Removal and Installation of Cylinder Head

PROCEDURE

Cylinder Head Bolt Tightening Sequence

Engine removed from vehicle PROCEDURE 1. Unscrew the bolt securing the alternator adjusting bracket to the cylinder head. 2. Remove the alternator drive belt and the upper camshaft drive cover (see

subsection 2.2.2.1).

3. Remove the cylinder head cover. 4. Unscrew the bolt securing the rear camshaft drive cover to the cylinder head. 5. Remove the intake pipe and exhaust manifold. 6. Turn the crankshaft so that the piston of No. 1 cylinder is at TDC (see subsection 2.2.2.1).

7. Loosen the camshaft drive belt tension and remove the belt from the camshaft gear (see subsection 2.2.2.1).

Warning After the camshaft drive belt has been removed, do not turn the crankshaft, camshaft or intermediate shafts. 8. Unscrew the cylinder head bolts. Loosen the bolts evenly in the reverse of the sequence shown in the figure Cylinder Head Bolt Tightening Sequence. 9. Remove the cylinder head and head gasket. If the cylinder head is stuck to the block, do not insert screwdrivers or any other tools between the head and block, as this may damage the head surface. Lightly tap the cylinder head with a mallet through a wooden block. After inspection and replacement of damaged or worn parts, install the cylinder head in the reverse order. Replace the cylinder head gasket and head cover gasket. Place the cylinder head gasket on the block surface with the marking "OBEN–TOP" facing up. Tighten the cylinder head bolts in the sequence shown in the figure Cylinder Head Bolt Tightening Sequence in three stages: – Stage 1: 40 N·m torque; – Stage 2: 60 N·m torque; – Stage 3: tighten an additional half turn (180°).

Engine installed in vehicle If valve lapping or replacement, carbon removal, cylinder head gasket replacement, etc. is required, the cylinder head can be removed without removing the engine from the vehicle. PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine cooling system (see subsection 2.4.1). 3. Disconnect the coolant hoses from the cylinder head. 4. Remove the air filter on vehicles equipped with a carburetor. 5. Disconnect the throttle cable. 6. Disconnect the wires from the oil pressure and coolant temperature sensors. 7. Unscrew the bolt securing the alternator adjusting bracket to the cylinder head. Remove the alternator drive belt. 8. Disconnect the spark plug wires and remove the spark plugs. 9. Disconnect the electrical wires from the carburetor. 10. Disconnect the fuel line from the carburetor. 11. Remove the spring clips and disconnect the muffler inlet pipe from the exhaust manifold. 12. Disconnect the crankcase ventilation hose. 13. Continue as for an engine removed from the vehicle (above).