Seal Installation Procedure
Cylinder Head RemovalCAUTION: Do not remove the cylinder head until the engine is cold (at ambient temperature). If the head is removed while the engine is hot, the head may warp and require replacement. Let the engine cool for at least six hours beforehand to avoid damaging the head.
1. Raise the vehicle on a hoist and disconnect the exhaust pipes at the manifold.
2. Disconnect the oxygen sensor wire and lower the vehicle.
3. Open the hood and disconnect the battery negative cable.
4. Drain the cooling system as described on page B-78 of the August, 1986 edition of the M.R. 245 manual.
5. Remove the air cleaner.
FIGURE 1:
6. Remove the splash shield (1) from the passenger side, front wheel well to provide access to the crankshaft pulley (Fig. 1).
FIGURE 2:
7. Remove the timing belt cover attaching bolts (2) and remove the cover (3) (Fig. 2).
FIGURE 3:
8. Have a helper rotate the crankshaft pulley in a clockwise direction. Rotate the pulley until the timing mark (4) on the camshaft sprocket (5) is about 25.4 mm (one-inch) away from the timing mark (6) on the timing belt cover mounting plate (7) (Fig. 3).
NOTE: Some early 1.7L engines do not have a timing mark (6) on the cover mounting plate. On these engines, it will be necessary to rotate the crankshaft pulley until the camshaft sprocket timing mark (5) is at the approximate center of the cover mounting plate upper flange.
FIGURE 4:
9. Remove the plug (8) from the TDC access hole in the side of the block (Fig. 4).
FIGURE 5:
10. Insert top dead center tool Mot. 861 through the access hole and into the timing slot (9) in the crankshaft counterweight. Be sure the tool is seated in the crankshaft timing slot. If necessary, slowly rotate the crankshaft pulley until the tool can be pushed all the way into the slot.
CAUTION: Be sure the tool is seated in the timing slot and not in one of the counterweight balancing holes (10).
FIGURE 3:
11. Check position of the camshaft sprocket timing mark (4). The mark should be now aligned with the timing mark (6 on the cover mounting bracket (Fig. 3).
If the timing marks are not aligned, the Mot. 861 tool is in one of the balancing holes and not the timing slot. Remove and reinstall the tool. When the tool is in the timing slot, the crankshaft can not be turned back and forth.
NOTE: On engines without a timing mark on the timing belt cover mounting plate (7) (Fig. 3), scribe or paint a timing mark on the cover at this time. Be sure the mark is properly aligned with the timing mark on the camshaft sprocket.
12. Loosen the accessory drive belt and slide the belt off the crankshaft pulley.
FIGURE 6:
13. Remove the crankshaft pulley bolt (11) and remove the pulley (12). Use hand tools only to remove the pulley bolt.
CAUTION: Do not use any type of power tool to remove the pulley bolt (11). The bolt is secured with a thread locking compound. The threads on the bolt and in the crankshaft could be stripped if power tools are used.
FIGURE 7:
14. Check position of the crankshaft sprocket timing mark (13). The mark should be aligned with the oil pan bolt (14) just below the sprocket (Fig. 7).
FIGURE 8:
15. Paint timing reference marks on the camshaft belt as follows:
a. Using white paint, place a mark (15) on the belt in line with the timing mark (16) on the cam sprocket (Fig. 8). Then write the word "cam" next to the painted mark with grease pencil.
FIGURE 9:
b. Paint a second timing reference mark
(17) on the belt in line with the crankshaft sprocket timing mark (18).
FIGURE 10:
16. Loosen the camshaft timing belt tensioner lock nut to release belt tension and remove the timing belt.
17. Disconnect the CCV hose (19) at the oil separator (20) (Fig. 10).
18. Disconnect the knock sensor electrical connector (21), accelerator cable (22) and the mounting clamp (23) (Fig. 10).
FIGURE 11:
19. Disconnect the MAT sensor connector (24), throttle body fuel lines (25), fuel injection connector (26), WOT switch connector (27), TPS connector (28) and the heater hose
(29) (Fig. 11).
FIGURE 12:
20. Disconnect the coolant bottle hose (30), coolant temperature sender connector (31), brake booster vacuum hose (32), MAP sensor hose (33), distributor cap (34), radiator upper hose (35) and the heat riser hose (36) (Fig. 12).
FIGURE 13:
21. Disconnect the idle speed motor connector
(37) and the coolant temperature connector (38).
FIGURE 14:
22. Disconnect the EGR connector (39).
23. Disconnect the MAP sensor hose.
24. Remove the spark plug wires and remove the distributor rotor.
NOTE: The rotor is bonded in place. It will be necessary to break the rotor to remove it.
FIGURE 15:
25. Remove the cylinder head cover (40) (Fig. 15).
FIGURE 16:
26. On models with air conditioning, loosen the compressor mounting bracket bolts and move the bracket away from the cylinder block.
27. Remove the cylinder head bolts with socket wrench tool Mot. 852, or equivalent (Fig. 16).
28. Remove the cylinder head by lifting it straight up and off the block.
NOTE: Two dowels position the head on the block. Do not attempt to twist the head from side to side to remove it. Lift the head straight up and off the block.
29. Insert clean, lint-free rags into the cylinder bores to prevent dirt entry.