Cylinder Head Assembly: Service and Repair

NOTE: On models with coded audio anti-theft systems, refer to Technician Safety Information for code procedures.

1. On models with air bag system, disarm airbag system as outlined under Technician Safety Information.
2. Remove turbocharger.
3. Raise and support vehicle, then remove lower engine cover and drain coolant.
4. Remove drive belt and No. 2 exhaust pipe.
5. Remove exhaust manifold as follows:
a. Remove manifold heat insulator nuts and the insulator.
b. Disconnect two main heated oxygen sensor connectors.
c. Remove 12 exhaust manifold bolts.
6. Disconnect power steering pump and position aside.
7. Disconnect brake booster vacuum hose and EVAP hose.
8. Remove throttle body and intake air connector assembly.
9. Disconnect the following connectors:
a. Six injectors.
b. Two camshaft position sensors.
c. Three engine wire clamps from injector holders.
10. Remove starter.
11. Remove air intake chamber stays and No. 2 vacuum pipe and VSV assembly.
12. Remove No. 3 timing belt cover and the cylinder head rear cover.
13. Remove timing belt from camshaft timing pulleys.
14. Remove water bypass outlet and No. 1 water bypass pipe
15. Disconnect fuel return lines and plug hose end.
16. Remove engine wire bracket and oil dipstick guide for engine and transmission.
17. Remove air intake chamber and vacuum control valve set.
18. Remove bolt and disconnect engine wire bracket from water pump.
19. Remove water outlet and No. 1 bypass hose assembly.
20. Remove intake manifold stay.
21. Remove fuel pressure pulsation damper and fuel inlet pipe.
22. Remove intake manifold and delivery pipe assembly.
23. Remove ignition coils assemblies, spark plugs, then Nos. 1 and 2 cylinder head covers.
24. Remove camshaft timing pulleys, then the No. 4 timing belt cover.
25. Remove camshafts by uniformly loosening and removing bearing cap bolts in sequence shown, Fig. 1.

Fig. 1 Cylinder Head Bolt Loosening Sequence.:

26. Remove cylinder head by uniformly loosening and removing cylinder head bolts in sequence shown, Fig. 2.

Fig. 2 Cylinder Head Bolt Loosening Sequence.:

27. Reverse procedure to install, noting the following:
.a Check cylinder head for warpage on all contact surfaces. Maximum warpage allowed is 0.0039 inch.
b. Using sequence shown in Fig. 3, torque cylinder head bolts in three steps; first step to 25 ft. lb. second step an additional 90°, third step an additional 90°.

Fig. 3 Cylinder Head Bolt Tightening Sequence.:

c. Reset audio coded anti-theft system, if equipped, as outlined under Technician Safety Information.
d. On models with air bag system, rearm airbag system as outlined under Technician Safety Information.