Cylinder Head Assembly: Service and Repair

1. Release fuel system pressure as follows:
a. Start engine and disconnect circuit opening relay electrical connector.
b. After engine stalls, turn ignition switch to Off.
c. Reconnect circuit opening relay.
2. Disconnect battery ground cable and drain engine coolant.
3. Disconnect air intake pipe and accelerator cable.
4. Remove timing belt as previously described.
5. Disconnect canister hoses, brake vacuum hoses and the fuel hoses. When disconnecting fuel hoses, cover with rag to prevent spillage. Plug fuel hoses to prevent leakage.
6. On vehicles with automatic transmission, disconnect A/T vacuum hose.
7. Remove three-way solenoid assembly.
8. Disconnect engine harness connectors and grounds.
9. Remove transmission oil dipstick and tube, then the distributor and EGR pipe.
10. Remove extension manifold.

Fig. 25 Intake manifold loosening sequence:

11. Remove intake manifold assembly, loosening attaching bolts in two or three steps in sequence, Fig. 25.
12. Remove cylinder head cover assembly, then the center exhaust pipe insulator.
13. Disconnect center exhaust pipe, then remove exhaust manifold insulator and the exhaust manifold.
14. Remove seal plate.

Fig. 2 Cylinder head bolt loosening sequence:

15. Remove cylinder head attaching bolts, loosening in two or three steps in sequence, Fig. 2, then remove cylinder head assembly.
16. Reverse procedure to install, noting the following:
a. Position hose clamps in original positions on hoses and squeeze clamps lightly with large pliers to ensure good fit.
b. Check that projection of oil control plugs from cylinder head is .209-.224 inch (5.3-5.7 mm).
c. Apply engine oil to new O-rings, then install O-rings on oil control plugs.
d. Thoroughly remove all dirt, oil or other material from top of cylinder block.
e. Place new cylinder head gasket on left bank with L mark facing upward.
f. Place new cylinder head gasket on right bank with R mark facing upward.
g. Install cylinder head to cylinder block.
h. Measure length of bolts, which should be 4.25 inch (108 mm) for intake and 5.43 inch (138 mm) for exhaust. If length is greater than 4.29 inch (109 mm) for intake or 5.47 inch (139 mm) for exhaust, replace bolts.
i. Apply engine oil to threads and seat faces of bolts.

Fig. 16 Cylinder head bolt tightening sequence:

j. Torque bolts in sequence, Fig. 16, to 14 ft.lbs.
k. Put paint mark on each bolt head and, using paint mark as reference, tighten bolts 90° in sequence, then an additional 90° in sequence.
l. Place cylinder head cover gasket in position, then install cylinder head cover with new seal washers, torquing to 30-39 inch lbs.

Fig. 23 Intake manifold tightening sequence:

m. Connect injector harness and place new intake manifold gasket in position, then install intake manifold assembly, torquing flange nuts in two or three steps in sequence, Fig. 23, to 14-19 ft.lbs.
n. Apply engine oil to new extension manifold O-ring, then install extension manifold with new gasket, torquing to 14-19 ft.lbs.
o. Connect all electrical connectors and grounds.
p. Install timing belt as previously described.

Fig. 24 Aligning distributor mating marks:

q. Apply engine oil to distributor O-ring and position O-ring on distributor, then apply engine oil to drive gear and align matching marks, Fig. 24.
r. Install distributor into cylinder head with marks facing straight up and loosely tighten distributor hold-down bolt.
s. Apply anti-seize compound to threads of spark plugs and torque plugs to 11-17 ft.lbs.