Removal and Installation

Cylinder Head And Valve Assembly:

Removal
1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect battery negative cable from auxiliary jumper terminal.
3. Drain cooling system.
4. Remove air cleaner inlet duct and air cleaner upper housing, disconnect all vacuum lines, electrical wiring and fuel lines from throttle body.
5. Remove throttle linkage.
6. Remove accessory drive belts.
7. Remove popover brake vacuum hose from intake manifold.
8. Raise vehicle and remove exhaust pipe from manifold.
9. Remove power steering fluid reservoir 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.

Checking Cylinder Head Flatness:

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

Installation
Examining Cylinder Head Bolts

Checking Bolts For Stretching (Necking):

NOTE: The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced.

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.

Cylinder Head Tightening Sequence:

1. Before installing the cylinder head bolts, the threads should be oiled with engine oil. The 4 short bolts 110 mm (4.330 inch) are to be installed in positions 7, 8, 9, and 10.
2. Tighten the cylinder head bolts in the sequence. 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.

Rocker Arm Tightening Sequence:

3. Install rocker shaft assemblies in correct order as removed. Tighten rocker arm shaft bolts in sequence shown in illustration to 28 Nm (250 inch lbs.).
4. Install inner timing belt cover and camshaft sprocket.
5. Install timing belt.
6. Install intake manifold..
7. Connect electrical connectors to cam sensor and fuel injectors.
8. Install cylinder head cover and tighten fasteners to 12 Nm (105 inch lbs.).
9. Install power steering reservoir.
10. Install ignition coil pack and tighten fasteners to 23 Nm (200 inch lbs.). Connect coil pack wiring connector.
11. Connect power brake booster vacuum hose to intake manifold.
12. Connect throttle linkage to throttle body.
13. Connect all vacuum lines and electrical wiring connectors.
14. Install air cleaner inlet duct and upper air cleaner housing.
15. Raise vehicle on hoist and connect exhaust system to exhaust manifold.
16. Lower vehicle and connect negative cable to auxiliary battery terminal
17. With the DRB scan tool use ASD Fuel System Test to pressurize fuel system. Check for fuel leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.