Cylinder Head Assembly: Service and Repair

1. Remove timing belt covers, timing belts, camshaft cases, lash adjusters and rockers.
2. Remove alternator, then the a/c compressor, if equipped.
3. Disconnect hoses, lines and electrical connections, then remove intake manifold attaching bolts and the intake manifold.
4. Remove water bypass pipe and alternator mounting brackets from cylinder head.
5. Remove spark plugs.

Fig. 24 Cylinder Head Bolt Tightening Sequence:

6. Loosen cylinder head bolts in two steps in reverse sequence as that shown in Fig. 24, then remove cylinder head from crankcase.
7. Using suitable valve spring compressor tool, compress valve springs and remove retainer keys.
8. Remove retainers, inner and outer springs, valves and valve seals.
9. Coat valve seals with engine oil, then install seals using tool 398852100 or equivalent. Intake and exhaust seals are not interchangeable. Intake seals measure .512 inch high, while exhaust seals are .425 inch high. Ensure seals are installed correctly.
10. Coat valve stems with engine oil, then install valves into guides.
11. Install inner and outer springs and retainer, then compress springs and install retainer keys. Tap retainers lightly with mallet to seat keys.
12. Install cylinder head onto crankcase using new gaskets.
13. Apply engine oil to head bolt threads, then install bolts through cylinder head and into crankcase, ensuring convex shaped washers face toward bolt head. Bolts 1, 2, 9 and 13 (silver colored), Fig. 24, are shorter than all remaining (yellow) bolts. Ensure bolts are properly positioned before tightening.
14. Torque cylinder head bolt to specifications in sequence shown Fig. 24.
15. Install spark plugs, water bypass pipe bracket, intake manifold and alternator mounting bracket.
16. Install alternator and a/c compressor, if equipped.
17. Install lash adjusters, rockers, camshaft cases, timing belts and timing belt covers.