Chrysler Colt/Vista 1990-1993 Repair Information

Cylinder Head

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REMOVAL & INSTALLATION



Never remove the cylinder head unless the engine is absolutely cold; the cylinder head could warp.

1990 1.5L

See Figures 1, 2, 3 and 4

  1. Disconnect the battery ground cable, remove the air cleaner assembly and the attached hoses.
  2.  
  3. Drain the coolant, remove the upper radiator hose and the heater hoses.
  4.  
  5. Release the fuel system pressure. Remove the fuel line, disconnect the accelerator linkage, distributor vacuum lines, purge valve and water temperature gauge wire.
  6.  
  7. Remove the spark plug wires and the fuel pump. Remove the distributor, where necessary.
  8.  
  9. Disconnect the exhaust pipe from the exhaust manifold flange.
  10.  
  11. Remove the exhaust manifold assembly.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: 1990 1.5L engine. Remove these parts, in the order shown, in preparation for cylinder head removal. When installing the head, reverse the removal sequence



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Fig. Fig. 2: 1990 1.5L engine. Cylinder head removal. When installing the head, reverse the removal sequence

  1. Remove the intake manifold.
  2.  
  3. Turn the crankshaft to No. 1 piston at TDC on the compression stroke.
  4.  

During the following procedure, do not turn the crankshaft after locating TDC.

  1. Remove the timing belt cover. Be sure the knockout pin is at 12 o'clock and the cam sprocket mark and cylinder head pointer are aligned at 3 o'clock. Loosen the timing belt tensioner mounting. Move the tensioner toward the water pump and secure it in that position. Remove the rocker arm cover.
  2.  

The cam pulley need not be removed.

  1. Loosen and remove the cylinder head bolts in sequence, 2-3 stages to avoid cylinder head warpage.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: 1990 1.5L engine cylinder head loosening sequence

  1. Remove the cylinder head from the engine block.
  2.  

To install:
  1. Clean the cylinder head and block mating surfaces and install a new cylinder head gasket.
  2.  
  3. Position the cylinder head on the engine block, engage the dowel pins front and rear and install the cylinder head bolts.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: 1990 1.5L engine cylinder head tightening sequence

  1. Tighten the head bolts in, 3 stages, to 50-54 ft. lbs. (68-73 Nm).
  2.  
  3. Locate the camshaft in original position. Pull the camshaft sprocket and belt or chain upward and install on the camshaft.
  4.  

If the dowel pin and the dowel pin hole does not line up between the sprocket and the spacer or camshaft, move the camshaft by bumping either of the 2 projections provided at the rear of the No. 2 cylinder exhaust cam of the camshaft, with a light hammer or other tool, until the hole and pin align. Be certain the crankshaft does not turn.

  1. Install the camshaft sprocket bolt and the distributor gear and tighten.
  2.  
  3. Install the timing belt upper front cover and spark plug cable support.
  4.  
  5. Apply sealant to the intake manifold gasket on both sides. Position the gasket and install the intake manifold.
  6.  

Be sure no sealant enters the jet air passages when equipped.

  1. Install the exhaust manifold gaskets and the manifold assembly.
  2.  
  3. Connect the exhaust pipe to the exhaust manifold and install the fuel pump. Install the purge valve.
  4.  
  5. Install the water temperature gauge wire, heater hoses and the upper radiator hose.
  6.  
  7. Connect the fuel lines, accelerator linkage, vacuum hoses and the spark plug wires.
  8.  
  9. Fill the cooling system and connect the battery ground cable. Install the distributor.
  10.  
  11. Temporarily adjust the valve clearance to the cold engine specifications.
  12.  
  13. Install the gasket on the rocker arm cover and temporarily install the cover on the engine.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine and bring it to normal operating temperature. Stop the engine and remove the rocker arm cover.
  18.  
  19. Adjust the valves to hot engine specifications.
  20.  
  21. Install the rocker arm cover and tighten securely.
  22.  
  23. Install the air cleaner, hoses, purge valve hose and any other removed unit.
  24.  

1991-93 1.5L

See Figures 5 and 6

  1. Disconnect the negative battery cable and drain the engine coolant.
  2.  
  3. Disconnect the accelerator cable, breather hose, air intake hose and radiator hoses.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: 1991-92 1.5L engine. Remove these parts, in the order shown, in preparation for cylinder head removal. When installing the head, reverse the removal sequence



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Fig. Fig. 6: 1991-92 1.5L engine. Cylinder head removal. When installing the head, reverse the removal sequence

  1. Label and disconnect the brake booster hose, EGR vacuum hoses and spark plug cables.
  2.  
  3. Relieve the fuel pressure. Disconnect the fuel hoses.
  4.  
  5. Disconnect the distributor connector, oxygen sensor, condenser connector, coolant temperature connectors, motor position sensor connector, idle speed control connector, TPS connector, injector connectors, EGR temperature sensor connector and control harness.
  6.  
  7. Remove the upper timing belt cover. Rotate the crankshaft clockwise and align the timing marks. Remove the camshaft sprocket and hold the sprocket and timing belt with a piece of wire. Remove the rocker cover and gasket.
  8.  
  9. Remove the exhaust manifold-to-pipe nuts.
  10.  
  11. Remove the cylinder head bolts using a special socket TW-10B or equivalent. Remove the cylinder head and gasket.
  12.  

To install:
  1. Clean the gasket mating surfaces and check for warpage.
  2.  
  3. Match the old gasket with the new and install the gasket with the identification mark facing upward and to the front of the engine.
  4.  
  5. Install the cylinder head and bolts. Using the special head bolt tool TW-10B and torque the bolts in 3 steps and in sequence. 1st step to 20 ft. lbs. (27 Nm), 2nd step to 40 ft. lbs. (54 Nm) and the 3rd step to 51-54 ft. lbs. (70-75 Nm) [Cold].
  6.  
  7. Install the exhaust manifold-to-pipe nuts and torque to 34 ft. lbs. (46 Nm).
  8.  
  9. Install the rocker cover, camshaft sprocket and upper timing belt cover.
  10.  
  11. Connect the distributor connector, oxygen sensor, condenser connector, coolant temperature connectors, motor position sensor connector, idle speed control connector, TPS connector, injector connectors, EGR temperature sensor connector and control harness.
  12.  
  13. Connect the fuel hoses.
  14.  
  15. Connect the brake booster hose, EGR vacuum hoses and spark plug cables.
  16.  
  17. Connect the accelerator cable, breather hose, air intake hose and radiator hoses.
  18.  
  19. Connect the negative battery cable and refill the engine coolant. Adjust the timing and idle if needed.
  20.  

1.6L

See Figures 7 and 8

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine and radiator coolant.
  4.  
  5. Remove the radiator assembly.
  6.  

  1. Disconnect the accelerator cable. Disconnect the air flow sensor wiring connector.
  2.  
  3. Disconnect all of the breather and vacuum hoses to the air intake. Remove the air cleaner assembly.
  4.  
  5. Remove the PCV hose. Disconnect the water bypass hose, the heater hose and vacuum lines from the water inlet connector.
  6.  
  7. Disconnect the vacuum hose to the power brake booster.
  8.  
  9. Release the fuel system pressure and disconnect the high pressure and fuel return lines. Remove the mounting O-rings.
  10.  
  11. Disconnect the oxygen sensor, engine coolant sensor, temperature gauge connection and the air conditioner coolant temperature switch.
  12.  
  13. Disconnect the fuel injector wiring harness, the ignition coil, power transistor, ISC motor and the EGR sensor connector.
  14.  
  15. Disconnect the detonation sensor, throttle position sensor and crankshaft angle sensor wiring connectors.
  16.  
  17. Remove the center cover and the spark plug wires. Disconnect the control wire harness connector.
  18.  
  19. Remove the timing belt.
  20.  
  21. Remove the rocker cover and rear half moon seal.
  22.  
  23. Remove the heat shield, turbocharger water and oil lines.
  24.  
  25. Disconnect the exhaust pipe from the turbocharger.
  26.  
  27. Remove the turbocharger, exhaust manifold and intake manifold assemblies.
  28.  
  29. Remove the head mounting bolts. Start at the outer ends of the head and loosen, in a crisscross manner, toward the center of the head. Make 2-3 passes to loosen the bolts, a little at a time, in sequence.
  30.  



Click image to see an enlarged view

Fig. Fig. 7: 1.6L engine cylinder head loosening sequence

  1. Remove the cylinder head. Clean all gasket mounting surfaces. Make sure no gasket material gets into the cylinders, coolant passages or oil passages.
  2.  

To install:
  1. Position the cylinder head, with a new gasket, on the engine. Install and tighten the head mounting bolts.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: 1.6L engine cylinder head tightening sequence

  1. Tighten the head bolts from the center outwards. Tighten in, 3 steps, to 65-72 ft. lbs. (88-98 Nm).
  2.  
  3. Install the turbocharger, exhaust manifold and intake manifold assemblies.
  4.  
  5. Connect the exhaust pipe to the turbocharger.
  6.  
  7. Install the heat shield, turbocharger water and oil lines.
  8.  
  9. Install the rocker cover and rear half moon seal.
  10.  
  11. Install the timing belt.
  12.  
  13. Install the center cover and the spark plug wires. Connect the control wire harness connector.
  14.  
  15. Connect the detonation sensor, throttle position sensor and crankshaft angle sensor wiring connectors.
  16.  
  17. Connect the fuel injector wiring harness, the ignition coil, power transistor, ISC motor and the EGR sensor connector.
  18.  
  19. Connect the oxygen sensor, engine coolant sensor, temperature gauge connection and the air conditioner coolant temperature switch.
  20.  
  21. Connect the high pressure and fuel return lines. Install the new O-rings.
  22.  
  23. Connect the vacuum hose to the power brake booster.
  24.  
  25. Install the PCV hose. Connect the water bypass hose, the heater hose and vacuum lines from the water inlet connector.
  26.  
  27. Connect all of the breather and vacuum hoses to the air intake. Install the air cleaner assembly.
  28.  
  29. Connect the accelerator cable. Connect the air flow sensor wiring connector.
  30.  
  31. Install the radiator assembly.
  32.  
  33. Replenish the engine and radiator coolant.
  34.  
  35. Connect the negative battery cable.
  36.  

1990 1.8L All 2.0L

See Figures 9 through 14

  1. Disconnect the negative battery cable. Remove the air cleaner assembly and the attached hoses.
  2.  



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Fig. Fig. 9: 1990 1.8L engine cylinder head loosening sequence



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Fig. Fig. 10: 1990 1.8L engine cylinder head tightening sequence



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Fig. Fig. 11: 2.0L engine. Remove these parts, in the order shown, in preparation for cylinder head removal. When installing the head, reverse the removal sequence



Click image to see an enlarged view

Fig. Fig. 12: 2.0L engine. Cylinder head removal. When installing the head, reverse the removal sequence

  1. Drain the coolant, remove the upper radiator hose and the heater hoses.
  2.  
  3. Release the fuel system pressure. Remove the fuel line, disconnect the accelerator linkage, distributor vacuum lines, purge valve and water temperature gauge wire.
  4.  
  5. Remove the spark plug wires and the fuel pump. Remove the distributor, where necessary.
  6.  
  7. Disconnect the exhaust pipe from the exhaust manifold flange.
  8.  
  9. Remove the exhaust manifold assembly.
  10.  
  11. Remove the intake manifold.
  12.  
  13. Turn the crankshaft to No. 1 piston at TDC on the compression stroke.
  14.  

During the following procedure, do not turn the crankshaft after locating TDC.

  1. Align the timing mark on the upper under cover of the timing belt with that of the camshaft sprocket. Matchmark the timing belt and the timing mark on the camshaft sprocket with a felt tip pen. Remove the sprocket and insert a 2 in. (51mm) piece of timing belt or other material between the bottom of the camshaft sprocket and the sprocket holder, on the timing belt lower front cover, to hold the sprocket and belt so the valve timing will not be changed. Remove the timing belt upper under cover and rocker arm cover.
  2.  
  3. Loosen and remove the cylinder head bolts in 2-3 stages to avoid cylinder head warpage.
  4.  



Click image to see an enlarged view

Fig. Fig. 13: 2.0L engine cylinder head loosening sequence

  1. Remove the cylinder head from the engine block.
  2.  

To install:
  1. Clean the cylinder head and block mating surfaces and install a new cylinder head gasket.
  2.  
  3. Position the cylinder head on the engine block, engage the dowel pins front and rear and install the cylinder head bolts.
  4.  



Click image to see an enlarged view

Fig. Fig. 14: 2.0L engine cylinder head tightening sequence

  1. Tighten the head bolts in 3 stages and then torque to:
  2.  



1.8L engine - 50-54 ft. lbs. (68-73 Nm).
 
2.0L engine - 65-72 ft. lbs. (88-97 Nm).
 

  1. Install the timing belt upper under cover.
  2.  
  3. Locate the camshaft in original position. Pull the camshaft sprocket and belt or chain upward and install on the camshaft.
  4.  

If the dowel pin and the dowel pin hole does not line up between the sprocket and the spacer or camshaft, move the camshaft by bumping either of the 2 projections provided at the rear of the No. 2 cylinder exhaust cam of the camshaft, with a light hammer or other tool, until the hole and pin align. Be certain the crankshaft does not turn.

  1. Install the camshaft sprocket bolt and the distributor gear and tighten.
  2.  
  3. Install the timing belt upper front cover and spark plug cable support.
  4.  
  5. Apply sealant to the intake manifold gasket on both sides. Position the gasket and install the intake manifold. Torque the nuts to 11-14 ft. lbs. (15-20 Nm).
  6.  

Be sure no sealant enters the jet air passages when equipped.

  1. Install the exhaust manifold gaskets and the manifold assembly. Tighten the nuts to 11-14 ft. lbs. (15-20 Nm).
  2.  
  3. Connect the exhaust pipe to the exhaust manifold and install the fuel pump. Install the purge valve.
  4.  
  5. Install the water temperature gauge wire, heater hoses and the upper radiator hose.
  6.  
  7. Connect the fuel lines, accelerator linkage, vacuum hoses and the spark plug wires.
  8.  
  9. Fill the cooling system and connect the battery ground cable. Install the distributor.
  10.  
  11. Temporarily adjust the valve clearance to the cold engine specifications.
  12.  
  13. Install the gasket on the rocker arm cover and temporarily install the cover on the engine.
  14.  
  15. Start the engine and bring it to normal operating temperature. Stop the engine and remove the rocker arm cover.
  16.  
  17. Adjust the valves to hot engine specifications.
  18.  
  19. Install the rocker arm cover and tighten securely.
  20.  
  21. Install the air cleaner, hoses, purge valve hose and any other removed unit.
  22.  

1992-93 1.8L

See Figures 15 through 18

  1. Relieve fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system. Disconnect the brake booster vacuum hose and PVC valve connection.
  4.  



Click image to see an enlarged view

Fig. Fig. 15: 1992-93 1.8L engine. Remove these parts, in the order shown, in preparation for cylinder head removal. When installing the head, reverse the removal sequence



Click image to see an enlarged view

Fig. Fig. 16: 1992-93 1.8L engine. Cylinder head removal. When installing the head, reverse the removal sequence

  1. Remove the upper radiator hose, overflow tube and the water hose from the thermostat to the throttle body.
  2.  
  3. Disconnect the air flow sensor connector. Remove the air cleaner case cover and the air intake hose.
  4.  
  5. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
  6.  
  7. Disconnect the fuel return hose and remove the O-ring.
  8.  
  9. Disconnect the accelerator cable connection from the throttle body and position aside.
  10.  
  11. Disconnect the electrical harnesses at the oil pressure switch, oxygen sensor, water temperature sensor connector, distributor, condenser, ISC, TPS, detonation sensor and the fuel injectors.
  12.  
  13. Disconnect the spark plug cables from each spark plug.
  14.  
  15. Unbolt the control harness assembly and position aside.
  16.  
  17. Remove the thermostat housing, thermostat and the thermostat case with O-ring from the engine.
  18.  
  19. Remove the rocker cover.
  20.  
  21. Remove the timing belt upper cover.
  22.  
  23. Rotate the crankshaft in the forward (right) direction to align the camshaft timing marks. Matchmark the camshaft sprocket and the timing belt. Tie the camshaft sprocket and the timing belt together so the sprocket will not move with respect to the timing belt.
  24.  
  25. While holding the camshaft sprocket in position using the appropriate wrench, remove the camshaft sprocket and with the belt attached. Wire the sprocket and belt aside making sure constant tension is maintained on the belt. Do not allow the belt to slacken or engine timing may be altered.
  26.  

When removing the camshaft sprocket, do not allow the crankshaft to rotate. If crankshaft rotation did occur, the engine timing may have been changed. Confirm proper engine timing during installation.

  1. Loosen the cylinder head bolts in 2 or 3 steps in the appropriate order and remove from the cylinder head.
  2.  



Click image to see an enlarged view

Fig. Fig. 17: 1992-93 1.8L engine head bolt loosening sequence

  1. Remove the cylinder head from the engine.
  2.  


CAUTION
When placing the removed cylinder head upside down, take care not to bend or damage the plug guide. The plug guide can not be replaced.

  1. Remove the cylinder head gasket from the block.
  2.  

To install:
  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.002 in. (0.05mm) normally with 0.008 in. (0.200mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. (0.200mm) maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks facing upward. Make sure the gasket has the proper identification mark for the engine. Do not use sealer on the gasket.
  4.  
  5. Carefully install the cylinder head on the block. Inspect the cylinder head bolt prior to installation, the length below the head of the bolts should be below the limit of 3.795 in. (96.4mm). Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt and install so the sagging side made by tapping out the washer is facing upward. (chamfer edge faces up).
  6.  



Click image to see an enlarged view

Fig. Fig. 18: 1992-93 1.8L engine head bolt tightening sequence

  1. Tighten the cylinder head bolts in the proper order as follows:
    1. In the proper tightening sequence, torque bolts to 54 ft. lbs. (75 Nm).
    2.  
    3. In the reverse order of the tightening sequence, fully loosen bolts.
    4.  
    5. In the proper tightening sequence, torque bolts to 14 ft. lbs. (20 Nm).
    6.  
    7. In the proper tightening sequence, tighten bolts an additional 1 / 4 turn (90 degrees).
    8.  
    9. In the proper tightening sequence, tighten bolts an additional 1 / 4 turn (90 degrees).
    10.  

  2.  
  3. Install the camshaft sprocket and tighten bolt to 65 ft. lbs. (90 Nm), while holding the sprocket in place using the appropriate wrench. Confirm proper timing mark alignment.
  4.  
  5. Install the upper timing belt cover and rocker cover.
  6.  
  7. Loosen the water pipe mounting bolt.
  8.  
  9. Apply a thin bead of sealant MD970389 or equivalent, to the water tube connection on the thermostat case.
  10.  
  11. Apply a small amount of water to the O-ring of the water inlet pipe and press the thermostat case assembly onto the water inlet pipe. Install the thermostat case assembly mounting bolt tightening to 16 ft. lbs. (22 Nm).
  12.  
  13. Tighten the water pipe mounting bolt.
  14.  
  15. Install the thermostat into the housing so the jiggle valve is located at the top. Tighten the housing bolts to 10 ft. lbs. (14 Nm).
  16.  
  17. Connect the upper radiator hose to the thermostat housing.
  18.  
  19. Connect or install all previously disconnected hoses, cables and electrical connections. Adjust the throttle cable(s).
  20.  
  21. Replace the O-rings and reconnect the fuel lines.
  22.  
  23. Install the air intake hose. Connect the breather hose, air cleaner case cover and air flow sensor connector.
  24.  
  25. Change the engine oil and oil filter. Reconnect the brake booster and the PCV vacuum hoses.
  26.  
  27. Fill the system with coolant.
  28.  
  29. Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator completely.
  30.  
  31. Check and adjust the idle speed and ignition timing.
  32.  
  33. Check all systems for leaks. Allow the engine to cool and recheck the coolant level.
  34.  

2.4L

See Figures 19 through 23

  1. Relieve fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the accelerator cable.
  6.  



Click image to see an enlarged view

Fig. Fig. 19: 2.4L engine. Remove these parts, in the order shown, in preparation for cylinder head removal. When installing the head, reverse the removal sequence



Click image to see an enlarged view

Fig. Fig. 20: 2.4L engine. Remove these parts, in the order shown, in preparation for cylinder head removal. When installing the head, reverse the removal sequence



Click image to see an enlarged view

Fig. Fig. 21: 2.4L engine. Cylinder head removal. When installing the head, reverse the removal sequence

  1. Remove the radiator.
  2.  
  3. Disconnect the air flow sensor connector and the air intake hose. Remove the air cleaner cover.
  4.  
  5. Disconnect the PCV hose.
  6.  
  7. Disconnect the water hose connection at the throttle body to water inlet pipe.
  8.  
  9. Disconnect the water hose connection at the throttle body to thermostat hose.
  10.  
  11. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
  12.  
  13. Disconnect the fuel return hose and remove the O-ring.
  14.  
  15. Disconnect the accelerator cables connection at the throttle body.
  16.  
  17. Disconnect the spark plug cables from the spark plugs.
  18.  
  19. Disconnect the electrical connectors from the oxygen sensor, water temperature gauge unit, engine coolant temperature sensor, TPS, power transistor connector, fuel injectors, ignition coil, distributor, and air conditioner compressor. Label prior to disconnecting to assure correct relocation on assembly.
  20.  
  21. Remove the bolt retaining the power steering hose and air conditioner hose clamp.
  22.  
  23. Remove the coolant reservoir. Remove the bolt holding the ground wire to the manifold.
  24.  
  25. Place a jack and wood block under the oil pan and carefully lift just enough to take the weight off the engine mounting bracket. Then remove the engine mounting bracket taking note of the position of the mount stopper.
  26.  
  27. Remove the valve cover, gasket and half-round seal.
  28.  
  29. Remove the timing belt front upper cover.
  30.  
  31. If possible, rotate the crankshaft clockwise until the timing marks on the cam sprocket and belt align. Matchmark the timing sprocket to the belt. Remove the sprocket bolt and remove the sprocket with the timing belt attached. Attach a flexible cord to the hood and suspend the sprocket so it cannot turn and there is no slack in the belt. Remove the timing belt rear upper cover.
  32.  



Click image to see an enlarged view

Fig. Fig. 22: 2.4L engine head bolt loosening sequence

  1. Loosen the head bolts in the correct sequence in 2 or 3 steps. Remove the cylinder head bolts and head assembly from the block.
  2.  

To install:
  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.002 in. (0.051mm) normally with 0.008 in. (0.200mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. (0.200mm) maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks at the top (upward) position. Make sure the gasket has the proper identification mark for the engine. Do not use sealer on the gasket.
  4.  



Click image to see an enlarged view

Fig. Fig. 23: 2.4L engine head bolt tightening sequence

  1. Carefully install the cylinder head on the block. Install the cylinder head bolts and washer torquing in 3 even progressions to 76-83 ft. lbs. (105-115 Nm). This torque applies to a cold engine.
  2.  

Install the head bolt washer so the sagging side made by tapping out the washer is facing upward.

  1. Install the camshaft sprocket and tighten bolt to 65 ft. lbs. (90 Nm), while holding the sprocket in place using the appropriate wrench. Confirm proper timing mark alignment.
  2.  
  3. Apply sealer to the perimeter of the half-round seal and to the lower edges of the half-round portions of the belt-side of the new gasket. Install the valve cover.
  4.  
  5. Install the engine mount positioning the stopper in the same direction as it was prior to removal.
  6.  
  7. Install the power steering and air conditioning compressor hose clamp in position and secure with the retainer bolt. Tighten the bolt to 9 ft. lbs. (12 Nm).
  8.  
  9. Install the coolant reservoir tank.
  10.  
  11. Reconnect all electrical harness connectors disconnect during disassembly. Connect the ground wire to the manifold.
  12.  
  13. Connect the accelerator cables and the spark plug cables.
  14.  
  15. Replace the O-rings and reconnect the fuel lines.
  16.  
  17. Reconnect the water hoses to throttle body, thermostat and the heater assembly.
  18.  
  19. Install the air intake case cover, air flow sensor connector and the radiator.
  20.  
  21. Fill the system with coolant. Adjust the accelerator cable.
  22.  
  23. Firmly set the parking brake. Start the engine and allow to idle until the thermostat opens, add coolant as required to fill system to the appropriate level.
  24.  
  25. Check all systems for leaks. Allow the engine to cool and recheck the coolant level.
  26.  

CLEANING AND INSPECTION



With the cylinder head removed from the engine, the rocker arm assemblies and camshaft removed, the valves, valve springs and valve stem oil seals can now be serviced.

See Figure 24

  1. Remove the cylinder head from the engine (see Cylinder Head Removal). Place the head on a workbench and remove any manifolds that are still connected. Remove all rocker arm assembly parts, if still installed and the camshaft (see Camshaft Removal).
  2.  
  3. Turn the cylinder head over so that the mounting surface is facing up and support evenly on wooden blocks.
  4.  



Click image to see an enlarged view

Fig. Fig. 24: Cleaning the head with a drill-mounted wire brush

  1. Use a scraper and remove all of the gasket material and carbon stuck to the head mounting surface. Mount a wire carbon removal brush in an electric drill and clean away the carbon on the valve heads and head combustion chambers.
  2.  

When scraping or decarbonizing the cylinder head, take car not to damage or nick the gasket mounting surface or combustion chamber.

  1. Number the valve heads with a permanent felt-tipped marker for cylinder location.
  2.  

RESURFACING



See Figure 25



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Fig. Fig. 25: Checking cylinder head flatness

If the cylinder head is warped, resurfacing by an automotive machine shop, will be required. After cleaning the gasket surface, place a straightedge across the mounting surface of the head. Using feeler gauges, determine the clearance at the center and along the length between the head and straightedge. Measure clearance at the center and along the lengths of both diagonals. If warpage exceeds 0.08mm in a 152mm span, or 0.15mm over the total length the cylinder head must be resurfaced.

 
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