Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable, then drain coolant from radiator and engine block.
2. Disconnect exhaust pipe from exhaust manifold.
3. On vehicles equipped with automatic transmission, remove throttle cable bracket from cylinder head cover.
4. On all models, remove accelerator and actuator cable bracket from cylinder head cover.
5. Disconnect all electrical connectors, emission control valve hoses, brake, cruise control actuator (if equipped), upper radiator hose and heater hoses from cylinder head. Disconnect fuel lines from cylinder head.
6. Remove air intake chamber bracket, bolts, vacuum line and ground strap.
7. Disconnect coil wire, then remove distributor from cylinder head.
8. Remove spark plugs, then disconnect cold start injector fuel hose from fuel line.
9. Remove air intake chamber attaching nuts and bolts, then the air intake chamber and gasket.
10. Disconnect EFI wire harness from ECU.
11. Remove pulsation damper and number 1 fuel line.
12. Remove water outlet housing attaching bolts, then the water outlet housing.
13. Remove intake manifold attaching bolts, then intake manifold and gasket.
14. Remove power steering drive belt, bolts, pulley and power steering pump.
15. Remove exhaust manifold attaching bolts, then the exhaust manifold.
16. Remove timing belt and camshaft sprockets. Refer to ``Timing Belt, Replace'' for procedure.
17. Remove two bolts and timing belt cover bracket. Remove three bolts, oil pressure regulator and gasket.
18. Remove bolts, nuts, number 2 timing belt cover and gasket.

Fig. 39 Cylinder head bolt removal sequence. 5M-GE engine:

19. Loosen and remove cylinder head bolts a little at a time in sequence shown in Fig. 39.
20. Remove cylinder head from engine block.

Fig. 40 Exhaust & intake side camshaft housing bolts removal sequence. 5M-GE engine:

21. Loosen and remove No. 1 and 2 camshaft housing bolts in sequence shown in Fig. 40. Remove camshaft housings from cylinder head.

Fig. 3 Measuring camshaft thrust clearance on overhead cam engine. Typical:

22. Using a dial indicator as shown in Fig. 3, measure camshaft thrust clearance. Camshaft standard thrust clearance should be .0020-.0098 inch with a maximum clearance of .0118 inch. If camshaft thrust clearance is not within specification, replace camshaft and or camshaft housings.
23. Remove camshafts from camshaft housings.

Fig. 41 Exhaust & intake side camshaft housing bolts tightening sequence. 5M-GE engine:

Fig. 42 Cylinder head bolt tightening sequence. 5M-GE engine:

24. Reverse procedure to install. Gradually tighten camshaft housing bolts in three steps and in sequence shown in Fig. 41. Torque camshaft housing bolts to 16 ft. lbs. Torque cylinder head bolts gradually in three steps in sequence shown in Fig. 42 to 58 ft. lbs. Torque number 2 timing belt cover bolts to 9 ft. lbs. Torque exhaust manifold bolts to 29 ft. lbs. Torque intake manifold bolts to 13 ft. lbs. Torque spark plugs to 12 ft. lbs.