Cylinder Head Assembly: Service and Repair

Fig. 1 Exploded View Of Engine.:

1. Disconnect battery ground cable.
2. Scribe engine compartment hood hinge locations, then remove hood.
3. Remove engine undercovers.
4. Drain oil and coolant from engine.
5. Remove intercooler assembly, Fig. 1.
6. Remove battery.
7. Label, then disconnect and cap, if necessary, all electrical connectors, fuel lines, wires, vacuum lines and hoses from cylinder head assembly.
8. Disconnect accelerator, throttle and cruise control cables, if equipped.
9. Remove air flow meter with No. 3 air cleaner hose attached.
10. Remove accelerator link, if equipped.
11. Remove radiator reservoir tank.
12. Remove all accessory drive belts and water pump pulley.
13. Carefully remove supercharger assembly.
14. Remove No. 2 air outlet duct.
15. Disconnect and cap No. 3 fuel pipe.
16. Remove No. 1 vacuum transmitting pipe.
17. Disconnect and cap No. 2 fuel hose.
18. Remove cylinder head cover.
19. Remove delivery pipe with injectors.
20. Disconnect and position engine wire harness aside.
21. Remove water outlet and bypass pipe.
22. Remove EGR valve and pipe.
23. Remove intake manifold.
24. Disconnect front exhaust pipe from manifold.
25. Remove air conditioner compressor and bracket, if equipped.
26. Remove distributor, alternator and alternator bracket.
27. Remove exhaust manifold.

Fig. 2 Bearing Cap Bolt Loosening Sequence.:

Fig. 3 Cylinder Head Bolt Loosening Sequence.:

28. Remove camshafts and cylinder head as follows:
a. Uniformly loosen and remove the camshaft bearing cap attaching bolts in several passes, in sequence shown in Fig. 2.
b. Remove the bearing caps, oil seal and camshaft.
c. Using tool 09205-16010 or equivalent, uniformly loosen and remove cylinder head attaching bolts in several passes, in sequence shown in Fig. 3.
d. Lift the cylinder head from the dowels on the block.

Fig. 4 Cylinder Head Bolt Location & Tightening Sequence.:

Fig. 5 Bearing Cap Bolt Tightening Sequence.:

29. Reverse procedure to install, noting the following;
a. The cylinder head bolts are tighten in three progressive steps to specification. If any of the cylinder head bolts break or deform, replace the attaching bolt.
b. Place a new cylinder head gasket onto block, then install cylinder head. Apply a light coat of clean engine oil to the bolt threads and under the bolts heads.
c. Using tool 09205-16010 or equivalent, install and uniformly tighten the cylinder head attaching bolts in several passes to 22 ft. lbs. in sequence shown in Fig. 4. The bolts indicated (A) are 3.54 inches long and the bolts indicated (B) are 4.25 inches long. Ensure the correct size bolt is installed or cracking of the cylinder head will result. If any of the attaching bolts does not meet the torque specification, replace bolt.
d. Mark the front of the cylinder head bolt with paint.
e. Tighten the bolts an additional 90° in numerical order shown.
f. Tighten the bolts an additional 90° again in numerical order shown.
g. Ensure paint mark on bolt(s) head is now facing rear of engine.
h. Place camshaft in position on the cylinder head. The exhaust camshaft incorporates a distributor drive gear. Apply seal packing No. 08826-0080 or equivalent. Install the bearing caps in their proper locations. Apply a light coat of clean engine oil to the bolt threads and under the bolt heads. Install and uniformly tighten the bearing cap attaching bolts in several passes, in sequence shown in Fig. 5.