Cylinder Head Assembly: Service and Repair

1. Release fuel system pressure as follows:
a. Start engine, then disconnect circuit opening relay connector.
b. After engine stalls, turn ignition switch Off.
c. Connect circuit opening relay connector.
2. Disconnect battery ground cable.
3. Drain coolant.
4. Remove air intake pipe, then the distributor together with spark plug wires.
5. Remove spark plugs.
6. Remove air bypass valve and hoses assembly, then the air pipe.
7. Remove radiator, then the engine side and under covers.
8. Disconnect exhaust pipe at manifold.
9. Remove turbocharger bracket, then the exhaust manifold and turbocharger insulators.
10. Remove exhaust manifold and turbocharger assembly.
11. Disconnect coolant bypass hose, accelerator cable, fuel hoses and engine harness connectors.
12. Remove surge tank bracket, then the cylinder head cover.
13. Remove timing belt as previously described.
14. Remove cylinder hear attaching bolts, then the cylinder head and exhaust manifold assembly.
15. Remove intake manifold assembly.
16. Remove thermostat and thermostat cover.
17. Reverse procedure to install, noting the following:

Fig. 33 Cylinder head bolt tightening sequence. DOHC engine:

a. Tighten cylinder head attaching bolts gradually in order, Fig. 33.
b. When installing timing belt, refer to ``Timing Belt, Replace.''
c. Torque crankshaft pulley attaching bolts to 109-152 inch lbs.
d. When installing cylinder head cover, apply a coat of suitable sealant to cylinder head cover slots where top of gasket contacts and torque attaching bolts to 26-35 ft.lbs.
e. When installing surge tank bracket, torque upper and lower attaching bolts to 23-34 ft.lbs. and centermost bolt to 14-19 ft.lbs.
f. Torque exhaust manifold and turbocharger assembly and coolant bypass pipe bracket attaching bolts to 29-42 ft.lbs. and the turbocharger bracket to turbocharger attaching bolt to 16-22 ft.lbs.
g. When connecting oil pipe to turbocharger and cylinder block, torque bolt to 104-156 inch lbs. and nut to 12-17 ft.lbs.
h. Torque attaching bolts for exhaust manifold and turbocharger insulators to 14-19 ft.lbs.
i. Torque exhaust pipe attaching bolts to 23-34 ft.lbs. and the spark plugs to 11-17 ft.lbs.