Cylinder Head Assembly: Service and Repair

CYLINDER HEAD

REMOVAL





1. Perform the Fuel System Pressure Release procedure. Disconnect the fuel supply line.
2. Disconnect the battery negative cable.
3. Drain cooling system.
4. Remove the air cleaner resonator and duct work.
5. Remove closed crankcase ventilation system.
6. Disconnect the evaporation control system.





7. Unplug the ignition coil (1).
8. Remove ignition coil mounting bolts (3).
9. Disconnect heater hoses.





10. Remove the power steering pump.
11. Disconnect the exhaust at the exhaust manifolds.
12. Remove the ignition coils (1).





13. Unbolt the cylinder head covers using the sequence provided.





14. Remove the cylinder head cover (1).





15. Remove intake manifold and throttle body as an assembly.
16. Remove rocker arm assemblies and push rods. Identify to ensure installation in original locations.





17. Remove the head bolts from each cylinder head, using the sequence provided, and remove cylinder heads. Discard the cylinder head gasket.

CLEANING
Clean all surfaces of cylinder block and cylinder heads.
Clean cylinder block front and rear gasket surfaces using a suitable solvent.

INSPECTION
1. Inspect the cylinder head for out-of-flatness, using a straightedge and a feeler gauge. If tolerances exceed 0.0508 mm (0.002 inch) replace the cylinder head.
2. Inspect the valve seats for damage. Service the valve seats as necessary.
3. Inspect the valve guides for wear, cracks or looseness. If either condition exist, replace the cylinder head.
4. Inspect pushrods. Replace worn or bent pushrods.

INSTALLATION





1. Clean all surfaces of cylinder block and cylinder heads.
2. Clean cylinder block front and rear gasket surfaces using a suitable solvent.

CAUTION: The head gaskets (1) are interchangeable between left and right sides. They are marked "UP" to indicate direction to face up.





NOTE: Rotate crankshaft 45°, so that all pistons are 1/2 the way down the cylinder bore to avoid piston to valve contact.

3. Position new cylinder head gaskets (5) onto the cylinder block.
4. Position cylinder heads (4) onto head gaskets (5) and cylinder block.





5. Tighten the cylinder head bolts in three steps using the sequence provided :
- Step 1- Snug tighten M12 cylinder head bolts, in sequence, to 34 Nm (25 ft. lbs.) and M8 bolts to 20 Nm (15 ft. lbs.) torque.
- Step 2- Tighten M12 cylinder head bolts, in sequence, to 54 Nm (40 ft. lbs.) and verify M8 bolts to 20 Nm (15 ft. lbs.) torque.
- Step 3- Turn M12 cylinder head bolts, in sequence, 90 degrees and tighten M8 bolts to 34 Nm (25 ft. lbs.) torque.





6. Install push rods and rocker arm assemblies in their original position, using pushrod retaining plate (1) special tool# 907.
7. Install the intake manifold and throttle body assembly.
8. If required, adjust spark plugs to specifications. Install the plugs.
9. Connect the heater hoses.
10. Install the fuel supply line.
11. Install the power steering pump.
12. Install the drive belt.





13. Install cylinder head covers (1).





14. Install the ignition coils (1).





15. Reconnect the ignition coil wiring (1).





16. Connect the evaporation control system.
17. Install the air cleaner duct (2).
18. Fill cooling system.
19. Connect the negative cable to the battery.
20. Start engine check for leaks.