Removal and Installation

Fig. 4 Cylinder Head Removal (Part 1 Of 2):

Fig. 4 Cylinder Head Removal (Part 2 Of 2):

Fig. 5 Engine Timing Marks:

Fig. 6 Securing Camshaft Sprocket:

Fig. 7 Cylinder Head Bolt Loosening Sequence:

REMOVAL

1. Release fuel system pressure as outlined under MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELEASE.
2. Disconnect battery ground cable.
3. Drain cooling system into an approved container.
4. Remove cylinder head and gasket in numbered sequence shown in Fig. 4, noting the following:
a. Rotate engine so No. 1 cylinder is at top dead center on the compression stroke and align camshaft timing mark, Fig. 5.
b. Tie camshaft sprocket and timing belt together so that position of camshaft sprocket will not move in respect to the timing belt, Fig. 6.
c. Remove camshaft sprocket as outlined under TIMING BELT ASSEMBLY.
d. Loosen cylinder head bolts in two or three steps in numbered sequence shown in Fig. 7. Use care not to damage plug guide, as plug guides cannot be replaced.
5. Inspect cylinder head gasket surface for flatness by using a straightedge.

INSTALLATION

Fig. 8 Cylinder Head Bolt Washer Installation Direction:

Fig. 9 Cylinder Head Bolt Tightening Sequence:

Fig. 10 Inlet Water Pipe Mounting Bolt Location:

Fig. 11 Thermostat Housing Sealant Location:

Reverse removal procedure to install, noting the following:
1. Clean cylinder gasket surface on both the cylinder head and engine block.
2. Place cylinder head gasket on cylinder block with identification mark facing upward on the intake side.
3. Measure cylinder head bolts and ensure bolts are less than 3.795 inches long.
4. Apply a small amount of oil to cylinder head bolt threads and to bolt washer. Ensure cylinder head bolt is installed as shown in Fig. 8.
5. Torque cylinder head bolts in numbered sequence shown in Fig. 9 in five steps as follows:
a. Torque bolts to 54 ft. lbs.
b. Completely loosen bolts.
c. Torque bolts to 14 ft. lbs.
d. Turn bolts 90° (1/4 turn).
e. Turn bolts an additional 90° (1/4 turn).
6. Loosen water inlet pipe bolt, apply sealant to thermostat case, Figs. 10 and 11.
7. Apply a small amount of water to O-ring of water inlet pipe and press the thermostat case assembly onto water inlet pipe.
8. Install thermostat case assembly mounting bolt, and tighten the water inlet pipe bolt.
9. Install thermostat so jiggle valve is at top.