Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable.
2. Remove under cover, then drain engine coolant and engine oil.
3. Disconnect air cleaner to throttle body hose, then remove air cleaner assembly.
4. Disconnect cruise control cable, if equipped, then the accelerator cable and connecting rod.
5. Remove accelerator link and speedometer cable clamp.
6. Mark and disconnect all necessary vacuum hoses.
7. Disconnect heater hose from cylinder head rear cover, then the radiator hose from water filler.
8. Remove PCV hose from cylinder head, then the EGR valve with pipes.
9. Disconnect cold start injector electrical connector, then remove two injector pipe attaching bolts and injector pipe.
10. Remove pulsation damper and pressure regulator assembly.
11. Disconnect coil wire and spark plug wires from cylinder head, then remove distributor attaching bolts and distributor.
12. Mark and disconnect all necessary electrical connectors.
13. Disconnect water bypass hoses from auxiliary air valve, then remove vacuum pipe and cylinder head rear cover.
14. Remove front exhaust pipe, then the exhaust manifold insulator and exhaust manifold.
15. Remove delivery pipe and injectors as an assembly. Use caution not to drop injectors.
16. Remove intake manifold and intake air control valve, then the A/C drive belt, if equipped.
17. Remove cylinder head valve covers and gaskets, then the four spark plugs.
18. Disconnect water bypass hose, then remove three bolts, water outlet with the No. 1 bypass pipe, drive belt adjusting bar and gasket.
19. Turn crankshaft pulley and align groove with idler pulley bolt. Ensure all valve lifters on the No. 1 cylinder are loose. If not, turn crankshaft pulley one complete revolution.
20. Slightly raise engine using a suitable jack, then remove right engine mount through bolt.
21. Remove right engine mount attaching bolts, then the engine mount.
22. Remove water pump pulley attaching bolts, then the water pump pulley.
23. Remove A/C idler pulley, if equipped with A/C, then the No. 2 and No. 3 timing belt covers.
24. If timing belt is to be replaced, refer to ``Timing Belt, Replace'' for procedure. If timing belt is to be reused, proceed as follows:
a. Place alignment marks on the camshaft timing pulleys and belt.
b. Loosen idler pulley bolt, then push idler pulley as far left as possible and temporarily tighten it.
c. Remove timing belt from camshaft timing pulleys. Support timing belt so meshing of crankshaft timing pulley and timing belt does not shift.
d. Remove camshaft timing pulleys, then the No. 4 timing belt cover.
25. Remove right mounting bracket attaching bolts, then the mounting bracket.

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

26. Measure camshaft thrust clearance, Fig. 3. If clearance is greater than .0098 inch on 1985-86 models, or .0118 inch on except 1985-86 models, replace camshaft and/or cylinder head.

Fig. 33 Camshaft bearing cap bolt removal sequence. 4A-GE, 4A-GEC, 4A-GEL & 4A-GELC engines:

27. Loosen and remove camshaft bearing cap attaching bolts gradually in sequence shown in Fig. 33.
28. Remove camshaft bearing caps, oil seal and camshaft.

Fig. 34 Cylinder head bolt removal sequence. 4A-GE, 4A-GEC, 4A-GEL & 4A-GELC engines:

29. Loosen and remove cylinder head attaching bolts gradually in sequence shown in Fig. 34. Head warpage or cracking could result from removing cylinder head in incorrect order.
30. Reverse procedure to install. Torque cylinder head attaching bolts gradually in three steps in reverse sequence as disassembly, Fig. 33, to 44 ft. lbs. Torque bearing cap attaching bolts gradually in three steps in reverse sequence as disassembly, Fig. 34, to 9 ft. lbs.