Cylinder Head Assembly: Service and Repair

1. Remove timing belt and related components.
2. Remove intake manifold as follows:
a. Remove EGR valve, EGR pipe and back pressure transducer, then disconnect auxiliary air control valve connector.
b. Disconnect blow-by, auxiliary air control valve and PCV hoses, then two water hoses from throttle body.
c. Remove collector, then intake manifold assembly.
3. Remove exhaust manifold and gasket.
4. Remove cylinder head cover and camshaft.
5. Remove dipstick, then heater pipe.
6. Separate cylinder head from cylinder block as follows:

Fig. 50 Cylinder Head Removal Sequence:

a. Remove cylinder head bolts in sequence shown in Fig. 50. Leave bolts 5 and 8 engaged by four threads to prevent cylinder head from falling. Cylinder head bolts come in two different lengths.
b. Using plastic hammer, tap on cylinder head while separating it from cylinder block.
c. Remove bolts 5 and 8 with cylinder head and gasket.
7. Remove hydraulic lash adjuster. Arrange adjusters in correct order. Adjusters must be installed in their original positions.
8. Using valve spring remover No. 49971-8000 or equivalent, compress valve spring, then remove spring retainer key.
9. Remove valves from cylinder head. Use caution not to damage oil seals. Keep all parts in order of removal for proper installation.
10. Install valve as follows:
a. Coat valve stem with clean engine oil and insert valve into valve guide. Use caution not to damage oil seal lip. Install all parts in same position as they were removed from.
b. Install valve spring with closed coil end facing cylinder head seat.
c. Use valve spring remover tool No. 499718000 or equivalent to compress valve spring and install retainer key. Seat valve spring retainer by tapping it with a soft hammer.
11. Apply coat of clean engine oil to hydraulic lash adjuster sliding surface, then install adjusters.
12. Install cylinder head with new gasket. Torque cylinder head bolts as follows:
a. Coat bolt threads and washers with clean engine oil.

Fig. 51 Cylinder Head Installation Sequence:

b. Install and torque all bolts in sequence shown in, Fig. 51, to 22 ft. lbs.
c. Torque all bolts in sequence shown in, Fig. 51, to 51 ft. lbs.
d. Back off all bolts 180°, then back all bolts of an additional 180°.
e. Torque all bolts in sequence shown in Fig. 51, to 20 ft. lbs.
f. Torque bolts 1, 2, 3 and 4, 80°-90° in sequence shown in Fig. 51. Do not tighten bolts more than 90°
g. Torque bolts 5, 6, 7 and 8 in sequence shown in Fig. 51, to 33 ft. lbs.
h. Torque all bolts an additional 80°-90° in sequence shown in Fig. 51. Ensure total retightening angle (steps f and h) does not exceed 180°.
13. Install camshafts, cylinder head covers and related parts.
14. Install exhaust manifold and gasket, then the collector and intake manifold assembly.
15. Connector blow-by, auxiliary air control valve and PCV hoses, then two water hoses from throttle body.
16. Install EGR valve, EGR pipe and back pressure transducer, then connect auxiliary air control valve connector.
17. Install timing belt and related components.