Cylinder Head Replacement
- Tools Required
- SA9102E Valve Seal Remover/Replacer
- SA9124E Regulator Valve Remover/Replacer
1. Clean all parts.
2. Oil the valve stems and install valves stem seals, valves, springs, retainers, and camshaft:
NOTICE: After each valve is installed, oil the valve stem and guide before installing the seal. If a valve stem seal is removed, it must be discarded.
a. Use seal installer SA9102E-A to install valve stem seals.
b. Install valves and springs.
NOTICE: Do not depress the spring cap too far, as it will cause seal and valve stem damage.
c. Use SA9124E to install valve spring caps and retainers.
d. If removed, clean the thrust plate bolts and camshaft bolt hole threads of any residual sealer, oil, or foreign material. Remove with solvent.
NOTICE: The dowel pin end of camshaft must be located at 12 o'clock position during installation to prevent valve and piston damage.
e. Oil the camshaft and install it into the cylinder head with the dowel pin at the 12 o'clock position.
f. Install thrust plate and two new TORX screws.
Torque: 25 Nm (19 ft. lbs.)
g. Coat the rear camshaft cylinder head and two oil gallery plugs with Saturn P/N 21485277 (Loctite 242 or equivalent) and install it using a standard bushing driver, if REMOVED. Refer to the "General Description" for plug locations.
h. Oil hydraulic lifters with clean engine oil and install in cylinder head. Rotate lifters until flat sides are parallel to intake and exhaust manifold flanges.
i. Install lifter guide plates.
IMPORTANT: Make sure the guide plates are properly seated (retaining spring slot upward) on the cylinder head and all lifters fit squarely in the guide plate.
j. Oil rocker arm shaft and install rocker arms on both shafts.
k. Snap one end of each lifter guide plate retaining spring onto the rocker arm shaft between No. 1 - 2 and No. 3 - 4 cylinder rocker arms.
NOTICE: Rocker arm tangs (slots) must be properly seated prior to tightening rocker arm shaft bolts or valve and piston damage will be occur.
l. Install the rocker arm and shaft assembly on the cylinder head. Make sure the rocker arm tangs (slots) are squarely seated on the hydraulic lifter plunger. The retaining spring must be positioned in the guide plate slot.
m. Tighten down the five rocker arm shaft bolts uniformly.
n. Install the second rocker arm assembly. Snap the lifter guide plate retaining spring onto the shaft. Make sure the rocker tangs (slots) are squarely seated on the hydraulic lifter plunger as the assembly is installed.
NOTICE: The rocker arm assembly must be properly assembled to prevent engine damage.
IMPORTANT: A flat piece of cardboard (2 inch x 14 inch) or extension bar can be placed on top of the rocker arm assemblies (both shafts with all rocker arms) during installation for alignment of rocker arms on valves and hydraulic lifters.
o. Check all lifters, guide plates, guide plate retaining springs and rocker arm tangs (slots) for proper installation.
Torque: 25 Nm (19 ft. lbs.)
IMPORTANT: Make sure all gasket surfaces are clean when installing manifolds and cylinder head assembly to prevent oil leakage.
3. Install intake manifold using a new intake manifold gasket. Tighten bolts in the following sequence:
Torque: 30 Nm (22 ft. lbs.)
4. Install exhaust manifold using new exhaust manifold gasket.
IMPORTANT: Install gasket with smooth side toward exhaust manifold. In sequence, torque the exhaust manifold attachments nuts. The center fasteners may lose torque when the outer fasteners are tightened. Therefore, re-torque all fasteners a second time.
Torque: 22 Nm (16 ft. lbs.)
5. Install rear engine support (lift) bracket if removed.