Cylinder Head Assembly: Service and Repair

1. Scribe hood hinge locations and remove hood.
2. Disconnect battery cables and remove battery from engine compartment.
3. Drain engine coolant from radiator and block.
4. On models with turbocharger, proceed as follows:
a. Remove distributor and distributor heat shield.
b. Disconnect suction pipe, pressure pipe and oil supply pipe from turbocharger. Oil supply pipe must also be disconnected from engine block.
c. Disconnect solenoid at turbocharger and charging pressure regulator.
d. Disconnect turbocharger support bracket from transaxle.
e. Remove oil dipstick pipe.
f. Disconnect oil return pipe from turbocharger.
g. Disconnect exhaust pipe from turbocharger.
h. Remove nuts, spacer sleeves and washers from exhaust manifold.
i. Lower exhaust manifold until clear of studs, then remove exhaust manifold and turbocharger unit as an assembly.
5. On models without turbocharger, disconnect exhaust pipe from exhaust manifold, then remove exhaust manifold.
6. On all models, remove tensioner pulley and compressor drive belt.
7. Remove power steering pump drive belt and position pump aside.
8. Unfasten wiring harness clips from cylinder head.
9. Remove two engine front cover-to-cylinder head attaching bolts.
10. Remove right side engine mount-to-cylinder head bolts and spacers.
11. Disconnect hose between thermostat housing and radiator at the thermostat housing end.
12. Remove fuel pressure regulator, then disconnect ground wires for left hand system.
13. Remove A.I.C. actuator, then the A/C compressor bracket, if equipped, from cylinder head.
14. Remove intake manifold as an assembly with injection valves and fuel injection manifold.
15. Disconnect electrical connector from temperature sender.
16. Remove lid on valve cover and ignition cables together with distributor cap.
17. Remove valve cover. Disconnect crankcase ventilation hose and remove rubber plug halves from cylinder head.
18. Unfasten A/C compressor and position aside.
19. Align flywheel (0) mark with line on clutch cover and notches on camshaft with marks on bearing cap, then remove chain tensioner, camshaft sprockets and timing chain.
20. Raise engine to lift cylinder head off engine mounts, then remove cylinder head attaching bolts.
21. Install a guide pin in one of the bolt holes and remove cylinder head. Ensure the pivoting guide for timing chain is not damaged during removal.
22. Rotate crankshaft so that (0) mark on flywheel is aligned with timing mark on end plate.
23. Align notches on camshaft with marks on bearing cap.

Fig. 4 Cylinder Head Bolt Tightening Sequence:

24. Reverse procedure to install, noting the following:
a. On cylinder heads with 17 mm bolts, torque cylinder head bolts in sequence shown in Fig. 4, first to 44 ft. lbs., then to 70 ft. lbs. Warm engine to operating temperature, then allow engine to cool for 30 minutes and loosen all cylinder head bolts, then retorque bolts in sequence shown in Fig. 4, to 70 ft. lbs., then an additional 90°.
b. On cylinder heads with 15 mm or Torx bolts, Torque cylinder head bolts in sequence shown in Fig. 4, first to 44 ft. lbs., then to 59 ft. lbs., then an additional 90°.
c. Install two bolts on underside of head and torque to 14.5 ft lbs.
d. Install camshaft sprocket for exhaust valve camshaft first. Ensure chain between camshaft and crankshaft sprockets is tight, then install camshaft sprocket for inlet valve camshaft.
e. Adjust chain tension with camshaft sprocket center bolts not fully tightened. Tighten tensioner bolt, then release tensioner by pressing pivoting guide firmly against it. Depress pivoting guide to verify proper tensioner operation, then rotate engine two complete turns. Ensure crankshaft and camshafts are still properly aligned, then tighten sprocket bolts to specifications.