Cylinder Head Assembly: Service and Repair

Cylinder Head Tightening Sequence & Torque Specifications:

TOOLS REQUIRED (or equivalent)
^ J 36660, Torque/Angle meter.

REMOVAL
1. Disconnect battery ground cable, then loosen fuel filler cap to relieve tank vapor pressure.
2. Remove air cleaner assembly, then drain cooling system.
3. Disconnect attaching vacuum hoses, electrical connectors and accelerator cable.
4. Remove coolant reservoir tank.
5. Remove serpentine belt, then remove alternator.
6. Loosen power steering pump attaching bolts, then position away.
7. Remove serpentine belt tensioner.
8. Remove ignition wires, then remove canister purge line beneath manifold.
9. Remove upper radiator hose, then remove upper and lower heater hose at manifold.
10. Remove throttle body cables from bracket.
11. Remove cylinder head coolant inlet hose.
12. Remove intake manifold brace to power steering bracket.
13. Remove attaching fuel lines.

CAUTION: Place shop towel over fuel line and fitting when disconnecting.

14. Remove rocker arm cover attaching bolts, then remove rocker arm cover.
15. Remove rocker arms and pushrods.

NOTE: Whenever valve train components are removed for service, they should be kept in order. They should be installed in the same locations and with the same mating surfaces as when removed.

16. Remove ignition cable bracket.
17. Disconnect exhaust pipe at exhaust manifold.
18. Remove cylinder head attaching bolts.
19. Remove transaxle fluid level indicator bracket if equipped.
20. Remove cylinder head assembly.

INSTALL

NOTE: When installing cylinder head, be sure all gasket surfaces, especially cylinder head gasket surfaces, are entirely free of dirt, sand, oil, and foreign matter directly before and during assembly. Do not use sealer.

1. Install cylinder head gasket over dowel pins on cylinder block.
2. Carefully guide cylinder head into place over dowel pins.
3. Install cylinder head bolts finger tight.
4. Tighten cylinder head bolts, refer below.
a. Tighten bolts in sequence (figure 1) to:
^ Long bolts to 63 Nm (46 ft lbs).
^ Short bolts to 58 Nm (43 ft lbs).
b. Tighten all bolts an additional angle of 90° in sequence using (J 36660).

5. Install transaxle fluid level indicator bracket if equipped.
6. Install exhaust pipe at exhaust manifold.
7. Install ignition cable bracket.
8. Install rocker arms and pushrods.
9. Install rocker arm cover and then install rocker arm cover attaching bolts.
10. Install attaching fuel lines.
11. Install intake manifold brace to power steering bracket.
12. Install cylinder head coolant inlet hose.
13. Install throttle body cables from bracket.
14. Install upper and lower heater hose at manifold, then install upper radiator hose.
15. Install canister purge line beneath manifold, then install ignition wires.
16. Install serpentine belt tensioner.
17. Position power steering pump then tighten attaching bolts.
18. Install alternator then install serpentine drive belt.
19. Install coolant reservoir tank.
20. Install accelerator cable then attach electrical connectors and vacuum hoses.
21. Install air cleaner assembly.
22. Refill coolant, and install negative battery cable.