Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable, then drain engine coolant.
2. Remove fuel filler cap to release any pressure in fuel tank, then reinstall the cap.
3. Remove air intake duct, then the oil filler cap and hoses.
4. Disconnect fuel lines from filter and the fuel return pipe.
5. Remove air control valve from intake manifold.
6. Disconnect leads from spark plugs, ignition coil and wire holders.
7. Remove fuel injectors from cylinder head and plug openings to prevent contamination.
8. Loosen distributor cap retaining clips.
9. Disconnect vacuum hose from fuel vapor canister.
10. Disconnect all vacuum hoses at intake manifold.
11. Remove front section of manifold. Plug openings to prevent contamination.
12. Disconnect throttle cable, kickdown cable and, if equipped, cruise control cable from throttle control pulley.
13. Disconnect wiring harness and position aside.
14. Remove control pressure regulator attaching bolts and position regulator aside.
15. Remove intake manifold attaching bolts, then the intake manifold.
16. If removing right cylinder head, proceed as follows:
a. Remove air conditioning compressor attaching bolts and position compressor aside.
b. Remove oil dipstick and tube, then disconnect upper radiator hose.
c. Disconnect heater hoses from cylinder head.
d. Disconnect ground lead and ignition timing sender electrical connector from cylinder head.
e. Remove distributor cap with ignition cables, then rotate crankshaft until rotor aligns with notch in distributor body, and remove distributor.
17. If removing left cylinder head, proceed as follows:
a. Remove vacuum pump, then the air intake heater tube.
b. Disconnect lower radiator hose from water pump, then the hose between water pump and cylinder head.
18. Remove exhaust crossover pipe flange nuts and the exhaust pipe support bolts at transmission.
19. Pry off rubber support rings at center muffler, then slide exhaust system rearward.
20. Remove valve cover attaching bolts, then the valve cover.
21. Remove cover plate from rear of cylinder head.
22. Remove timing gear cover plug using an 8 mm Allen wrench, and on right side, remove cover plate.
23. Remove four upper timing gear cover attaching bolts.
24. Loosen timing gear sprocket bolt using a 10 mm Allen wrench.

Fig. 2 Cylinder head tightening sequence.:

25. Remove rocker arm shaft assembly. Bolts must be removed in the proper sequence, Fig. 2.

Fig. 5 Camshaft Locking Fork Installed:

26. Loosen camshaft lock plate bolt and move plate to one side, Fig. 3.
27. Install tool 5213. Hook holder under timing chain and tighten nut hand tight, then fasten holder to timing gear cover. Tension the chain and sprocket by turning knob on tool. The tool holds tension on the timing chain when the camshaft is removed. If the chain loosens, the tensioner will take up any slack. If this occurs, the timing gear cover will have to be removed.
28. Remove camshaft sprocket center bolt, then move camshaft to the rear and disconnect it from sprocket.

Fig. 6 Cylinder Liner Retainers Installed:

29. Pry up cylinder head at inner edge with the wooden handle of a hammer, then remove cylinder head from block. Do not pull head straight up during removal, as cylinder liners may be disturbed. As soon as cylinder head is removed, install cylinder liner retainers, Fig. 4.
30. Reverse procedure to install. Note the following:

Fig. 2 Cylinder head tightening sequence.:

a. Torque cylinder head bolts in three steps, in sequence, Fig. 2. Torque first to 10 Nm (7 ft. lbs.), then to 30 Nm (22 ft. lbs.) and finally to 60 Nm (44 ft. lbs.). Allow head to stabilize for at least 10-15 minutes.
b. While head is stabilizing, install camshaft into timing gear sprocket and install retaining bolt and camshaft lock.
c. Loosen cylinder head bolts in sequence, Fig. 2, then retorque to 15-20 Nm (11-15 ft. lbs.). Install tool 5098 onto socket, then, using protractor, tighten bolts an additional 113-117°.