Cylinder Head Assembly: Service and Repair
NOTE: On models with coded audio anti-theft systems, refer to Technician Safety Information for code procedures. On models with air bag system, disarm airbag system as outlined under Technician Safety Information.REMOVAL
1. Disconnect battery ground cable, then drain coolant from radiator and engine block.
2. Remove PCV hoses.
3. Remove air cleaner cap, volume air flow meter and resonator.
4. Disconnect cruise control actuator, throttle and accelerator cables from throttle body.
5. Disconnect engine ground straps.
6. Disconnect connector on intake manifold from LH fender apron.
7. Disconnect heater hoses.
8. Disconnect heater valve and engine wire from cowl panel.
9. Remove No. 2 and No. 3 cylinder head covers.
10. Disconnect distributor wires and connector, then remove distributor.
11. Disconnect power steering reservoir tank.
12. Disconnect radiator inlet hose.
13. Disconnect No. 3 water bypass hose.
14. Remove generator and generator bracket.
15. Remove water outlet.
16. Disconnect throttle body connectors and remove throttle body.
17. Remove No. 2 water bypass pipe with hoses.
18. Disconnect connector for emission control valve set assembly.
19. Disconnect hoses and connectors from EGR valve, then remove EGR valve and vacuum modulator.
20. Remove heater inlet pipe and air intake chamber retaining bolt.
21. Remove oil dipsticks, engine guides and transmission guides.
22. Remove hoses from air intake chamber, then remove air intake chamber.
23. Remove fuel return pipe, No. 1 water bypass hose and No. 1 fuel pipe.
24. Disconnect fuel inlet hose.
25. Remove delivery pipe and injectors.
26. Disconnect engine connectors and engine wire.
27. Remove front exhaust pipe assembly.
28. Remove heater pipe, air pipe and pair reed valve.
29. Remove No. 1 and No. 2 exhaust manifolds.
30. Remove Engine hangers.
31. Remove water outlet bypass and pipe.
32. Remove cylinder head cover and spark plugs.
33. Turn crankshaft pulley to set No. 1 cylinder to TDC on compression stroke.
Fig. 1 Camshaft Timing Gear & Chain Matchmarks:
34. Place matchmarks on camshaft timing gear and timing chain, then remove chain tensioner and camshaft timing gear,Fig. 1.
Fig. 2 Service Bolt Hole:
Fig. 3 Camshaft Gear Timing Mark:
Fig. 4 Remove Bearing Cap Bolts:
35. Remove camshafts as follows:
a. Turn hexagon portion of intake camshaft with wrench to bring service bolt hole of driven sub-gear upward, Fig. 2.
b. Attach exhaust camshaft sub-gear to driven gear with service bolt.
c. Set timing mark of camshaft driven gear approximately 35° angle by turning hexagon wrench head portion of intake camshaft, Fig. 3.
d. Gently push camshaft toward rear of engine. Loosen and remove bearing cap bolts as shown in Fig. 4.
e. Remove two remaining bearing cap bolts and remove exhaust camshaft.
f. Set timing mark on intake camshaft drive gear at 25° angle, then lightly push camshaft toward front of engine.
g. Remove bearing caps and exhaust camshaft.
Fig. 5 Cylinder Head Bolt Removal Sequence:
36. Remove cylinder head bolts in sequence shown in Fig. 5, then remove cylinder head.
37. Remove Heater inlet pipe and hose.
38. Remove intake manifold with fuel filter.
INSTALLATION
1. Install fuel filter and intake manifold. Torque to specifications.
2. Install heater inlet pipe and hose.
Fig. 6 Cylinder Head Bolt Tightening Sequence:
3. Install cylinder head and tighten bolts in sequence shown in Fig. 6. Torque cylinder head bolts to 29 ft. lb.
4. Mark the front of the head bolts with paint. Retorque the head bolts in the same pattern by 90° and then an additional 90°.
4. Install intake and exhaust camshafts and bearing caps. Torque bearing caps to specifications, then remove service bolt.
5. Set No. 1 cylinder to TDC on compression stroke.
Fig. 7 Camshaft Gear Alignment:
6. Turn camshafts until timing marks align as in Fig. 7.
7. Install camshaft gear over straight pin of intake camshaft.
Fig. 8 Distributor Gear Alignment:
8. Align straight pin of distributor gear with straight pin groove of intake camshaft, Fig. 8, then install and torque bolt to specification.
9. Install and set chain tensioner, then check valve timing.
10. Reverse steps 1 through 32 of removal procedure to complete installation.
11. On models with air bag system, rearm airbag system as outlined under Technician Safety Information. If audio system was disabled, activate as outlined under Technician Safety Information.