Cylinder Head Assembly: Service and Repair

REMOVAL
1. Remove crankshaft damper.
2. Remove timing belt covers.
3. Remove camshaft sprockets. Refer to Camshaft Sprocket and Engine Timing.
4. Remove intake manifold assembly.

Figure 39-Rear Timing Belt Cover Attaching Bolts:

5. Remove rear timing belt cover to cylinder head fasteners. Remove the rear covers.

Figure 40 Right Side Timing Belt Cover Water Pump O - Rings:

6. The right side timing belt cover has O-rings located behind it for water pump passages.
7. Remove cylinder head bolts and remove cylinder head.

INSTALLATION

Figure 41-Checking Bolts For Stretching (Necking):

The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.
Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced.

CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.

1. Clean sealing surfaces of cylinder head block.

Figure 42 Cylinder Head Gasket Identification:

2. Install head gasket over locating dowels. Ensure the gasket is installed on the correct side.
3. Install cylinder head over dowels.
4. Before installing the bolts, lubricate the threads with engine oil.

Figure 43 Cylinder Head Bolt Tightening Sequence:

5. Tighten the cylinder head bolts. Using the 4 step torque-turn method, tighten according to the following values:
- Step 1: All to 61 Nm (45 ft. lbs.)
- Step 2: All to 88 Nm (65 ft. lbs.)
- Step 3: All (again) to 88 Nm (65 ft. lbs.)
- Step 4: + 90° Turn Do not use a torque wrench for this step.

6. Bolt torque after 90° turn should be over 122 Nm (90 ft. lbs.)in the tightening direction. If not, replace the bolt.
7. Install rear timing belt covers. Use new O-ring on the water pump passages on the right side cover. Tighten bolts to specified torque:

- M10-54 Nm (40 ft. lbs.)
- M8-28 Nm (20 ft. lbs.)
- M6-12 Nm (105 inch lbs.)

8. Install camshaft sprockets and timing belt.
9. Install timing belt covers.
10. Install intake and exhaust manifolds.
11. Install crankshaft damper.