Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable, then mark hood hinge positions on hood for installation.
2. Remove engine hood, then drain radiator coolant.
3. Position engine timing mark at 0°TDC.
4. Remove starter motor assembly, then install flywheel holder tool No. J-35271 or equivalent.
5. Remove throttle cable from throttle valve.
6. Remove air cleaner and air duct assembly.
7. Mark vacuum hose for installation, then disconnect vacuum hoses from engine.
8. Mark electrical connectors for installation, then disconnect electrical connections from engine.
9. Loosen alternator adjusting bolt, then remove drive belt.
10. Disconnect exhaust pipe from manifold, then remove exhaust manifold from vehicle.
11. On turbo models, remove exhaust manifold and turbocharger as an assembly.
12. On all models, remove the crankshaft bolt and remove the boss and the crank pulley.
13. Remove timing cover. Ensure mark on the cam pulley is aligned with the upper surface of the cylinder head, and the dowel pin on the camshaft is positioned at the top.
14. Remove spark plug wire retainers from valve cover, then valve cover.
15. Disconnect spark plug wires from spark plugs, then remove distributor hold-down bolt.
16. Mark distributor housing and cylinder head for installation, then remove distributor from cylinder head.
17. Insert a box wrench into the timing belt tension pulley hexagonal hole, then loosen the timing belt tension by rotating the tension pulley clockwise.
18. Remove the timing belt.
19. Loosen and remove the rocker arm shaft retaining bolts starting with the outermost one, and remove the rocker arm shaft with the brackets as an assembly.
20. Loosen and remove the cylinder head bolts working from the outer bolts inward.
21. Hoist cylinder head with intake manifold from vehicle.

Fig. 7 Cylinder head tightening sequence:

Fig. 8 Rocker arm tightening sequence:

22. Reverse procedure to install, noting the following:
a. Apply engine oil to cylinder head bolt threads and seating area prior to installation.
b. Tighten cylinder head bolts in two steps, Step 1; torque cylinder head bolts in sequence as shown in Fig. 7, to 28.9 ft. lbs. Step 2; retorque cylinder head bolts in sequence shown to 57.9 ft. lbs.
c. Torque rocker arm retaining bolts in sequence as shown in Fig. 8, to 16 ft. lbs.
d. Apply sealant No. TB-1207B or equivalent to the arched areas of the valve cover.