Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable.
2. Remove breather hose, then the air cleaner.
3. Remove radiator and water hoses, fuel lines, then the vacuum hoses.
4. Remove ignition cables, distributor, then the surge tank.
5. Remove intake manifold, heat cowl, then the exhaust manifold assembly.
6. Remove timing belt cover, then move belt tensioner pulley toward water pump and secure.
7. Remove timing belt front camshaft sprocket. Do not remove timing belt from crankshaft sprocket.
8. Remove rocker cover.

Fig. 5 Cylinder Head Bolt Loosening Sequence:

9. Remove cylinder head bolts using tool No. 09221-11001, or equivalent, as shown, Fig. 5. Loosen bolts evenly, in three steps to prevent cylinder head warpage.
10. Remove cylinder head and gasket. Ensure no gasket pieces fall into engine.
11. Reverse procedure to install, noting following:
a. Do not apply sealer to cylinder head gasket. Install gasket with ID mark toward timing belt.
b. Prior to installing cylinder head on engine, ensure crankshaft and camshaft timing marks are aligned.

Fig. 6 Cylinder Head Bolt Tightening Sequence:

c. Tighten cylinder head bolts to specifications in sequence shown in, Fig. 6. Tighten bolts in two steps to ensure proper seating of cylinder head to cylinder block.
d. Tighten intake and exhaust manifold nuts and bolts to specification.
e. After cylinder head has been installed, adjust timing belt tension.
f. Tighten rocker cover bolts to specification.