Cylinder Head Assembly: Service and Repair

Fig. 16 Exploded View Of Cylinder Head.:

Refer to Fig. 16, when servicing this cylinder head.

1. Disconnect battery ground cable, then drain cooling system.
2. Remove fuel tank lid cap to release fuel pressure, then replace fuel tank lid cap.
3. Remove air cleaner and accelerator cable, then disconnect PCV hose.
4. On automatic transmission models, remove throttle cable.
5. On all models, remove rubber hoses at top and rear of surge tank, then modulator and EGR valve assembly.
6. Remove engine wiring harness as follows:
a. Disconnect throttle position sensor and intake air temperature sensor connectors, then pressure sensor and idle speed control VSV connectors.
b. Disconnect EGR VSV connector, then oil pressure switch wire connector.
c. On manual transmission models, disconnect spark advance VSV.
d. On all models, disconnect injector connectors, then remove engine wire clamp.
e. Remove engine wiring harness.
7. Remove throttle body, then vacuum pipe assembly.

Fig. 17 Surge Tank Bolt Loosening Sequence.:

8. Remove surge tank stays, then remove surge tank bolts progressively over three stages following sequence shown in Fig. 17.
9. Disconnect fuel return hose and fuel hose No. 1 from delivery pipe. Use cloth to prevent fuel splashing.
10. Remove delivery pipe, then injectors from manifold.
11. Remove injector vibration and delivery pipe insulators, then disconnect radiator thermo control switch connector from thermostat housing.
12. Remove thermostat housing inlet from cylinder block, then thermostat and hose from thermostat housing.
13. Disconnect water by-pass inlet hose, then heater inlet hose at cylinder head.
14. Remove timing belt, refer to TIMING BELT.

Fig. 18 Intake Manifold Bolt Loosening Sequence.:

15. Remove intake manifold bolts progressively over three stages following sequence shown in Fig. 18, then remove intake manifold.
16. Remove radiator cooling fan and engine oil level gauge, then oxygen sensor.
17. On radio equipped models, remove engine ground cable from cylinder head cover.
18. On all models, remove exhaust manifold covers, then oil level gauge guide.
19. Remove exhaust pipe from exhaust manifold No. 2, then exhaust manifold stay.

Fig. 19 Exhaust Manifold Bolt Loosening Sequence.:

20. Remove exhaust manifold bolts progressively over three stages following sequence shown in Fig. 19, then remove exhaust manifold and gasket.
21. Remove resistive cords, then spark plugs.
22. Remove distributor, then disconnect vacuum hoses from Bimetal VSV.
23. Disconnect water temperature sender gauge connector, then water temperature sensor connector.
24. On models with A/C, disconnect A/C water temperature switch connector.
25. On all models, remove radiator upper hose, water by-pass hose and pipe.
26. Remove valve rocker shaft attaching bolts progressively over three stages, then valve rocker shafts with rocker arms.
27. Remove camshaft cap No. 5 attaching bolts, then camshaft bearing caps.
28. Remove camshaft from cylinder head.

Fig. 20 Cylinder Head Bolt Loosening Sequence.:

29. Remove cylinder head bolts progressively over three stages following sequence shown in Fig. 20. Bolts No. 1 and No. 3 are shorter than other bolts.
30. Remove cylinder head from cylinder block.
31. Reverse procedure to install, noting the following:
a. Install all new gaskets. Do not reuse old gaskets.

Fig. 21 Cylinder Head Bolt Tightening Sequence.:

b. Tighten cylinder head bolts progressively over three stages following sequence shown in Fig. 21.

Fig. 22 Applying Sealing To Camshaft Bearing.:

c. Apply Three Bond 1104 to camshaft cap No. 1 where shown in Fig. 22.
d. Fill oil well of each cylinder with engine oil.

Fig. 23 Exhaust Manifold Bolt Tightening Sequence.:

e. Tighten exhaust manifold bolts progressively over three stages following sequence shown in Fig. 23.

Fig. 24 Intake Manifold Bolt Tightening Sequence.:

f. Tighten intake manifold bolts progressively over three stages following sequence shown in Fig. 24.

Fig. 25 Surge Tank Bolt Tightening Sequence.:

g. Tighten surge tank bolts progressively over three stages following sequence shown in Fig. 25.
h. Install new O-ring on each injector. Do not reuse old O-rings.
i. Lubricate O-ring of each injector before installing delivery pipe.
j. Torque all bolts/nuts to specifications.