Cylinder Head Assembly: Service and Repair

1. Drain coolant from radiator, then remove engine block drain plug from right side of engine.
2. Remove air cleaner assembly, timing belt cover attaching bolts and timing belt cover.
3. Rotate crankshaft until cylinder No. 1 is at TDC compression stroke, then align camshaft timing marks. If cover plate behind camshaft sprocket does not have a timing mark, scribe a reference mark in line with camshaft alignment mark.
4. Loosen accessory drive belt tensioner, then remove drive belt. Loosen timing belt tensioner and remove timing belt.
5. On 1987 models, remove timing belt tensioner.
6. Remove secondary ignition cables, then the valve cover.
7. Remove cylinder head retaining bolts, then using a suitable block of wood, pry off cylinder head. Lift cylinder head only. Do not attempt to rotate, as it is positioned by dowel pins.
8. Remove cylinder head with manifolds attached.
9. After cylinder head removal, ensure head bolt threads are clean and the bolts thread easily in and out of cylinder block.
10. Ensure camshaft and crankshaft timing marks are properly aligned, then install cylinder head gasket and cylinder head on cylinder block. Lubricate bolt threads and underside of bolt heads with clean engine oil and install head bolts.
11. Tighten cylinder head bolts as follows:

Fig. 5 Cylinder head tightening sequence:

a. Torque to 22 ft.lbs. following sequence shown in Fig. 5.
b. Torque to 52 ft.lbs. following sequence shown in Fig. 5.
c. Wait at least 3 minutes, then completely loosen all bolts.
d. Torque to 15 ft.lbs. following sequence shown in Fig. 5.
e. Attach angular wrench Mot. 591.03(M) or equivalent to torque wrench and tighten head bolts an additional 121-125 degrees.
12. Reverse remaining steps to complete installation, noting the following:
a. Ensure valve timing is correct and install timing belt as outlined under ``Timing Belt, Replace.''
b. Refill and bleed cooling system as outlined.