CAUTION:Rotate crankshaft in clockwise direction only.
Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect fuel inlet and return lines. Plug all fuel hoses to avoid leakage. Disconnect negative battery cable. Drain cooling system. Remove air inlet duct. Note locations and disconnect all necessary electrical connectors, ground wires, vacuum hoses, coolant hoses and control cables for cylinder head removal. Rotate crankshaft clockwise until timing mark is at TDC. Remove timing covers.
Remove spark plug wires and spark plugs. Remove distributor. Remove all drive belts. Remove water pump pulley. Remove timing belt cover(s). Loosen timing belt tensioner bolt, relieve timing belt tension and tighten tensioner bolt. Remove timing belt from camshaft sprocket(s). Secure timing belt aside. Remove valve cover.
Remove exhaust downpipe and support bracket from exhaust manifold. Remove intake manifold support bracket. Loosen all cylinder head bolts evenly, in reverse order of tightening sequence, in 2-3 steps. Remove bolts. Remove cylinder head and manifolds as an assembly.
Carefully clean carbon and gasket material from all mating surfaces. Clean threads of cylinder head bolts. Use tap to clean threads in engine block. Check cylinder head for warpage and cracks. Resurface or replace head if it is not within specification. Check valve train components. Replace or resurface components if they are not within specification. See CYLINDER HEAD and VALVES & VALVE SPRINGS tables under ENGINE SPECIFICATIONS.
NOTE:If intake and exhaust manifolds were remove for machining, install manifolds onto cylinder head before installing cylinder head onto block.
Install cylinder head gasket. Install cylinder head assembly and cylinder head bolts. See Fig. 6 or Fig. 7. Using 2 steps, tighten cylinder head bolts in specified sequence. See TORQUE SPECIFICATIONS.
Ensure No. 1 piston is at TDC and timing mark is aligned. Install timing belt. Ensure timing belt has no slack at idler pulley or between camshaft sprockets (DOHC). Release timing belt tensioner and tighten tensioner bolt. Rotate crankshaft 2 full revolutions (clockwise), and verify all timing marks are aligned. See TIMING BELT. To complete installation, reverse removal procedure.
Thursday, February 19th, 2009 AT 10:04 PM