Cylinder Head Assembly: Service and Repair

Cylinder Head

Removal
Both cylinder heads
1. Remove the lower intake manifold.
2. Remove the LH valve cover.
3. Remove the RH valve cover.
4. Remove the exhaust manifold.





LH cylinder head
5. Position the power steering pump reservoir aside.
1 Remove the bolts.
2 Position the power steering reservoir aside.
6. Remove the AC compressor, if equipped.





7. Remove and support the AC compressor mounting bracket and power steering pump.
1 Remove the bolts.
2 Remove the nuts.
3 Loosen the remaining (A) bolt until the (B) AC compressor mounting bracket and power steering pump are from the LH cylinder head. Support the AC compressor mounting bracket and power steering pump and position aside.





8. Disconnect the Cylinder Head Temperature (CHT) sensor and the knock sensor electrical connectors.

RH cylinder head
9. Remove the Generator (GEN).





10. Remove the idler pulley.
1 Remove the bolt.
2 Remove the idler pulley.





11. Remove the generator mounting bracket.
1 Remove the bolts.
2 Remove the generator mounting bracket.





Both cylinder heads

12. CAUTION: The components are to be rein staffed, they must be instanced in the same position. Mark the components for location.

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





13. Remove the push rods.





14. NOTE: Discard the cylinder head bolts.

NOTE: Record the location of the long and the short bolts.

Remove the cylinder head.
- Remove and discard the bolts.

Installation
Both cylinder heads
1. Clean and inspect the cylinder head for flatness.





2. Position a new cylinder head gasket and install the cylinder head.





3. CAUTION: Always use new bolts.

NOTE: Lubricate bolts with clean engine oil.

Install new bolts. Refer to the location note made during removal and make sure the bolts are installed in the correct location.
1 Install the new long bolts.
2 Install the new short bolts.





4. Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten the bolts to 20 Nm (15 ft. lbs.).
- Stage 2: Tighten the bolts to 40 Nm (30 ft. lbs.).
- Stage 3: Tighten the bolts to 50 Nm (37 ft. lbs.).





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

NOTE: The short bolts are numbered 2, 4, 6 and 8 and the long bolts numbered 1, 3, 5 and 7.

Loosen, then tighten the bolts in the sequence shown:
- Tighten the short bolts to 25 Nm (18 ft. lbs.), then tighten an additional 180 degrees.
- Tighten the long bolts to 45 Nm (33 ft. lbs.), then tighten an additional 180 degrees.





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

NOTE: Lubricate the push rods with clean engine oil.

Install the push rods.





7. Install the rocker arms, tighten the bolts in two stages.
- Stage 1: Tighten the bolts to 5 Nm (44 inch lbs.).
- Stage 2: Tighten the bolts to 35 Nm (26 ft. lbs.).
8. If new valve train components have been installed, inspect the valve clearance.





RH cylinder head
9. Install the generator mounting bracket.
1 Position the generator mounting bracket.
2 Install the long bolts.
3 Install the short bolt.





10. Install the idler pulley.
1 Position the idler pulley.
2 Install the bolt.
11. Install the generator.





LH cylinder head
12. Install the AC compressor mounting bracket and power steering pump.
1 Position the AC compressor mounting back set and power steering pump.
2 Start the bolt.
3 Install the bolts.
4 Install the nuts.





13. Connect the Cylinder Head Temperature (CHT) sensor and the knock sensor electrical connectors.
14. Install the AC compressor, if equipped.





15. Install the power steering fluid reservoir.
1 Position the power steering fluid reservoir.
2 Install the bolts.

Both cylinder heads
16. Install the exhaust manifolds.

17. NOTE: Inspect the LH valve cover gasket for damage. Install a new gasket, if necessary.

Install the LH valve cover.

18. NOTE: Inspect the RH valve cover gasket for damage. Replace if necessary.

Install the RH valve cover.
19. Install the lower intake manifold.