Cylinder Head Assembly: Service and Repair
REMOVE1. Drain cooling system, then disconnect battery ground cable.
2. Remove the air duct, then the timing belt.
3. Remove intake plenum, then disconnect spark plug wires and high tension lead.
NOTE: Make note of spark plug wire location for reassembly.
4. Remove distributor.
5. Disconnect Exhaust Gas Recirculation Control (EGRC) solenoid, Mass Air Flow (MAF) sensor, pulse signal generator, valve body wiring harness, Manual Lever Position (MLP) switch, Park/Neutral Position (PNP) switch, magnetic clutch, power transistor, A/C high pressure switch, fuel injectors, ignition coil, temperature gauge sender and Engine Coolant Temperature (ECT) sensor electrical connectors.
6. Remove main wiring harness bracket from intake manifold coolant outlet, then the fuel line bracket bolt from EGRC solenoid bracket.
7. Disconnect coolant bypass hose from intake manifold coolant outlet, then remove Allen-head fuel rail bolts and position fuel rail and injectors aside.
Intake Manifold Bolt Removal Sequence:
8. Disconnect upper heater hose, then remove Allen-head intake manifold bolts and nuts in two steps in sequence shown in Fig. 1.
9. Remove intake manifold, then the rocker arm cover.
10. Use camshaft pulley holding tool T92P-6312-AH to hold camshaft sprocket while removing camshaft sprocket bolt, then remove camshaft sprocket.
11. Remove rear timing belt cover, then the dipstick bracket, if removing front (lefthand) cylinder head.
12. Remove front exhaust manifold flange cover, if removing front (lefthand) cylinder head.
13. Remove exhaust manifold to converter inlet pipe nuts, then the gasket and discard.
14. Remove lower A/C compressor to accessory bracket bolts, if removing front (lefthand) cylinder head.
15. Lower vehicle.
16. If removing front (lefthand) cylinder head, proceed as follows:
a. Loosen upper A/C compressor to accessory bracket bolts and wire A/C compressor aside, then remove upper accessory bracket bolts. Upper A/C compressor to accessory bracket bolts are too long to remove from A/C compressor until it is moved aside.
b. Remove radiator heater/heater pipe bracket bolts.
Front (Lefthand) Cylinder Head Bolt Removal Sequence:
c. Remove cylinder head bolts in two steps in sequence shown in Fig. 6. Discard bolts. Ensure that first bolt in removal sequence is located in number one position outside of cylinder head. This bolt is easily forgotten and tab can be broken off if cylinder head is moved before bolt is removed.
17. If removing rear (righthand) cylinder head, proceed as follows:
Front (Righthand) Cylinder Head Bolt Removal Sequence:
a. Remove cylinder head bolts in two steps in sequence shown in Fig. 7. Discard bolts.
Exhaust Manifold Bolt Removal Sequence:
18. Remove cylinder head, then if necessary, the exhaust manifold. Refer to Fig. 3, for exhaust manifold bolt removal procedure.
INSTALL
Exhaust Manifold Bolt Tightening Sequence:
1. If necessary, install exhaust manifold, tightening bolts in sequence shown in Fig. 4, to specifications.
Cylinder Head Bolt Washer Installation Position:
Cylinder Head Bolt Tightening Sequence:
2. Ensure that cylinder head bolt washers are installed as shown in Fig. 8, and that cylinder head bolts are installed in correct positions. Cylinder head bolts located in positions 4, 5, 12 and 13, Fig. 9, are 5 inches long and 1 through 3 and 6 through 11 are 4.17 inches long.
3. Install new cylinder head bolts and tighten numbered bolts in sequence shown in Fig. 9, in the following steps:
a. Torque bolts to 22 ft. lbs., then 43 ft. lbs.
b. Completely loosen all bolts.
c. Torque bolts to 22 ft. lbs., then finally,40---47 ft. lbs.
4. Install cylinder head bolt located at position ``A,'' Fig. 9, and torque to 6 ft. lbs.
5. If installing front (lefthand) cylinder head, proceed as follows:
a. Position lower radiator/heater pipe on bracket on cylinder head, then install bolt.
b. Install upper accessory bracket bolts and tighten bolts securely.
c. Position A/C compressor bracket on accessory bracket and install bolts. Tighten bolts to 33-44 ft lbs.
6. Raise and support vehicle.
7. Install lower A/C compressor to accessory bracket bolts and tighten to 33-44 ft lbs, if installing front (lefthand) cylinder head.
8. Install rear exhaust manifold to converter inlet pipe nuts and tighten to 32-40 ft lbs, if installing rear (righthand) cylinder head.
9. If installing front (lefthand) cylinder head, proceed as follows:
a. Install front exhaust manifold to converter inlet pipe nuts and tighten to 32 - 40 ft. lbs.
b. Install front exhaust manifold flange cover on exhaust manifold and tighten bolts to 48 - 59 inch lbs.
10. Lower vehicle.
11. Install dipstick bracket and tighten bolts to 70 in lbs, if installing front (lefthand) cylinder head.
12. Install rear timing belt cover and tighten bolts to 27-44 in lbs.
13. Use camshaft pulley holding tool to hold camshaft sprocket while installing and tightening bolt to 58-65 ft lbs.
14. Install rocker arm cover and tighten bolts to 9-26 in lbs.
Intake Manifold Bolt Tightening Sequence:
15. Install intake manifold and tighten bolts and nuts in sequence shown in Fig. 2, as follows:
a. Torque bolts and nuts to 27---44 inch lbs., then to 12---14 ft. lbs.
16. Connect upper heater hose, then position fuel injectors in their respective ports, install Allen head bolts and tighten to 17-20 ft lbs.
17. Connect coolant bypass hose to intake manifold coolant outlet, then position fuel line bracket on EGRC solenoid bracket and install bolt.
18. Attach main wiring harness bracket to intake manifold coolant outlet.
19. Connect EGRC solenoid, MAF sensor, pulse signal generator, valve body wiring harness, MLP switch, magnetic clutch, power transistor, A/C high pressure switch, fuel injectors, ignition coil, temperature gauge sender and ECT sensor electrical connectors.
20. Install distributor.
21. Connect spark plug wires and high tension lead, then install intake plenum.
22. Install timing belt, then the air duct.
23. Connect battery ground cable, fill cooling system, then check ignition timing.