Cylinder Head Assembly: Service and Repair

Fig. 4 Fuel Pressure Relief:

Do not remove cylinder head until temperature is below 100°F.
1. Disconnect battery ground cable.
2. Position No. 1 cylinder at TDC compression stroke, then drain coolant.
3. Relieve fuel pressure, then remove fuel filler cap. Place shop towel over area, then slowly loosen service bolt on fuel filter one turn at a time, Fig. 4.
4. Remove airflow tube and air cleaner.
5. Disconnect fuel feed hose and charcoal canister vacuum hose from intake manifold.
6. Disconnect throttle cable from throttle body.
7. On automatic transmission models, remove throttle control cable from throttle body.
8. Disconnect fuel return hose and brake booster vacuum hose.
9. Disconnect the following electrical connectors:
a. Fuel injectors.
b. TA sensor.
c. Throttle angle sensor.
d. Ground cable.
e. Thermo switch.
f. Coolant temperature sender gauge.
g. EACV and oxygen sensor.
h. TW sensor.
i. Temperature sender and oil pressure switch.
j. Spool valve connector.
10. Remove wire harness clamps from cylinder head.
11. Remove spark plug caps and distributor.
12. Disconnect distributor electrical connectors, then remove distributor.
13. Disconnect radiator upper hose and heater hose.
14. Disconnect engine ground cable from cylinder head cover.
15. Remove power steering belt and pump, leaving hoses connected.
16. Remove heat shield.
17. Remove intake manifold bracket.
18. Remove exhaust pipe to manifold attaching nuts, then disconnect front exhaust pipe from manifold.
19. Remove timing belt middle cover, then loosen adjusting bolt and release timing belt tension.
20. Remove belt from camshaft pulleys, then remove cam pulleys.
21. Loosen adjusting screw and camshaft holders, then remove camshafts and rocker arms.

Fig. 28 Cylinder Head Bolt Loosening Sequence.:

22. Remove cylinder head attaching bolts in sequence, Fig. 28. Remove bolts 1/3 a turn at a time to prevent warpage. Remove cylinder head.
23. Remove intake and exhaust manifold attaching bolts, then remove manifolds.

Fig. 29 Cylinder Head Bolt Tightening Sequence.:

Fig. 26 Timing Gear Marks:

24. Reverse procedure to install, noting the following:
a. Clean cylinder head and engine block mating surfaces prior to installation.
b. Ensure UP mark on timing belt pulley is positioned on top when installing cylinder head.
c. Install cylinder head using a new gasket, ensuring dowel pins and oil control jet are properly aligned with cutouts in gasket.
d. Apply clean engine oil to cylinder head attaching bolts and washers.
e. Torque cylinder head attaching bolts in two steps; first to 22 ft. lbs., then to 61 ft. lbs. in sequence, Fig. 29.
f. Install camshafts as described under CAMSHAFTS & ROCKER ARMS.
g. Install timing belt with cylinder No. 1 at TDC of compression stroke and timing marks aligned as shown in Fig. 26.
h. Torque intake manifold nuts to specifications using a crossing pattern in two or three steps.