Removal and Installation

Fig. 15 Suspending camshaft sprocket:

Removal and installation of cylinder head requires separation of camshaft sprocket from camshaft. In order to maintain camshaft, intermediate shaft and crankshaft timing, timing belt is left indexed on camshaft sprocket while assembly is suspended under light tension.

When removing camshaft sprocket from camshaft, adequate tension on sprocket and belt assembly must be maintained to prevent timing belt from disengaging from intermediate or crankshaft timing sprockets. Failure to maintain adequate tension on timing belt may result in incorrect engine timing.

REMOVAL

WORKING ABOVE ENGINE COMPARTMENT

1. Relieve fuel system pressure. Refer to MAINTENANCE PROCEDURES.
2. Disconnect battery ground cable, then drain cooling system.
3. Remove air cleaner and disconnect all vacuum lines and electrical wiring from throttle body.
4. Disconnect fuel lines from the fuel rail.
5. Disconnect throttle linkage.
6. Disconnect power brake vacuum hose from intake manifold.

WORKING BELOW VEHICLE

7. Raise and support vehicle, then disconnect exhaust pipe from turbo charger.
8. Remove turbocharger support bracket and turbocharger oil return tube.
9. Remove turbocharger coolent hose from fitting in block and remove coolent hose support bracket.

WORKING ABOVE ENGINE COMPARTMENT

10. Remove turbocharger oil supply hose at the fitting near the oil pressure sending unit.
11. Disconnect dipstick tube from thermostat housing, then rotate bracket from stud. Do not bend bracket. Disconnect coil wiring connector and coil wire.

Fig. 18 Alternator & A/C compressor mounting bracket removal:

12. Remove upper two air conditioner compressor bracket mounting bolts from the cylinder head (numbers 6 & 7).

Fig. 12 Timing belt cover removal:

13. Remove upper timing belt cover.
14. Rotate engine to number 1 TDC, then remove cam gear retaining bolt.
15. Mark position between cam gear and timing belt and secure timing belt to gear with tie-wraps.
16. Carefully slide cam gear from camshaft and suspend cam gear and timing belt.
17. Remove cylinder head cover attaching bolts, then the cover.

Fig. 19 Cylinder head bolt removal sequence:

18. Remove cylinder head bolts in sequence shown, then cylinder head assembly.

INSPECTION

1. Ensure cylinder head is flat within .004 inch (0.1 mm).
2. Inspect camshaft journals for scoring.

INSTALLATION

Head bolt diameter is either 10 mm or 11 mm. These bolts are not interchangeable. 11 mm bolts are identified by an 11 on the head of the bolt. 10 mm bolts have plain heads. 10 mm bolts will thread into the 11 mm hole, but will strip the cylinder block bolt hole. Follow the proper procedure according to the size head bolt used.

Fig. 20 Checking cylinder head bolts:

Inspect bolts as shown. Replace bolts if any sign of stretching is evident.

10 mm Bolts:

Fig. 21 Cylinder head bolt tightening sequence:

1. Position cylinder head on block.
2. Tighten cylinder head bolts in sequence using 4 steps as follows:
a. Torque all bolts 30 ft. lbs.
b. Torque all bolts to 45 ft. lbs.
c. Torque all bolts again to 45 ft. lbs.
d. Tighten each bolt an additional 1/4 turn (90°)
3. Reverse remaining removal procedure to complete installation. Tighten to specifications.

11 mm Bolts:

Fig. 21 Cylinder head bolt tightening sequence:

1. Position cylinder head on block.
2. Tighten cylinder head bolts in sequence using 4 steps as follows:
a. Torque all bolts 45 ft. lbs.
b. Torque all bolts to 65 ft. lbs.
c. Torque all bolts again to 65 ft. lbs.
d. Tighten each bolt an additional 1/4 turn (90°), noting bolt torque. If bolt torque is not over 90 ft. lbs. after tightening an additional 1/4 turn, bolt should be replaced.
3. Reverse remaining removal procedure to complete installation.