Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable and drain cooling system.
2. Remove air cleaner and disconnect control cables from throttle lever and bracket.
3. Disconnect exhaust pipe from manifold.
4. Disconnect upper radiator hose and heater hoses as needed.
5. Disconnect spark plug wires.
6. Remove power steering pump mounting bolts and drive belt, then secure pump aside leaving hoses connected.
7. Mark and disconnect necessary electrical connectors and vacuum hoses, release harness clamps and secure harness aside to prevent damage.
8. Remove timing belt upper cover and rocker arm cover.

Fig. 5 Camshaft timing marks. 2000cc engine:

9. Rotate crankshaft in normal direction of rotation until No. 1 cylinder is at TDC and crankshaft and camshaft timing marks are aligned, Fig. 5.
10. Place chalk mark between timing belt and camshaft sprocket, remove camshaft sprocket bolt, separate sprocket from camshaft leaving belt in place on sprocket, then secure sprocket and belt on lower timing cover. Take care that sprocket does not disengage from belt and fall, and maintain tension on belt to maintain proper timing. Do not rotate crankshaft after sprocket is removed from camshaft.

Fig. 2 Cylinder head bolt loosening sequence. 1400cc, 1600cc & 2000cc engines:

11. Remove cylinder head attaching bolts in sequence shown in Fig. 2. Loosen bolts evenly, in three steps, to prevent cylinder head warpage, then remove cylinder head and gasket. Take care not to dislodge camshaft sprocket during cylinder head removal.
12. Reverse procedure to install, noting the following:
a. Do not apply sealer to cylinder head gasket. Ensure that proper I.D. mark is on gasket and install with mark towards cylinder head.
b. Prior to installing cylinder head on engine, ensure that crankshaft and camshaft timing marks are aligned.

Fig. 3 Cylinder head bolt tightening sequence. 1400cc, 1600cc & 2000cc engines:

c. When installing cylinder head, tighten bolts in sequence shown in Fig. 3. Tighten bolts in two steps to ensure proper seating of cylinder head to cylinder block.
d. After cylinder head has been installed, adjust timing belt tension and valve clearance as outlined.
e. When installing rocker cover, apply 3M sealant 8660 or equivalent to semicircular packing.