Front Cylinder Head

CAUTION: The camshafts must not be rotated because the valves could touch the pistons or each other and become damaged. The crankshaft may only be turned between 0° and 60° BTDC when the camshafts of both cylinder heads are locked with locking tools.





1. Drape the wings with protective covers and disconnect the negative cable from the battery.
2. Raise the car and undo the nuts that secure the front exhaust pipe to the exhaust manifold. Undo the bracket for the check valves.
3. Remove the center air shield, place a collecting tray under the engine and drain the coolant





4. Lower the car and remove the engine covers.
5. Unfasten the cruise control cable, detach the throttle cable from the bracket, unclip the control rod, detach the bracket and move it aside.
6. Unfasten the hose clamps between the inlet pipes and the intake manifold and between the resonator and the mass air flow sensor and raise the inlet pipes somewhat. Disconnect the vacuum hoses and the electrical connectors and remove the pipes complete with the resonator.





7. Undo the intake manifold bolts. Detach the throttle body preheater hoses, the crankcase ventilation hose and the vacuum hoses from the intake manifold.
8. Unplug the Idle Air Control (IAC) valve connector, detach the fuel pressure regulator hose and remove the wiring harness conduit under the throttle body.
9. Detach the throttle position indicator connector and the ignition coil, unplug the Traction Control System (TCS) throttle body connector and lift off the intake manifold. Plug the holes with paper.





10. Unplug the injector connector and disconnect the camshaft position sensor.
11. Disconnect the fuel lines and plug the connectors.
12. Remove the bolts securing the center intake manifold complete with fuel rail and place it to one side.
13. Mark the position of the lower part of the intake manifold and remove it. Plug with paper.
14. Detach the coolant bridge and bend it aside.
15. Disconnect ignition leads 2-4-6.and the ignition coil. Bend the coil aside and detach the ignition coil bracket.





16. Remove the lifting eye and the heat shield over the exhaust manifold.
17. Detach the resonator bracket and unfasten the secondary air injection pipe from the exhaust manifold.
18. Lift the power steering servo oil reservoir.
19. Detach the lead from the torque arm engine mounting and remove the torque arm.
20. Remove the servo line clamp from the torque arm engine mounting and remove the engine mounting.
21. Detach the upper hose from the expansion tank and the upper part of the generator air intake.





22. Slightly loosen the pulley bolts. Remove the multi-groove belt, the multi-groove belt tensioner, the power steering servo pump, the coolant pump pulley and the timing cover.
23. Remove the crankshaft pulley (remove the six bolts, not the center bolt).
24. Zero the engine. The markings on the camshaft sprocket and the timing cover should align as should the marking on the crankshaft. Insert the locking tool for the camshaft sprocket on the cylinder head.
25. Before removing the toothed belt. mark its direction of rotation. To facilitate installing, the belt can be marked at both the camshaft marking and at the crankshaft marking.
26. Release the belt from tension and remove the toothed belt. Undo the adjuster pulley bolts.
27. Turn the crankshaft back to 60° BTDC.





28. Remove the timing cover. Make sure that the O-rings are in position and that they do not fall into the engine.
29. Remove the cylinder head camshaft sprockets and remove the timing cover bolts in the cylinder head. The camshaft sprockets are marked 3 and 4.

CAUTION: The open ended wrench used as a holding tool to remove the camshaft sprockets must not have jaws that are too long. There is a risk of damaging the casting so that the tappet locks.

30. Remove the bearing caps on the exhaust camshaft. It is important to finish removal at the bearing cap where valve depressors are compressed. Note the marking on the bearing caps. Undo the bolts in stages of 1/2 to 1 turn and lift out the camshaft.

NOTES:
^ The intake camshaft need not be removed when removing the cylinder head.
^ There is still a lot of coolant in the engine.

31. Undo the cylinder head bolts in the order shown. First slacken them a 1/4 turn and then 1/2 a turn. Lift off the cylinder head. Be careful when putting it down as the intake camshaft is still in place and the valve stems could be bent accidentally.
32. When working on the cylinder head: Remove the spark plugs, the intake camshaft, the tappets and the exhaust manifold.