Removal/Installation

1. Relieve fuel system pressure as described under Technician Safety Information.
2. Disconnect battery ground cable, then 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 fuel hoses. When disconnecting fuel hoses, cover with rag to prevent spillage. Plug fuel hoses to prevent leakage.
6. 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 distributor and EGR pipe.
10. Remove extension manifold.

Fig. 3 Intake Manifold & Fuel Distribution Bolt Loosening Sequence:

Fig. 4 Intake Manifold Bolt Loosening Sequence:

11. Remove intake manifold assembly, loosening attaching bolts in two or three steps in sequence shown in Fig. 3 and 4.
12. Remove cylinder head cover assembly, then center exhaust pipe insulator.
13. Disconnect center exhaust pipe, then remove exhaust manifold insulator and exhaust manifold.
14. Remove seal plate.
15. Remove cylinder head bolts, loosening in two or three steps, 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 0.209 - 0.224 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. Bolts 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. 5 Righthand Cylinder Head Bolt Tightening Sequence:

Fig. 6 Lefthand Cylinder Head Bolt Tightening Sequence:

j. Torque cylinder head bolts in sequence as shown in Fig. 5 and 6 to 14 ft.lb.
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, tightening to specifications.

Fig. 7 Intake Manifold Bolt Tightening Sequence:

m. Connect injector harness and place new intake manifold gasket in position, then install intake manifold assembly, tightening flange nuts in two or three steps in sequence, Fig. 7, to specifications.
n. Apply engine oil to new extension manifold O-ring, then install extension manifold with new gasket, tightening to specifications.
o. Connect all electrical connectors and grounds.
p. Install timing belt as previously described.
q. Apply engine oil to distributor O-ring and position O-ring on distributor, then apply engine oil to drive gear and install.
r. Install distributor into cylinder head with marks facing straight up and hand tighten distributor hold-down bolt.
s. Apply anti-seize compound to threads of spark plugs and tighten plugs to specifications.