Cylinder Head Assembly: Service and Repair

REMOVAL

CAUTION: Cylinder head must not be set on head face. If valves are open, damage will occur.

1. Disconnect battery ground cable.
2. Drain cooling system and remove fan blade and fan shroud.
3. Relieve fuel system pressure.
4. Remove air cleaner outlet tube and the windshield wiper governor.
5. Release drive belt tensioner and remove drive belt.
6. Disconnect ignition wires from spark plugs. Do not pull on ignition wires.
7. Disconnect ignition wire and brackets from camshaft cover studs.
8. Remove bolts retaining power steering oil reservoir to the left ignition coil bracket and position clear of area.
9. Remove three nuts retaining right ignition coil bracket to engine front cover.
10. Remove left ignition coil and ignition wires as an assembly.
11. Remove four nuts retaining left ignition coil bracket to engine front cover.
12. Slide ignition coil brackets and ignition wire bracket assembly off mounting studs and remove from vehicle.
13. Remove water pump pulley.
14. Disconnect alternator wiring harness from junction block, front fender apron and alternator.
15. Remove two bolts retaining alternator mounting bracket to intake manifold.
16. Remove two bolts retaining alternator to cylinder block and remove alternator.
17. Disconnect and remove positive crankcase ventilation valve from camshaft cover.
18. Disconnect 42-pin engine harness connector and 8-pin connector leading to mass airflow sensor.
19. Remove nut retaining A/C liquid line to right strut tower.
20. Lift A/C liquid line and feed the 42-pin connector under the A/C liquid line. Position the 42-pin connector clear of area.
21. Disconnect crankshaft position sensor, A/C clutch and canister purge solenoid connectors.
22. Raise and support vehicle on a hoist, then remove bolts retaining power steering pump to cylinder block and engine front cover.

NOTE: The front lower bolt on the power steering pump will not come all the way out.

23. Secure power steering pump clear of area with suitable wire.
24. Remove four bolts retaining oil pan to front engine cover.
25. Remove crankshaft pulley bolt and crankshaft pulley retaining washer from crankshaft.
26. Install crankshaft damper remover tool T58P-6316-D or equivalent, on crankshaft pulley and pull crankshaft pulley from crankshaft.
27. Disconnect EVO sensor and oil pressure sender.
28. Disconnect EGR valve to exhaust manifold tube from right exhaust manifold.
29. Disconnect catalytic converter from right and left exhaust manifolds.

Securing Catalytic Converter To Crossmember:

30. Lower exhaust and secure with wire to crossmember as shown.
31. Remove bolt retaining starter wiring harness to rear of right cylinder head.
32. Remove bolts and stud bolts retaining right valve cover to cylinder head and remove valve cover.
33. Disconnect accelerator cable and speed control actuator.
34. Remove accelerator cable bracket from intake manifold and position clear of area.
35. Remove bolts and stud bolts retaining left valve cover to cylinder head and remove valve cover.
36. Disconnect throttle valve control actuating cable from throttle body.
37. Disconnect vacuum hose from throttle body adapter vacuum port.
38. Disconnect both heated oxygen sensors, then disconnect heater water hose.
39. Remove two bolts retaining thermostat housing to intake manifold and position upper radiator hose and thermostat housing out of the way.
40. Remove nine bolts retaining intake manifold to cylinder heads and remove intake manifold.
41. Remove intake manifold gaskets, then remove seven stud bolts and four bolts retaining engine front cover to engine and remove engine front cover.
42. Remove timing chains.
43. Remove 10 bolts retaining left cylinder head to cylinder block, noting the following:
a. The lower rear bolt cannot be removed due to interference with the power brake booster.

LH Lower Rear Head Bolt Removal:

b. Use a rubber band or similar item to retain the bolt away from the cylinder block as shown.
44. Remove left cylinder head.
45. Remove ground strap, one stud and one bolt retaining water heater hose to right cylinder head.
46. Remove 10 bolts retaining the right cylinder head to the cylinder block, noting the following:
a. The lower rear bolt cannot be removed due to interference with the A/C evaporator housing.

Right Cylinder Head Removal:

b. Use a rubber band or similar item to hold bolt away from cylinder block as shown.
47. Remove right cylinder head.
48. Clean cylinder head, intake manifold, camshaft cover and cylinder block sealing surfaces.
49. Inspect head face surface for scratches near coolant passage and combustion chamber.

INSTALLATION
1. Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.
2. Rotate crankshaft to a stable position where valves do not extend below cylinder head face.
3. Position new head gasket on cylinder block. Install lower rear cylinder head bolts and retain in position with rubber bands as described during removal procedure.
4. Position left cylinder head on cylinder block. Apply clean engine oil to all head bolt spot-faces.
5. Remove rubber band from lower rear bolt and install nine remaining bolts hand tight.
6. Tighten left cylinder head bolts as follows:

Cylinder Head Bolt Tightening Sequence:

a. Torque bolts in sequence shown to 25-30 ft lb.
b. Rotate all bolts in same sequence 85-95°.
c. Final tighten all bolts an additional 85-95° in same sequence.
7. Position right cylinder head on cylinder block dowels. Apply clean engine oil to all head bolt spot-faces.
8. Remove rubber band from lower rear bolt and install nine remaining bolts hand tight.
9. Tighten right cylinder head bolts as follows:

Cylinder Head Bolt Tightening Sequence:

a. Torque bolts in sequence shown to 25-30 ft lb.
b. Rotate all bolts in same sequence 85-95°.
c. Final tighten all bolts an additional 85-95°.
10. Position heater water hose on cylinder head and install two bolts.
11. Rotate camshafts using flats matched at center of camshaft until both are in time and install Cam Positioning tool T92P-6256-A or equivalent on flats of camshaft. This will prevent camshafts from rotating.
12. Position crankshaft at No. 1 TDC by rotating crankshaft 45°.

CAUTION: Crankshaft must only be rotated in clockwise direction and only as far as TDC.

13. Install timing chains.
14. Reverse remainder of removal procedure to complete cylinder head installation, noting the following:

Intake Manifold:

a. Tighten intake manifold bolts to 15-22 ft lb in sequence.
b. Apply silicone gasket and sealant No. F1AZ-19562-A or equivalent, at both places where the engine front cover meets the cylinder head.
c. Ensure exhaust system clears the No. 3 crossmember. Adjust as necessary.

Crankshaft Pulley Keyway Silicone Gasket Sealant Application Locations:

d. Apply silicone gasket and sealant F1AZ-19562-A or equivalent, in keyway of crankshaft pulley as shown.