Cylinder Head Assembly: Service and Repair

1. Relieve fuel system pressure as outlined under Technician Safety Information. On models with airbag system, refer to Technician Safety Information for system disarming and arming procedures.
2. Disconnect battery ground cable, then mark hood hinge positions for installation reference.
3. Remove engine hood, then drain radiator coolant.
4. Remove accelerator cable from throttle valve and common chamber assembly.
5. Mark vacuum hoses for installation reference, then disconnect vacuum hoses from engine.
6. Mark electrical connectors for installation reference, then disconnect electrical connections from engine.
7. Remove heater hoses from engine assembly, then disconnect upper radiator hose from radiator.
8. Disconnect throttle valve heating hose from coolant bypass line.
9. Remove coolant bypass line brace from engine, then disconnect fuel lines.
10. Remove right engine undercover, then disconnect exhaust pipe from manifold.
11. Support engine, then remove right side engine mount.
12. Remove coolant recovery tank and bracket.
13. Remove power steering pump and bracket from engine, leaving hoses connected and position aside.
14. Remove alternator drive belt, then engine mounting bridge from front of engine.
15. Remove cylinder head center cover, then disconnect spark plug wires from spark plugs and ignition coil.
16. Disconnect PCV hose from cylinder head cover. then remove upper timing cover.
17. Disconnect power steering pump bracket from engine.
18. Remove cylinder head cover.

Fig. 5 Aligning Camshaft Timing Marks:

Fig. 6 Tension Adjusting Hole Cover Removal:

19. Align camshaft timing marks as shown in Fig. 5, then remove tension adjusting hole cover, Fig. 6.
20. Loosen tension pulley lock bolt, then remove timing belt by turning tension pulley with box wrench.

Fig. 7 Cylinder Head Removal Sequence:

21. Remove timing belt, then cylinder head bolts in sequence shown in Fig. 6.
22. Lift cylinder head from engine block slightly, then remove coolant hose from oil cooler.
23. Remove cylinder head from engine block.

Fig. 8 Cylinder Head Oil Relief Valve Transfer:

Fig. 9 Cylinder Head Tightening Sequence:

Fig. 10 Camshaft Sealant Bearing Location:

Fig. 11 Cylinder Head Coveer Tightening Sequence:

24. Reverse procedure to install, noting the following:
a. When installing a new cylinder head, transfer old oil check and relief valve and/or cylinder head plug to new assembly, Fig. 8.
b. Apply engine oil to thread and seating surface of cylinder head bolts prior to installation.
c. Using sequence shown, Fig. 9, torque cylinder head bolts in two steps, first to 29 ft. lbs., then to 58 ft. lbs.
d. Apply a 1/8 inch bead of sealant No. TB/1207B, or equivalent to arched areas of camshaft bearing caps, Fig. 10.
e. Torque cylinder head cover retaining bolts to 53 inch lbs., in sequence shown, Fig. 11.
25. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.