Removal and Installation

Fig. 17 Exploded View Of Cylinder Head:

Fig. 18 Engine Outer Components (Part 1 Of 2):

Fig. 18 Engine Outer Components (Part 2 Of 2):

REMOVAL
When replacing cylinder heads, refer to Figs. 17 and 18 for component identification and locations.
With the timing belt removed, avoid turning the camshaft or crankshaft. If movement is required, exercise extreme caution to avoid valve damage caused by piston contact.
1. Relieve fuel system pressure as outlined under Technician Safety Information.
2. Remove intake manifold collector, then injector pipe assembly and valve covers.
3. Remove timing belt. Refer to Timing Belt.
4. Remove idler pulley and its stud bolt.
5. Remove intake manifold.
6. Disconnect front exhaust tube from exhaust manifold.
7. Loosen cylinder head bolts in thee steps.
8. Remove cylinder head with exhaust manifold.

INSTALLATION
1. Set No. 1 cylinder at TDC of compression stroke as follows:
a. Align crankshaft sprocket aligning mark with mark on oil pump body.
b. Align camshaft sprocket aligning mark with mark on timing belt rear cover.

2. Install cylinder head with new gasket. Ensure washers between bolts and cylinder head are installed with flat side towards cylinder head. Do not rotate crankshaft and camshaft separately or valves will strike piston heads.

Fig. 19 Right cylinder head bolt tightening sequence:

Fig. 20 Left cylinder head bolt tightening sequence:

Fig. 21 Final cylinder head bolt tightening sequence:

3. Install cylinder head bolts, then tighten in numerical order, Figs. 19 through 21. Tighten in following sequence:
a. First, torque all bolts to 29 ft. lbs., then torque all bolts to 90 ft. lbs.
b. Loosen all bolts completely.
c. Torque all bolts to 25-33 ft. lbs.
d. Torque all bolts to 90 ft. lbs., or if an angle wrench is available, tighten bolts marked L1 to 70-75° and bolts marked L2 to 65-70° clockwise, Fig. 21.
e. Torque bolts marked X in Fig. 21 to 7-9 ft. lbs.

4. Install valve covers. When installing exhaust side valve covers, apply liquid gasket.
5. Install remaining parts