Contents: Removal ⇓ Installation ⇓
Note: Whenever cylinder block bolts are loosened or removed, the engine must be cold.
Removal
1. Disconnect the negative battery cable and remove the air cleaner assembly and air injection tubes.
2. Drain the cooling system and disconnect the upper radiator hose.
3. Remove the distributor Section 5 and the rear cover of the gearbox (Chapter 10).
4. Remove the timing belt cover and belt.
5. Remove the fuel pump (Section 4).
6. Remove the intake manifold (Chapter 14).
7. Remove the generator. On models with air conditioning, remove the compressor pinch bolt and move the compressor away, being careful not to damage the wires (which contain high pressure) or radiator. Remove the alternator/air conditioner bracket bolts to the cylinder head and loosen the remaining bracket bolts.
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8. Remove the camshaft cover (Chapter 2).
9. Remove the three bolts securing the exhaust manifold to the catalytic converter or tailpipe and separate the tailpipe from the manifold.
10. Loosen the cylinder head mounting bolts several turns at a time, in the sequence shown in the accompanying illustration.
Loosening the cylinder head bolts (A) and tightening sequence (B)
11. Once they are all free, remove the cylinder head bolts and place them on a piece of cardboard so they can be easily reinstalled (photo).
Use a cardboard box to store the cylinder head bolts
12. If the cylinder head does not lift immediately, break the gasket using a rod inserted between the generator-compressor bracket and the cylinder head.
13. Separate the cylinder head from the engine and remove the gasket.
Installation
14. Remove all traces of gasket material from the engine block and cylinder head (photo). Ensure that the cylinder head bolt threads and bolt holes in the block are clean, as this may affect the tightening torque during installation.
Use a scraper to remove the gasket material
15. Place a new gasket on the cylinder head, camshaft and rocker arm assembly (if deleted). Make sure the gasket is installed correctly.
16. Install the cylinder head bolts and tighten them gradually to the torque specified in the Specifications in the sequence shown in the accompanying illustration.
17.The rest of the installation procedure is the reverse of removal. Cm. Chapter 11 for the sequence of tightening the rocker arm bolts.
18. After warming up the engine, check the valve clearances and tighten the cylinder head bolts as described in Section 1, Chapter 37.