Cylinder Head Assembly: Service and Repair
REMOVE1. Drain cooling system, then disconnect battery ground cable.
2. Remove air cleaner intake tube.
3. Remove timing belt.
4. Remove upper intake manifold.
5. Disconnect distributor to spark plug wires and ignition coil to distributor high tension wiring. Note distributor to spark plug wire location for installation reference.
6. Remove distributor.
7. Disconnect Exhaust Gas Recirculation Control (EGRC) solenoid, Mass Air Flow (MAF) sensor, Vehicle Speed Sensor (VSS) and valve body wiring harness connectors.
8. Disconnect Transaxle Range (TR) switch, A/C clutch pulley, power transistor, A/C pressure cutoff switch, fuel injectors, ignition coil, water temperature indicator sender unit and Engine Coolant Temperature (ECT) sensor electrical connectors.
9. Remove main wiring harness bracket from water hose connection, then fuel tube bracket bolt from Exhaust Gas Recirculation (EGR) valve bracket.
10. Disconnect water bypass hose from water hose connection, then remove fuel injection supply manifold bolts. Position manifold and injectors aside.
11. Disconnect upper heater water hose.
Fig. 3 Lower Intake Manifold Nut & Bolt Removal Sequence:
12. Remove intake manifold to cylinder block nut and bolts in sequence, Fig. 3, then remove lower intake manifold from vehicle. Discard intake manifold gaskets.
13. Remove front valve cover screws, then front valve cover and valve cover gasket.
14. Using camshaft pulley holding tool No. T92P-6312-AH, or equivalent, hold camshaft sprocket while removing camshaft sprocket bolt.
15. Remove camshaft sprockets, then seal plate bolts and seal plate.
16. On front cylinder head, remove oil level indicator tube bracket bolts and bracket.
17. On both cylinder heads, raise and support vehicle.
18. On front cylinder head, remove exhaust manifold to exhaust inlet pipe nuts. Remove and discard gasket.
19. On both cylinder heads, remove front exhaust manifold to mounting bracket bolt.
20. On front cylinder head, remove A/C compressor bolts.
21. Lower vehicle.
22. On front cylinder head, proceed as follows:
a. Loosen two upper A/C compressor bolts and wire compressor aside. b. Remove upper alternator regulator mounting bracket bolts, then coolant crossover tube bracket bolts.
Fig. 14 Front (Lefthand) Cylinder Head Bolt Removal Sequence:
c. Remove front cylinder head bolts in two steps in sequence, Fig. 14. Ensure first bolt in removal sequence is located in No. 1 position outside of cylinder head. This bolt is easily forgotten and tab can be broken off if cylinder head is before bolt is removed.
d. Remove cylinder head bolt washers and discard cylinder head bolts.
e. Remove front cylinder head and front head gasket.
Fig. 7 Front Exhaust Manifold Nut Removal & Tightening Sequence:
f. Remove front exhaust manifold from front cylinder head, the exhaust manifold nuts in sequence, Fig. 7, if necessary.
23. On rear cylinder head, proceed as follows:
Fig. 9 Rear Exhaust Manifold Nut Removal & Tightening Sequence:
a. Remove rear exhaust manifold nuts in sequence, Fig. 9, then discard rear exhaust manifold gasket.
b. Remove rear valve cover screws, then valve cover and gasket. Discard gasket.
Fig. 15 Rear (Righthand) Cylinder Head Bolt Removal Sequence:
c. Remove rear cylinder head bolts in two steps in sequence, Fig. 15. Ensure first bolt in removal sequence is located in No. 1 position outside of cylinder head. This bolt is easily forgotten and tab can be broken off if cylinder head is moved before bolt is removed.
d. Remove cylinder head bolt washers, then discard cylinder head bolts
e. Remove rear cylinder head and rear head gasket. Discard rear head gasket.
INSTALL
1. Install new front exhaust manifold gasket on front exhaust manifold if removed, then position front exhaust manifold on front cylinder head.
2. Install front exhaust manifold nuts, if removed. Torque front exhaust manifold nuts, in sequence, Fig. 7, to 13-16 ft. lb.
Cylinder Head Bolt Washer Installation Position:
3. Install new head gasket and position either front or rear cylinder head on cylinder block. Ensure cylinder head bolt washers are installed correctly, Fig. 12.
Fig. 16 Cylinder Head Bolt Tightening Sequence:
4. Ensure cylinder head bolts are installed in correct positions (5.00 inch bolts at positions 4, 5, 12 and 13; 4.17 inch bolts at other positions), then tighten new cylinder head bolts in sequence, Fig. 16, as follows:
a. Torque cylinder head bolts to 22 ft. lb.
b. Torque cylinder head bolts to 43 ft. lb.
c. Loosen all bolts completely, using loosening sequence, Figs. 14 and 15.
d. Torque cylinder head bolts to 22 ft. lb.
e. Turn all cylinder head bolts 60 to 65° clockwise. If suitable torque angle wrench is not available, Torque cylinder head bolts to 40-47 ft. lb.
f. Install cylinder head bolt at position A, Fig. 16. Torque cylinder head bolt (A) to 6 ft. lb.
5. If removed, install new rear exhaust manifold gasket and rear exhaust manifold.
Fig. 9 Rear Exhaust Manifold Nut Removal & Tightening Sequence:
6. If removed, install rear exhaust manifold nuts. Torque rear exhaust manifold nuts in sequence, Fig. 9, to 13-16 ft. lb.
7. On front cylinder head, proceed as follows:
a. Position coolant crossover tube on bracket on cylinder head, then install bracket bolt.
b. Install alternator regulator mounting bracket bolts and tighten to specifications.
c. Position A/C compressor on alternator mounting bracket, then A/C compressor bolts. Tighten A/C compressor bolts to specifications.
8. On both cylinder heads, raise and support vehicle.
9. On front cylinder head, install lower A/C compressor bolts. Tighten bolts.
10. On both cylinder heads, install new gasket between front exhaust manifold and rear exhaust manifold crossover tub.
11. Install manifold to crossover tube nuts and bolt.
12. Install front exhaust manifold to mounting bracket bolt, then tighten to specifications.
13. Install new gasket and position exhaust inlet pipe on exhaust manifold.
14. On front cylinder heads, install front exhaust manifold to exhaust inlet pipe nuts to 32-40 ft. lb.
15. On both cylinder heads, lower vehicle.
16. On front cylinder heads, position oil level indicator tube bracket and install bracket bolts. Tighten bolts to specifications.
17. On both cylinder heads, position rear engine front cover, then install seal plate bolts. Tighten seal bolts.
18. Using camshaft pulley holding tool No. T92P-6312-AH, or equivalent, hold camshaft sprocket while installing sprocket retaining bolt. Tighten bolt 58-65 ft. lb.
19. Position front valve cover or rear valve cover on cylinder as necessary, then install valve cover screws.
20. Install new lower intake manifold gaskets on cylinder heads and position lower intake manifold.
Intake Manifold Bolt Tightening Sequence:
21. Install Allen-head lower intake manifold bolts and four lower intake manifold nuts. Tighten lower intake manifold nuts and bolts in sequence, Fig. 4, as follows:
a. Torque lower intake manifold nuts and bolts to 27-44 inch lbs.
b. Torque lower intake manifold nuts and bolts to 12-14 ft. lb.
c. Torque lower intake manifold nuts and bolts to 12-14 ft. lb.
22. Connect upper heater water hose.
23. Position fuel injectors in respective ports, then install fuel injection supply manifold bolts.
24. Connect water bypass hose to intake manifold water hose connection, then position fuel tube bracket on EGR valve bracket and install fuel line bracket bolt.
25. Attach main wiring harness bracket to intake manifold water hose connection.
26. Connect EGRC solenoid, MAF sensor, VSS, valve body wiring harness, TR switch and A/C clutch pulley electrical connectors.
27. Connect power transistor, A/C pressure cutoff switch, fuel injector, ignition coil, water temperature indicator sender unit and ECT sensor electrical connectors.
28. Install distributor.
29. Connect distributor to spark plug wires and ignition coil to distributor high tension wiring. Refer to reference mark made during removal for correct location of distributor to spark plug wires.
30. Install upper intake manifold.
31. Install timing belt.
32. Install air cleaner intake tube.
33. Fill cooling system, then check ignition timing.