Cylinder Head Assembly: Service and Repair
1. Disconnect battery ground cable.
2. Remove under cover and drain coolant.
3. Remove fan shroud, alternator belt, cooling fan and water pump pulley.
4. Remove ten bolts securing upper dust cover, remove dust cover.
5. Remove bypass hose.
Fig. 2 Timing mark locations.:
Fig. 10 Timing mark location on damper pulley.:
Fig. 11 Injection pump pulley installation:
Fig. 12 Injection pump pulley installation:
Fig. 3 Fixing plate installation:
7. Remove cam cover and loosen valve adjustment screws so rocker arms are in a free state. Fix the camshaft by installing fixing plate, tool No. J-29761 into the slit in rear end of the camshaft, Fig. 13.
Fig. 14 Timing belt holder:
8. Remove crankshaft damper pulley, lower dust cover and timing belt holder, Fig. 14. Under no circumstances should the crankshaft be disturbed from TDC.
9. Remove tension pulley spring, then loosen tension pulley and plate bolts, remove timing belt.
10. Remove camshaft pulley bolt, using a suitable puller remove camshaft pulley.
Fig. 34 Rocker arm bracket bolt loosening sequence.:
Fig. 35 Rocker arm shaft bolts removal sequence.:
11. Using sequence shown in Fig. 34 and 35, remove rocker arm shaft bracket bolts and nuts, then remove rocker arm shaft and rocker arm assembly.
Fig. 39 Removing front head plate:
12. Remove bolts attaching front head plate and remove, Fig. 39.
13. Remove the camshaft bearing cap bolts, then remove bearing caps with cap side bearing.
14. Remove camshaft oil seal followed by the camshaft.
Fig. 1 Sensing resistor assembly:
15. Remove sensing resistor, Fig. 1.
Fig. 2 Fuel injection pipe sleeve nut:
16. Remove fuel injection clips and pipes, Fig. 2.
17. Remove fuel leak off hose clip, then remove hose.
18. Disconnect exhaust pipe from manifold.
19. Disconnect joint bolt attaching oil feed pipe to cylinder head.
20. Remove heater hose from thermostat housing.
Fig. 3 Cylinder head loosening sequence:
21. Remove ten cylinder head bolts in sequence shown in Fig. 3. Remove cylinder head and gasket.
Fig. 4 Cylinder head tightening sequence:
22. Clean all gasket surfaces thoroughly, install a new cylinder head gasket, install head, and tighten cylinder head bolts in sequence shown in Fig. 4.
23. Install heater hose onto thermostat housing.
24. Reconnect joint bolt attaching oil feed pipe to cylinder head.
25. Reconnect exhaust pipe to manifold.
26. Install fuel leak off hose, and then the clip.
27. Install fuel injection pipes and clips, Fig. 2.
28. Install sensing resistor, Fig. 1.
29. Install camshaft oil seal and camshaft.
30. Apply a generous amount of engine oil to the rocker arm shaft, rocker arms and valve stem end caps.
Fig. 36 Rocker arm bracket bolt tightening sequence.:
Fig. 37 Rocker arm shaft bolts installation sequence.:
31. Install rocker arm shaft assembly and tighten bolts in sequence as shown in Fig. 36 and 37.
32. Install camshaft pulley and bolt. Tighten bolt just enough to allow the pulley to be turned smoothly by hand.
Fig. 15 Timing belt installation sequence:
33. Install new timing belt using sequence shown in Fig. 15. Ensure that belt cogs are properly installed in pulleys. Do not disturb crankshaft setting.
Fig. 16 Semi-tightening sequence of tension pulley:
34. Concentrate belt looseness on tension pulley, depress tension pulley with finger and install tension spring. Semi-tighten bolts in numerical sequence 1 and 2 to prevent movement of tension pulley, Fig. 16.
35. Tighten camshaft pulley bolt.
36. Remove injection pump pulley lock bolt and camshaft fixing plate.
37. Install crankshaft damper pulley, ensure No. 1 cylinder is at TDC.
38. Ensure injection pump pulley mark is in alignment with mark on plate and fixing plate fits smoothly into the rear slit of the camshaft. Remove plate.
Fig. 17 Bolt Torque Sequence:
39. Loosen tensioner plate bolts and pulley. Concentrate looseness of belt on tensioner, then tighten the bolts in numerical sequence 1, 2 and 3, Fig. 17. Torque bolts 1 and 2, 11 to 18 ft. lbs. Bolt 3, 47 to 61 ft. lbs.
40. Using a belt tension gauge, check tension between camshaft pulley and injection pump pulley. Tension should be 47 to 64 lbs.
41. Remove crankshaft damper and install timing belt holder.
42. Bring No. 1 cylinder to TDC on compression stroke.
43. Adjust valve clearances of cylinder No. 1, intake valve of No. 2 and exhaust valve of No. 3. Turn crankshaft one full revolution to bring cylinder No. 4 TDC on compression stroke. Adjust clearances of cylinder No. 4, exhaust valve of No. 2 and intake valve of No. 3.
44. Reinstall cam cover.
45. Reinstall crankshaft damper pulley, lower dust cover and timing belt holder.
46. Install bypass hose.
47. Install upper dust cover, fan shroud, alternator belt, cooling fan and water pump pulley.
48. Install under cover and refill the cooling system.
49. Reconnect the negative battery cable.
50. Run the engine and check for leaks.