Cylinder Head Assembly: Service and Repair

1. Obtain audio anti-theft code, if equipped, as outlined in Technician Safety Information. Disable airbag system, refer to Technician Safety Information.
2. Drain coolant and oil from engine.
3. Drain coolant from intercooler assembly.
4. Remove suspension under brace.
5. Disconnect accelerator cable from throttle body assembly.
6. Remove reservoir tank and air cleaner assembly.
7. Remove alternator.
8. Raise and support vehicle.
9. Remove righthand front wheel.
10. Remove engine undercovers.
11. Remove suspension lower crossmember.
12. Remove front exhaust pipe.
13. Remove catalytic converter.
14. Remove alternator brackets.
15. Remove turbocharger and exhaust manifold assemblies.
16. Remove distributor.
17. Remove No. 2 air pipe.
18. Remove lefthand engine hanger.
19. Remove oil pressure switch and water outlet.
20. Remove water bypass pipe.
21. Remove throttle body.
22. Disconnect cold start injector connector. Remove EGR valve, vacuum modulator and EGR control VSV.
23. Remove vacuum pipe and intake manifold stays.
24. Remove No. 1 air pipe.
25. Remove fuel pressure VSV.
26. Remove T-VIS, VSV, vacuum tank and turbocharger pressure VSV.
27. Remove intake manifold and air control valve.
28. Remove power steering oil reservoir tank without disconnecting lines.
29. Remove spark plugs.
30. Remove No. 2 timing belt cover.
31. Remove timing belt as follows:
a. Place No. 1 cylinder to TDC of compression stroke by turning crankshaft pulley (sprocket) and aligning pulley groove with No. 1 timing belt cover marking `0'.
b. Check that the alignment marks on the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft one revolution (360°).
c. With timing marks properly aligned, remove timing belt.
32. Remove PCV pipe and cylinder head cover.
33. Remove camshaft timing pulleys (sprockets).
34. Remove No. 1 idler pulley (sprocket) and tension spring.
35. Remove No. 3 timing belt cover.

Fig. 6 Intake & Exhaust Camshaft Bearing Cap Bolt Loosening Sequence.:

36. Remove intake and exhaust camshafts as follows:
a. Uniformly loosen and remove the twenty bearing cap bolts in several passes, in sequence shown, in Fig. 6.
b. Remove the ten bearing cap, two oil seals and two camshaft assemblies. Arrange the intake and exhaust camshaft and components in order removed.
37. Remove righthand rear engine hanger.

Fig. 7 Cylinder Head Bolt Loosening Sequence.:

38. Remove cylinder head as follows:
a. Using tool 09043-38100 or equivalent, uniformly loosen and remove the ten cylinder head attaching bolts in several passes, in sequence shown in Fig. 7. Cylinder head warpage or cracking could result from loosening the bolts in incorrect order.
b. Lift the cylinder head from the dowels on the cylinder block and place it on a suitable workbench.
39. If cylinder head is difficult to remove, pry cylinder head off using a suitable screwdriver. When doing so, do not damage cylinder head or block surfaces.

Fig. 8 Cylinder Head Bolt Tightening Sequence.:

Fig. 9 Bearing Cap Location & Identification.:

Fig. 10 Intake & Exhaust Camshaft Bearing Cap Bolt Tightening Sequence.:

40. Reverse procedure to install, noting the following:
a. The cylinder head bolts are tighten in steps.
b. If any of the bolts break or deform, replace them.
c. Apply a light coat of clean engine oil onto bolt threads and under the heads of the bolts.
d. Using tool 09043-38100 or equivalent, install a uniformly tighten cylinder head bolts in several passes, in sequence shown in Fig. 8.
e. Torque bolts to specifications, on 1989 models to 36 ft. lb. and 40 ft. lb. and on 1991-93 models. If any of the bolts do not meet the required torque specification, replace the bolt.
f. Mark the front of the cylinder head bolt head with paint.
g. Tighten the ten cylinder head bolts an additional 90° in sequence shown.
h. Ensure paint mark applied, is now at a 90° angle from the front.
i. During installation of the intake and exhaust camshafts, place the camshaft onto the cylinder with the No. 1 camshaft lobe facing outward. Apply seal packing to the No. 1 bearing cap.
j. Install the bearing caps in their correct locations, as shown in Fig. 9. Each bearing cap has a number and front mark. Apply a light coat of clean engine oil onto the threads and under the heads of the bearing cap attaching bolts. Install and uniformly tighten the twenty bearing cap bolts in several passes, in sequence shown in Fig. 10. Torque bolts to 14 ft. lb.
k. Rearm airbag system, refer to Technician Safety Information.
l. If audio system was disabled, activate as outlined under Technician Safety Information.