Cylinder Head Assembly: Service and Repair
CAUTION:^ After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
^ When installing sliding parts such as camshafts, chain tensioner and oil seal, be sure to apply new engine oil on their sliding surfaces.
^ When tightening cylinder head bolts; camshaft sprocket bolts, crankshaft pulley bolt and camshaft bracket bolts, apply new engine oil to thread portions and seat surfaces of bolts.
^ Before disconnecting fuel hose, release fuel pressure from fuel line.
REMOVAL
1. Drain coolant from drain plug on water pipe and radiator drain cock.
2. Remove vacuum hoses, fuel hoses, wires, harness and connectors and so on.
3. Remove the following parts.
^ Generator and bracket.
^ Upper radiator hose.
^ Air duct.
^ Front exhaust tube.
4. Remove intake manifold collector supports, intake manifold collector and exhaust manifold.
5. Set No.1 piston at TOP DEAD CENTER (TDC) on its compression stroke.
6. Remove distributor.
7. Set a suitable transmission jack under aluminum oil pan and remove front engine mounting.
8. Remove rocker cover.
9. Remove cam-sprocket.
10. Remove cam brackets and camshafts.
^ These parts should be reassembled in their original positions.
Fig. 8 Cylinder Head Bolt Loosening Sequence:
11. Loosen cylinder head bolts.
^ A warped or cracked cylinder head could result from removing in incorrect order.
^ Cylinder head bolts should be loosened in two or three steps.
12. Remove cam sprocket cover.
^ Upper timing chain will not be disengaged from idler sprocket. For this reason, a stopper need not be used. Cast portion of cam sprocket cover is located on lower side of idler sprocket so upper timing chain need not be disengaged from idler sprocket.
13. Remove upper chain tensioner and upper chain guides.
14. Remove upper timing chain.
15. Remove idler sprocket bolt.
16. Remove cylinder head with intake manifold, intake manifold collector and exhaust manifold assembly.
17. Remove cylinder head gasket.
INSTALLATION
^ Apply a continuous bead of liquid gasket to cam sprocket cover.
^ Be careful not to damage cylinder head gasket.
^ Be careful upper timing chain does not slip or jump when installing cam sprocket cover.
Fig. 10 Cylinder Head Bolt Tightening Sequence:
1. Tighten cylinder head bolts.
^ Tightening procedure:
^ Tighten all bolts to 29 Nm (3.0 kg-m, 22 ft-lb).
^ Tighten all bolts to 79 Nm (8.1 kg-m, 59 ft-lb).
^ Loosen all bolts completely.
^ Tighten all bolts to 25 to 34 Nm (2.5 to 3.5 kg-m, 18 to 25 ft-lb).
^ Turn all bolts 86 to 91 degrees clockwise, or if an angle wrench is not available, tighten bolts to 75 to 84 Nm (7.6 to 8.6 kg-m, 55 to 62 ft-lb). (1993-94 ONLY)
^ Turn all bolts 86 to 91 degrees clockwise, or if an angle wrench is not available, mark all cylinder head bolts on the side facing engine front. Then, turn each cylinder head bolt 86 to 91 degrees clockwise. (1995-96 ONLY)
2. Install camshafts and camshaft brackets.
^ Camshaft bracket bolts tightening procedure.
^ Tighten all bolts to 2 Nm (0.2 kg-m, 1.4 ft-lb).
^ Tighten all bolts to 9.0 to 11.8 Nm (0.92 to 1.2 kg-m, 6.7 to 8.7 ft-lb).
Fig. 12 Aligning Upper Timing Chain On Camshafts:
3. Install camshaft sprockets.
4. Install chain guide between both camshaft sprockets.
5. Install rubber plugs as follows. (1993-94 ONLY)
^ Apply liquid gasket to rubber plugs.
^ Install rubber plugs, then move them by hand to uniformly spread the gasket on cam sprocket cover surface.
^ Mating surfaces of liquid gasket should be installed flush.
6. Install distributor.
^ Make sure that No.1 piston is set at TDC and that distributor rotor is set at No.1 cylinder spark position.
7. . Install rocker cover.
^ Tightening procedure:
^ Tighten nuts 1-5-6-4 in that order to to 4 Nm (0.4 kg-m, 2.9 ft-lb).
^ Tighten nuts 1 to 11 as indicated in figure, to 8 to 11 Nm (0.8 to 1.1 kg-m, 5.8 to 8.0 ft-lb).
8. . Install all spark plugs with high-tension cords.
9. Install vacuum hoses, fuel tubes, wires, harness and connectors and so on.