Cylinder Head Assembly: Service and Repair

1. Remove drive belt, power steering pump, alternator and bracket.
2. Remove timing belt and related components.
3. Remove valve rocker assembly.
4. Remove camshaft.
5. Disconnect spark plug wires, oil pressure switch electrical connector and blow-by hose.
6. Remove connector bracket retaining bolts, crank-angle and knock sensors.
7. Remove intake manifold and gasket.
8. Remove water pipe.
9. Separate cylinder head from cylinder block as follows:

Fig. 38 Cylinder Head Bolt Loosening Sequence:

a. Loosen cylinder head retaining bolts No. 1 and 3 as shown, Fig. 38. Do not remove bolts at this time.
b. Remove remainder of cylinder head retaining bolts in numerical order as shown Fig. 38.
c. Using a plastic hammer, tap on cylinder head while separating it from cylinder block.
d. Remove bolts No. 1 and 3 with cylinder head and gasket.
10. Remove valves from cylinder head using valve spring remover tool No. 499718000 or equivalent. Use caution not to damage oil seals. Keep all parts in order of removal for proper installation.
11. For lefthand cylinder head, remove plug only if service is needed.
12. For lefthand cylinder head, install plug using oil seal installer tool No. 499587100 or equivalent.
13. For either cylinder head, install valves as follows:
a. Coat valve stem with clean engine oil and insert valve into valve guide. Use caution not to damage oil seal lip. Install all parts in same order as which they were removed.
b. Install valve spring with closed coil end facing cylinder head seat.
c. Use valve spring remover tool No. 499718000 or equivalent to compress valve spring and install retainer. Seat valve spring retainer by tapping it with a soft hammer.
14. Install camshaft and valve rocker assemblies as outlined previously in this section.
15. Install cylinder head with new gasket.

Fig. 39 Cylinder Head Bolt Tightening Sequence:

16. On 1990 models, torque cylinder head bolts as follows:
a. Coat bolt threads and washers with clean engine oil.
b. Install and torque all six bolts in numerical order as shown, Fig. 39 to 51 ft. lbs.
c. Back off all bolts 180°.
d. Retorque bolts 1 and 2 to 25 ft. lbs.
e. Retorque bolts 3, 4, 5 and 6 to 14 ft. lbs.
f. Retorque all bolts in numerical order 80-90°.
g. Retorque all bolts again in numerical order 80-90°.
17. On 1991-93 models, torque cylinder head bolts as follows:
a. Coat bolt threads and washers with clean engine oil.

Fig. 40 Cylinder Head Bolt Tightening Sequence:

b. Install and torque all six bolts in sequence shown in, Fig. 40, to 22 ft. lbs.
c. Torque all bolts in sequence shown in, Fig. 40, to 51 ft. lbs.
d. Back off all bolts 180°, then back all bolts off an additional 180°.
e. On non-turbo models, torque bolts 1 and 2 to 25 ft. lbs.
f. On turbo models, torque bolts 1 and 2 to 27.1 ft. lbs.
g. On non-turbo models, torque bolts 3, 4, 5 and 6 to 11 ft. lbs.
h. On turbo models, torque bolts 3, 4, 5 and 6 to 14 ft. lbs.
i. On all models, torque all bolts 80°-90° in sequence shown in Fig. 40. Do not tighten bolts more than 90°
j. Torque all bolts an additional 80°-90° in sequence shown in Fig. 40. Ensure total retightening angle does not exceed 180°
18. Install timing belt and related components as outlined previously in this section.
19. Install water pipe.
20. Install intake manifold and gasket.
21. Install connector bracket retaining bolts, crank-angle and knock sensors.
22. Connect spark plug wires, oil pressure switch electrical connector and blow-by hose.
23. Install power steering pump, alternator and bracket.
24. Install drive belt. Refer to DRIVE BELT SERVICE for belt routing and tension data.