Cylinder Head Removal and Installation

This article has been updated with bulletin No: 99-06-01-016.

Fig. 9 Chain Guide Access Plug Removal:

Cylinder Head Bolt Tightening Sequence:

REMOVE OR DISCONNECT
1. Engine assembly.
2. The following subassemblies:
^ Intake manifold.
^ Cam covers.
^ Harmonic balancer.
^ Front cover.
^ Oil pump.

3. Chain tensioner from timing chain for cylinder head being removed. Align all timing marks first!
4. Cam sprockets from head being removed. Timing chain remains in chain case.
5. Timing chain guides. Access to retaining screws is through plugs at front of cylinder head.
6. Water crossover.
7. Exhaust manifold.
8. Cylinder head bolts. Discard bolts.

NOTE: Do not reuse head bolts after removal. New bolts have special coating used for bolt retention after installation. This coating remains in the cylinder block threads after removal so proper cleaning of the cylinder block threads is important.

9. Cylinder head and gasket.
10. Clean the gasket surfaces and combustion chambers.
^ Head bolt threads in cylinder block with soft brush or equivalent.
^ Head bolt bosses in cylinder head with compressed air.

CAUTIONS:
^ With camshafts remaining in cylinder head some valves will be open at all times. For this reason cylinder head cannot rest on a flat surface with cylinder face down, or valve damage will result.

^ Caution must be exercised when cleaning aluminum gasket surfaces to prevent damage to the sealing surfaces. Use only plastic, wood, or dull gasket scrapers such as J-28410. Chemical agents to dissolve gasket materials can also be used effectively by following the manufacturers recommendations.

INSTALL OR CONNECT
1. New cylinder head gasket.
2. Cylinder head.









3. The torque specification and sequence for the cylinder head bolts (1--10) using J 36660-A is:
a. First Pass 40 Nm (30 lb. ft.).
b. Second Pass 70 Degrees.
c. Third Pass 60 Degrees.
d. Fourth Pass 60 Degrees (190 Degrees total).
e. The 3 front M6 cylinder head bolts 12 Nm (106 lb. in.).

4. Camshafts.
5. Set camshaft timing.
6. Camshaft guide bolt access hole plugs in cylinder heads. Plugs should be seated and snug.
7. The following sub assemblies:
^ Cam covers.
^ Oil pump.
^ Front cover.
^ Harmonic balancer.
^ Intake manifold.
Water crossover.

8. Exhaust manifold and tighten nuts to 30 Nm (22 lbs ft). Tighten the manifold bolts to 25 Nm (18 lbs ft).
9. Engine assembly.