Cylinder Head Assembly: Service and Repair

Fig. 43 Cylinder Head Removal (Part 1 Of 2):

Fig 43:

Remove cylinder head in numbered sequence noting the following:
1. Relieve fuel pressure as follows:
a. With engine running, disconnect fuel pump connector.
b. Allow engine to deplete fuel supply, then turn ignition Off. Failure to release pressure prior to disconnecting fuel lines may cause fire or personal injury.
2. Disconnect battery ground cable.
3. Drain cooling system as follows:
a. Place heater control lever in Hot position.
b. Carefully remove radiator cap.
c. Remove radiator drain plug.
4. Prior to removing upper radiator hose, mark hose clamp in relation to hose for installation reference.
5. When disconnecting high pressure fuel hose, cover fuel pipe line with a shop towel. Some residual fuel pressure may be present.
6. Remove timing belt as follows:
a. Remove undercover.
b. Disconnect battery ground cable.
c. Remove clamp securing power steering pressure hose and air conditioner high pressure hose to body.
d. Using a wood block and a jack, place wood block on engine oil pan and raise engine only enough to relieve tension on top engine mount, then remove mount and bracket.
e. Remove engine drive belts. Prior to removing water pump drive belt, loosen water pump pulley bolts.
f. Remove tensioner pulley and bracket.
g. Remove crankshaft pulley and water pump pulley.
h. Remove upper and lower timing covers.
i. Remove center cover, spark plug wires, rocker cover, gasket and semicircular packing.

Fig. 13 Timing Mark Locations:

Fig. 14 Timing Belt Assembly (Part 1 Of 2):

Fig. 14 Timing Belt Assembly (Part 2 Of 2):

Fig. 40 Cylinder Head Bolt Loosening Sequence:

Fig. 41 Cylinder Head Gasket Identification Mark:

Fig. 42 Cylinder Head Bolt Tightening Sequence:

j. Rotate crankshaft clockwise to bring No. 1 cylinder to top dead center compression stroke. Rotate crankshaft only in clockwise direction. The No. 1 cylinder is at top dead center compression stroke when the timing marks on camshaft sprockets are aligned with upper surface of cylinder head and dowel pins on camshaft sprockets are facing up as shown, Fig. 13.
k. Remove auto tensioner, Fig. 14.
l. Remove timing belt. If timing belt is to be reused, mark timing belt indicating direction of rotation.
7. Using wrench tool No. MD998051 or equivalent, remove cylinder head attaching bolts in sequence as shown, Fig. 40. Loosen head bolts evenly, in two or three steps to prevent cylinder head warpage. When removing cylinder head use care not to disturb the camshaft sprockets. After removing cylinder head, clean gasket surfaces on head and block.
8. Remove intake and exhaust manifolds.
9. Reverse procedure to assemble noting the following:
a. Tighten exhaust manifold nuts to specifications.
b. Tighten intake manifold bolts to specifications.
c. Clean both cylinder head and cylinder block gasket surfaces.
d. Install gasket with identification mark toward cylinder head, Fig. 41.
e. Install cylinder head bolts and tighten in sequence, Fig. 42. Tighten cylinder head bolts to specifications. Fig.43. Ensure head bolt washers are correctly installed.
f. Ensure camshaft and crankshaft timing marks are correctly aligned.
g. Tighten auto tensioner bolt to specifications.
h. Tighten timing cover bolts to specifications.
i. Tighten tensioner pulley bolt to specifications.
j. Tighten crankshaft pulley bolts to specifications.
k. Tighten water pump pulley bolts to specifications.
l. Tighten top engine mount bolt to specifications.
m. Tighten top engine mount bracket bolts to specifications.
n. Tighten intake manifold support bolts to specifications.
o. Tighten engine center cover and rocker cover bolts to specifications.
p. When installing rocker cover, apply 3M sealant No. 8660 or equivalent to semi-circular packing.
q. When installing high pressure fuel line, apply a small amount of gasoline to hose union. Use caution not to damage O-ring.
r. Torque fuel return hose fitting bolts to 3-4 ft. lbs.