Cylinder Head Assembly: Service and Repair

1. Release residual fuel pressure as follows:
a. Start engine, then disconnect electrical connector from fuel pump.
b. When engine stops from lack of fuel, turn off ignition. Failure to release pressure prior to disconnecting fuel lines may cause fire or personal injury.
2. Disconnect battery ground cable and drain crankcase and cooling system.
3. On models with A/C, loosen compressor drive belt tensioner and remove drive belt.
4. On all models, remove master cylinder and turbocharger heat shields and disconnect oxygen sensor lead from harness connector.
5. Remove air cleaner assembly.
6. On models with intercooler, proceed as follows:
a. Disconnect intercooler hoses from turbocharger and air inlet tube.
b. Disconnect boost sensor hose.
c. Disconnect electrical connector from air intake temperature sensor on air intake tube.
7. On all models, disconnect upper radiator hose and remove air intake tube.
8. Remove secondary air cleaner, then disconnect PCV hose.
9. Disconnect control cables from throttle lever and brackets.
10. Remove bolt securing boost sensor tube.
11. Remove rocker arm cover, gasket and semi-circular packing.

Fig. 6 Camshaft sprocket & timing chain timing mark alignment. 2600cc engines:

12. Rotate crankshaft clockwise until No. 1 cylinder is at TDC on compression stroke and camshaft sprocket timing mark and plated link on timing chain are aligned as shown in Fig. 6.
13. Remove distributor cap and spark plug wires, mark position of distributor rotor and installation position of distributor, then remove distributor. Do not rotate crankshaft with distributor removed.
14. Disconnect fuel hoses, water hoses and brake booster hose.
15. Mark and disconnect necessary electrical connectors and vacuum hoses, release harness clips and secure harness aside to prevent damage.
16. Remove dipstick tube and O-ring seal, and plug opening.
17. Disconnect and plug turbocharger oil lines.
18. Disconnect water hoses from turbocharger, if equipped, and disconnect exhaust pipe.
19. Remove camshaft sprocket bolt and distributor drive gear.
20. Separate camshaft sprocket leaving timing chain on sprocket, then seat sprocket and chain assembly on sprocket holder inside timing cover. Maintain tension on chain and do not allow chain to come off sprocket. Do not rotate crankshaft with camshaft sprocket removed.

Fig. 7 Cylinder head bolt loosening sequence. 2600cc engines (Typical):

21. Remove cylinder head attaching bolts in sequence shown in Fig. 7. Loosen bolts evenly, in three steps, to prevent cylinder head warpage, then remove cylinder head and gasket. Take care not to dislodge camshaft sprocket during cylinder head removal.
22. Reverse procedure to install, noting the following:
a. Do not apply sealer to cylinder head gasket. Apply a thin bead of sealer at joint between timing cover and cylinder block. Ensure that proper I.D. mark is on gasket and install with mark at front of engine and facing up.
b. Prior to installing cylinder head on engine, ensure that crankshaft and camshaft timing marks are aligned.

Fig. 8 Cylinder head bolt tightening sequence. 2600cc engines (Typical):

c. Tighten cylinder head bolts in sequence shown in Fig. 8. Tighten bolts in two steps to ensure proper seating of cylinder head to cylinder block.

Fig. 6 Camshaft sprocket & timing chain timing mark alignment. 2600cc engines:

d. Install sprocket and chain on camshaft, then the distributor drive gear and sprocket bolt, and torque bolt to 37-43 ft. lbs. Ensure that timing marks are aligned, Fig. 6.
e. Install distributor, aligning matching marks made during disassembly.
f. When installing rocker cover, apply 3M sealant 8660 or equivalent to semi-circular packing.