Cylinder Head Assembly: Service and Repair

DISASSEMBLE

1. Disconnect battery ground cable, then drain cooling system.
2. Remove air cleaner, then 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 attaching bolts and drive belt, then position pump aside.
7. Mark and disconnect necessary electrical connectors and vacuum hoses, release harness clamps, then position harness aside to prevent damage.
8. Remove timing belt upper cover, then the rocker arm cover.
9. Rotate crankshaft in normal direction of rotation until No. 1 cylinder is at top dead center and camshaft and crankshaft timing marks are aligned.
10. Place a chalk mark between timing belt and camshaft sprocket, then remove camshaft sprocket bolt, separate sprocket from camshaft, leaving belt in place on sprocket. Secure sprocket and belt on lower timing cover. Ensure 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. 6 Cylinder Head Bolt Loosening Sequence:

11. Remove cylinder head attaching bolts in sequence shown, Fig. 6. 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.

INSPECTION

Check cylinder head gasket surface for squareness, using a suitable straightedge and feeler gauge. Place a straightedge across cylinder head, then check for warpage with feeler gauge. If clearance exceeds .004 inch in any direction, replace or lightly machine cylinder head. If machining, do not remove more than .008 inch from gasket surface.

ASSEMBLE

1. Reverse disassembly procedure to assemble and note the following:
a. Clean both cylinder head and cylinder block gasket surfaces.
b. Install gasket with identification mark toward cylinder head.

Fig. 7 Cylinder Head Bolt Tightening Sequence:

c. Install cylinder head bolts and tighten in sequence, Fig. 7.
d. Install intake and exhaust manifolds and gaskets. Tighten bolts to specifications.