Replacing d16a1 head gasket.

From RPRWiki

This is in order of what you need to do first to last. This is for a brown top d16a1 but the black top may be simular. I think it is easyer to keep the intake maifold on but it is up to you. Put the number 1 cylinder at top dead center (TDC) Drain oil, water, remove every thing that will get in your way, including battery, air intake tubing, vaccume lines conected to the Intake maifold, throtal cable, clutch cable, and other miss items... be sure to lable all the hoses with a sharpe marker and masking tape. Complete check list of things to disconect: battery ground cable relive fuel pressure and disconect fuel lines and engine harness. remove: air intake duct and vacum hose fuel lines brake booster vacuum tube throttle cable ignition wires distributor assembly vacuum lines form charcoal canister #1 control box emission hoses engine sub-harness connectors and couplers oxygen sensor connector upper radiator hose, heater inlet hose and bypass inlet hose remove coolant hose between thermostat housing and intake manifold remove exhust manifold remove intake manifold remove hose between intake manifold and breather chamber remove valve cover and upper timing belt cover Loosen timing belt tension bolt and remove the belt from the cam gear remove timing belt lower cover attaching bolts from cylinder head remove the camshaft holders, camshaft,and rocker arms (lable all the arms). Removing the head... turn each of the 10 bolts, 1/3 at a time taking turns on each bolt untill they can be finger loosened. Once all the head bolts are off, remove the head, remove old head gasket... if you have to scrape it only use copper or a softer metal. Clean the cylinder head and block mating surfaces before reinstall Be sure the UP mark is positioned on top when installing the cylinder head Replace new head gasket... be sure the dowel pin and oil control jet are properly alinged with cutouts in the new gasket Place the head in to place, apply clean engine oil to cylinder head attaching bolts and washers To tighten the head bolts use this pattern... [ <--distributor / intake side ] 8 6 2 4 10 9 3 1 5 7 [ exhuast ] Torque cylinder head attaching bolts in two steps; first to 22 ft. lbs., then to 48 ft. lbs. in the above sequence starting with #1 Install the timing belt with cylinder #1 at TDC and aligne all the timing marks, the pointer on timing belt cover and the TDC mark painted white on the alt pully... and also the two marks on the cam gears Then reinstall all parts in reverse order, add oil and water. Once the engine is installed, turn the motor with a socket going in the counter clock ways, a few times to be sure the timeing is proper. Then start her up. Note that if the head or block was worped... they will need to be milled or decked. Good job! Thank you Bellingham Technical College!