Cylinder Head Assembly: Service and Repair

Special Tool(s)

Special Tool(s):

Removal

WARNING: FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN OR PERSONAL INJURY OR DAMAGE TO VEHICLE MAY OCCUR. A VALVE IS PROVIDED ON THE FUEL INJECTION SUPPLY MANIFOLD FOR THIS PURPOSE.

CAUTION: The fuel system is normally pressurized to 255-314 kPa (37-46 psi). The fuel pressure is 268.9-310 kPa (39-45 psi) with the pressure regulator hose disconnected.

1. Remove fuel pressure relief valve cap (9H323) from the fuel pressure relief valve (9H321).

2. With the tool fitting open, attach the Fuel Pressure Gauge T80L-9974-B to the fuel pressure relief valve, making sure the fitting is fully seated.

3. Open the valve on the side of gauge and drain fuel into an appropriate container until fuel pressure is fully relieved.

4. Disconnect the battery ground cable (14301).

5. Drain the cooling system.

6. Remove the air intake system.

7. Remove the power steering hose bracket bolts from the valve cover (6582).

8. Disconnect the power steering pressure (PSP) switch electrical connector.

9. Remove the two power steering pump drive belt idler pulley shield bolts.






10. Remove the accessory drive belts.

11. Remove the power steering pump through bolt and lock bolt and position the power steering pump (3A674) out of the way.

12. Remove the Exhaust Manifold (9431).

13. Carefully remove the Valve Cover.

14. Remove the Timing Chain/Belt (6268).

15. Raise the vehicle on a hoist. Refer to Section 00-02.

16. Remove the two intake manifold support bolts and remove the intake manifold support (9J444).






17. Lower the vehicle.

18. Disconnect the distributor electrical connector.

19. Disconnect the following electrical connectors from the water hose connection (8592):

Engine coolant temperature sensor (ECT sensor) (12A648)
Water temperature indicator sender unit (10884)






20. Remove the four water hose connection bolts and then remove the water hose connection from the cylinder head (6049) and discard the water hose connection gasket (8255).






21. CAUTION: Plug the front fuel tubes (9A318) once they have been removed from the fuel injection supply manifold (9F792) to prevent fuel leakage.

NOTE: Label the front fuel tubes during the removal procedure to ease installation.

Disconnect and position the front fuel tubes aside.

22. Disconnect and position aside all engine wiring connectors.

The following electrical connectors should be disconnected:

-Idle switch
-Throttle position sensor (TP sensor) (9B989)
-Idle air control valve (IAC valve) (9F715)
-Fuel charging wiring (9D930) (includes four fuel injector electrical connectors)
-EGR solenoid vacuum valve (9D474)
-Generator electrical connector

23. Disconnect the vacuum hose from the vacuum fitting on the RH side of the intake manifold (9424).






24. Disconnect the vacuum hose connecting the evaporative emissions canister (EVAP canister) (9D653) to the metal vacuum tube.

25. Disconnect the accelerator cable (9A758).

26. Disconnect the brake vacuum booster hose from the LH side of the intake manifold.






27. Remove the distributor (12127) .

28. Remove the Camshafts (6250). Refer to the procedure in this section.

29. Support the engine with a suitable tool and remove the three bar support.

30. Disconnect the water hose from the throttle body.

31. Disconnect the water hose from the air bypass.

32. Remove the cylinder head bolts in three steps, in the sequence shown.






33. Remove the cylinder head from the engine.

34. Remove and discard the head gasket (6051).

35. If necessary, remove the Intake Manifold.

Installation

1. If removed, install the Intake Manifold.

2. Be sure the cylinder head and the cylinder block gasket surfaces are clean.

3. Install a new head gasket.

4. Measure the length of each cylinder head bolt before reinstalling. If the cylinder head bolt length is longer than 105.5mm (4 inches) then replace the cylinder head bolt with a new one.






Install the cylinder head. Tighten the cylinder head bolts in two steps to 18-22 Nm (13-16 lb-ft) in the sequence shown.

5. After the initial tightening, apply a paint mark to the cylinder head bolts and turn the cylinder head bolts 90�5 degrees in the sequence shown. Turn all the cylinder head bolts another 90� 5 degrees in the sequence shown.










6. CAUTION: Ensure none of the camshaft lobes are located directly on the hydraulic lash adjusters (HLA) (6C501).

7. Install the Camshafts.

8. Install the camshaft sprocket holding tool T92C-6256-AH.

9. Install the distributor.

10. Connect the brake vacuum booster hose from the LH side of the intake manifold.

11. Connect the accelerator cable.

12. Connect the vacuum hose connecting the EVAP canister to the metal vacuum tube.

13. Connect the vacuum hose to the vacuum fitting on the RH side of the intake manifold.

14. Connect the following engine wiring connectors:

-Generator electrical connector
-EGR solenoid vacuum valves
-Fuel charging wiring (includes four fuel injector electrical connectors)
-IAC valve
-TP sensor
-Idle validation switch
-Connect the front fuel tubes to the fuel injection supply manifold.

15. Connect the distributor connector.

16. Install the three bar engine support.

17. Install the Timing Chain/Belt.

18. Raise the vehicle on the hoist.

19. Install the intake manifold support. Tighten the intake manifold support bolts to 38-51 Nm (28-38 lb-ft).

20. Lower the vehicle.

21. Install the Valve Cover.

22. Install the Exhaust Manifold.

23. Install and adjust the generator drive belt.

24. Loosely install the power steering pump through bolt.

25. Loosely install the power steering pump lock bolt.

26. Connect the PSP switch electrical connector.

27. Install and adjust the power steering drive belt. Refer to Section 03-05A for the procedures.

28. Tighten the power steering pump through bolt to 43-61 Nm (32-45 lb-ft).

29. Tighten the power steering pump lock bolt to 31-46 Nm (23-34 lb-ft).

30. Install the power steering pump drive belt idler pulley shield. Tighten the power steering pump drive belt idler pulley shield bolts to 7-9 Nm (61-86 lb-in).

31. Install the power steering hose brackets (3C510) to the valve cover. Tighten the power steering hose bracket bolts to 8-10 Nm (71-88 lb-in).

32. Clean the water hose gasket surface.

33. Position a new water hose connection gasket on the water hose connection and install the water hose connection.

34. Tighten the four water hose connection bolts to 19-25 Nm (14-18 lb-ft).

35. Connect the water hose to the air bypass.

36. Connect the water hose to the throttle body.

37. Connect the following items to the water hose connection:

-ECT sensor electrical connector
-Water temperature indicator sender unit electrical connector
-Install the air intake system.

38. Connect the battery ground cable.

39. Fill the cooling system and check for leaks.

40. Install the fuel pressure relief valve cap. Tighten the fuel pressure relief valve cap to 1 Nm (8 lb-in).

41. CAUTION: The fuel system is normally pressurized to 255-314 kPa (37-46 psi). The fuel pressure is 268.9-310 kPa (39-45 psi) with the vacuum line disconnected.

42. Turn the ignition switch (11572) ON/OFF several times without starting engine to check for fuel leaks.

Check all connections at the fuel injection supply manifolds (9D280), hose and tube fittings for leakage.