Cylinder Head Assembly: Service and Repair

Cylinder Head

Removal
1. Remove the intake manifold.
2. If removing the right head, remove the ignition coil assembly.





3. Remove the valve cover.
1 Remove the bolts.
2 Remove the stud bolts.
3 Remove the valve cover.
4. Remove the exhaust manifold.
5. If removing the LH cylinder head and if so equipped, remove the A/C compressor.





6. If removing the LH cylinder head, remove and support the A/C compressor mounting bracket and power steering pump.
1 Remove the bolts.
2 Remove the nuts.
3 Loosen the remaining (A) bolt until the (B) A/C compressor mounting bracket and power steering pump are free from the LH cylinder head. Support the A/C compressor mounting bracket and power steering pump and position aside.





7. Disconnect the knock sensor and the Cylinder Head Temperature (CHT) sensor electrical connectors.
8. If removing the RH cylinder head, remove the Generator (GEN).





9. If removing the RH cylinder head, remove the idler pulley.
1 Remove the bolt.
2 Remove the idler pulley.





10. If removing the RH cylinder head, remove the generator mounting bracket.
1 Remove the bolts.
2 Remove the generator mounting bracket.

CAUTION: If components are to be reinstalled, they must be installed in the same position. Mark the components for location.





11. Remove the rocker arms.
1 Remove the bolts.
2 Remove the rocker arms.





12. Remove the push rods.





13. Remove and discard the bolts.





14. Remove the cylinder head and the head gasket. Discard the head gasket.

Installation

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.





1. Install a new head gasket on the cylinder block with the small hole to the front of the engine. Position the cylinder head.





2. CAUTION: Always use new bolts.

NOTE: Lubricate the bolts with clean engine oil prior to installation.

Install the four new (A) short bolts and the four new (B) long bolts.





3. NOTE: Make sure to tighten the bolts in three steps.

Tighten the bolts in three stages in the sequence shown:
- Stage 1: 20 Nm (14 ft. lbs.)
- Stage 2: 40 Nm (29 ft. lbs.)
- Stage 3: 50 Nm (36 ft. lbs.)





4. CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened and the final tightening completed prior to working on the next bolt in the sequence.

In the sequence shown, loosen the bolt three turns, then tighten the (A) short bolt or (B) long bolt to the specification indicated, and then further tighten the bolt to the (C) degrees indicated.

CAUTION: Refer to location note made during removal and make sure components are installed in the correct location.





5. NOTE: Lubricate the push rods with clean engine oil prior to installation.

Install the push rods.





6. Install the rocker arms.
- Position the rocker arms.
- Install the bolts.
7. If new valve train components have been installed, inspect the valve clearance.





8. If installing the RH cylinder head, install the generator mounting bracket.
- Position the generator mounting bracket.
- Install the bolts.





9. If installing the RH cylinder head, install the idler pulley.
1 Position the idler pulley.
2 Install the bolt.
10. If installing the RH cylinder head, install the generator.





11. If installing the LH cylinder head, install the A/C compressor mounting bracket and power steering pump.
1 Position the A/C compressor mounting bracket and power steering pump.
2 Start the bolt.
3 Install the bolts.
4 Install the nuts.





12. Connect the knock sensor and Cylinder Head Temperature (CHT) sensor electrical connectors.
13. If installing the LH cylinder head and if so equipped, install the A/C compressor.
14. Install the exhaust manifold.





15. NOTE: Inspect the valve cover gasket for damage.

Install a new valve cover gasket if necessary.
Install the valve cover.
1 Position the valve cover.
2 Install the bolts.
3 Install the stud bolts.
16. If the right head was removed, install the ignition coil.
17. Install the intake manifold.