Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable.
2. Drain cooling system, then remove cooling fan and shroud.
3. Relieve fuel system pressure.
4. Remove air inlet tube and wiper module.
5. Release belt tensioner, then remove accessory drive belt.
6. Disconnect ignition wires from spark plugs. Do not pull on ignition wire.
7. Disconnect ignition wire brackets from valve cover studs.
8. Remove bolt attaching A/C high pressure line to right coil bracket.
9. Disconnect both ignition coils and CID sensor.
10. Remove right and left coil bracket to front cover attaching nuts.
11. Slide ignition coil brackets and ignition wire assembly off mounting studs, then remove from vehicle.
12. Remove water pump pulley, then disconnect alternator wiring harness from junction block, fender apron and alternator.
13. Remove alternator and mounting bracket.
14. Disconnect positive battery cable at power distribution box, then remove attaching bolt from positive battery cable bracket located on right side of cylinder head.
15. Disconnect vent hose from canister purge solenoid, then place positive battery cable aside.
16. Disconnect canister purge solenoid vent hose from PCV valve, then remove PCV valve from valve cover.
17. Remove 42-pin engine harness connector from retaining bracket on brake vacuum booster, then disconnect and position aside.
18. Disconnect HDR sensor, A/C compressor clutch and canister purge solenoid electrical connectors.
19. Raise and support vehicle.
20. Remove bolts retaining power steering pump to engine block and cylinder front cover.

NOTE: Front lower bolt on power steering will not come all the way out.

21. Remove bolts attaching oil pan to front cover.
22. Remove crankshaft damper retaining bolt and washer from crankshaft.
23. Install crankshaft damper remover T58P-6316-D, or equivalent, on damper, then pull damper from crankshaft.
24. Disconnect EVO sensor and oil sending unit and position aside.
25. Disconnect EGR tube from right exhaust manifold.
26. Disconnect exhaust for right and left manifolds, then suspend with wire.
27. Remove bolt retaining starter wiring harness to rear of right cylinder head, then lower vehicle.
28. Remove right and left valve cover to cylinder head.
29. Disconnect accelerator and speed control cables.
30. Remove accelerator bracket from intake manifold and position aside.
31. Disconnect throttle valve cable from throttle body, then the vacuum hose from throttle body elbow port.
32. Disconnect both HEGO sensor and heater supply hose.
33. Remove thermostat housing, then disconnect upper hose and position aside.

Fig. 13 Front Cover Removal:

34. Remove bolts attaching intake manifold, then the intake manifold and gaskets.
35. Remove timing chain.
36. Remove bolts attaching left cylinder head.

LH Lower Rear Head Bolt Removal:

NOTE: The lower rear bolt cannot be removed due to interference with the brake vacuum booster. Use a rubber band or similar item to hold bolt away from engine.

37. Remove left cylinder head.
38. Remove ground strap retaining heater return line to right cylinder head.
39. Remove bolts retaining EVR sensor, then the sensor.
40. Remove bolts attaching right cylinder head.

Fig. 15 Righthand Lower Rear Head Bolt Removal:

NOTE: The lower rear bolt cannot be removed due to interference with the evaporator housing. Use a rubber band or similar item to hold bolt away from engine.

41. Remove right cylinder head.
42. Reverse procedure to install, noting the following:
a. Rotate crankshaft counterclockwise 45°. This ensures that all pistons are below top of engine block deck face.

Cylinder Head Bolt Tightening Sequence:

b. Using sequence shown, torque, cylinder head bolts in three steps. First step is to 27-32 ft lb. Second step, rotate bolts an additional 85-95°, third step, rotate bolts an additional 85-95°.
c. Rotate crankshaft clockwise 45°. This will position crankshaft at TDC No. 1.

CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as TDC.