Removal and Installation

REMOVAL
1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect negative battery cable. Drain cooling system.
3. Remove air cleaner duct and air cleaner, disconnect all vacuum lines, electrical wiring and fuel line from fuel rail and throttle body.
4. Remove throttle linkage.
5. Remove accessory drive belts.
6. Remove power brake vacuum hose from intake manifold.
7. Raise vehicle and remove exhaust pipe from manifold.
8. Remove power steering pump assembly and set aside.
9. Disconnect coil pack wiring connector and remove coil pack from engine.
10. Remove cam sensor and fuel injectors wiring connectors.
11. Remove timing belt, timing belt tensioner, and camshaft sprocket.
12. Remove inner timing belt cover.
13. Remove cylinder head cover.
14. Remove camshaft and cam follower assemblies.
15. Remove cylinder head bolts.

CAUTION: Use only a plastic scraper to remove gasket material on the aluminum head sealing surfaces to prevent damage to cylinder head.

CYLINDER HEAD FLATNESS

Checking Cylinder Head Flatness:

1. Cylinder head must be flat within 0.1 mm (0.004 inch).

NOTE: Inspect camshaft bearing journals for scoring.

INSTALLATION
1. Position new cylinder head gasket onto block.

Cylinder Head Tightening Sequence - L4 DOHC:

2. Before installing the bolts the threads should be oiled with engine oil. The 4 short bolts 110 mm (4.330 inch) are to be installed in positions 7, 8, 9, and 10.
3. Tighten the cylinder head bolts in sequence shown. Follow the four step procedure listed below:
- Step 1: Bolts 1 - 6 to 34 Nm (25 ft. lbs.) and flip 7 - 10 to 28 Nm (20 ft. lbs.)
- Step 2: Bolts 1 - 6 to 68 Nm (50 ft. lbs.) and bolts 7 - 10 to 28 Nm (20 ft. lbs.)
- Step 3: Bolts 1 - 6 to 68 Nm (50 ft. lbs.) and bolts 7 - 10 to 28 Nm (20 ft. lbs.)
- Step 4: Turn all bolts an additional 90° (1/4 turn). Do not use a torque wrench for this step.
4. Install cam follower assemblies and camshafts.
5. Install cylinder head cover.
6. Install inner timing belt cover and camshaft sprockets.
7. Install timing belt tensioner and timing belt.
8. Connect electrical connectors to cam sensor and fuel injectors.
9. Install coil pack and connect electrical connector.
10. Install power steering pump.
11. Connect power brake booster hose to intake manifold.
12. Install throttle linkage to throttle body.
13. Connect all vacuum lines and electrical connectors to throttle body.
14. Connect fuel supply hose to fuel rail.
15. Install air cleaner duct and air cleaner.
16. Install accessory drive belts.
17. Raise vehicle and connect exhaust system to exhaust manifold.
18. Lower vehicle and connect negative cable to battery.
19. With DRB scan tool use ASD Fuel System Test to pressurize fuel system. Check for fuel leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes, or until the ignition switch is turned to the OFF position, or Stop All Test is selected.

20. Perform camshaft and crankshaft timing relearn procedure as follows:
- Step 1: Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel; near the steering column.
- Step 2: Turn the ignition switch on and access the "miscellaneous" screen.
- Step 3: Select re-learn cam/crank option and follow directions on DRB screen.