Cylinder Head Assembly: Service and Repair

Fig. 16 Cylinder Head Removal (Part 1 Of 2).:

Fig. 16 Cylinder Head Removal (Part 2 Of 2).:

REMOVAL

Remove cylinder head in numbered sequence, Fig. 16, noting the following:
1. Before disconnecting high pressure fuel line, relieve fuel system pressure as follows:
a. Disconnect fuel pump harness connector at fuel tank.
b. Start engine and let it run until it stalls, then turn ignition switch to off.
c. Disconnect negative battery cable.
d. Reconnect fuel pump harness connector.
2. Before removing upper radiator hose, mark hose clamp in relation to hose for assembly reference, then drain coolant as follows:
a. Place instrument panel temperature control lever in Hot position.
b. Carefully remove radiator cap.
c. Remove radiator drain plug.
3. To remove engine mount bracket, slightly raise and support engine, removing weight of engine from mount.

Fig. 17 Timing Mark Alignment.:

4. Remove camshaft sprocket as follows:
a. Turn crankshaft clockwise and align timing marks, Fig. 17. Do not turn crankshaft counterclockwise.
b. Remove camshaft sprocket with timing belt attached, then lay sprocket and belt on timing belt front lower cover. Do not rotate crankshaft once camshaft sprocket is removed.

Fig. 18 Head Bolt Removal Sequence.:

5. Using cylinder head bolt wrench No. TW-10B or equivalent, remove cylinder head bolts in sequence as shown in Fig. 18.

INSTALLATION

Reverse removal procedure to install, noting the following:
1. Install cylinder head gasket as follows:
a. Using a suitable scraper, remove old gasket material from cylinder block, using care not to allow old gasket material to fall into cylinder or passages.
b. Clean head and block surfaces which come in contact with head gasket.
c. Place head gasket on block with identification mark at top front. Do not apply sealant to head gasket.

Fig. 19 Head Bolt Tightening Sequence.:

2. When installing cylinder head, torque head bolts to specifications in two or three steps and in order as shown in Fig. 19.
3. When installing semi-circular packing, apply liberal amount of gasket sealant onto circumference of packing.
4. When installing high pressure fuel line (5), apply small amount of gasoline to hose union. Use care to avoid damaging O-ring.