Cylinder Head Assembly: Service and Repair

Cylinder Head










Remove or Disconnect

1. Drain engine coolant.
2. Negative battery cable.
3. Mass air flow sensor and air intake duct.
4. T.V. and accelerator cables (cruise control cable if equipped).
5. Crankcase ventilation pipe.
6. Vacuum lines and electrical connections as needed.
7. Exhaust crossover pipe.
8. Heater hoses.
9. Fuel lines and wiring connector.
10. Top radiator hose.
11. Generator and bracket.
12. Power steering pump and bracket. Refer to: Service and Repair
13. Right exhaust manifold.

Clean
- With hose and wiping rags, clean dirt from the cylinder head, manifolds and adjacent areas. Avoid getting DIRT into the engine.

14. A/C compressor bracket bolt.
15. Left exhaust manifold.
16. Valve covers.
17. Intake manifold.
18. Rocker arms and pushrods.
- Keep all valve train parts in order so they may be reinstalled in the same locations and with the same mating surfaces as when removed.
19. Cylinder head bolts and heads.

Clean
- All gasket mating surfaces.
- Cylinder head bolts holes in block.

Install or Connect

1. Clean threads in cylinder block using appropriate tap.
2. Cylinder head gasket on block.
3. Cylinder head.
4. Apply part no. 1052080, Loctite PST (592), Fel-Pro TST or equivalent sealer on bolt threads.
5. Cylinder head bolts.

NOTICE: This engine uses special torque-to-yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage.






6. Tighten cylinder head bolts to 34 Nm (25 lbs. ft.) per sequence.

Important: Should you reach 81 Nm (60 lbs. ft.) at any time in Steps 7 and 8, you should stop at this point. Do not complete the balance of the 90° turn.

7. Tighten each bolt 1/4 turn (90°) in sequence.
8. Tighten each bolt an additional 1/4 (90°) in sequence.
9. Rocker arms and pushrods.
- Be sure to place components in their original location.
10. Intake manifold.
11. Valve covers.
12. Left exhaust manifold.
13. A/C compressor bracket bolt.
14. Right exhaust manifold.
15. Power steering pump and bracket.
16. Generator and bracket.
17. Top radiator hose.
18. Fuel line and wiring connector.
19. Heater hoses.
20. Exhaust crossover pipe.
21. Vacuum lines and electrical connections.
22. Crankcase ventilation pipe.
23. T.V. and accelerator cables (cruise control cable if equipped).
24. Mass air flow sensor and air intake duct.
25. Negative battery cable.
26. Engine coolant.

Inspect
- Oil and coolant level.
- Fluid leaks.