Note: Installation will require a new cylinder head gasket, valve cover gasket and exhaust valve O-ring.
Removal
1. Remove the battery as described in Section 5A.
2. Remove the hood as described in Section 11.
3. Drain the cooling system as described in Section 1. Also drain the fluid from the cylinder block by unscrewing the drain plug on the right rear wall of the engine. After draining the liquid, replace the plug.
4. Drain the engine oil as described in Section 1. Install the plug after draining the fluid using a new washer.
5. Remove the air cleaner assembly or air intake duct according to the corresponding Part Section 4.
6. Remove the toothed drive belt, see Chapter 5.
7. Remove the camshaft sprocket, see Chapter 7.
8. Unscrew the toothed drive belt shield from the right end of the cylinder head (see illustration).
11.8. Cylinder head view - F3P engine.
9. Disconnect the gas pedal cable and move it to the side, following the relevant Section Section 4.
10. Disconnect the exhaust outlet pipe from the manifold, referring to the relevant Section Section 4.
11. If necessary, the intake and exhaust manifolds can be removed at this stage. Otherwise, disconnect the various fuel, vacuum, coolant hoses and electrical wiring from the throttle body and intake manifold (see the relevant Part of Section 4).
12. Remove the spark plugs and distributor cap, following the relevant Sections 1 and 5.
13. Unscrew the nuts from the valve cover and remove the cover from the engine. Remove the gasket.
14. Disconnect the wire from the coolant temperature sensor on the cylinder head. Also disconnect the fuel injection system coolant temperature sensor wiring.
15. Where applicable, disconnect the multi-pin connector from the knock sensor on the front of the cylinder head.
16. Disconnect the upper radiator hose from the thermostat housing.
17. Using a suitable Allen socket, loosen the cylinder head bolts, turning them half a turn at a time, in the reverse order to that shown in Illustration 11.29. Then remove all bolts.
18. Lift the cylinder head up from the block. If this does not work, hit it with a wooden mallet.
Inspection
19. The mating surfaces of the cylinder head and block must be completely clean. Using a scraper, remove all traces of gasket and carbon deposits and clean the tops of the pistons. Work especially carefully with the aluminum cylinder head, as the soft metal can be easily damaged. Also, be careful not to let dirt get into the oil and water passages - this is especially important for the lubrication chain, as carbon deposits can block the oil supply to the camshaft and crankshaft bearings or rocker arms. Use masking tape and paper to seal the water and oil passages and bolt holes in the cylinder block. Clean the piston heads in a similar manner.
20. Check the block and head for nicks, deep scratches and other damage. If there are small scratches, they can be carefully removed with a file. More serious damage can be repaired by resharpening, but this work should be entrusted to a specialist.
21. Using a ruler placed on its edge, check the warpage of the cylinder head. If necessary, see Part F of this Section.
22. Clean all bolt holes in the block. Make sure there is no oil left in them, otherwise there is a risk that the block may crack under hydraulic pressure when tightening the bolts.
23. Inspect the bolt threads and the threads in the cylinder block for damage. If necessary, use a tap of the appropriate size to renew the threads in the block and use a thread-cutting die to clean the threads on the bolts. It is recommended to replace the bolts after each removal.
Installation
24. Check that the mating surfaces of the cylinder block and head are spotlessly clean, that the threads of the mounting bolts are clean and dry and that they screw in easily.
25. Make sure that the piston of cylinder #1 is at TDC and that the camshaft is in the correct position (the working surfaces of the cam lobes of cylinder #1 are facing up). If the camshaft is in a different position, the valves may strike the pistons.
26. Install the new head gasket onto the cylinder block, positioning it on the pins and orienting it correctly.
27. Lower the head onto the cylinder block.
28. Lightly lubricate the cylinder head mounting bolts with oil. Insert the bolts and tighten them by hand.
29. In the sequence shown (see illustration) tighten the bolts to the torque specified in the Specifications for Stage 1. Then, in the same sequence, for Stage 2.
11.29. Cylinder Head Bolt Tightening Sequence - All F-Series Engines.
30. Wait three minutes, then gradually loosen all bolts in the reverse order of tightening until they are completely loose. These are Stages 3 and 4.
31. Again, tighten the bolts in the sequence shown to the torque specified in the Stage 5 Specifications.
32. Final tightening is achieved by turning the bolts to the angle specified in the Specifications for Stage 6 (see illustration).
11.32. Tightening the cylinder head mounting bolts - F3P engine.
There is no need to re-tighten the bolts after the engine has warmed up.
33. Connect the upper radiator hose to the thermostat housing and tighten the clamp.
34. Where applicable, connect the knock sensor connector.
35. Connect the coolant temperature sensors.
36. Install the valve cover using a new gasket and tighten the nuts.
37. Install the spark plugs and distributor cap, following the relevant Sections 1 and 5.
38. Install the intake and exhaust manifolds (if they were deleted), following the appropriate Section 4. Or connect the various hoses and wiring to the intake manifold and to the throttle body.
39. Connect the exhaust outlet pipe using a new O-ring.
40. Connect the accelerator pedal cable, referring to the relevant Section Section 4.
41. Install the timing belt shield to the right side of the cylinder head.
42. Install the camshaft sprocket, see Chapter 7.
43. Install the toothed drive belt, see Chapter 5.
44. Check valve clearances if necessary (Chapter 4).
45. Install the air filter or air intake duct.
46. Fill the engine with oil as described in Section 1.
47. Fill the cooling system as described in Section 1.
48. Install the hood (see Section 11).
49. Connect the battery wiring.