Cylinder Head Assembly: Service and Repair

Fig. 5 Cylinder Head Bolt Loosening Sequence:

REMOVAL
1. Remove intake manifold as outlined in Intake Manifold.
2. Remove camshaft sprockets and rear timing belt cover
3. Remove exhaust manifold front exhaust tube, then the rocker covers.
4. Remove air conditioning compressor and alternator, then the brackets.
5. Remove cylinder head bolts in order, Fig. 5 then cylinder head with exhaust manifold.

Fig. 7 Cylinder Head Bolt Tightening Sequence:

INSTALLATION
1. Set No. 1 piston at TDC on compression stroke as follows by aligning crankshaft sprocket alignment mark with oil pump body mark, Fig. 6, and confirm knock pin on camshaft is set at top.
2. Apply sealant to threads and install drain plugs in each side of cylinder block.
3. Install cylinder head with new gasket and washers between bolts and heads. Do not rotate crankshaft and camshaft separately or valves will hit pistons.
4. Install cylinder heads bolts in order, Fig. 7, and tighten as follows:
a. Bolts 4, 5, 12 and 13 are 5 inches long, other bolts are 4.17 inches.
b. Torque bolts to 22 ft. lbs.
c. Torque bolts to 43 ft. lbs.
d. Loosen bolts completely.
e. Torque bolts to 22 ft. lbs.
f. Use angle wrench and turn bolts clockwise 60-65°.
g. If angle wrench is not available, torque bolts to 40-47 ft. lbs.

5. Install exhaust manifold front tube.
6. Install rear belt cover and camshaft sprockets. Camshaft sprocket market R3 is for righthand; sprocket L3 is for lefthand.
7. Install timing belt as outlined in Timing Belt.