Cylinder Head Assembly: Service and Repair

1. Relieve fuel pressure as follows:
a. Remove rear seat and pull back carpet.
b. With engine running, disconnect fuel pump connector.
c. Allow engine to deplete fuel supply, then turn ignition Off. Failure to release pressure prior to disconnecting fuel lines may cause fire or personal injury.
2. Disconnect battery ground cable, remove left engine under cover and drain cooling system, then disconnect upper radiator hose.
3. Disconnect and plug oil return line from turbocharger.
4. Disconnect air flow sensor electrical connector, then remove air cleaner.
5. Remove bolts securing power steering pump to bracket and position pump aside, then remove pump bracket.
6. Remove alternator and position aside, then remove condenser fan motor, if equipped.
7. Disconnect hose from air injection tube, then remove air injection and dipstick tubes.
8. Mark and disconnect necessary electrical connectors and vacuum hoses, release harness from clips and secure aside.
9. Remove bolt securing engine ground to manifold.
10. Disconnect coil high tension lead and remove plug wires.
11. Remove solenoid valve bracket from above distributor.
12. Disconnect fuel hoses, heater and manifold water hoses and the brake booster hose.
13. Disconnect control cables from throttle body.
14. Disconnect breather and PCV hoses, and the air intake pipe.
15. Remove left engine mount and bracket assembly, then the rocker arm cover and gasket. Support engine with suitable jack, as needed, to prevent engine from twisting in mounts.

Fig. 4 Camshaft timing marks. 1600cc engines:

16. Remove timing belt upper front cover, then rotate crankshaft in normal direction of rotation 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.
17. Place an alignment mark on timing belt, in line with mark on camshaft sprocket, Fig. 4.
18. Remove camshaft sprocket attaching bolt, then detach sprocket from camshaft with timing belt attached. Position camshaft sprocket on lower belt cover or suspend sprocket and belt from hood to maintain proper timing alignment. Do not rotate crankshaft after removing sprocket from camshaft.
19. Remove timing belt upper under cover and turbocharger heat shield, if equipped.

Fig. 2 Cylinder head bolt loosening sequence. 1400cc, 1600cc & 2000cc engines:

20. 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.
21. Reverse procedure to install, noting the following:
a. Do not apply sealer to cylinder head gasket.
b. Prior to installing cylinder head on engine, ensure that crankshaft and camshaft 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.
f. When installing rocker cover, apply 3M sealant 8660 or equivalent to semi-circular packing.