Cylinder Head Assembly: Service and Repair

1. 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.
2. Disconnect battery ground cable, then drain engine coolant.
3. Remove intake air duct, then remove throttle cable and cruise control cable. Tag all cables and hoses for installation reference.
4. Remove starter cable from strut brace, then remove strut base.
5. Relieve fuel pressure as outlined under Technician Safety Information.
6. Remove fuel feed hose from fuel filter, then remove brake booster vacuum hose, evaporative emission (EVAP) control canister hose and fuel return hose.
7. Remove vacuum hoses, water bypass hose and breather hose.
8. Remove intake manifold cover, then positive crankcase ventilation (PVC) hose.
9. Loosen idler pulley center nut and adjusting bolt, then remove A/C compressor belt.
10. Remove ground cable, then vacuum pipes.
11. Loosen alternator mounting bolt, nut and adjusting bolt, then remove the alternator belt.
12. Remove bolts, then loosen mount bolt and pivot side engine mount out of way. Use a suitable jack to support engine before removing the side engine mount.
13. Loosen mounting nuts and adjusting nut, then remove power steering pump belt.
14. Disconnect inlet hose from power steering pump, then plug hose and pump. Remove power steering pump.
15. Remove harness cover and ground cable from water passage, then remove engine wire harness connectors and wire harness clamps from cylinder head and intake manifold.
16. Remove spark plug caps and distributor from cylinder head, then remove upper and lower radiator hoses and heater hoses.
17. Remove intake air bypass (IAB) vacuum tank, then remove water passage.
18. Remove harness covers from intake manifold, then remove exhaust gas recirculation (EGR) pipe.
19. Remove intake manifold, then remove exhaust manifolds.
20. Remove cylinder head covers and cylinder head side covers, then remove timing belt.
21. Remove camshaft pulley and back cover.
22. Remove camshaft holder plates, camshaft holders and camshafts.
23. Remove intake rocker arms, exhaust inside rocker arms and pushrods. Tag parts as they are removed for installation reference.

Fig. 12 Cylinder Head Bolt Loosening Sequence:

24. Remove cylinder head bolts in sequence, Fig. 12, then remove cylinder heads. To prevent warpage, unscrew bolts in sequence 1/3 turn at a time; repeat until all bolts are loosened.
25. Align cylinder head dowel pins, then install oil control orifice.

Fig. 13 Cylinder Head Bolt Tightening Sequence:

26. Tighten cylinder head bolts in two steps. First torque all bolts in sequence, Fig. 13, to 29 ft. lbs., then torque all bolts in sequence to 56 ft. lbs. Apply engine oil to cylinder head bolts and washers.
27. Fill hydraulic tappet mounting hole and oil fillers with engine oil, then install hydraulic tappets. Inspect hydraulic tappets before installing. Do not rotate hydraulic tappets while installing.
28. Install pushrods and rocker arms. Install each part in its original position. Loosen exhaust rocker arm adjusting screws and locknuts before installation.
29. Install camshafts and rubber cap, then install camshaft seals with open side (spring) facing in. Note locations of camshafts. Ensure rocker arms are properly positioned on valve stems. Advance crankshaft by 30 degrees from TDC to prevent interference between the piston and valve. Position rear camshaft on cylinder head so the cam is not pushing a valve. Do not apply oil to camshaft holder mating surface of camshaft seal. Apply liquid gasket around rubber cap.
30. Apply liquid gasket to camshaft holders, then install camshaft holders and plates.

Fig. 14 Camshaft Bolt Tightening Sequence:

31. Tighten bolts to specifications in sequence, Fig. 14.
32. Install back covers and camshaft pulleys, then set camshaft pulley at TDC.
33. Turn crankshaft counterclockwise to set it at TDC.
34. Install timing belt, then set No. 1 piston at TDC.
35. Tighten adjusting screws for No. 1, No. 2 and No. 4 cylinders. When screw contacts valve, tighten screw 1-1/8 turns. Tighten locknut firmly.
36. Rotate crankshaft pulley one turn clockwise, then tighten adjusting screws for No. 3, No. 5 and No. 6 cylinders. When you feel screw contact valve, tighten screw 11/8 turns. Tighten locknut firmly.
37. Install head cover gasket in groove of cylinder head cover, then install cylinder head side covers.
38. Tighten bolts in two or three steps to a final torque of 11 ft. lbs.
39. Install intake manifold and tighten nuts and bolts in a crisscross pattern in two or three steps, beginning with inner bolt.
40. Install exhaust manifolds and tighten nuts in a crisscross pattern in two or three steps, beginning with inner nut.
41. Install water passage.
42. Install all hoses, cables and electrical connections.
43. 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.