Cylinder Head Assembly: Service and Repair

1. Relieve fuel system pressure as follows:
a. Remove fuel pump fuse from fuse panel.
b. Start engine. After engine stalls, crank for ten seconds to relieve residual pressure from fuel system.
c. Turn ignition off and install fuel pump fuse.
2. Disconnect battery ground cable.
3. Remove air cleaner assembly, then drain cooling system.
4. Unfasten alternator and position aside.
5. Remove distributor and ignition wires.
6. Disconnect cables from intake manifold bracket, throttle body and downshift cable.
7. Disconnect ECM electrical connectors at the throttle body and intake manifold.
8. Disconnect fuel inlet and return lines, then the coolant and heater hoses from intake manifold and water outlet. Place shop towel over fuel line and fitting when disconnecting.
9. Disconnect breather and PCV hoses at camshaft carrier.
10. Remove upper radiator hose.
11. Disconnect exhaust pipe from manifold, then disconnect oxygen sensor electrical connector.
12. Disconnect engine wiring harness and the thermostat housing electrical connector.
13. Remove timing belt as described under TIMING BELT.

Fig. 4 Cylinder Head Bolt Loosening Sequence:

Fig. 5 Compressing Valve Springs:

Fig. 6 Cylinder Head Bolt Tightening Sequence:

14. Loosen cylinder head attaching bolts gradually in sequence, Fig. 4, until all bolts are removed.
15. Remove valve cover, then compress valve springs using a suitable tool, Fig. 5, and remove rocker arms and valve lash compensators. Identify components for installation reference.
16. Remove cylinder head as an assembly with intake and exhaust manifolds.
17. Reverse procedure to install, noting the following:
a. Clean all cylinder head, valve cover and block mating surfaces.
b. Apply a continuous bead (3 mm) of anaerobic sealant to cam carrier sealing surface.
c. Install new cylinder head gasket.
18. Toque the cylinder head/camshaft carrier following the sequence shown in figure:
a. All retaining bolts to 25 Nm (18 ft lb).
b. An additional 60° (to the 60° position).
c. An additional 60° (to the 120° position).
d. An additional 30° (to the 150° position).
19. After installation completion, start engine until thermostat opens.
20. Torque all cylinder head/camshaft carrier bolts an additional 30° - 50° in sequence shown in figure.