount bracket
     
    Timing belt middle and lower covers
     

  8.  
  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.  
  11. Remove or disconnect the following:
    NOTE
    Do not rotate the crankshaft until the timing belt is reinstalled.



    Timing belt tensioner, loosen it
     
    Timing belt.
     



    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
     

  12.  
  13. On the 1.5L engine, remove the tappets. Identify each tappet as it is removed so it can be reinstalled in the same position.
  14.  
  15. 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.
  16.  
  17. Remove or disconnect the following:

    Intake manifold bracket
     
    Intake manifold
     
    Cylinder head bolts, in 2-3 steps, in sequence
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-4-cylinder engines



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-6-cylinder engines

     

  18.  

To install:

  1. 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).
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. Install new head gasket on the engine block.
  6.  
  7. Be sure the camshaft sprocket timing marks are still aligned, as set during the removal procedure.
  8.  
  9. Install the cylinder head.
  10.  
  11. Lubricate the bolt threads and seat surfaces with clean engine oil and install them as follows:
    1. On the 1.5L engine, torque 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, plus an additional 90 degrees.
    2.  
    3. On the 1.8L (BP) engine, torque the bolts in 2-3 steps to 56-60 ft. lbs. (75-81 Nm) in the proper sequence.
    4.  

  12.  
  13. Install or connect the following:

    Intake manifold. Torque the bolts to 19 ft. lbs. (25 Nm)
     
    Intake manifold bracket
     
    Exhaust manifold using a new gasket. Torque the nuts to 34 ft. lbs. (46 Nm)
     
    Exhaust pipe using a new gasket. Torque the nuts to 34 ft. lbs. (46 Nm)
     
    Tappets in their original positions lubricated with engine oil
     
    Camshaft and sprockets
     

  14.  
  15. Be sure the crankshaft and camshaft sprocket timing marks are aligned.
  16.  
  17. 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. Torque the bolts to 70-95 inch lbs. (8-11 Nm)
     
    No. 3 engine mount bracket. Torque the nut to 70-95 inch lbs. (8-11 Nm) and the bolt to 14-16 ft. lbs. (19-22 Nm)
     

  18.  
  19. Remove the engine support tool.
  20.  
  21. Install or connect the following:

    Upper timing belt cover. Torque the bolts to 70-95 inch lbs. (8-11 Nm)
     
    Oil dipstick and bracket
     

  22.  
  23. Apply silicone sealant to the cylinder surface in the area adjacent to the front camshaft bearing caps.
  24.  
  25. Install the cylinder head cover using a new gasket and sealant.
  26.  
  27. Torque 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.  
    3. 1.8L (BP) engines: 44-78 inch lbs. (5-9 Nm).
    4.  

  28.  
  29. Install or connect the following:

    Power steering hose brackets. Torque 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. Torque 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
     

  30.  
  31. Torque the through-bolt to 32-44 ft. lbs. (44-60 Nm) and the lockbolt to 24-33 ft. lbs. (32-46 Nm).
  32.  
  33. Install or connect the following:

    Power steering belt shield. Torque 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
     

  34.  
  35. Fill the cooling system.
  36.  
  37. Adjust the ignition timing.
  38.  
  39. Start the engine, check for leaks and repair if necessary.
  40.  

1.6L (Zm) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine coolant.
  6.  
  7. 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
     
    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 sequence
     
    Cylinder head
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt removal sequence-1.6L (ZM) and 1.8L (FP) engines



Click image to see an enlarged view

Fig. Replace any bolts that exceed the maximum length-1.6L (ZM) and 1.8L (FP) engines



Click image to see an enlarged view

Fig. Cylinder head gasket positioning-6-cylinder engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-1.6L (ZM) and 1.8L (FP) engines

  1. Thoroughly, clean the cylinder head and the block contact surfaces.
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. Measure the length of the cylinder head bolts, as shown, maximum bolt length is 3.956 inch (100.5mm).
  6.  
  7. Install or connect the following:

    New head gasket
     
    Cylinder head
     

  8.  
  9. Torque the cylinder head bolts, in sequence, as follows:
    1. Step 1: 13-16 ft. lbs. (17-22 Nm).
    2.  
    3. Step 2: Turn 85-95 degrees.
    4.  
    5. Step 3: Turn an additional 85-95 degrees.
    6.  

  10.  
  11. Install or connect the following:

    Camshafts
     
    Camshaft pulleys, install the pulleys so that the I mark on the intake side or E mark on the exhaust side are facing up. Torque the bolts to 37-44 ft. lbs. (50-60 Nm).
     
    Heater hoses
     
    Intake manifold support bracket
     
    Fuel hoses
     
    Engine wiring harness connector
     
    Any vacuum hoses that were removed
     
    Accelerator cable and bracket
     
    Air cleaner assembly and fresh air duct
     
    EGR system
     
    Exhaust manifold insulator and front exhaust pipe
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill the cooling system.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.
  16.  

1.6L And 1.8L (FP) Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine coolant.
  6.  
  7. 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
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt removal sequence-1.6L and 1.8L (FP) engines



Click image to see an enlarged view

Fig. Replace any bolts that exceed the maximum length-1.6L and 1.8L engines

  1. Thoroughly, clean the cylinder head and the block contact surfaces.
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. 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.
  6.  
  7. Install or connect the following:

    New head gasket
     
    Cylinder head
     

  8.  
  9. Torque the cylinder head bolts, in sequence, as follows.
    1. Step 1: 13-16 ft. lbs. (17-22 Nm).
    2.  
    3. Step 2: Turn 85-95 degrees.
    4.  
    5. Step 3: Turn an additional 85-95 degrees.
    6.  

  10.  
  11. Install or connect the following:

    Camshafts
     
    Camshaft pulleys. Torque the bolts to 37-44 ft. lbs. (50-60 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
     

  12.  
  13. Fill the cooling system.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Cylinder head gasket positioning-6-cylinder engines

  16.  

1.8L (Bp) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Air cleaner assembly and front pipe
     
    Exhaust manifold
     
    Vacuum hoses
     
    All engine harness connectors necessary to access the cylinder head
     
    Fuel hose
     
    Intake manifold bracket
     
    Accelerator cable bracket
     
    Cylinder head bolts, in 2-3 steps, in sequence
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head assembly-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-1.8L (BP) engines

     

  8.  

To install:

  1. 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 inch (0.10mm).
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. Install new head gasket on the engine block.
  6.  
  7. Install the cylinder head.
  8.  
  9. Lubricate the bolt threads and seat surfaces with clean engine oil and install them as follows:
    1. Torque the bolts in 2-3 steps to 56-60 ft. lbs. (75-81 Nm) in the proper sequence.
    2.  

  10.  
  11. Install or connect the following:

    Accelerator cable bracket
     
    Intake manifold bracket
     
    Fuel hose
     
    All engine harness connectors removed to access the cylinder head
     
    Vacuum hoses
     
    Exhaust manifold using a new gasket
     
    Front pipe and air cleaner assembly
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Change the oil and filter.
  16.  
  17. Run the engine and check for proper operation.
  18.  

1.8L (Fp) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    negative battery cable
     
    timing belt
     
    front exhaust pipe
     
    Air cleaner assembly
     
    power steering pump and bracket, if necessary, and move it aside leaving the hoses attached
     
    accelerator cable
     
    fuel supply and return hoses
     
    Ignition coil
     
    Camshaft pulleys by holding the them with a wrench
     
    camshafts
     
    Cylinder head bolts in sequence
     
    Cylinder head
     

  8.  

To install:



Click image to see an enlarged view

Fig. Make sure the camshaft sprocket pulleys are positioned with the pins facing up-1.8L (FP) engine

  1. Thoroughly, clean the cylinder head and the block contact surfaces.
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. Measure the length of the cylinder head bolts, as shown, maximum bolt length is 4.153 inch (105.5mm).
  6.  
  7. Install or connect the following:

    new head gasket
     
    cylinder head
     

  8.  
  9. Torque the cylinder head bolts, in sequence, as follows.
    1. Step 1: 13-16 ft. lbs. (17-22 Nm).
    2.  
    3. Step 2: Turn 85-95 degrees.
    4.  
    5. Step 3: Turn an additional 85-95 degrees.
    6.  

  10.  
  11. Install or connect the following:

    camshafts
     
    Camshaft pulleys, install the pulleys so that the dowels are facing up. Torque the bolts to 37-44 ft. lbs. (50-60 Nm).
     
    Ignition coil
     
    fuel supply and return hoses
     

  12.  
  13. When connecting the accelerator cable, perform the following adjustment:
    1. Move the white locking tab A to the unlock position.
    2.  
    3. Turn stopper B to the to the unlock position.
    4.  

  14.  


    Click image to see an enlarged view

    Fig. Accelerator cable adjustment components-Protege models equipped with the 1.8L (FP) engine



NOTE
If stopper B will not unlock, it may be necessary to carefully bend back tab C out a little using a suitable pry tool.

  1. Push or pull the cable housing directly behind the spring.
  2.  
  3. Turn the stopper B to the lock position.
  4.  
  5. Measure the free play which should be 0.04-0.11 inch (1-3mm) and make sure the cable free play is within specification.
  6.  
  7. Move the white locking tab to the lock position and check for proper accelerator operation.
  8.  
  9. power steering pump and bracket
  10.  
  11. Air cleaner assembly
  12.  
  13. front exhaust pipe
  14.  
  15. timing belt
  16.  
  17. negative battery cable
  18.  



Fill the cooling system.
 
Start the vehicle, check for leaks and repair if necessary.
 

2.0L (Fs) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Front exhaust pipe
     
    Air cleaner assembly
     
    Power steering pump with the lines attached and set aside, if necessary on Protégé models
     
    Accelerator cable
     
    Fuel hose
     
    Ignition coil
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt.
     
    Camshaft
     
    Intake manifold bracket
     

  10.  
  11. Temporarily install the Number 3 engine mount to support the engine, on 626 models.

    Cylinder head bolts by loosening them, in 2-3 steps, in the sequence illustrated
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.0L (FS) engines

     

  12.  

To install:

Click image to see an enlarged view

Fig. Replace any bolts that exceed the maximum length of 4.154 inch (105.5mm)-2.0L (FS)engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.0L (FS) engines

  1. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     

  2.  
  3. Apply clean engine oil to the bolt threads and seating faces.
  4.  
  5. Install new cylinder head bolts and torque in 2-3 steps, in sequence, to 13-16 ft. lbs. (17-22 Nm). If reusing old bolts, which is not recommended, ; make sure the maximum length of the bolt is 4.154 inch (105.5mm). The standard length of the bolt should be 4.103-4.125 inch (104.2-104.8mm).
  6.  
  7. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 85-95 degrees. Again, turn each bolt, in sequence, an additional 85-95 degrees.
  8.  
  9. Support the engine assembly with a suitable lifting device and remove the number 3 mount.
  10.  
  11. Install or connect the following:

    Intake manifold bracket
     
    Camshafts
     
    Camshaft pulley, make sure the camshaft sprocket pulleys are positioned with the pins facing up. Hold the camshaft pulley with a back-up wrench while tightening the pulley bolt to 37-44 ft. lbs. (50-60 Nm).

    Click image to see an enlarged view

    Fig. Make sure the camshaft sprocket pulleys are positioned with the pins facing up-2.0L (FS) engine

     
    Ignition coil
     
    Fuel hose
     
    Accelerator cable
     
    Power steering pump, if removed
     
    Air cleaner assembly
     
    Front exhaust pipe
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Change the oil and filter.
  16.  
  17. Run the engine and check for proper operation.
  18.  

2.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Splash shield, fresh air duct and air cleaner assembly

    Click image to see an enlarged view

    Fig. 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
     

  8.  
  9. Loosen the cover bolts in 5-6 steps, in the reverse order of the tightening sequence.
  10.  
  11. 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
     

  12.  
  13. 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.
  14.  
  15. Remove or disconnect the following:

    Cylinder head bolts by loosening them, in 2-3 steps, in sequence
     
    Cylinder head
     

  16.  
  17. 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).
  18.  

To install:

  1. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     

  2.  
  3. Apply clean engine oil to the bolt threads and seating faces.
  4.  
  5. Install new cylinder head bolts and torque in 2-3 steps, in sequence, to 13-16 ft. lbs. (17-22 Nm).
  6.  
  7. 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.
  8.  
  9. Apply clean engine oil to the hydraulic lifters and install them in their original positions. Be sure they move freely in the bores.
  10.  
  11. 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. Torque 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. Torque 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. Torque the through bolt to 45 ft. lbs. (61 Nm) and the lockbolt to 34 ft. lbs. (46 Nm)
     
    Power steering pump belt shield. Torque the bolts to 86 inch lbs. (9 Nm)
     
    Power steering hose brackets to the cylinder head cover. Torque the bolts to 88 inch lbs. (10 Nm)
     
    Coolant temperature sensor housing using a new gasket. Torque 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
     

  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Run the engine and check for proper operation.
  16.  

2.3L (Kj) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen (O 2 S) 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
     

  8.  
  9. 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.
  10.  
  11. 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.
  12.  
  13. 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.
  14.  
  15. Remove or disconnect the following:

    Camshafts and oil seals
     
    Lifters and adjustment shims
     

  16.  
  17. Identify and mark each lifter as it is removed so it can be reinstalled in the same position.
  18.  
  19. 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
     

  20.  
  21. Temporarily install the No. 3 engine mount, which was removed with the timing belt, to support the engine.
  22.  
  23. Remove or disconnect the following:

    Engine support device
     
    Cylinder head bolts, in 2-3 steps, in the sequence illustrated
     
    Cylinder heads
     
    Oil control plug O-rings
     

  24.  
  25. 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 inch (0.10mm).

    Click image to see an enlarged view

    Fig. Loosen the cylinder head bolts in this sequence using several passes-Millenia models equipped with the 2.3L (KJ) engine

  26.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-Millenia models equipped with the 2.3L (KJ) engine

  1. Apply clean engine oil to the O-rings, and install them onto the oil control plugs.
  2.  
  3. 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.
  4.  
  5. Install the cylinder heads.
  6.  
  7. Apply clean engine oil to the threads of new cylinder head bolts and install. Torque the bolts in 2-3 steps, in sequence, to 17-19 ft. lbs. (23-26 Nm).
  8.  
  9. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 85-95 degrees. Again, turn each bolt, in sequence, an additional 85-95 degrees.
  10.  
  11. Install the rubber insulator onto the left-hand cylinder head.
  12.  
  13. Fit the knock sensor harness into the drill hole on the cylinder block. Pass the harness under the rubber insulator.
  14.  
  15. Install or connect the following:

    Engine support device and remove the No. 3 engine mount
     
    Alternator bracket bolt. Torque the bolt to 12-16 ft. lbs. (16-22 Nm).
     
    Compressor bracket. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Water inlet pipe. Torque 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
     

  16.  
  17. Apply clean engine oil to the camshaft lobes, journals and supports.
  18.  
  19. Install or connect the following:

    Camshafts so the gear marks align
     
    Thrust caps. Torque the bolts, in 5-6 steps, until they are fully seated on the cylinder head
     

  20.  
  21. Apply silicone sealant, at a thickness of 0.06-0.09 inch (1.5-2.5mm), to the cylinder head surface in the area forward of the camshaft gear cavity.
  22.  
  23. Install or connect the following:

    Remaining camshaft caps in their original positions. Torque 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 inch (0-0.5mm). Tap in a new blind cap
     
    Camshaft sprockets. Torque the bolts to 91-103 ft. lbs. (123-140 Nm).
     

  24.  
  25. Measure and adjust the valve clearances.
  26.  
  27. Remove any sealant and gasket material from the cylinder head cover contact surfaces.
  28.  
  29. Apply silicone sealant to the cylinder head in the area adjacent to the front and rear camshaft caps.
  30.  
  31. Install or connect the following:

    Cylinder head cover using a new gasket. Torque 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. Torque 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. Torque the nuts to 28-38 ft. lbs. (38-51 Nm).
     
    O 2 S connectors
     
    Negative battery cable
     

  32.  
  33. Fill and bleed the coolant system.
  34.  
  35. Run the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head and related components-2.3L engine

  36.  

 
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