Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable, drain coolant from radiator and engine block.
2. Disconnect hose from air cleaner.
3. Disconnect throttle cable from throttle body and air intake chamber.
4. Disconnect gas filter to fuel pressure regulator, gas filter to distributor and throttle body to distributor vacuum hoses. Disconnect throttle body to charcoal canister vacuum hose.
5. Disconnect spark plug wires from spark plugs.
6. Disconnect all electrical connectors, fuel lines and heater hoses from cylinder head.
7. Remove spark plugs and two air intake chamber brackets.
8. Remove air intake line, air intake chamber and air valve.
9. Disconnect EFI solenoid wire harness from fuel line.
10. Raise and support vehicle.
11. Drain engine oil, then remove front exhaust pipe and bracket.
12. Lower vehicle, then remove intake and exhaust manifolds.
13. Remove nuts, washers and cylinder head cover.

Fig. 35 Rocker arm assembly attaching bolt removal sequence. 4K-E engine:

14. Remove rocker shaft assembly bolts in sequence shown in Fig. 35, then remove rocker shaft assembly and pushrod. Identify pushrod so that they can be installed in their original locations.

Fig. 36 Cylinder head bolt removal sequence. 4K-E engine:

15. Loosen and remove cylinder head bolts in sequence shown in Fig. 36, then remove cylinder head.

Fig. 37 Rocker arm assembly attaching bolt tightening sequence. 4K-E engine:

Fig. 38 Cylinder head bolt tightening sequence. 4K-E engine:

16. Reverse procedure to install. Torque rocker shaft assembly bolts in sequence shown in Fig. 37 to 14-17 ft. lbs. (1.8-2.4 kg-m). Torque cylinder head bolts to 40-47 ft. lbs. (5.4-6.6 kg-m) in sequence shown in Fig. 38.