Cylinder Head Assembly: Service and Repair
REMOVAL
1. Drain engine coolant from radiator and cylinder block. Be careful not to spill coolant on drive belts.
2. Release fuel pressure.
3. Remove the following belts.
- Power steering pump drive belt
- Alternator drive belt
- Air conditioner drive belt
4. Remove power steering pump bracket.
5. Remove air duct to intake manifold collector.
6. Remove front right-side wheel.
7. Remove front right-side splash cover.
8. Remove front undercovers.
9. Remove front exhaust tube.
10. Remove engine front mounting bracket.
11. Remove rocker cover.
12. Remove distributor cap.
13. Remove all spark plugs.
14. Remove intake manifold support.
15. Set No.1 piston at T.D.C. on its compression stroke.
- Make sure No.1 cylinder is at T.D.C. by looking at distributor rotor position.
16. Remove distributor.
17. Remove cam sprocket cover and gusset.
18. Remove water pump pulley.
19. Remove thermostat housing.
20. Remove chain tensioner.
21. Remove chain tensioner and chain guide.
22. Loosen idler sprocket bolt.
23. Remove camshaft sprocket bolts.
24. Remove camshaft sprockets.
25. Remove camshaft brackets, distributor bracket and camshafts.
Note:
These parts should be reassembled in their original positions.
Bolts should be loosened in two or three steps.
26. Remove idler sprocket bolt.
27. Remove cylinder head with manifolds.
- Head warpage or cracking could result from removing in incorrect order.
- Cylinder head bolts should be loosened in two or three steps.
INSTALLATION
1. Install cylinder head with new gasket.
Note:
Be sure to install washers between bolts and cylinder head.
Do not rotate crankshaft and camshaft separately, or valves will strike piston heads.
Tightening procedure
a. Tighten bolts to 29 Nm (22 ft lb).
b. Tighten bolts to 59 Nm (43 ft lb).
c. Loosen bolts completely.
d. Tighten bolts to 29 Nm (22 ft lb).
e. Turn bolts 50 to 55 degrees clockwise or if angle wrench is not available, tighten bolts to 59 +/- 5 Nm (43.4 +/- 3.6 ft lb).
f. Tighten bolts (11-15) to 6.3 to 8.3 Nm (4.6 to 6.1 ft lb).
2. Install idler sprocket bolt.
3. Install camshaft.
Note:
Make sure camshafts are aligned as shown in figure.
Identification marks are present on camshafts.
4. Install camshaft brackets and distributor bracket.
Note:
- Make sure camshaft brackets are aligned as shown in figure.
- Apply liquid gasket to distributor bracket.
- Tighten camshaft bracket bolts gradually in two or three stages.
- If any part of valve assembly or camshaft is replaced, check valve clearance according to reference data.
Reference data valve clearance (Cold):
Intake - 0.30 mm (0.012 in)
Exhaust - 0.35 mm (0.014 in)
5. Assemble camshaft sprocket with chain.
Note:
- Set timing chain by aligning mating marks with those of camshaft sprockets.
- Make sure sprocket's mating marks face engine front.
6. Install camshaft sprocket bolts
7. Install upper chain tensioner and chain guide.
Note: Make sure that hook used to retain chain tensioner is released.
8. Install lower chain tensioner.
CAUTION:
- Check no problems occur when engine is rotated.
- Make sure that No.1 piston is set at T.D.C. on Its compression stroke.
- Make sure of the direction of the gasket before installing lower chain tensioner.
9. Apply liquid gasket to thermostat housing.
10. Install thermostat housing.
11. Install water pump pulley.
12. Install distributor.
Note: Make sure that position of camshaft is as shown in figure.
13. Install cam sprocket cover gusset and cam sprocket cover.
- Apply liquid gasket to cam sprocket cover gusset.
- Apply liquid gasket to cam sprocket cover.
14. Apply liquid gasket to rocker cover and cylinder head.
15. Install rocker cover.
16. Install all spark plugs.
17. Install engine front mounting bracket.
18. Install front exhaust tube.
19. Install front undercover.
20. Install front right splash cover.
21. Install front right wheel.
22. Install air cleaner.
23. Install power steering pump bracket.
24. Install the following belts.
- Alternator drive belt
- Power steering pump drive belt
- Air conditioner compressor drive belt