Cylinder Head Assembly: Service and Repair

REMOVAL
1. Drain cooling system.
2. Remove air cleaner assembly.
3. Remove one heater hose retaining screws to rocker cover.
4. Disconnect distributor cap and spark plug wire and remove assembly.
5. Remove spark plugs.
6. Disconnect required vacuum hoses.
7. Remove dipstick tube and bracket.
8. Remove rocker cover retaining bolts and remove cover.
9. Remove intake manifold retaining bolts.
10. Loosen alternator retaining bolts and remove belt from the pulley. Remove alternator mounting bracket retaining bolts to the head.
11. Disconnect upper radiator hose at both ends and remove from vehicle.
12. Remove timing belt cover bolt and remove cover. Move power steering pump bracket.
13. Loosen timing belt idler retaining bolts. Position idler in the unloaded position and tighten the retaining bolts.
14. Remove timing belt from the cam pulley and auxiliary pulley.
15. Remove four nuts and/or stud bolts retaining heat stove to exhaust manifold.
16. Remove the eight exhaust manifold retaining bolts.
17. Remove the cam belt idler and two bracket bolts.
18. Remove cam belt idler spring stop from the cylinder head.
19. Remove cylinder head retaining bolts.
20. Remove the cylinder head.
21. Clean cylinder head gasket surface at the block.
22. Clean intake manifold gasket surface at the intake manifold.
23. Clean exhaust manifold gasket surface at the exhaust manifold.
24. Clean exhaust manifold gasket surface at the cylinder head.
25. Clean cylinder head gasket surface at the cylinder head.
26. Clean intake manifold gasket surface at the cylinder head.
27. Blow oil out of the cylinder head bolt block holes.
28. Clean rocker cover gasket surface on the head.
29. Check cylinder head for flatness.

INSTALLATION
1. Position head gasket on the block.
2. Clean rocker arm cover (cam cover).
3. Install rocker cover gasket to the rocker cover. Use D7AZ-19B508-A or equivalent contact cement.






4. With the camshaft in the proper position, install the cylinder head onto the cylinder head gasket.
5. Install all ten (10) cylinder head bolts (F3ZZ-6065-A) into the cylinder block and tighten to specification Fig. 17






6. Connect oil sending unit lead wire
7. Install cam belt idler spring stop to the cylinder head.
8. Position cam belt idler spring stop to the cylinder head. and install retaining bolts.
9. Install the eight exhaust manifold retaining bolts and/or stud bolts and tighten to: 27-40.5 Nm (20-30 ft lb)






10. Install heat stove to exhaust manifold three nuts and two retaining bolts.
11. Align distributor rotor with number one plug location in the distributor cap.
12. Align cam gear with pointer.
13. Align crank pulley (TDC) with pointer on cam belt cover.
14. Position timing belt to pulleys (cam and auxiliary).
15. Loosen idler retaining bolts, rotate engine and check timing alignment.
16. Adjust belt tensioner and tighten retaining bolts.
17. Install cam belt cover four retaining bolts.
18. Connect upper radiator hose to engine and radiator and tighten retaining clamps.
19. Position alternator bracket to cylinder head and install retainers.
20. Position drive belt to pulley and adjust belt tension using Belt Tension Gauge Rotunda 021-00045 or equivalent.
21. Install rocker arm cover and retaining bolts.
22. Install spark plugs.
23. Install dipstick tube and bracket.
24. Connect appropriate vacuum hoses.
25. Position and connect spark plug wires.
26. Install one retaining heater/hose screws to the rocker cover.
27. Fill cooling system.
28. Start engine and check for leaks.
29. Adjust ignition timing and connect distributor vacuum line.
30. Install air cleaner.