Cylinder Head Assembly: Service and Repair
1. Drain cooling system, then disconnect upper radiator hose from engine.
2. Remove canister purge hose and PCV valve breather hose, then the air cleaner assembly and disconnect fuel line at carburetor.
3. Disconnect vacuum hose at distributor and purge control valve.
4. Disconnect spark plug wires at spark plugs, then remove distributor.
5. Disconnect heater hose from intake manifold.
6. Disconnect coolant hose at carburetor.
7. Disconnect coolant temperature wire connector, then remove fuel pump.
8. Disconnect exhaust pipe from exhaust manifold, then remove exhaust manifold from cylinder head.
9. Remove intake manifold and carburetor as an assembly from cylinder head.
Fig. 4 Camshaft timing marks. 1600cc engines:
10. Remove timing belt upper front cover, then rotate crankshaft to bring No. 1 cylinder to top dead center compression stroke. The No. 1 cylinder is at top dead center compression stroke when the mark on the upper timing under cover is aligned with the mark on the camshaft sprocket, Fig. 4.
11. Place an alignment mark on timing belt, in line with mark on camshaft sprocket, Fig. 4.
12. Remove camshaft sprocket attaching bolt, then detach sprocket from camshaft with timing belt attached. The timing belt lower cover incorporates a holder which will retain the camshaft sprocket in position. If clearance between camshaft sprocket and lower front cover is considerable, a piece of timing belt or other suitable spacer should be inserted between sprocket and holder. This is done to prevent the timing belt from becoming dislodged from the crankshaft sprocket or oil pump sprocket. Use care not to rotate crankshaft after sprocket has been detached from camshaft.
13. Remove three timing belt upper under cover bolts, then remove cover.
14. Remove rocker arm cover attaching bolts, then the rocker cover.
Fig. 2 Cylinder head bolt loosening sequence. 1400cc, 1600cc & 2000cc engines:
15. Remove cylinder head attaching bolts in sequence shown in Fig. 2. Loosen bolts evenly, in three steps, to prevent cylinder head warpage. Two dowel pins are used to locate the cylinder head on the cylinder block. When removing cylinder head use care not to disturb the camshaft sprocket and timing belt. After removing cylinder head, clean gasket surfaces on head and block.
16. Reverse procedure to install, noting the following:
a. When applying sealer, use care not to allow sealer to contact jet air passage.
b. Prior to installing cylinder head on engine, ensure that crankshaft and camshaft timing marks are aligned.
Fig. 3 Cylinder head bolt tightening sequence. 1400cc, 1600cc & 2000cc engines:
c. When installing cylinder head, tighten bolts in sequence shown in Fig. 3. Tighten bolts in two steps to ensure proper seating of cylinder head to cylinder block.
d. Before installing intake manifold gasket, apply sealer to both sides of gasket at water passage openings.
e. After cylinder head has been installed, adjust timing belt tension and valve clearance as outlined.