The temperature of the cylinder head must be below 38°C; let the engine cool down for a few hours. Rotate the flywheel so that the number one piston is at top dead center.
Withdrawal
1. Disconnect the earth cable from the battery.
2. Drain the coolant from the cooling system.
3. Disconnect the brake booster vacuum hose from the intake manifold.
4. Remove the motor earth cable from the valve cover. Disconnect the radio noise silencer connector and ignition coil wires.
5. Remove the air filter assembly. Reduce fuel pressure using the appropriate procedure.
6. Disconnect the fuel lines and the fuel return line. Remove the air intake hose and resonator hose. Disconnect the throttle cable from the throttle body.
7. For automatic transmissions, disconnect the throttle control cable from the throttle body.
8. Disconnect the carbon filter hose from the throttle valve. Disconnect and tag all harness connectors from the cylinder head. Remove the emission control box and vacuum reservoir, then disconnect the two connectors. Do not remove emission hoses.
9. Disconnect the upper radiator hose. Remove the heater hoses from the cylinder head. Remove the bypass hoses from the water pump inlet pipe.
10. Remove the power steering pump belt and alternator belt. Also remove the air conditioning belt if the vehicle is equipped with one.
11. Disconnect the inlet hose from the power steering pump and plug the hose immediately to prevent leakage. Remove the power steering pump from the cylinder head. Remove the generator.
When the power steering hose is disconnected, fluid will flow out. Cover the generator with a rag to prevent any internal damage.
12. Remove the intake manifold bracket. Remove the exhaust manifold bracket and then the main exhaust pipe.
13. Remove and mark the ignition wires, remove the distributor assembly. Be sure to mark the lines linking the location of the distributor assembly in relation to the engine for ease of installation.
14. Remove the cylinder sensor. Remove the valve cover.
15. Remove the middle camshaft belt cover.
16. Loosen but do not remove the camshaft drive belt adjusting bolt; remove the camshaft drive belt from the camshaft pulleys.
17. Remove the camshaft holders, camshafts and rocker arms. Remove the cylinder head bolts (mark the holes occupied by the two longer bolts) and remove the cylinder head. The head may resist removal, even with the bolts removed. Tap the edge of the head with a plastic or rubber mallet; lift the head strictly straight until it is removed.
18. Remove the exhaust manifold cover and EGR pipe, then remove the exhaust manifold from the cylinder head.
19. Remove the intake manifold from the cylinder head.
For installation:
20. Assemble the intake and exhaust manifolds to the head. Use new gaskets.
21. Install a new cylinder head gasket, making sure it is installed correctly. Cylinder head dowel pins and oil jet must be in place. Refer to Fig. 109 if necessary.
22. Install the head. Lower it directly onto the block, aligning correctly.
23. Apply clean engine oil to the bolt threads and the contact surface of the bolt head. Tighten the head bolts by hand.
24. Tighten the head bolts in two passes following the order shown in fig. 110. And after the first pass, the bolts must be tightened to approximately 30 Nm; after the second and final pass - up to 68 Nm.
25. Install the camshaft, valves and camshaft holders.
26. Double check the position of the engine; it must be at TDC for cylinder number 1. All of the following conditions must be met: the pointer on the back of the cylinder block aligns with the white mark on the flywheel, "UP" the marker on each camshaft pulley is up and the alignment marks on each camshaft pulley are aligned with the surface of the cylinder head.
Each of the camshafts can be held in the TDC position with a 5mm diameter punch inserted into the alignment holes behind each camshaft pulley. This will make installing the belt much easier.
27. Install the camshaft drive belt so that it rotates in the same direction as before. Remove the punches holding the camshafts, if fitted.
28. Loosen the adjuster, allowing it to tension the belt. Tighten the regulator bolt.
29. Install belt covers.
30. Install the crankshaft pulley and key. Lightly coat the bolt threads with oil, but do not lubricate the surfaces that come into contact with the washer. On engines with fuel injection, tighten the bolt to 150 Nm; on carbureted engines - up to 115 Nm.
This tightening is best done with the parking brake engaged and in gear for a manual transmission, for an automatic transmission, set the selector lever to position "PARK"; wheels must be locked.
31. Rotate the engine counterclockwise until the camshaft pulley has rotated 3 teeth. Loosen the adjusting bolt, then retighten it to 43 Nm.
32. Install the valve cover and upper belt cover. Install the cylinder sensor. Install the ignition wires and harness protection.
33. Install the distributor and ignition wire.
34. Install the intake manifold bracket.
35. Install the alternator and belt. Tighten the through bolt to 45 Nm.
36. Install the power steering pump and belt, tightening the bolts to 27 Nm. Connect the inlet hose.
37. Install side engine mount and cruise control actuator if removed. Tighten the engine support bolts to 40 Nm and nuts to 65 Nm.
38. Connect the coolant bypass hoses to the water pump inlet pipe. Connect the heater hose to the cylinder head and the upper radiator hose to the thermostat housing.
39. Install the emission control box, and connect the wiring connectors. Double check those vacuum hoses.
40. Connect the harness and electrical connectors located on and around the head.
41. Connect the carbon filter hose to the throttle valve.
42. Connect the throttle control cable and/or the accelerator cable to the throttle body.
43. Install the air intake hose and resonator.
44. Connect the fuel supply hose and fuel return line.
45. Install the air filter cover.
46. Connect the radio noise suppressor and the coil wire. Connect the motor earth cable.
47. Connect the vacuum hose to the brake booster.
48. Fill in coolant. Release the air from the cooling system.
49. Connect the cable to the negative terminal of the battery.
50. Start the engine, allowing it to idle. Carefully check the work area for any sign of leakage or belt rubbing against the guard.