Cylinder Head Assembly: Service and Repair

REMOVAL

Fig. 20 Cylinder Head Removal (Part 1 Of 2).:

Fig. 20 Cylinder Head Removal (Part 2 Of 2).:

Remove cylinder head in numbered sequence, Fig. 20, noting the following:
1. Before disconnecting high pressure fuel line, 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 negative battery cable.
d. Reconnect fuel pump harness connector.
e. Cover fuel line connection with rags to prevent spraying of fuel during disconnection.
2. Before removing upper radiator hose, mark hose clamp in relation to hose for assembly reference, then drain coolant as follows:
a. Place instrument panel temperature control lever in Hot position.
b. Carefully remove radiator cap.
c. Remove radiator drain plug.
3. Refer to TIMING BELT when removing timing belt.

Fig. 21 Head Bolt Removal Sequence.:

4. Using cylinder head bolt wrench No. MD998051 or equivalent, remove cylinder head bolts in sequence as shown in Fig. 21.

INSTALLATION

Reverse removal procedure to install, noting the following:
1. Install cylinder head gasket as follows:
a. Using a suitable scraper, remove old gasket material from cylinder block, using care not to allow old gasket material to fall into cylinder or passages.
b. Clean head and block surfaces that come in contact with head gasket.
c. Place head gasket on block with identification mark at top front. Do not apply sealant to head gasket.

Fig. 22 Head Bolt Tightening Sequence.:

2. When installing cylinder head, install head bolt washers, then torque head bolts to 65-72 ft.lbs.(90-100 Nm) in two or three steps and in order as shown in Fig. 22.

Fig. 23 Installing Rocker Cover.:

3. When installing semi-circular packing, apply liberal amount of gasket sealant onto circumference of packing.
4. When installing rocker cover, apply gasket sealant to area as shown in Fig. 23.
5. Refer to TIMING BELT when installing timing belt.
6. When installing high pressure fuel line (5), apply small amount of gasoline to hose union. Use care to avoid damaging O-ring.