Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable.
2. Drain engine coolant, then remove accelerator cable.
3. Remove secondary air pipe assemblies.
4. Remove distributor assembly, then the rear housing.
5. Remove air hose and oil pipe, as required.
6. Remove insulator Nos. 1, 2 and 3, then the bracket.
7. Remove front catalytic converter.
8. Remove oil return hose, then the water inlet and outlet hoses.
9. Remove EGR pipe, then the exhaust manifold, gasket and turbocharger assembly, as required.
10. Remove intake manifold assembly and gasket.
11. Remove timing belt cover, then turn crankshaft to align ``A'' mark on camshaft pulley with front housing timing mark.
12. Remove timing belt tensioner, spring and timing belt.

Fig. 2 Cylinder head bolt loosening sequence:

13. Remove valve cover, then gradually loosen and remove cylinder head attaching bolts in sequence shown above.
14. Remove cylinder head and gasket.

Fig. 18 Cylinder head bolt tightening sequence:

15. Reverse procedure to install. Torque cylinder head attaching bolts to 59 - 64 ft.lbs in sequence shown above.