Cylinder Head Assembly: Service and Repair

REMOVAL

Fig. 9 Cylinder Head Bolt Loosening Sequence:

1. On models with fuel injection, relieve fuel pressure as follows:
a. With engine running, disconnect fuel pump connector.
b. Allow engine to deplete fuel supply, then turn ignition Off. Failure to release pressure prior to disconnecting fuel lines may cause fire or personal injury.
2. On all models, disconnect battery ground cable, then drain cooling system.
3. Remove air cleaner, if necessary, then disconnect control cables from throttle lever and bracket.
4. On models with fuel injection, disconnect fuel high pressure hose. Cover fuel pipe line with a shop towel. Some residual fuel pressure may be present.
5. On all models, disconnect exhaust pipe from manifold.
6. Disconnect upper radiator hose and heater hoses as needed.
7. Disconnect spark plug wires.
8. Remove power steering pump attaching bolts and drive belt, then position pump aside.
9. Mark and disconnect necessary electrical connectors and vacuum hoses, release harness clamps, then position harness aside to prevent damage.
10. Remove engine mounting bracket, if applicable.
11. Remove timing belt upper cover, then the rocker arm cover.
12. Rotate crankshaft in normal direction of rotation until No. 1 cylinder is at top dead center and camshaft and crankshaft timing marks are aligned.
13. Place a chalk mark between timing belt and camshaft sprocket, then remove camshaft sprocket bolt, separate sprocket from camshaft, leaving belt in place on sprocket. Secure sprocket and belt on lower timing cover. Ensure sprocket does not disengage from belt and fall, and maintain tension on belt to maintain proper timing. Do not rotate crankshaft after sprocket is removed from camshaft.
14. Remove cylinder head attaching bolts in sequence shown, Fig. 9. Loosen bolts evenly in three steps, to prevent cylinder head warpage, then remove cylinder head and gasket. Take care not to dislodge camshaft sprocket during cylinder head removal.

INSPECTION

Check cylinder head gasket surface for squareness, using a suitable straightedge and feeler gauge. Place a straightedge across cylinder head, then check for warpage with feeler gauge. If clearance exceeds .008 inch in any direction, replace or lightly machine cylinder head. If machining, do not remove more than .008 inch from gasket surface.

INSTALLATION

Fig. 10 Cylinder Head Gasket Identification Mark:

Fig. 11 Cylinder Head Bolt Tightening Sequence:

1. Reverse disassembly procedure to assemble and note the following:
a. Clean both cylinder head and cylinder block gasket surfaces.
b. Install gasket with identification mark toward cylinder head, Fig. 10.
c. Install cylinder head bolts and tighten in sequence, Fig. 11.
d. Install intake and exhaust manifolds and gaskets. Tighten bolts to specifications.