Cylinder Head Assembly: Service and Repair

REMOVAL PROCEDURE





1. Disconnect the battery negative cables from the batteries.
2. Drain the cooling system.
3. Remove the upper intake manifold from the lower intake manifold.
4. Remove the lower intake manifold from the cylinder heads.
5. Remove the radiator hoses from them engine block.
6. Remove the thermostat housing crossover from the cylinder heads.
7. Raise the vehicle and support with safety stands.
8. Remove the exhaust crossover pipe from the exhaust manifolds.
9. Lower the vehicle.
10. Remove the exhaust manifold (s) from the cylinder head (s) from the engine block.





11. Remove the air conditioning compressor and mounting bracket and secure to the side.
12. Remove the vacuum pump if necessary.
13. Remove the generator and bracket form the engine assembly.





14. Remove the ground strap from the cylinder head.
15. Remove the valve rocker arm, shaft, and push rods from the cylinder head.





16. Remove the cylinder head bolts (in sequence) from the cylinder head.





17. Remove the cylinder head from the engine block.
18. Remove the cylinder head gasket from the engine block.
19. Disassemble the cylinder head (if necessary). Refer to Cylinder Head Disassemble under Engine Unit Repair.

INSTALLATION PROCEDURE

IMPORTANT: The engine block surfaces must be clean. Do not use a sealer on the cylinder head gaskets. The cylinder head gaskets are manufactured with the proper amount of sealant "Printed" on its surface. Additional sealer may cause leakage or a malfunction. In addition, some sealers may attack the sealant already on the cylinder head gasket.

IMPORTANT: The cylinder head gasket material is soft. Handle the cylinder head gasket with care and make sure that the sealing surfaces are not damaged.





1. Assemble the cylinder head (if necessary). Refer to Cylinder Head Assemble under Engine Unit Repair.

IMPORTANT: Connect the rear cylinder head bolt to the cylinder head (left cylinder head only) with a rubber band. Due to the clearances, the bolt must be installed at this time.





2. Install the cylinder head bolts in the cylinder head.

NOTICE: Refer to Fastener Notice in Caution and Notices.





3. Install the cylinder head bolts and tighten in sequence.
3.1. Tighten the bolts in four passes.
3.2. Tighten the bolts to 25 Nm (20 ft. lbs.).
3.3. Tighten the bolts to 75 Nm (55 ft. lbs.).
3.4. In sequence, tighten all bolts an additional 90 to 100 degrees (1/4 + turn).

4. Install the push rods, valve rocker arm, and the shafts to the cylinder head.
5. Install the thermostat housing crossover to the cylinder heads.
6. Install the generator and mounting bracket to the cylinder head.
7. Install the vacuum pump if necessary.





8. Install the air conditioning compressor and mounting bracket.
9. Install the exhaust manifold (s) to the cylinder head (s).
10. Raise the vehicle.
11. Install the exhaust crossover pipe to the exhaust manifolds.
12. Lower the vehicle.
13. Install the lower intake manifold to the engine block.
14. Install the upper intake manifold lower intake manifold.
15. Install the radiator hoses on the engine block.
16. Refill the cooling system.
17. Connect the battery negative cables to the batteries.