Cylinder Head Assembly: Service and Repair

1. Position No. 1 cylinder at top dead center compression stroke.
2. Drain cooling system, then disconnect upper radiator hose at engine.
3. Remove crankcase breather hose connected between rocker arm cover and air cleaner, then remove air cleaner assembly.
4. Disconnect vacuum hose, coolant hose, accelerator linkage and fuel line at carburetor.
5. Disconnect spark plug wires at spark plugs, then remove distributor assembly.
6. Remove carburetor assembly, then remove intake manifold.
7. Remove heat cowl and exhaust manifold.

Fig. 1 Positioning timing belt tensioner toward water pump. 1400cc engine:

8. Remove timing belt cover, then move timing belt tensioner toward water pump as far as possible and secure in this position, Fig. 1.
9. Remove timing belt from camshaft sprocket. Do not remove belt from crankshaft sprocket. Do not rotate crankshaft or camshaft independently.

Fig. 2 Cylinder head bolt loosening sequence. 1400cc, 1600cc & 2000cc engines:

10. Remove rocker arm cover, then remove cylinder head bolts in sequence shown in Fig. 2, using tool No. TW-10B. Loosen cylinder head bolts evenly, in three steps, to avoid cylinder head warpage.
11. Remove cylinder head assembly from engine, then clean cylinder head and cylinder block gasket surfaces.
12. Reverse procedure to install, noting the following:
a. Do not apply sealer to cylinder head gasket or gasket surfaces.
b. When installing intake manifold gasket, apply sealer to both sides of gasket at passage opening. Do not allow sealer to contact jet air passage.
c. Prior to installing cylinder head on engine, ensure that crankshaft and camshaft timing marks are aligned as outlined in ``Timing Belt, Replace.''

Fig. 3 Cylinder head bolt tightening sequence. 1400cc, 1600cc & 2000cc engines:

d. When tightening cylinder head bolts, refer to Fig. 3 for tightening sequence and torque bolts in two steps to ensure proper cylinder head to cylinder block seating.
e. Before installing timing belt, position belt tensioner toward water pump as far as possible. After installing timing belt check to ensure that tension side is tight, by turning camshaft sprocket slightly in the reverse direction of rotation and noting that all marks are aligned. Refer to ``Timing Belt, Replace.''
f. After cylinder head has been installed, adjust timing belt tension and valve clearance as outlined.