Cylinder Head Assembly: Service and Repair

Fig. 1 Cylinder head bolt tightening sequence:

Fig. 2 Intake manifold bolt tightening sequence:

REMOVAL
1. Disconnect battery ground cable.
2. Remove mass air flow sensor and air intake duct.
3. Remove serpentine drive belt.
4. Remove alternator.
5. Remove ignition module complete with wiring.
6. Disconnect vacuum lines and electrical connectors necessary for cylinder head removal.
7. Disconnect throttle, throttle valve and cruise control (if equipped) cables from throttle body.
8. Remove fuel lines and fuel rail.
9. Disconnect throttle body and intake manifold heater and radiator hoses and drain coolant.
10. Disconnect ignition wires from spark plugs, then remove intake manifold and valve covers.
11. Remove radiator and cooling fan.
12. Remove left exhaust manifold, then the rocker arms, pedestals and pushrods.
13. On models equipped with power steering, remove power steering pump.
14. On all models, remove engine oil level indicator and tube.
15. Remove left cylinder head attaching bolts and the cylinder head.
16. Raise and support vehicle.
17. Disconnect exhaust pipe from exhaust manifold, then lower vehicle.
18. Remove right cylinder head attaching bolts and the cylinder head.

INSTALLATION
1. Install cylinder head(s) noting the following:
a. If steel replacement gasket is used, coat both sides of gasket with suitable sealer.
b. Use new head bolts when installing cylinder head.
c. Torque bolts to specifications in sequence shown in (figure 1):
First, torque bolts to 25 ft-lbs (35Nm).
Second, tighten each bolt 90 degrees in sequence shown.
Third, tighten each bolt an additional 90 degrees in sequence shown.

CAUTION: If at any time you should reach 60 ft-lbs (81 Nm), you must stop and not complete the balance of the 90° turn(s).

2. Raise and support vehicle. Connect exhaust pipe to exhaust manifold, then lower vehicle.
3. Install engine oil level indicator and tube.
4. On models equipped with power steering, install power steering pump.
5. Install left exhaust manifold, then the rocker arms, pedestals and pushrods and torque bolts to 65 Nm (45 ft lbs).
6. Install intake manifold and torque bolts in sequence to 32 ft-lbs (44 Nm), (figure 2).
7. valve covers, radiator and cooling fan.
8. Connect Ignition wires and all heater and radiator hoses.
9. Install fuel lines and rail, then connect throttle, cruise control and T.V. cables at the throttle body.
10. Connect vacuum lines and electrical connectors as necessary.
11. Install the ignition module complete with wiring and then the alternator, bracket and serpentine drive belt.
12. Install mass air flow sensor and air intake duct. Connect the negative battery cable and fill cooling system.

Inspect For
^ Correct fluid levels.
^ Oil, fuel and coolant leaks.