Cylinder Head Assembly: Service and Repair

*** THIS ARTICLE INCLUDES REVISED UPDATES, FOR ADDITIONAL INFORMATION NOT INCLUDED HERE, REFER TO TSB #98-4-9, DATED MARCH 2, 1998 ***

Cylinder Head Bolt Tightening Sequence:

REMOVE
1. Drain cooling system.
2. Disconnect battery ground cable.
3. Remove air cleaner assembly including air intake duct and heat tube.
4. Loosen accessory drive belt idler. Remove drive belt.
5. If LH cylinder head is being removed perform the following:
a. Remove oil fill cap.
b. Remove power steering pump. Leaving hoses connected, place pump/bracket assembly aside in a position to prevent fluid from leaking out.
c. If equipped with air conditioning, remove mounting bracket attaching bolts. Leaving hoses connected, position compressor aside.
d. Remove alternator and bracket.

6. If RH cylinder head is being removed perform the following:
a. Disconnect Thermactor air control valve or bypass valve hose assembly at the air pump.
b. Disconnect Thermactor tube support bracket from the rear of cylinder head.
c. Remove accessory drive idler.
d. Remove Thermactor pump pulley. Remove Thermactor pump.
e. Remove PCV valve.

7. Remove upper intake manifold.
8. Remove valve rocker arm cover attaching screws.
9. Remove injector fuel rail assembly.

CAUTION: Perform Fuel system Pressure Relief Procedure prior to removing fuel rail.

10. Remove lower intake manifold.
11. Remove exhaust manifold(s).
12. Loosen rocker arm fulcrum attaching bolts enough to allow rocker arm to be lifted off the push rod and rotate to one side.
13. Remove push rods. Identify position of each rod. Rods should be installed in their original position during assembly.
14. Remove cylinder head attaching bolts and discard.
15. Remove cylinder head(s).
16. Remove and discard old cylinder head gasket(s).

INSTALL

NOTE: Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant.

1. Clean cylinder head, intake manifold, valve rocker arm cover and cylinder head gasket surfaces. If cylinder head was removed for a cylinder head gasket replacement, check flatness of cylinder head and block gasket surfaces.
2. Position new head gasket(s) onto cylinder block using dowels for alignment.

3. Position cylinder head(s) onto block.
4. Apply a thin coating of Pipe Sealant with Teflon� D8AZ-1 9554-A (ESG-M4G1 94-A and ESR-MF1 8P7-A) or equivalent to threads of short cylinder head bolts (nearest to the exhaust manifold). Do not apply sealant to the long bolts. Install cylinder head bolts (eight each side).

CAUTION: Always use new cylinder head bolts to ensure a leak-tight assembly. Torque retention with used bolts can vary, which may result In coolant or compression leakage at the cylinder head mating surface area.

FWD 3.8L:

5. Reassemble and torque the new head bolts to the following specifications. Torque all bolts in numerical sequence in three steps as follows:
a. 20 N.m (15 lb-ft)
b. 40 N.m (30 lb-ft)
c. 50 N.m (37 lb-ft)
6. In numerical sequence, retorque the bolts per the following Steps:
LONG BOLTS (Bolt Numbers 1, 3, 5, 7):
a. Loosen long bolt and back out 2-3 turns.
b. Retorque long bolt to 40-50 N.m (30-37 lb-ft).
c. Rotate long bolt an additional 175-185 degrees (approximately 1/2 turn).
d. Go to the next bolt in sequence.
SHORT BOLTS (Bolt Numbers 2, 4, 6, 8):
a. Loosen short bolt and back out 2-3 turns.
b. Retorque short bolt to 20-30 N.m (15-22 lb-ft).
c. Rotate short bolt an additional 175-185 degrees (approximately 1/2 turn).
d. Go to the next bolt in sequence.
7. Dip each push rod end in Oil Conditioner D9AZ-19579-CA (ESR-M99C80-A) or equivalent heavy engine oil. Install push rods in their original position.
8. For each valve, rotate crankshaft until tappet rests on the heel (base circle) of the camshaft lobe, before tightening fulcrum attaching bolts. Position rocker arms over push rods, install fulcrums. Tighten fulcrum attaching bolts to 5 Nm (43 in lb). maximum.
9. Lubricate all rocker arm assemblies with Oil Conditioner D9AZ-19579-CA (ESR-M99C80-A) or equivalent heavy engine oil.

Final tighten the fulcrum bolts to 25-35 Nm (19.25 ft lb). For final tightening, camshaft may be in any position.

NOTE: If original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check.

10. Install exhaust manifold(s).
11. Install lower intake manifold.
12. Install injector fuel rail assembly.
13. Position cover and new gasket on cylinder head and install attaching bolts. Note location of spark plug wire routing clip stud bolts. Tighten attaching bolts to 9-12 Nm (80-106in lb).
14. Install upper intake manifold.
15. Install spark plugs, if removed.
16. Connect secondary wires to the spark plugs.
17. If LH cylinder head is being installed, perform the following:
a. Install oil fill cap.
b. If equipped with air conditioning, install compressor mounting and support brackets.
c. Install power steering pump mounting and support brackets.
d. Install alternator/support bracket.

18. If RH cylinder head is being installed, perform the following:
a. Install PCV valve.
b. Install alternator bracket. Tighten attaching nuts to 40-55 Nm (30-40 ft lb).
c. Install Thermactor pump and pump pulley.
d. Install accessory drive idler.
e. Install Thermactor air control valve or air bypass valve hose. Tighten clamps securely to the air pump assembly.

19. Install accessory drive belt and tighten to specification.
a. Attach Thermactor tube(s) support bracket to the rear of the cylinder head. Tighten attaching bolts to 40-55 Nm (30-40 ft lb).
20. Connect battery ground cable.
21. Fill cooling system with specified coolant.

CAUTION: This engine has an aluminum cylinder head and requires a special unique corrosion inhibited coolant formulation to avoid radiator damage.

22. Start engine and check for coolant, fuel and oil leaks.
23. Check and, if necessary, adjust curb idle speed.
24. Install air cleaner assembly including air intake duct and heat tube.