Removal and Installation

Figure 39 Cylinder Head:

REMOVAL
The alloy aluminum cylinder head is held in place by 12, 1/2 inch bolts and 8, 1/4 inch bolts. The spark plugs are located in peak of the chamber between the valves
1. Disconnect negative battery cable.
2. Drain cooling system.
3. Remove intake manifold, and throttle body assemblies.
4. Disconnect coil wires, sending unit wire, and heater hoses.
5. Remove closed ventilation system and cylinder head covers.
6. Remove coolant tubes from engine.
7. Remove exhaust manifold heat shields.
8. Remove exhaust manifold(s) and gasket(s).
9. Remove rocker arm and pedestal assemblies. Remove push rods.

NOTE: Identify to each component to insure installation in original locations.

Figure 40 Cylinder Head Bolt Locations:

10. Remove the 12 head bolts and 8 valley seal bolts from cylinder head(s).
11. Remove cylinder head(s) and gasket(s).

INSTALLATION
1. Clean all surfaces of cylinder block and cylinder heads.

CAUTION: Remove all gasket material from cylinder head and block using a plastic scraper only. DO NOT use a metal scraper, as damage to sealing surface may occur.

NOTE: A multi-layer steel head gasket is used.

Figure 41 Head Gasket Installation:

2. Install new gasket(s) on cylinder block.

CAUTION: Cylinder head bolts are coated, DO NOT oil.

Figure 42 Cylinder Head Tightening Sequence:

3. Tighten the cylinder head bolts 1 - 12.
- First to 47 Nm (35 ft. lbs.).
- Second to 122 Nm (90 ft. lbs.)

4. Tighten valley bolts A - H in sequence to 11 Nm (95 inch lbs.) after head bolts 1 - 12 have been tightened to specifications.
5. Inspect push rods. Replace worn or bent push rods as necessary.
6. Install push rods, rocker arm, and pedestal assemblies into position. Tighten bolts to 41 Nm (30 ft. lbs.).

Figure 43 Engine Valve Cover Tightening Sequence:

7. Place new cylinder head cover gasket(s) in position and install cylinder head covers. Tighten bolts in sequence to 11 Nm (95 inch lbs.).

INTAKE MANIFOLD SEALING
The intake manifold gaskets are one-piece fiber gaskets with a molded silicone beads applied from the manufacturer.
1. Clean all surfaces of intake manifold and cylinder heads.

Figure 44 Intake Manifold Gaskets Installation:

2. Carefully install intake manifold gaskets using the plastic alignment pins.

Figure 45 Intake Manifold Bolt Tightening Sequence:

3. Install intake manifold. Install and tighten bolts initially to 1 Nm (10 inch lbs.). Then tighten bolts to 11 Nm (95 inch lbs.).
4. Install exhaust manifold gaskets.
5. Install exhaust manifold. The lower center and outer bolts must be installed first to ensure proper alignment of exhaust manifolds. Tighten bolts to 23 Nm (200 inch lbs.). Install the stud bolts in the upper 5 positions of the manifold.
6. Install heat shields on exhaust manifolds. Tighten all attaching nuts to 10 Nm (90 inch lbs.).
7. Adjust spark plug gap and install spark plugs.