Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable.
2. Relieve fuel system pressure.
3. Drain coolant from cooling system.
4. Remove air intake pipe from throttle body assembly.
5. Remove accelerator cable, bracket and kickdown cable from throttle body by sliding cable clip at lever.
6. Disconnect electrical connections at throttle body, intake manifold and from the following:
a. Throttle position sensor (TP).
b. Idle air control valve (IAC).
c. Engine coolant temperature sensor (ECT).
d. ECT ending unit.
e. A/C ECT switch.
f. Evaporative emission solenoid purge valve (EVAP SP).
g. EGR temperature sensor.
h. EGR solenoid vacuum valve.
i. Fuel injectors.
j. Engine ground wire from intake surge tank.
7. Disconnect vacuum lines from throttle body and throttle opener.
8. Disconnect the following vacuum hoses:
a. EVAP SP.
b. EGR valve.
c. EGR valve modulator.
d. On models equipped with automatic transmission, vacuum modulator supply hose.
e. Brake booster supply hose.
9. Disconnect coolant hose and air hose from ISC solenoid valve.
10. Remove fuel feed pipe from throttle body and intake manifold, then remove the following:
a. PCV hose at PCV valve.
b. Upper radiator hose at thermostat housing.
c. Coolant bypass hose at intake manifold.
d. Generator adjusting bracket.
e. Front and rear intake manifold reinforcement brackets.
11. Remove upper and lower intake manifold support brackets.
12. Remove intake manifold intake surge tank and throttle body from cylinder head.
13. Remove upper and lower exhaust manifold heat shields.
14. Loosen all valve lash adjusting screws fully, then remove timing belt.
15. Disconnect exhaust pipe from manifold, then remove exhaust manifold support.

Fig. 10 Cylinder Head Bolt Loosening Sequence.:

16. Loosen cylinder head bolts in sequence shown in Fig. 10.
17. Carefully remove cylinder head from engine.
18. If valves and springs are to be removed, proceed as follows:

Fig. 11 Valve Keeper Replacement.:

a. Using valve spring compressor tool Nos. J8062 and J37979, or equivalents, compress valve springs and remove valve keepers, Fig. 11.
b. Release valve lifter tool and remove spring retainers and valve springs.
c. Remove valve stem oil seals.

Fig. 12 Valve Guide Replacement.:

d. Using tool No. J37968, or equivalent, drive valve guide from combustion side of cylinder head, Fig. 12
e. Repeat procedure for remaining valve assemblies.
19. Reverse procedure to install, noting the following:
a. Using reamer tool No. J37972, or equivalent, ream valve guide hole to remove burrs.
b. If valve guides are replaced, use valve guide installer tool No. J37968, or equivalent, to drive new valve guide in until tool contacts cylinder head.

Fig. 13 Valve Guide Protrusion Measurement.:

c. Measure valve guide protrusion, Fig. 13; guide should protrude 11.5 mm (0.45 of an inch).

Fig. 14 Valve Guide Bore Ream.:

d. Using reamer tool No. J37971, or equivalent, ream valve guide, Fig. 14, then clean bore.

e. Apply coat of clean engine oil to valve stem seals, guides, and valve stems.
f. Use valve seal installer tool No. J37968, or equivalent, to install valve stem seal on guide.

Fig. 8 Valve Spring Installation.:

g. Install valve springs, Fig. 8, with small pitch end (bottom) to valve spring seat; then, using tool No. J8062, or equivalent, install retainers and keepers.
h. Install new cylinder head gasket with side marked TOP facing upward toward the crankshaft pulley side.
i. Ensure oil jet (venturi plug) is installed and not plugged.
j. Apply engine oil to cylinder head bolts.

Cylinder Head Bolt Tightening Sequence:

k. Using sequence shown in Fig. 15, torque cylinder head bolts in three steps; first step to 26 ft. lbs., second step to 41 ft. lbs., third step to 52 ft. lbs.
l. Adjust accessory belt tensions, valve clearance, accelerator and kickdown cables, and ignition timing.
m. Check all fluid levels. Inspect for fuel, coolant and exhaust leaks.