Removal and Installation

REMOVAL

Cylinder Head:

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

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

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.

Head Gasket Installation:

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

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

Cylinder Head Tightening Sequence:

3. Tighten the cylinder head bolts 1-12 in the sequence shown in above image) 2 Step Torque Sequence:
^ First to 47 Nm (35 ft. lbs.).
^ Second to 122 Nm (90 ft. lbs.).
4. Tighten valley bolts A-H in sequence shown in above image to 11 Nm (95 inch lbs.) after head bolts 1-12 have been tightened to specifications.
5. Inspect the push rods. Replace worn or bent push rods as necessary.
6. Install the push rods, rocker arms, and pedestal assemblies into position. Tighten bolts to 41 Nm (30 ft. lbs.).
7. Place the new cylinder head cover gasket(s) in position and install the cylinder head covers. Tighten bolts in sequence shown in above image to 11 Nm (95 inch lbs.).

INTAKE MANIFOLD SEALING

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

Intake Manifold Gaskets Installation:

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

Intake Manifold Bolt Tightening Sequence:

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