Cylinder Head Assembly: Service and Repair

1. Release fuel pressure as follows:
a. Start engine and disconnect circuit opening relay.
b. After engine stalls, turn ignition switch to Off.
c. Reconnect circuit opening relay.
2. Drain engine coolant.
3. Disconnect accelerator cable and, on automatic transaxle models, the throttle cable.
4. Remove air intake pipe and fuel hoses. Cover fuel hoses with rag to prevent spillage, then plug hoses to prevent leakage.
5. Disconnect upper radiator hose, water bypass hose and heater hoses.
6. On turbocharged models, remove oil cooler hose.
7. On all models, disconnect brake vacuum hose, then remove three way solenoid assembly and EGR solenoid assembly.
8. Disconnect engine harness connector and ground.
9. Remove vacuum chamber, then the exhaust manifold insulator.
10. Remove EGR pipe and turbocharger oil pipe, if equipped.
11. Disconnect exhaust pipe at manifold, then remove exhaust manifold and turbocharger as equipped.
12. Remove intake manifold bracket and the manifold assembly.
13. Remove distributor with high tension wires, then the spark plugs.
14. Remove upper timing belt cover and the timing belt tensioner spring.

Fig. 28 Aligning camshaft timing mark. 12 valve engine:

15. Turn crankshaft to align camshaft pulley timing marks, Fig. 28.
16. Loosen timing belt tensioner locknut and shift tensioner outward as far as possible, then temporarily tighten it.
17. Remove timing belt and secure it out of way to prevent damage during removal and installation of cylinder head.
18. Remove cylinder head cover.

Fig. 2 Cylinder head bolt loosening sequence:

19. Loosen cylinder head attaching bolts in two or three steps in proper sequence, Fig. 2.
20. Remove cylinder head and gasket.
21. Reverse procedure to install, noting the following:
a. Position hose clamps in original locations on hoses and squeeze lightly with large pliers to ensure good fit.

Fig. 30 Cylinder head gasket identification. 12 valve engine:

b. Install new cylinder head gasket, ensuring proper gasket is used, Fig. 30.

Fig. 18 Cylinder head bolt tightening sequence:

c. Place cylinder head in place, apply engine oil to bolt threads and seat faces and tighten cylinder head bolts to 59-64 ft.lb ( 80-86 Nm) in two or three steps in proper sequence, Fig. 18.
d. Apply suitable sealant to front and rear corner cylinder head cover to cylinder head contact surfaces and install cylinder head cover, torquing to 52-69 inch lbs. (6-8 Nm).
e. Install timing belt as previously described.
f. Apply engine oil to O-ring and position it on distributor.
g. Apply engine oil to distributor blade.
h. Install distributor into rear housing and loosely tighten distributor hold down bolt.