Operation CHARM: Car repair manuals for everyone.

Cylinder Head Assembly: Service and Repair

1. Rotate crankshaft until No. 1 cylinder is at TDC on compression stroke,with camshaft sprocket and flywheel timing marks aligned as outlined under Timing Belt.
2. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.
3. Disconnect battery ground cable, then the positive battery cable.
4. Drain engine coolant, then remove throttle cable, throttle control cable and cruise control cable.
5. Remove intake air duct.
6. Remove breather hose, Positive Crankcase Ventilation (PCV) hose and evaporative emission (EVAP) control canister hose.
7. Relieve fuel pressure as described under Technician Safety Information.
8. Remove fuel feed hose, fuel return hose and vacuum hoses.
9. Remove brake booster vacuum hose and vacuum hoses.
10. Remove power steering hose clamp, wire harness clamp and engine ground cable.
11. Remove battery cable and alternator cable, then the power steering pump belt and power steering pump.
12. Remove alternator belt, then the engine wire harness holder and water bypass hose.
13. Remove engine wire harness connectors and wire harness clamps from cylinder head and intake manifold.
14. Remove distributor assembly, then the upper and lower radiator hoses and heater hose.
15. Remove water bypass hose, then the side engine mount.
16. Remove cylinder head cover.
17. Remove timing belt, then the camshaft pulley and back cover.
18. Remove splash shield, then the exhaust and intake manifolds.

Fig. 11 Cylinder Head Bolt Loosening Sequence:




Fig. 9 Cylinder Head Bolt Tightening Sequence:





19. Remove cylinder head bolts in sequence, Fig. 11, 1/3 turn at a time.
20. Separate cylinder head from block.
21. Reverse procedure to install, noting the following:
a. Always use new head gasket and ensure cylinder head and block surfaces are clean.
b. Ensure UP mark on camshaft pulley is at top, then turn crankshaft so No. 1 piston is at TDC.
c. Using sequence shown in Fig. 10, torque cylinder head attaching bolts in three steps; first step to 29 ft. lbs., second step to 51 ft. lbs., third step to 72 ft. lbs.
d. After filling cooling system, bleed cooling system.
22. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.