Cylinder Head Assembly: Service and Repair

1. Relieve fuel system pressure as follows:
a. Remove fuel pump fuse from fuse panel.
b. Start engine. After engine stalls, crank for ten seconds to relieve residual pressure from fuel system.
c. Turn ignition off and install fuel pump fuse.
2. Disconnect battery ground cable.
3. Remove air cleaner assembly, then drain cooling system.
4. Unfasten alternator and position aside.
5. Remove distributor and ignition wires.
6. Disconnect cables from intake manifold bracket and throttle body.
7. Disconnect fuel inlet and return lines, then the coolant and heater hoses from intake manifold and water outlet.
8. Disconnect exhaust pipe from manifold, then disconnect oxygen sensor electrical connector.
9. Disconnect engine wiring harness and the thermostat housing electrical connector.
10. Remove timing belt as described under ``Timing Belt, Replace.''

Fig. 4 Cylinder head bolt loosening sequence:

11. Loosen cylinder head attaching bolts gradually in sequence, Fig. 4, until all bolts are removed.

Fig. 5 Compressing valve springs:

12. Remove valve cover, then compress valve springs using a suitable tool, Fig. 5, and remove rocker arms and valve lash compensators. Identify components for installation reference.

Fig. 6 Cylinder head bolt tightening sequence:

13. Remove cylinder head as an assembly with intake and exhaust manifolds.
14. Reverse procedure to install, noting the following:
a. Clean all cylinder head, valve cover and block mating surfaces.
b. Apply a continuous bead (3 mm) of anerobic sealant to cam carrier sealing surface.
c. Install new cylinder head gasket.
d. Torque cylinder head attaching bolts in sequence, Fig. 6, in four steps; first torque to 18 ft.lbs, then tighten an additional 150° in three steps of 60, 60 and 30° each.
e. Following completion of installation, run engine until normal operating temperature is reached, then tighten all cylinder head bolts an additional 30-50° in sequence.