Cylinder Head Assembly: Service and Repair
1. Raise and secure hood.2. Relieve fuel pressure.
3. Disconnect battery ground cable.
4. Drain cooling system and disconnect heater hose at fitting located under intake manifold.
5. Remove air cleaner assembly.
6. Remove PCV hose from air cleaner assembly.
7. disconnect the following electrical connectors:
a. Fuel charging wiring (9D930) (RH strut tower)
b. Generator harness (back side of generator )GEN)(10346))
c. Crankshaft Position Sensor (CKP) sensor 6C315)
d. Heated Oxygen Sensor (H02SX9F472
e. Ignition coil (12029)
f. Noise filter condenser (18827) (mounted on the ignition coil mounting strap (12043)
g. Engine coolant Temperature Sensor (ECT sensor)(12A648), water temperature indicator sender unit (10884) (Located on the heater hot water tube (188402), by the water hose connection (8592).)
8. Remove upper radiator hose.
9. Remove the ground strap from the stud on the LH side of the cylinder head (6049).
10. Disconnect the LH heater hot water hose at the bulkhead..
11. Remove the upper radiator hose (8260).
12. WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. this pressure must be relieved before disconnecting any fuel lines or fuel system components.
- Relieve the fuel system pressure and disconnect the fuel supply and return lines. Service and Repair
13. Remove the oil level indicator tube retainer nut from the cylinder head stud.
14. Remove the power steering hose and the A/C line retainer bracket bolts from the generator bracket (1OA313).
15. Remove the drive belt (8620). Drive Belt
16. Remove the generator.
17. Remove the drive belt tensioner (68209).
18. Remove the Three Way Catalytic Converter (TWC)(5E212) from the exhaust manifold (9430). Service and Repair
19. Remove the starter motor wiring harness from the retaining clip below the intake manifold.
20. Remove the engine front cover (6019).
21. Loosen the timing chain / belt tensioner bolt (6K282) attaching bolt and pry the timing chain / belt tensioner (6K254) as far toward the rear of the vehicle as possible. Tighten the timing chain / belt tensioner bolt while it is in this position.
22. NOTE: Set the No.1 cylinder at TDC prior to removing the timing chain / belt (6268). Remove the timing chain / belt. Timing Belt
23. Remove the starter motor bolt (11A091) which retains the support bracket. Then, remove the heater hot water tube and hose assembly.
24. Remove the generator bracket-to-cylinder head mounting bolt.
25. Remove the valve cover.
26. NOTE: The cylinder head bolts may be used to check piston squish height before discarding.
- Remove and discard the cylinder head bolts.
27. CAUTION: Do not lay the cylinder head flat. Damage to the spark plugs (12405), exhaust valve (6505) and intake valve (6507) or gasket surfaces may result.
- Remove the cylinder head with the exhaust manifold and intake manifolds attached.
28. NOTE: The head gasket (6051) may be used to check squish height before discarding.
- Discard the head gasket.
Installation
1. CAUTION: Do not use abrasive grinding discs to remove gasket material.Use only manual scrapers. Take added care to prevent scratching or gouging aluminum sealing surfaces. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block (6010). Clean out the bolt holes in the cylinder block.
2. CAUTION: Before installing the cylinder head, check the piston squish height as outlined.
- Install the cylinder head to block dowels (6A008). Check the cylinder head to block dowel height chamber: 10.40mm [0.407 inch], total: 11.75mm [0.40inch]). When using replacement parts, a long cylinder head to block dowel may be encountered. A long cylinder head to block dowel will not allow the cylinder head to sit properly and should not be used.
3. Position the head gasket on the cylinder block.
4. Apply a light coating of engine oil to the threads of the new cylinder head bolts. Install the new cylinder head bolts to the cylinder head. Following the sequence shown below, tighten the cylinder head bolts to 40-60 N.m (29-44 lb-ft). Loosen all cylinder head bolts approximately two turns, then retighten the cylinder head bolts to 60 N.m (44 lb-ft) following the sequence shown. After tightening, turn all bolts 90 degrees, in the same sequence. Complete bolt tightening by turning them an additional 90 degrees, in the same sequence.
5. Install the valve cover.
6. Install the generator bracket-to-cylinder head bolt.
7. 8e sure that cylinder No.1 is at TDC.
8. Install the timing chain / belt. Timing Components
9. Install the starter motor wiring harness on the retaining clip below the intake manifold.
10. Install the three way catalytic converter (TWC). Service and Repair
11. Install the generator.
12. Install the drive belt. Drive Belt
13. Install the drive belt tensioner. Drive Belt Tensioner
14. Install both the power steering hose and A/C line retainer bracket bolts.
15. Install the oil level indicator tube retainer nut.
16. Connect the fuel supply and return lines. Service and Repair
17. Install the upper radiator hose.
18. Connect the heater hot water tube and hose assembly to their proper locations on the vent valve cover gasket (9592) and at the bulkhead.
19. Install the heater hot water tube support bracket retaining bolt.
20. Install the accelerator cable and throttle valve control actuating cable (4EAT) on the throttle control lever.
21. Install the ground strap at the LH side of the cylinder head.
22. Connect the following electrical connectors:
a. ECT sensor and water temperature indicator sender unit.
b. Ignition coil to distributor high tension wiring (12298)
c. Noise filter condenser
d. Ignition coil
e. H02S
f. Generator harness
g. CKP sensor
h. Fuel charging wiring
23. Install the vacuum booster hose to the intake manifold.
24. Install the crankcase ventilation tube (6758) and vacuum hose at the throttle body.
25. Install the air cleaner intake tube.
26. Connect the battery ground cable.
27. Fill and bleed the cooling system.
28. Start the engine (6007) and check for vacuum, coolant, fuel and oil leaks.