Cylinder Head Assembly: Service and Repair

CYLINDER HEAD
Removal

Warning: Release the Fuel Pressure. When disconnecting fuel hoses, cover with rag to prevent spillage. Plug fuel hoses to prevent leakage. refer to Powertrain Management/Fuel Delivery and Air Induction/Service and Repair.

A. Disconnect the negative battery cable.
B. Drain the engine coolant.






C. Remove in the sequence shown in the figure, refering to removal notes.
1. Air intake pipe
2. Accelerator cable
3. Timing belt Refer to timing Belt, Service and Repair. Service and Repair
4. Brake vacuum hose
5. Fuel hose
6. Emission harness connectors and grounds
7. Distributor
8. Extension manifold
9. Intake manifold assembly
10. Intake manifold gaskets
11. Cylinder head cover assembly
12. Center exhaust pipe insulator
13. Center exhaust pipe
14. Exhaust manifold insulator
15. Exhaust manifold
16. Seal plate
17. Cylinder head bolt
18. Cylinder head assembly
19 Cylinder head gasket

Fig. 5 Torque:

Reverse procedure to install, noting the following:
a. Position hose clamps in original positions on hoses and squeeze clamps lightly with large pliers to ensure good fit.

Fig. 6 Oil Control Plugs:

b. Check that projection of oil control plugs from cylinder block is .209-.224 inch (5.3-5.7mm).
c. Apply engine oil to new O-rings, then install O-rings on oil control plugs.
d. Thoroughly remove all dirt, oil or other material from top of cylinder block.

Fig. 7 Head Gasket Placement:

e. Place new cylinder head gasket on left bank with L mark facing upward.
f. Place new cylinder head gasket on right bank with R mark facing upward.

Caution: Do not damage the O-ring when installing cylinder head.

g. Install cylinder head to cylinder block.

Fig. 8 Head Bolts:

h. Measure length of bolts, which should be 4.25 inch (108mm) for intake and 5.43 inch (138mm) for exhaust. If length is greater than 4.29 inch (109mm) for intake or 5.47 inch (139mm) for exhaust, replace bolts.
i. Apply engine oil to threads and seat faces of bolts.

Fig. 9 Head Torque Sequence:

j. Torque bolts in sequence as shown in Fig. 9 to 15 ft. lbs.

Fig. 10 Additional Torque:

k. Put paint mark on each bolt head and, using paint mark as reference, tighten cylinder head bolts 90° in sequence, then an additional 90° in sequence.

Fig. 11 Head Cover Gasket:

l. Place cylinder head cover gasket in position, then install cylinder head cover with new seal washers, torquing to specification.

Fig. 12 Intake Torque Sequence:

m. Connect injector harness and place new intake manifold gasket in position, then install intake manifold assembly, torquing flange nuts in two or three steps in sequence, Fig. 12 to 14-18 ft lb.

Fig. 13 Extension Manifold:

n. Apply engine oil to new extension manifold O-ring, then install extension manifold with new gasket, torquing to 14-18 ft lb.

Fig. 14 Harness:

o. Connect all electrical connectors and grounds.