Cylinder Head Assembly: Service and Repair
Removal
1. Disconnect negative battery cable.
2. Relieve fuel system pressure. Refer to Powertrain Management; Fuel Delivery and Air Induction.
3. Drain engine coolant.
4. Drain engine oil.
5. Remove PCV hose and ventilation hose.
6. Remove accelerator cable and auto-cruise control cable if equipped.
7. Remove air intake hose and fresh air duct.
8. Disconnect brake vacuum hose and purge control vacuum hose at dynamic chamber.
9. Remove upper radiator hose.
10. Disconnect fuel hose from injector rail.
Warning: Keep open flames and sparks away from open fuel lines or a fire or explosion may result.
11. Remove heater hoses.
12. Disconnect IAC and throttle position sensor connectors.
13. Disconnect injector connectors.
14. Disconnect electrical connectors, remove bracket and re-install engine hanger.
Tightening torque: 27.5 - 38.3 ft. lbs. (37.2 - 51.9 Nm, 3.8 - 5.3 kg-m)
15. Disconnect ground strap.
16. Remove exhaust manifold heat shield.
17. Remove exhaust manifold pipe.
18. Remove coolant bypass pipe.
19. Remove intake manifold support bracket.
20. Remove HLA's.
21. Loosen cylinder head bolts in two or three steps following order shown in figure.
22. Remove cylinder head.
Inspection
1. Check cylinder head gasket for obvious signs of leakage, coolant stains on gasket, or combustion burns across cylinders.
2. Clean cylinder head and cylinder block mounting surfaces of all gasket material.
Notice: Do not allow gasket material to fall into oil passages or oil control plug.
3. Measure cylinder head for straightness in six directions as shown in figure.
Distortion: 0.004 inch (0.10 mm) Maximum
4. If distortion exceeds specification, resurface or replace cylinder head. Only remove the amount of material required to achieve a flat surface.
Maximum material removal: 0.004 inch (0.1 mm)
5. Check cylinder head height.
Height: 5.272 - 5.280 inch (133.9 - 134 mm)
6. If cylinder head height is not within specification, replace cylinder head.
Notice: If cylinder head requires machining, remove intake and exhaust manifolds and check their mounting surfaces for straightness.
7. Measure intake and exhaust manifold mating surface distortion at two directions shown in figure.
Distortion: 0.008 inch (0.20 mm) Maximum
8. If distortion exceeds specification, resurface or replace cylinder head.
Maximum material removal: 0.008 inch (0.20 mm)
9. Check cylinder block for distortion of cylinder head mating surface (block deck) in six directions shown in figure.
Distortion: 0.006 inch (0.15 mm) Maximum
10. If distortion exceeds specification, resurface block deck.
Maximum material removal: 0.008 inch (0.20 mm)
Replacement
1. Install new cylinder head gasket onto cylinder block and lower cylinder head onto engine.
2. Install cylinder head bolts.
3. Tighten cylinder head bolts according to following procedure:
Cylinder Head Bolt Tightening Sequence:
a. Tighten cylinder head bolts in order shown.
Tightening torque: 36.1 ft. lbs. (49 Nm, 5 kg-m)
b. Loosen bolts in reverse of order shown.
c. Retighten cylinder head bolts in order shown.
Tightening torque: 28.9 ft. lbs. (39.2 Nm, 4 kg-m)
d. Mark cylinder head bolts for rotational reference.
e. Rotate cylinder head bolts 90° (1/4 Turn) in order shown.
f. Rotate cylinder head bolts another 90° (1/4 Turn) in order shown.
4. Install HLA's.
5. Install intake manifold support bracket.
Tightening torque: 27.5 - 38.3 ft. lbs. (37.2 - 51.9 Nm, 3.8 - 5.3 kg-m)
6. Install coolant bypass pipe
Tightening torque: 65.8 - 86 ft. lbs. (89.2 - 116.6 Nm, 9.1 - 11.9 kg-m)
7. Install exhaust manifold pipe.
Tightening torque:
(A): 28 - 34 ft. lbs. (38 - 46 Nm, 3.9 - 4.7 kg-m)
(B): 16 - 21 ft. lbs. (22 - 28 Nm, 2.2 - 2.9 kg-m)
8. Install exhaust manifold heat shield.
Tightening torque: 13.7 - 22.4 ft. lbs. (18.6 - 30.3 Nm, 1.9 - 3.1 kg-m)
9. Reconnect ground strap.
10. Install connector bracket and reconnect electrical connectors.
Tightening torque (engine hanger bolt): 27.5 - 38.3 ft. lbs. (37.2 - 51.9 Nm, 3.8 - 5.3 kg-m)
11. Connect injector connectors.
12. Connect IAC and throttle position sensor connectors.
13. Install heater hoses.
14. Connect fuel hose to fuel injector rail.
15. install upper radiator hose.
16. Connect brake vacuum hose and purge control vacuum hose.
17. Install air intake hose and fresh air duct.
18. Install accelerator cable and check cable deflection. If deflection is not correct, adjust by turning nut "A".
Deflection: 0.04 - 0.12 inch (1 - 3 mm)
19. Install cruise control cable if equipped.
20. Install PCV hose and ventilation hose.
21. Fill engine with specified amount and type of engine oil.
22. Fill engine with specified amount and type of coolant.
23. Connect negative battery cable.
24. Start engine and check for oil and coolant leaks and HLA noise.
25. Operate engine until cooling fans cycle and check ignition timing.