Cylinder Head Assembly: Service and Repair

Removal
1. Disconnect battery ground cable.
2. Remove air filter/air flow sensor assembly and the air duct.
3. Remove timing belt and disconnect all electrical wiring and hoses leading to cylinder head.
4. Disconnect exhaust header pipe and remove intake manifold assembly.
5. Remove valve cover, head bolts and rocker arms.
6. Remove cylinder head by tilting and lifting up.
7. Install sleeve retaining straps No. 0132 A1Z and bolts No. 0144 CZ or equivalents, to retain cylinder liners.

Installation
Reverse removal procedure to install, noting the following:

1. Apply a fine coat of ``Molykote Spray 321 R'' No. 9728.62 or equivalent, onto rocker pads while protecting rocker oil holes.

Fig. 16 Camshaft Stop Installation:

2. Install rocker arm assembly while inserting stop (4) into groove of camshaft. Fig. 16.

Fig. 17 Cylinder Head Tightening Sequence:

3. Install head bolts with new washers. Tighten as follows:
a. Torque in sequence to 36.25 ft. lbs., as shown in Fig. 17, then in sequence to 58 ft. lbs.
b. Loosen each bolt 1/4 turn and retorque to 86.88 ft. lbs., in sequence.
4. Fill and bleed cooling system.
5. Run engine at 2000 RPM for 12 minutes.
6. Allow engine to cool for minimum of two hours.
7. Starting with bolt No. 1, Fig. 17, loosen 1/4 turn and torque to 68.88 ft. lbs. Repeat for remaining bolts in sequence.