Cylinder Head Assembly: Service and Repair

1. Mark position of hood to hood hinges for alignment during installation, then remove hood.
2. Disconnect battery ground cable, then isolate cable end with electrical tape or equivalent.
3. Drain radiator coolant, then remove air cleaner assembly.
4. Remove radiator fan lower cover from radiator.
5. Disconnect radiator hoses from engine, then coolant reserve hose from radiator.
6. Disconnect transmission cooling lines from radiator, then remove radiator.
7. Disconnect the accelerator cable from the throttle body assembly.
8. Mark position of all vacuum hoses, then disconnect vacuum hoses from the engine assembly.
9. Mark position of all engine electrical connectors, then disconnect from engine.
10. Disconnect spark plug wires from cylinder head covers, then three DIS electrical connectors.
11. Remove the three DIS module bracket retaining bolts, then DIS module with spark plug wires attached.
12. Remove four throttle body retaining bolts, then EGR assembly.
13. Remove the four bolts, four nuts and three bracket bolts retaining the common chamber duct.
14. Disconnect ground cable from the rear side of common chamber.
15. Disconnect coolant hose from throttle body.
16. Remove common chamber from engine assembly, then disconnect fuel supply and return hoses from fuel rail. Relieve fuel system pressure. When removing fuel lines, cover line to be removed with a shop towel to prevent personal injury due to high fuel system pressures that may still be present.
17. Remove intake manifold.
18. Disconnect heater hoses from coolant manifold, then remove four coolant manifold retaining bolts.
19. Remove coolant manifold.
20. Remove power steering drive belt, then air conditioning and alternator drive belts.
21. Remove power steering pump from engine, then position aside.
22. Using Crankshaft Holding tool No. J-8614-01 or equivalent, remove crankshaft pulley.
23. Remove two oil cooler bracket retaining bolts from the timing belt cover.
24. Remove timing belt cover.
25. Remove belt tensioner pusher cylinder. Do not allow air to enter the pusher oil chamber. To prevent air from entering the pusher, the inner rod must always be facing upward.
26. Remove timing belt, then cylinder head covers from engine assembly.
27. Disconnect ground cable from power steering bracket, then remove bracket from engine assembly.
28. Disconnect front exhaust pipe from manifolds.
29. Remove cylinder head from engine.

Fig. 13 Cylinder head bolt tightening sequence:

Fig. 14 Alignment of crankshaft timing mark:

Fig. 15 Timing belt installation & timing mark alignment locations:

30. Reverse procedure to install, noting the following:
a. Torque cylinder head M11 X 1.5 bolts in sequence shown in Fig. 13, to 47 ft. lbs.
b. Torque cylinder head M8 X 1.25 bolts in sequence shown in Fig. 13, to 15 ft. lbs.
c. Torque cylinder head cover to 69 inch lbs.
d. Install timing belt by aligning the groove of the crankshaft timing pulley with mark on oil pump as shown in Fig. 14.
e. Align mark on camshaft timing pulley with mark on front plate shown in Fig. 15.
f. For correct timing belt installation, the letters printed on the belt should be read as viewed from the front of the engine assembly.

Fig. 16 Belt tension pusher installation:

Fig. 17 Belt tension pusher clearance:

g. Install belt tension pusher as follows:
1. Press the pusher inner cylinder inward, then insert a 1.4 mm pin as shown in Fig. 16.
2. Push tensioner pulley against the belt, then install the pusher. Torque pusher retaining bolts to 16 ft. lbs.
3. Loosen adjusting bolt on tension pulley, rotate tension pulley counterclockwise with pliers to tension the belt, then torque adjusting bolt to 32 ft. lbs.
4. Pull the locking pin out of the pusher.
5. Install the crankshaft pulley temporarily, then tighten the center by hand. Do Not use a wrench at this time.
6. Rotate crankshaft clockwise two turns, ensure that the rod protrusion is within 0.16-0.24 inch as shown in Fig. 17.
7. If not within limits, remove pusher, loosen adjusting bolt and repeat procedure.
8. Remove crankshaft pulley previously installed.
h. Torque timing belt cover bolts to 13 ft. lbs.
i. Torque transmission cooling lines to 13 ft. lbs.
j. Torque crankshaft pulley to 123 ft. lbs.
k. Torque fan pulley to 16 ft. lbs.
l. Torque power steering pump to 41 ft. lbs.
m. Torque coolant manifold to 16 ft. lbs.
n. Torque intake manifold and common chamber retaining bolts to 17 ft. lbs.
o. Torque throttle valve assembly to 16 ft. lbs.