Cylinder Head Assembly: Service and Repair

Remove or Disconnect

1. Battery negative (-) cable.
- Drain coolant.
2. Air cleaner assembly.
3. Cruise control cable.
4. Throttle cable from throttle linkage.
5. Heater hose from the cylinder head rear cover.
6. Vacuum hoses from the throttle body.
7. Cruise control actuator and bracket assembly.
8. Ignition coil.
9. Coolant outlet hose from the radiator and cylinder head.
10. Brake booster vacuum hose.
11. PCV hose.
12. Fuel pressure regulator and fuel line.
13. EGR valve with lines.
14. Cold start injector hose.
15. Coolant by-pass hoses from the auxiliary air valve.
16. Vacuum pipe and cylinder head rear cover.
17. Distributor.
18. Exhaust manifold from the cylinder head.
19. Delivery pipe with injectors.
20. Intake manifold.
21. Power steering drive belt.
22. Generator drive belt.
23. Cylinder head covers.
24. Spark plugs.
- Set the number 1 cylinder at TDC on the compression stroke and align the groove in the crankshaft pulley with the idler pulley bolt.
- Check that the valve lifters on the number 1 cylinder are loose. If not, turn the crankshaft one revolution.
25. Right engine mount.
26. Coolant pump pulley.
27. Timing belt covers.
28. Timing belt.
29. Camshafts.

Cylinder Head Bolt Removal Sequence:

30. Cylinder head bolts.
31. Cylinder head from vehicle.

Disassemble

Tools Required:
J 37134 Valve Spring Compressor
J 37133 Valve Guide Bushing Remover and Replacer

1. Valve lifters with shims arranged in order.
2. Bond cable from the right engine hanger.
3. Temperature sensor bracket and the left engine hanger.
4. Valve keepers using a J 37134 valve spring compressor.
5. Spring retainer, spring. seat valve and oil seal.
- Arrange components in order.

Clean
- Top of pistons using a gasket scraper. Be careful not to scratch surface.
- Gasket material from the block, manifold and head surfaces, using a gasket scraper.
- Carbon and oil from the bolt holes using compressed air.
- Valves using a gasket scraper and a wire brush.
- Valve guides using a valve guide brush and solvent.
- Cylinder head using a soft brush and solvent.

Inspect
- Cylinder head for cracks. Replace as necessary.

Measure
- Valve guide inside diameter, using a caliper gage. If the inside diameter is 6.01 to 6.03 mm (0.2366 to 0.2374-inch), replace the valve guide.
- Valve stem diameter using a micrometer. If the diameter is not between 5.970 to 5.985 mm (0.2350 to 0.2356-inch) on the intake valve and 5.965 to 5.980 mm (0.2348 to 0.2354-inch) on the exhaust valve, replace the valve.
- Valve stem-to-valve guide clearance. The standard clearance on the intake valve is 0.025 to 0.060 mm (0.0010 to 0.0024-inch), and the standard clearance on the exhaust valve is 0.030 to 0.065 mm (0.0012 to 0.0026-inch). If the clearance on the intake valve is more than 0.08 mm (0.0031-inch), replace the intake valve. If the clearance on the exhaust valve is more than 0.10 mm (0.0039-inch), replace the exhaust valve.

6. Valve guide using a J 37133 valve guide remover and a hammer.

Measure
- Valve guide bushing bore using a caliper gage. If the valve guide is more than 11.027 mm (0.4341-inch), machine the bore to 11.050 to 11.077 mm (0.435010 0.4361-inch) and use a 0.05 mm oversize valve guide in the rebored bushing bore.

Assemble

Tools Required:
J 37133 Valve Guide Remover and Replacer
J 37134 Valve Spring Compressor
J 37280 Valve Guide Seal Installer

1. New valve guide using a J 37133 valve guide replacer.
- Ream the valve guide to obtain the standard clearance of 0.025 to 0.060 mm (0.0010 to 0.0024-inch) on the intake valve and 0.030 to 0.065 mm (0.0012 to 0.0026-inch) on the exhaust valve between the valve guide and the valve using a 6 mm (0.25-inch) reamer.

Measure
- Valve lifter oil clearance using a micrometer.
- Valve lifter outside diameter and the inside diameter of the lifter bore. The standard oil clearance is 0.015 to 0.046 mm (0.0006 to 0.0008-inch). If the oil clearance is greater than 0.10 mm (0.0039-inch), replace the valve lifter and/or the cylinder head.

Inspect
- Valve seats and valve seat angle. Grind face angle and valve seat as necessary.

Measure
- Valve margin using a dial caliper. If the margin is less than 0.8 mm (0.0315-inch), replace the valve.

2. New oil seals on the valve guides using a J 37280 valve guide seal installer.
3. Valves into the cylinder head.
4. Spring seats, springs, spring retainers, and valve keepers using a J 37134 valve spring compressor.
5. Valve lifters and selective shims.

Install or Connect

1. Cylinder head onto the cylinder block.

Cylinder Head Bolt Tightening Sequence:

2. Cylinder head bolts in sequence.

Tighten
- Cylinder head bolts to 60 N.m (44 lb.ft.).

3. Camshafts.
4. Timing belt.
5. Timing belt covers.
6. Coolant pump pulley.
7. Right engine mount.
8. Spark plugs.
9. Cylinder head covers.
10. Generator drive belt.
11. Power steering drive belt.
12. Intake manifold.
13. Delivery pipe with injectors.
14. Exhaust manifold and heat shield to the cylinder head.
15. Distributor.
16. Vacuum pipe and cylinder head rear cover.
17. Coolant by-pass hoses to the auxiliary air valve.
18. Cold start injector hose.
19. PCV hose.
20. Brake booster vacuum hose.
21. Coolant outlet hose from the radiator and cylinder head.
22. Ignition coil.
23. Cruise control actuator and bracket assembly.
24. Vacuum hoses to the throttle body.
25. Heater hose to the cylinder head rear cover.
26. Throttle cable to the throttle linkage.
27. Cruise control cable.
28. Air cleaner assembly.
- Fill coolant.
29. Battery negative (-) cable.