Cylinder Head Assembly: Service and Repair

Fig. 1 Cylinder Head Bolt Loosening Sequence:

Fig. 2 Camshaft Bearing Cap Bolt Loosening Sequence:

1. Disconnect battery ground cable, then drain coolant from radiator and engine block into suitable container.
2. Disconnect exhaust pipe from exhaust manifold.
3. Disconnect cruise control cable, accelerator cable and, on models equipped with auto. trans., throttle valve cable.
4. Disconnect ground strap from rear of engine.
5. On models less turbo, remove air cleaner hose with intake air connector pipe. On models with turbo, remove air cleaner pipe with air cleaner hoses.
6. On all models, disconnect cruise control vacuum hose, charcoal canister hose and brake booster vacuum hose.
7. Remove radiator inlet hose, then disconnect heater inlet hose.
8. Remove alternator drive belt, then the alternator and adjusting bracket.
9. On turbo models, remove power steering reservoir tank, then cam position sensor.
10. On all models, remove air intake chamber with connector.
11. On turbo models, remove ignition coil cover, connectors, ground wire and attaching nut, then the ignition coil with bracket.
12. On all models, identify, then disconnect any wiring that may interfere with cylinder head removal.
13. Remove fuel pulsation damper, vacuum switching valve and No. 1 fuel pipe.
14. Remove No. 3 fuel pipe, then, on turbo models, remove auxiliary air pipe.
15. On all except turbo models, remove oil dipstick and secondary cables from spark plugs, then distributor.
16. On turbo models, remove turbocharger.
17. On all except turbo models, remove exhaust manifold attaching bolts, then the exhaust manifold. On turbo models, remove heat insulator, bracket and exhaust manifold attaching bolts, then the manifold.
18. On all models, remove coolant outlet housing, then the cylinder head covers and spark plugs.
19. Remove timing belt and camshaft sprockets. Refer to TIMING BELT.
20. Loosen cylinder head bolts in increments, following sequence, Fig. 1. If loosening sequence is not followed, cylinder head warpage or cracking could occur.
21. Lift cylinder head from block, then disconnect No. 5 coolant bypass hose from union. Continue to remove cylinder head and place on suitable wooden blocks.
22. Remove rear timing belt cover, alternator bracket, heater inlet hose, heater union and fuel delivery pipe with injectors from cylinder head.
23. Remove intake manifold, No. 2 engine hanger, ground strap and EGR cooler from cylinder head.
24. Loosen camshaft bearing cap bolts in increments, following sequence, Fig. 2, then remove bearing caps and camshafts.
25. Reverse procedure to install. Torque camshaft bearing cap attaching bolts gradually in three steps in reverse sequence as disassembly, Fig. 2, to 14 ft. lbs. Torque cylinder head attaching bolts gradually in three steps in reverse sequence as disassembly, Fig. 1, to 58 ft. lbs.