Removal and Installation

CYLINDER HEAD

Suspending Camshaft Sprocket:

Removal and installation of the cylinder head require separation of camshaft (timing) sprocket from camshaft. To maintain engine timing, the timing belt is left indexed on the sprocket while the assembly is suspended under light tension.

REMOVAL

1. Disconnect the negative cable from the battery.

2. Remove the cylinder head cover and oil vapor curtain.

3. Disconnect dipstick tube from thermostat housing and ROTATE bracket from stud. DO NOT bend the bracket.

4. Remove the solid mount compressor bracket.

Engine (Sprocket) Timing:

5. When removing sprocket from the camshaft, maintain adequate tension on the sprocket and belt assembly. Failure to maintain adequate tension on the camshaft, intermediate and crankshaft sprocket belt can result in lost engine timing.

Cam Cap Bolt Removal Sequence:

6. Remove cam cap bolts in sequence.

7. Lift the cylinder head off the cylinder block.

8. Remove the old gasket material from the head and the block.

INSPECTION

Checking Cylinder Head Flatness:

Check the cylinder head for flatness. Cylinder head must be flat within 0.10 mm (0.004 inch).

Inspect camshaft journals for scoring and journal caps for oversize markings. When servicing cylinder head or camshaft, it is necessary to be certain that oversized camshafts are used only in oversized heads.

- Cylinder Head: Top of bearing caps painted green and "O/SJ" stamped rearward of oil gallery plug on air pump end of head.
- Camshaft: Barrel of camshaft painted GREEN and "O/SJ" stamped on transmission end of shaft.

INSTALLATION

1. Position a new gasket on the cylinder block.


CAUTION: Head bolt diameter is 11 mm. These bolts are identified with "11" on the head of the bolt. 10 mm bolts will thread into the 11 mm hole but will strip the cylinder block bolt hole.

Cylinder Head Tightening Sequence:

2. Tighten the cylinder head bolts in sequence using the Torque Turn Method:

a. Tighten all bolts to 61 Nm (45 ft. lbs.) torque.

b. Tighten all bolts to 88 Nm (65 ft. lbs.) torque.

c. Tighten all bolts (again) to 88 Nm (65 ft. lbs.) torque.

d. Tighten all bolts 1/4 turn more.

Bolt torque after 1/4 turn should be over 122 Nm (90 ft. lbs.). If not, replace the bolt.

3. Install the solid mount compressor bracket.

4. Rotate dipstick tube on bracket. DO NOT bend the bracket.

6. Tighten bracket retaining nut to 23 Nm (17 ft. lbs.) torque.

6. Install the cylinder head cover and oil vapor curtain.

7. Connect the negative cable to the battery.