Cylinder Head Assembly: Service and Repair

1. Relieve fuel system pressure.
2. Rotate crankshaft to Top Dead Center (TDC) on the compression stroke.
3. Disconnect battery ground cable, then drain cooling system.
4. Remove air cleaner outlet tube.
5. Remove intake manifold.
6. Using a 1/2 inch drive breaker bar inserted into the automatic belt tensioner, rotate and relax tension on the serpentine belt, then remove belt. Remove generator if lefthand side cylinder head is being removed.
7. Remove power steering pump bracket attaching bolts, then the pump and bracket as an assembly with hoses attached. Position pump and bracket assembly aside in an upright position to prevent leakage of fluid.
8. If lefthand side cylinder head is being removed, remove coil bracket and dipstick tube. If righthand side cylinder head is being removed, remove ground strap and throttle cable support bracket.
9. Remove exhaust manifolds, then the PCV valve and valve covers.
10. Loosen remaining rocker arm fulcrum bolts enough to allow the rocker arms to be swung aside and the pushrods removed.

NOTE: Keep pushrods in order so they can be installed in original positions.

11. Remove cylinder head attaching bolts, then the cylinder head and gasket. Discard gaskets and bolts.
12. Reverse procedure to install, noting the following:
a. Using new cylinder head bolts, lightly oil bolt threads prior to installation.
b. Replace any damaged gasket alignment dowels.

Fig. 8 Cylinder Head Bolt Tightening Sequence:

c. Torque cylinder head bolts in sequence shown to 52-66 ft lb, then loosen bolts in sequence one full turn.
d. Finally, torque cylinder head bolts, in sequence shown, in two steps: first to 34-40 ft lb, then to 63-73 ft lb.
e. Prior to installation, lubricate rocker arm assemblies and dip each pushrod end in oil conditioner part No. D9AZ-19579-C, or other suitable heavy engine oil.
f. Starting with engine at TDC compression No. 1 cylinder, rotate crankshaft 1 full turn clockwise, then install No. 2 and No. 5 exhaust and No. 1 and No. 4 intake push rod and rocker arm assemblies.
g. Torque rocker arm bolts in two steps: first to 6-11 ft lb, then to 20-28 ft lb.
h. Rotate crankshaft 1/3 turn clockwise, then install remaining push rod and rocker arm assemblies.
i. Torque rocker arm bolts in two steps: first to 6-11 ft lb, then to 20-28 ft lb.
j. Ensure all rocker arm bolts are fully seated to their shoulder after tightening.
k. If any valve train components were replaced or intermixed, inspect valve clearance.