Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable, then drain cooling system.
2. Disconnect accelerator and throttle cables.
3. Remove air intake hose, then disconnect air flow meter electrical connector and remove air flow meter.
4. Remove air cleaner assembly.
5. Remove power steering pump and position aside. Do not disconnect hoses from pump.
6. Remove A/C compressor and position aside. Do not disconnect hoses from compressor.
7. Remove power steering pump and A/C compressor mounting brackets.
8. Disconnect spark plug wires from spark plugs and ignition coil.
9. Disconnect hoses from water outlet, water pump, oil cooler and heater water pipe.
10. Remove heater water pipe from cylinder head.
11. Disconnect upper radiator hose, then the fuel hoses.
12. Raise and support vehicle.
13. Disconnect exhaust pipe from exhaust manifold.
14. Remove air pump.
15. Mark emission control hoses, then disconnect hoses.
16. Disconnect necessary electrical connectors.
17. Remove EGR pipe, then the cold start injector pipe.
18. Disconnect the water hoses, then remove the water bypass pipe.
19. Remove the two intake chamber stays.
20. Remove intake chamber attaching bolts, then the intake chamber.
21. Remove manifold temperature sensor, then disconnect engine wire harness from intake manifold.
22. Remove fuel pipes, pulsation damper and necessary vacuum hoses.
23. Remove delivery pipe and injectors as an assembly.
24. Remove air injection manifold.
25. Remove intake and exhaust manifold attaching bolts, then the manifolds.
26. Disconnect water bypass hose, then remove water outlet assembly.
27. Remove spark plugs, then the cylinder head cover.
28. Remove valve rocker shaft assembly.
29. Remove pushrods. Ensure pushrods are installed in their original position during assembly.
30. Loosen head bolts evenly in several passes, then remove bolts. Head warpage or cracking may result if bolts are improperly removed.

Fig. 1 Cylinder Head Bolt Tightening Sequence:

Fig. 2 Rocker Arm Shaft Bolt Tightening Sequence:

31. Reverse procedure to install, noting the following:
a. Torque cylinder head bolts to 90 ft. lbs. in sequence shown in Fig. 1.
b. Torque rocker shaft bolts in sequence shown in Fig. 2, 12mm bolt head to 17 ft. lbs., 14mm bolt head to 25 ft. lbs.
c. Adjust valve clearance, refer to Engine/Cylinder Head Assembly/Valve, Intake/Exhaust/Adjustments.
d. Torque cylinder head cover, water outlet, intake and exhaust manifold attaching bolts to specifications.
e. Torque air injection manifold attaching bolts and exhaust pipe to manifold attaching nuts to specifications.