Removal and Installation

REMOVAL
1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect negative battery cable.
3. Drain cooling system.

Figure 39:

4. Remove air cleaner inlet duct and air cleaner (Fig. 39), disconnect all vacuum lines, electrical wiring and fuel lines from throttle body.
5. Remove throttle linkage.
6. Remove accessory drive belts. Refer to Drive Belts, Mounts, Brackets and Accessory for procedure.
7. Remove power brake vacuum hose from intake manifold.
8. Raise vehicle and remove exhaust pipe from manifold.
9. Remove power steering pump assembly and set aside.
10. Disconnect coil pack wiring connector and remove coil pack and bracket from engine.
11. Remove cylinder head cover.
12. Remove cam sensor and fuel injectors wiring connectors.
13. Remove intake manifold.
14. Remove timing belt and camshaft sprocket.
15. Remove rocker arm shaft assemblies.
16. Remove cylinder head bolts.

Figure 40:

NOTE: Inspect camshaft bearing journals for scoring. Cylinder head must be flat within 0.1 mm (0.004 inch) (Fig. 40).

INSTALLATION
Examining Cylinder Head Bolts

Figure 41:

NOTE: The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolt(s) should be replaced (Fig. 41).

Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt(s) should be replaced.

Cleaning Cylinder Head Sealing Surfaces

Figure 42:

CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper. Sealing surfaces could be cut or ground, resulting in gasket leaks. Use ONLY a wooden or plastic scraper (Fig. 42).

1. Clean the cylinder head and cylinder block sealing surfaces.
2. Position a new cylinder head gasket on the locating dowels.
3. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.

Figure 43:

4. Before installing cylinder head bolts, the threads should be oiled with engine oil. The 4 shorter bolts 164 mm (6.45 inch), are to be installed in positions 7, 8, 9, and 10 (Fig. 43).
5. Tighten the cylinder head bolts in the sequence shown. Using the 4 step torque method, tighten according to the following values:
^ First All to 34 Nm (25 ft. lbs.)
^ Second All to 68 Nm (50 ft. lbs.)
^ Third All to 68 Nm (50 ft. lbs.)
^ Fourth Turn an additional 1/4 Turn, Do not use a torque wrench for this step.
6. Install rocker arm shaft assemblies.
7. Install inner timing belt cover, camshaft sprocket, and timing belt.
8. Install intake manifold.
9. Install cam sensor and fuel injectors wiring connectors.
10. Install cylinder head cover.
11. Install coil pack and bracket. Connect coil pack wiring connector.
12. Install power steering pump assembly.
13. Install exhaust pipe to exhaust manifold.
14. Connect power brake vacuum hose to intake manifold.
15. Install accessory drive belts.
16. Install throttle linkage.
17. Connect all vacuum lines, electrical wiring and fuel lines to throttle body.
18. Install air cleaner inlet duct and air cleaner.
19. Fill cooling system. Refer to Cooling System for procedure.
20. Connect negative cable to battery.
21. Perform camshaft and crankshaft timing relearn procedure as follows:
- Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel; near the steering column.
- Turn the ignition switch on and access the "miscellaneous" screen.
- Select "re-learn cam/crank" option and follow directions on DRB screen.