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.





15. Turn crankshaft to align camshaft pulley timing marks, Fig. 20.
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.

Fig. 22 Cylinder Head Gasket Identification:

Fig. 16 Cylinder Head Bolt Tightening Sequence:

Fig. 19 Valve Cover Sealant Application:

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.
b. Install new cylinder head gasket, ensuring proper gasket is used, Fig. 22.
c. Set cylinder head in place, apply engine oil to bolt threads and seat faces and, making two or three passes, torque cylinder head bolts 59-64 ft. lbs. in sequence shown in Fig. 16.
d. Apply silicone sealant to cylinder head cover (on 1992 models, apply sealant to new cover gasket as well) as shown in Fig. 19, then install and tighten fasteners to specification.
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.