Removal and Installation

REMOVAL
1. Drain cooling system.
2. Disconnect negative cable from battery.
3. Remove upper and lower intake manifolds.

WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE.

4. Disconnect coil wires, sending unit wire, heater hoses and bypass hose.
5. Remove PCV system hoses, evaporation control system hose and cylinder head covers.
6. Remove exhaust manifolds.
7. Remove rocker arm and shaft assemblies. Remove push rods and mark positions to ensure installation in original locations.

Cylinder Head Bolts Location and Tightening Sequence:

8. Remove the nine head bolts from each cylinder head and remove cylinder heads.

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

Head Gasket Installation:

2. Install new gaskets on cylinder block.

Checking Bolts For Stretching (Necking):

3. The cylinder head bolts are torqued using the torque yield method, they should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced.
4. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced.
5. Tighten the cylinder head bolts 1-8 in the sequence. Using the 4 step torque turn method, tighten according to the following values:
^ Step 1: Bolts 1-8 to 61 Nm (45 ft. lbs.)
^ Step 2: Bolts 1-8 to 88 Nm (65 ft. lbs.)
^ Step 3: Bolts 1-8 (again) to 88 Nm (65 ft. lbs.)
^ Step 4: Bolts 1-8 turn an additional 1/4 Turn. (Do not use a torque wrench for this step.)

NOTE: Bolt torque after 1/4 turn should be over 122 Nm (90 ft. lbs.). If not, replace the bolt.

6. Tighten head bolt number 9 to 33 Nm (25 ft. lbs.) after head bolts 1-8 have been tightened to specifications.
7. Inspect push rods and replace worn or bent rods.

Rocker Arm Shaft Retainers:

8. Install push rods, rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 inch lbs.).
9. Place new cylinder head cover gaskets in position and install cylinder head covers. Tighten to 12 Nm (105 inch lbs.).
10. Install exhaust manifolds and tighten bolts to 27 Nm (20 ft. lbs.) and nuts to 20 Nm (15 ft. lbs.).
11. Install upper and lower intake manifolds.
12. Connect ignition cables, ignition coil connector, and sending unit connector.
13. Connect heater and coolant by-pass hose.
14. Fill cooling system.
15. Connect negative cable to battery.