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 insulate cable end with electrical tape, or equivalent.
3. Mark position of hood to hood hinges for alignment during installation, then remove hood.
4. Drain engine coolant from radiator, then remove accelerator cable from throttle valve and common chamber.
5. Mark position of all vacuum lines for installation, then disconnect vacuum lines from throttle valve, evaporation canister, MAP sensor and vacuum booster.
6. Disconnect oxygen sensor connector, then ignition coil high tension wire from ignition coil.
7. Disconnect ground cable connector from thermostat housing flange.
8. Disconnect coolant temperature sensor electrical connector, then two engine harness connectors near lefthand strut tower.
9. Disconnect heater hoses, then upper radiator hose from radiator.
10. Disconnect throttle valve heating hose from coolant bypass pipe.
11. Disconnect fuel rail supply and return hoses from fuel rail.
12. Raise and support vehicle, then remove right side undercover.
13. Disconnect exhaust pipe from exhaust manifold.
14. Using an engine support bar, or equivalent, support engine assembly.
15. Remove right side engine mount, then lower vehicle.
16. Remove coolant recovery tank with bracket.
17. Remove power steering pump drive belt, then the serpentine drive belt.

Fig. 12 Engine Mounting Bridge Bracket Location:

18. Remove engine mounting bridge bracket from engine assembly, Fig. 12.
19. Remove cylinder head center cover, then disconnect spark plug wires from spark plugs and ignition coil.
20. Remove upper timing belt cover, then the power steering pump bracket.
21. Remove cylinder head main cover, then round plastic belt tension adjusting hole cover.
22. Align crankshaft pulley timing marks as shown in Fig. 12.
23. Loosen timing belt tension pulley lock bolt.
24. Using a hex wrench, loosen timing belt by turning tension pulley clockwise.
25. Remove timing belt from camshaft pulleys.

Fig. 13 Cylinder Head Bolt Removal Sequence:

26. Using sequence shown in Fig. 13, remove cylinder head bolts.
27. Lift cylinder head assembly, then remove coolant hose from oil cooler.
28. Remove cylinder head.

Fig. 14 Cylinder Head Bolt Tightening Sequence:

Fig. 15 Cylinder Head Cover Sealant Application:

29. Reverse procedure to install, noting the following:
a. Apply a thin coat of engine oil to cylinder head bolt thread area and seating face of bolt head.
b. Using sequence shown in Fig. 14, torque cylinder head bolts in two steps, first to 29 ft. lbs., then to 58 ft. lbs.
c. Apply a 0.08-0.12 inch width bead of RTV sealant, or equivalent to arched area of No. 1 and No. 5 camshaft bearing caps as shown in Fig. 15.
d. Torque cylinder head cover attaching bolts in sequence shown, Fig. 11 to 53 inch lbs.
30. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.