Cylinder Head Assembly: Service and Repair

1. Remove fuel pump fuse from fuse panel, then start and operate engine until it stalls. After stalling, crank engine for approximately 3 seconds to deplete fuel pressure in fuel lines.
2. Disconnect battery ground cable, then remove air cleaner assembly.
3. Drain cooling system, then remove serpentine drive belt.
4. Remove alternator and bracket assembly, then remove ignition coil.
5. Mark position of distributor rotor to distributor body and distributor body to cylinder head, then remove distributor.
6. Disconnect cables from intake manifold brackets.
7. Disconnect throttle and TV cables from throttle body.
8. Disconnect electrical connectors from throttle body and intake manifold.
9. Disconnect power brake unit vacuum hose at filter.
10. Disconnect fuel lines from throttle body unit. Place shop towel over fuel line and fitting when disconnecting.
11. Disconnect radiator, heater and bypass hoses from cylinder head and intake manifold.
12. Disconnect breather hose from camshaft carrier cover.
13. Disconnect exhaust pipe from exhaust manifold.
14. Disconnect electrical connectors from oxygen sensor, wiring harness, thermostat housing, coolant temperature switch and other components to permit cylinder head, intake manifold and exhaust manifold to be removed as an assembly.
15. Remove timing belt, as described under TIMING BELT then remove timing belt rear cover.

Fig. 5 Cylinder Head/camshaft Carrier Bolt Loosening Sequence:

Fig. 6 Cylinder Hard/camshaft Carrier Bolt Tightening Sequence:

16. With engine cold, loosen cylinder head/camshaft carrier attaching bolts in sequence shown in Fig. 5.
17. Remove camshaft carrier, rocker arms and hydraulic valve lash adjusters.
18. Remove cylinder head, intake manifold and exhaust manifold as an assembly. If necessary, separate intake and exhaust manifolds from cylinder head after removal from engine.
19. Reverse procedure to install. Prior to installation, the intake and exhaust manifolds must be assembled to cylinder head, if removed. Apply a continuous bead (3 mm) of anaerobic sealant 1052942 or equivalent to cam carrier sealing surface prior to installation. Tighten cylinder head bolts to torque listed under SPECIFICATIONS/MECHANICAL SPECIFICATIONS/TIGHTENING SPECIFICATIONS in sequence shown in Fig. 6.