Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable.
2. Relieve fuel system pressure as follows:
a. Disconnect fuel pump harness connector at fuel tank.
b. Start engine and let it run until it stalls, then turn ignition switch to off.
c. Disconnect battery ground cable.
d. Reconnect fuel pump harness connector.

3. Drain engine coolant, then drain crankcase.
4. Disconnect electrical connectors from A/C compressor clutch, power steering pump switch, oxygen sensor, engine coolant temperature switch and sensor, MAP sensor and intake air temperature sensor.
5. Disconnect accelerator cable.
6. Disconnect TPS, IAC motor and injector harness electrical connectors.
7. Disconnect ignition coil, camshaft position sensor and EGR solenoid electrical connectors.
8. Disconnect heater hose, upper radiator hose, overflow tube and water hose connection.

NOTE: Mark relationship between radiator hose and clamp for installation reference.

9. Disconnect fuel high pressure and return hoses.
10. Disconnect purge air hose.
11. Disconnect power brake booster vacuum hose connection.
12. Remove intake manifold stay.
13. Remove intake and exhaust camshafts as described under Engine/Camshaft, Engine/Service and Repair/Camshaft Replacement.
14. Disconnect exhaust pipe from exhaust manifold.
15. Remove cylinder head attaching bolts, then remove cylinder head and gasket. After cylinder head removal, remove intake and exhaust manifold as necessary.

Fig. 28 Cylinder Head Bolt Tightening Sequence:

16. Reverse procedure to install, noting the following:
a. Prior to installation, inspect cylinder head bolts for stretching by placing a straightedge against bolt threads. If all threads do not contact straightedge, replace bolt.
b. Clean bolt threads and lubricate with clean engine oil.

Without Multi Layer Steel Head Gasket

c. Tighten cylinder head bolts in sequence shown in Fig.28.
^ Torque bolts 1 through 6 to 25 ft.-lbs., and bolts 7 through 10 to 20 ft.-lbs.
^ Next, torque bolts 1 through 6 to 50 ft.-lbs. and bolts 7 through 10 to 20 ft.lbs.
^ Again, torque bolts 1 through 6 to 50 ft.-lbs., then bolts 7 through 10 to 20 ft.-lbs.
^ Finally, tighten all bolts an additional 90°.

With Multi Layer Steel Head Gasket

Note: The four short bolts are placed in the corners.

Step 1
Torque all center bolts to 34 Nm (25 Ft Lbs), Torque the 4 corner bolt to 27 Nm (20 Ft Lbs)
Step 2
Torque all center bolts to 68 Nm (50 Ft Lbs), Torque the four corner bolts to 47 Nm (35 Ft Lbs),
Step 3
Re-torque all center bolts to 68 Nm (50 Ft Lbs), Re-torque the 4 corner bolts to 47 Nm (35 Ft Lbs).
Step 4
Tighten all bolts in the Specified sequence an additional 90° (1/4 turn).

d. When installing radiator hoses, align marks on clamps and respective hoses

CAUTION: When the following parts are replaced with new ones, be sure to use the scan tool to synchronize the camshaft position sensor with the crankshaft position sensor again or disconnect the negative battery cable for 10 seconds or more:
- Camshaft
- Camshaft Sprocket
- Timing Belt
- Tensioner
- Cylinder Head
- Head Gasket
- Crankshaft Sprocket
- Crankshaft
- Cylinder Block, etc.