Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable, drain cooling system, then remove air cleaner assembly.
2. On models equipped with A/C, unfasten A/C compressor and brackets, then position aside.
3. On all models, disconnect PCV hose, then remove EGR valve.
4. Disconnect spark plug wires from rocker arm cover.
5. Disconnect vacuum line and wiring harness from water outlet stud and position aside.
6. Disconnect vacuum lines from intake manifold stud, then remove rocker arm cover attaching bolts and the cover.
7. Remove rocker arms and pushrods.
8. Disconnect electrical connectors, fuel and vacuum lines from throttle body unit.
9. Disconnect vacuum lines from intake manifold.
10. Disconnect accelerator, TV and cruise control cables, as equipped, from throttle levers and brackets.
11. Remove alternator and mounting brackets and position aside.
12. Disconnect water pump bypass and heater hoses from intake manifold.
13. Disconnect exhaust pipe from manifold.
14. Disconnect upper radiator hose, then remove fuel filter and fuel line brackets from rear of cylinder head.
15. Remove dipstick tube.
16. Remove wiring harness bracket, then disconnect ground strap from rear of cylinder head.
17. Disconnect electrical connectors from rear of cylinder head and thermostat housing.
18. Disconnect spark plug and ignition coil wires.
19. Disconnect oxygen sensor electrical connector.
20. Remove cylinder head attaching bolts, then the cylinder head and manifolds as an assembly.
21. Thoroughly clean gasket from head and block mating surfaces.
22. Install new head gasket, then the cylinder head, ensuring gasket and head are seated over dowel pins in block.

Fig. 2 Cylinder Head Installation & Bolt Torque Sequence:

23. Apply sealant to threads of bolts indicated in Fig. 2.
24. Tighten bolts in three steps using sequence shown, Fig. 2. Torque all bolts to 18 ft. lbs., then retorque all bolts except No. 9 to 26 ft. lbs. Finally, tighten all bolts except No. 9 an additional 120° and bolt No. 9 an additional 90°. On 1988-92 models, torque all bolts to 18 ft. lbs., then retorque all bolts except No. 9 to 27 ft. lbs. Finally, tighten all bolts an additional 90°.
25. Reverse remaining steps to complete installation.