Cylinder Head Assembly: Service and Repair

Removal
1. Disconnect and remove battery.
2. Drain coolant and disconnect oxygen sensor connectors.
3. Remove front exhaust header pipe.
4. Remove intercooler if equipped, then remove turbocharger lower mounting screws.
5. Remove A/C compressor, without disconnecting freon lines.
6. Remove compressor mount and disconnect turbocharger lubrication feed pipe.
7. Remove access plug to hydraulic chain tensioner adjustment.

Fig. 12 Chain Tensioner Release:

8. Insert a screwdriver in plug hole (5), Fig. 12. Push in shaft (7) against its stop, then rotate right approximately 1/3 of a turn.
9. Remove radiator hoses, spark plug leads and distributor cap.
10. Loosen mounting clamps from manifold and remove hose from studs.
11. Pull manifold back from head and secure. Remove valve cover.

Fig. 13 Timing Alignment:

12. Position engine at top dead center (TDC) as follows:
a. TDC notch (3) on crankshaft pulley should be lined up with ``0'' notch (4) on timing chain housing. Fig. 13.
b. No. 4 cylinder should be ``firing'' with No. 1 cylinder rockers in rocking position.
13. At TDC position, camshaft pinion reference mark is in alignment with casting boss on cylinder head.
14. Remove distributor and upper timing chain housing.
15. Remove camshaft pinion mounting bolts.
16. Bring timing chain over camshaft pinion one row at a time to remove.
17. Chain may be turned all around crankshaft pinion as at it has no timing reference marks on it.
18. Install timing chain retaining straps No. J35-325 or equivalent.
19. Separate cylinder head from block. Remove head toward rear to clear camshaft from timing chain.
20. Remove cylinder head from vehicle.

Installation
Revere removal procedure to install, noting the following:

1. Install head gasket onto two guides with inscription ``DESSUS'' facing up.
2. Install new O-ring seal on turbocharger lubricating flange inlet.

Fig. 14 Cylinder Head Tightening Sequence:

3. Ensure TDC notch (3) on crankshaft pulley is in line with ``0'' notch (4) of timing chain housing. Fig. 13.
4. Ensure No. 1 cylinder valves are in rocking position.

Fig. 14 Cylinder Head Tightening Sequence:

5. Torque head bolts in sequence shown in Fig. 14, first to 36 ft. lbs., then in sequence to 62 ft. lbs.

Fig. 15 Timing Chain Tension Adjustment:

6. Adjust timing chain tension as follows;
a. Loosen upper bolt (7), Fig. 15.
b. Push pad (8) as far as possible against chain.
c. While maintaining pressure against pad (8), tighten bolt (7) to avoid having pad slip away and causing the eventual loosening of lower bolt (9).
7. Install turbocharger lower mount as follows:
a. Torque bolts, then screws to 4 ft. lbs.
b. Final torque in same order to 25 ft. lbs.
8. Fill and bleed cooling system.
9. Prime turbocharger's lubrications circuit as follows;
a. Disconnect connector from distributor and crack engine for 30 seconds.
10. After starting engine, wait 30 seconds before accelerating engine.
11. After first rise to engine operating temperature, with RPM stabilized at 3000, wait for 2 cycles of declutchable fan operation and cool down period of 6 hours. Retorque head bolts as follows:
a. Loosen bolt No. 1, Fig. 14, then torque to 62 ft. lbs.
b. Repeat procedure for remaining bolts, in sequence.