Cylinder Head Assembly: Service and Repair
REMOVAL1. Relieve fuel system pressure.
2. Remove air cleaner outlet tube.
3. Remove upper intake manifold and throttle body as an assembly.
4. Remove heater hose retaining screws to rocker cover.
5. Remove engine and alternator wiring harnesses, then spark plug wires and spark plugs.
6. Disconnect oxygen sensor electrical connector, then required vacuum hoses. Remove engine oil dipstick and bracket.
7. Remove EGR valve to exhaust manifold tube.
8. Remove rocker cover.
9. Proceed as follows:
a. Rotate drive belt tensioner, with a flex handle, counterclockwise and remove drive belt.
b. Recover refrigerant from A/C system, then disconnect A/C compressor electrical connections.
c. Remove A/C compressor bolts and compressor, then set aside without disconnecting hoses. Do not allow compressor hang by hoses.
d. Remove A/C compressor mounting bracket with power steering pump and set aside without disconnecting hoses.
e. Disconnect alternator electrical connections, then remove alternator bracket together with alternator.
10. Disconnect and remove upper radiator hose.
11. Remove timing belt cover.
12. Remove timing belt.
13. Proceed as follows:
a. Remove timing belt tensioner adjuster bolt, spring pivot bolt, timing belt tensioner spring, then tensioner.
b. Remove lower intake manifold.
14. Remove exhaust manifold bolts, then manifold.
15. Remove cylinder head bolts, then cylinder head.
16. Thoroughly clean all gasket surfaces, then blow oil out of cylinder block bolt holes.
17. Check cylinder head for flatness.
INSTALLATION
Fig. 7 Cylinder Head Bolt Tightening Sequence:
1. Position cylinder head gasket onto engine block, then the cylinder head.
CAUTION: Cylinder head must be installed with camshaft positioned as shown in Fig. 7, or valve damage may occur.
2. Torque cylinder head bolts in sequence to 51 ft lb, loosen all bolts, then tighten in sequence to 51 ft. lbs., then tighten all bolts an additional 90-100°. Install rocker cover and gasket.
5. Install intake manifold(s) and bolts.
6. Install timing belt tensioner and timing belt tensioner spring on cylinder head placing one leg of timing belt tensioner spring under stud on cylinder head and other leg against pin on timing belt tensioner, then install spring pivot bolt.
7. Install timing belt.
8. Proceed as follows:
a. Spring bolt must be tightened after timing belt is installed. Adjustment bolt is tightened as a part of timing belt installation.
b. Install outer timing belt cover.
9. Install alternator mounting bracket and alternator together.
10. Proceed as follows:
a. Install A/C compressor mounting bracket with attached power steering pump.
b. Install A/C compressor with attached hoses.
c. Install crankshaft pulley, tighten to 103-133 ft lb.
d. Install water pump pulley and fan clutch, then snug bolts. Position drive belt, then using a flex handle, rotate drive belt tensioner, position drive belt and rest tensioner pulley on drive belt.
e. Tighten fan clutch and pulley to water pump bolts to 12-18 ft lb.
f. Position fan shroud over fan clutch shaft, then install fan shroud and fan guard.
11. Install spark plugs, then oil level indicator tube.
12. Connect engine and alternator wiring, then install spark plug wires and vacuum hoses.
13. Install heater hose retaining screws to rocker cover.
14. Install upper intake manifold, then EGR valve to exhaust manifold.
15. Fill cooling system, then install air cleaner tube/outlet.
16. Connect battery cable, then recharge air conditioning system.
17. Start engine and check for leaks.