Cylinder Head Assembly: Service and Repair

1. Release fuel system pressure as outlined under ``Fuel System Pressure Release.''
2. Remove camshaft sprockets as outlined under ``Timing System & Seal Service.''
3. Remove intake manifold as outlined under ``Intake Manifold, Replace.''

Fig. 7 Rear Timing Belt Cover Bolts:

4. Remove timing belt cover to cylinder head fasteners, Fig. 7.

Fig. 8 Water Pump O Rings:

5. If right side timing belt cover is removed, there are O-rings located behind it for water pump passages, Fig. 8.
6. Remove cylinder head bolts then the cylinder head.
7. Check for cracks, leaks or damage.
8. Clean mating surfaces of cylinder head and engine block.
9. Clean cylinder head and oil passages.
10. Ensure cylinder head flatness is within .002 inch.

Fig. 9 Checking Bolts For Stretching:

11. Check cylinder head bolts for necking by holding a scale or straightedge against threads. If all threads do not contact the scale, bolts should be replaced, Fig. 9.
12. Reverse procedure to install, noting the following:
a. Lightly coat threads of cylinder head bolts with engine oil.

Fig. 10 Cylinder Head Gasket Identification:

b. Install cylinder head gasket as shown in Fig. 10.

Fig. 11 Cylinder Head Bolt Tightening Sequence:

c. Tighten cylinder head bolts in sequence shown in Fig. 11, in four steps as follows: First torque bolts to 45 ft-lbs, Second torque 65 ft-lbs, Third torque bolts again to 65 ft-lbs, Forth turn bolts an additional 1/4 turn. If bolt torque is not greater than 90 ft-lbs, replace bolt.