Cylinder Head Assembly: Service and Repair

Warning: Before servicing the fuel pump, fuel lines, fuel filter, throttle body or fuel injectors, the fuel system pressure must be released.

Notes: ^ Removal and installation of cylinder head requires separation of camshaft sprocket from camshaft.

^ In order to maintain camshaft, intermediate shaft and crankshaft timing, the timing belt should remain indexed on the camshaft sprocket while the assembly is suspended under light tension, Fig. 7.

^ When removing camshaft sprocket from camshaft, adequate tension on sprocket and belt assembly must be maintained to prevent the timing belt from disengaging from the intermediate or crankshaft timing sprockets. Failure to maintain adequate tension on timing belt may result in incorrect engine timing. Refer to ``Timing Belt, Sprockets & Oil Seals,'' for camshaft sprocket removal.

Removal

1. Release fuel system pressure.
2. Disconnect battery ground cable, then drain cooling system.
3. Remove air cleaner and disconnect all vacuum lines, electrical wiring and fuel lines from throttle body.
4. Disconnect throttle linkage.
5. On models with power steering, loosen power steering pump, then remove power steering belt.
6. Disconnect power brake vacuum hose from intake manifold.
7. Disconnect water hoses from water crossover.
8. Raise and support vehicle, then disconnect exhaust pipe from exhaust manifold.
9. Lower vehicle, remove power steering pump assembly and position aside.
10. Disconnect dipstick tube from thermostat housing, then rotate bracket from stud. Do not bend bracket.

Fig. 7 Accessory & Solid Mount Compressor Bracket:

11. Remove solid mount compressor bracket as shown, Fig. 7.
12. Remove cylinder head cover attaching bolts, then the cover.

Fig. 8 Cylinder Head Bolt Removal Sequence:

13. Remove cylinder head bolts in sequence shown in Fig. 8, then the cylinder head assembly.

Inspection

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

Fig. 9 Checking Cylinder Head Bolts:

Fig. 10 Cylinder Head Bolt Tightening Sequence. Except 1991-92 2.2L/4-135 Turbo III Engine (VIN A):

Installation

Notes: ^ Always use the specific head gasket for the engine's year and displacement since they are not interchangeable.

^ Ensure proper head bolts are used. This bolt can be identified by an ``11'' stamped on bolt head. These bolts are used on all engines. Do not intermix 10 and 11 mm head bolts, as stripping of threads or cracking of the block may result.

^ Inspect bolts to determine if they are stretched, Fig. 9. If all bolt threads are not straight on line, replace bolt.

1. Position cylinder head on block.
2. Refer to tightening sequence, Fig. 10, and tighten cylinder head bolts in 4 steps as follows:
a. Torque all bolts 45 lb-ft.
b. Torque all bolts to 65 lb-ft.
c. Torque all bolts again to 65 lb-ft.
d. Tighten each bolt an additional 1/4 turn (90°), noting bolt torque. If bolt torque is not over 90 lb-ft. after tightening an additional 1/4 turn, bolt should be replaced.
3. Reverse remaining removal procedure to complete installation, torquing all bolts to specifications.