Cylinder Head Assembly: Service and Repair

REMOVAL

1. Disconnect battery ground cable.
2. Remove drive belts, water pump pulley, timing belt cover, crankshaft damper and pulley, valve cover, timing belt, camshaft sprocket, timing belt tensioner and timing belt inner cover.
3. Remove alternator and mounting bracket to cylinder head bolts.
4. Remove exhaust manifold to cylinder head attaching bolts.
5. Remove timing belt tensioner spring stop stud from cylinder head.
6. Remove cylinder head attaching bolts and the cylinder head.

Fig. 2 Align Timing Marks On Crankshaft Sprocket & Engine Front Cover:

Fig. 3 Aligning Timing Marks On Camshaft Sprocket & Inner Timing Belt Cover:

INSTALLATION

1. Ensure that cylinder head and cylinder block gasket surfaces are clean.
2. Position new cylinder head gasket on block.
3. Ensure that crankshaft sprocket and camshaft sprocket timing marks align as shown in Figs. 2 and 3, then lower cylinder head assembly onto cylinder block, ensuring head fits over two dowels on head surface of block.
4. Install valve cover gasket on valve cover using suitable sealant and place cover aside.

Fig. 12 Cylinder Head Bolt Tightening Sequence:

5. Oil cylinder head bolts and install in cylinder head, torquing in two steps in proper sequence, Fig. 11. Torque first to 50-60 ft. lbs., then to 80-90 ft. lbs.
6. Install timing belt tensioner spring stop stud into cylinder head, torquing to 14-21 ft. lbs.

Fig. 8 Installing exhaust manifold:

7. Position exhaust manifold on cylinder head and install attaching bolts, torquing in two steps in proper sequence, Fig. 8. Torque first to 5-7 ft. lbs., then to 16-23 ft. lbs.
8. Install alternator bracket to cylinder head bolts.
9. Install fuel supply manifold, timing belt inner cover, auxiliary sprocket, timing belt tensioner, camshaft sprocket and seal, timing belt, crankshaft damper and pulley, timing belt cover, water pump pulley, drive belts and valve cover.