L>Cylinder Head

Cylinder Head

REMOVAL & environment 2.2L Engine relax the fuel mechanism pressure if an injected model. Disconnect the an adverse battery cable and also drain the cooling system. fist once draining the coolant, store in mind the cats and dogs room attracted by the ethylene glycol antifreeze, and are quite most likely to drink any type of that is left in an uncovered container or in pool on the ground. This will certainly prove fatal in adequate quantity. Constantly drain the coolant into a sealable container. Coolant must be reused uneven it is contaminated or several years old. Disconnect the spark plug wires and also remove the spark plugs. Disconnect the accelerator cable. If equipped through automatic transmission, disconnect the throttle cable. Remove the wait intake pipe. Remove the wait cleaner and fuel hose. Sheathe the fuel hose to avoid leakage, if equipped with a carburetor. If injected, eliminate the wait intake hose. If equipped with a carburetor, remove the fuel pump. caution never smoke once working roughly gasoline! stop all resources of sparks or ignition. Petrol vapors are exceptionally volatile! eliminate the top radiator hose, water by-pass hose, heater hose, and also brake vacuum hose. Remove the 3-way and also EGR solenoid valve assemblies. Disconnect the engine harness connector and also ground wire. Remove the vacuum chamber and also exhaust manifold insulator. Eliminate the EGR pipe and also exhaust pipe. Remove the exhaust manifold. Eliminate the entry manifold bracket and the input manifold. Remove the distributor. Loosen the air air conditioning compressor and bracket, position it turn off to the side and tie it the end of the way. Do not disconnect the refrigerant lines! remove the upper timing belt cover and also the time belt tensioner spring. To eliminate the timing belt, carry out the following: turn the crankshaft so the the 1 top top the camshaft wheel is aligned through the timing note on the prior housing. When timing marks space aligned, loosen the timing belt tensioner lock bolt. Pull the tensioner as much out as will go and then in the interim tighten the lock bolt to hold it there. Background the timing belt native the camshaft pulley and also position it out of the way. eliminate the cylinder head cover and also cover gasket.
Fig. 1: Cylinder head bolt removal succession
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loosen the cylinder head bolts in the proper sequence and remove the cylinder head and head gasket. When the cylinder head has been removed, it must be cleaned and inspected before installing it onto the engine or gift replaced. Refer to the "Engine Reconditioning" later on in this section. To install: place a brand-new head gasket ~ above the cylinder block and also install the cylinder head. Apply oil come the threads and seat deals with of the cylinder head bolts and also install.
Fig. 2: Cylinder head bolt tightening succession
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Tighten the cylinder head bolts in 2–3 steps in the proper sequence. The final torque specification is 59–64 ft. Lbs. (80–86 Nm). Use silicone sealer to each side that the front and rear camshaft bearing caps wherein the cap meets the cylinder head. Install the rocker arm cover. Download the timing belt and tensioner. Install the time belt former cover. Install the intake and exhaust manifolds. Download the upper radiator and also water by-pass hoses. If carburetor equipped, install the an additional air pipe. Install the distributor. Install the spark plugs and connect the spark plug wires. Affix all vacuum hoses and also electrical connectors. Affix the heater hoses and also the brake vacuum hose. If equipped, install the fuel pump. Attach the fuel lines. Install the cooling fan and also shroud. Affix the accelerator cable. Download the air cleaner or air intake hose. Download the splash shield. Attach the negative battery cable. Fill and bleed the cooling system. Run the engine and also check for leaks. Examine and change the ignition timing. 2.6L Engine 1987-88 relax fuel mechanism pressure, if injected. Disconnect the an unfavorable battery cable. Drain the cooling system. caution once draining the coolant, save in mind that cats and also dogs are attracted by the ethylene glycol antifreeze, and are quite most likely to drink any that is left in one uncovered container or in swimming pool on the ground. This will certainly prove deadly in enough quantity. Always drain the coolant into a sealable container. Coolant need to be reused uneven it is contaminated or several years old. eliminate the wait cleaner assembly. Remove the exhaust manifold. Eliminate the water by-pass pipe. Disconnect all crucial vacuum hoses and also electrical connectors. Disconnect the fuel lines. fist never smoke once working approximately gasoline! protect against all resources of sparks or ignition. Petrol vapors are extremely volatile! eliminate the carburetor and also intake manifold. Remove the distributor. Remove the rocker eight cover. Eliminate the rocker arm and shaft assembly, leaving the bolts in place in the column to store the assembly together. Install hydraulic lash adjuster holder tools 49 U012 001 or equivalent to save the adjusters from falling. Host the crankshaft sheave bolt through a wrench to save it native turning, then remove the camshaft sprocket bolt. Remove the camshaft. With the camshaft sprocket and timing chain meshed together, ar the sprocket ~ above the sprocket holder. NOTE: perform not revolve the engine through the camshaft removed. As soon as the cylinder head is removed, carry out not permit the sprocket to autumn from the sprocket holder. remove the cylinder head-to-timing chain instance bolts.
Fig. 3: Cylinder head bolt removal sequence
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ease the cylinder head bolts in 2–3 measures in the proper sequence. Eliminate the bolts and remove the cylinder head. Clean every gasket adjustment surfaces. As soon as the cylinder head has been removed, it must be cleaned and also inspected before installing it onto the engine or gift replaced. Describe the "Engine Reconditioning" later in this section. To install:
use a thin coat that sealer to the cylinder block and also timing chain cover call surfaces, download a new head gasket and the cylinder head. Execute not apply sealer to the cylinder head gasket.
Fig. 4: Cylinder head bolt tightening succession
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apply oil to the threads and seat deals with of the cylinder head bolts and also install. Through the engine cold, tighten the cylinder head bolts, in succession in 2–3 steps. Final torque on bolts 1–10 should be 65–72 ft. Lbs. (88–98 Nm) and on bolts 11 and also 12, 11–16 ft. Lbs. (15–22 Nm). Use engine oil come the camshaft journals and also install the camshaft, aligning the dowel pin through the camshaft sprocket. Install the distributor drive gear and the lock bolt. Tighten the lock bolt by hand only at this time. Coat the one packing with sealant and install in the behind of the cylinder head. Download the rocker arms/shafts assembly and also tighten the mounting bolts, in sequence, to 14–15 ft. Lbs. (19–20 Nm) other than for the No. 5 bearing cap rear bolt, which should be tightened come 15–20 ft. Lbs. (20–26 Nm). Tighten the distributor journey gear/camshaft sprocket lock bolt to 36–43 ft. Lbs. (49–58 Nm). Remove the hydraulic lash adjuster holders. Change the jet valve clearance. Install the half-circle pack in the prior of the cylinder head and also apply sealer across the top of the packing and also on both political parties of the pack on the cylinder head. Install the rocker arm cover and tighten the bolts to 43–61 inch lbs. (5–7 Nm). Install the remaining components. Fill and bleed the cooling system. Run the engine and check because that leaks. Inspect and adjust the ignition timing. 1989-93 appropriately relieve the fuel mechanism pressure. caution never smoke once working about gasoline! stop all resources of sparks or ignition. Gasoline vapors are very volatile! Disconnect the an unfavorable battery cable. Eliminate the waiting cleaner assembly. Drainpipe the coolant. fist once draining the coolant, store in mind that cats and dogs are attracted through the ethylene glycol antifreeze, and also are quite most likely to drink any that is left in one uncovered container or in puddles on the ground. This will prove deadly in sufficient quantity. Always drain the coolant right into a sealable container. Coolant should be reused unless it is contaminated or numerous years old. place the engine in ~ TDC top top the compression punch so that all the pulley matchmarks space aligned. Remove the accelerator cable. Remove the air intake pipe and resonance chamber. Remove the accessory drive belts and also AC belt idler. Eliminate the upper radiator hose. Eliminate the brake vacuum hose. Remove the spark plug wires. Remove the spark plugs. Eliminate the oil cooler coolant hose. Eliminate the canister hose. Remove the fuel lines. Disconnect the oxygen sensor. Remove the solenoid valves. Disconnect the emissions harness. Remove the rocker cover. Examine to for sure the engine is collection on TDC. The timing note on the camshaft sprocket should be 90 levels to the right, parallel come the top of the cylinder head. Make sure the yellow crankshaft sheave timing note is aligned through the indicator pin. Eliminate the distributor. Carry out not turn the engine after distributor removal. Hold the crankshaft sheave with a an ideal tool and remove the distributor drive gear/camshaft sheave retaining bolt and also the journey gear. Remove the top timing sheathe assembly. Press the timing chain adjuster sleeve in in the direction of the left, and also insert a pen (2mm <0.0787 in.> diameter by 45mm <1.77 in.> long) right into the lever hole to hold it in place. Cable the chain come the pulley and remove the pulley-block from the camshaft. Execute not enable the sprocket and chain to fall down into the engine and cause the chain to come to be disengaged native the crankshaft sprocket. Remove the entry manifold bracket. Disconnect the exhaust pipe.
Fig. 5: Cylinder head bolt removal succession
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remove the 2 former head bolts. Eliminate the remaining head bolts starting from the middle and working exterior toward the end of the head. Lift turn off the head. Discard the head gasket. As soon as the cylinder head has been removed, it need to be cleaned and also inspected prior to installing that onto the engine or being replaced. Describe the "Engine Reconditioning" later in this section. Come install:
use RTV sealer come the peak front the the block together shown. Place a new head gasket on the block. Place the head on the block. Clean the head bolts and also apply oil come the threads.
Fig. 6: Cylinder head bolt tightening succession
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Tighten the head bolts, in 2 also steps, to 64 ft. Lbs. (87 Nm). Torque the 2 front bolts, come 17 ft. Lbs. (23 Nm). Place the camshaft pulley-block on the camshaft and tighten the bolt come to 95 inch lbs. (11 Nm).; the nut to 87 inch lbs. (10 Nm). Connect the exhaust pipe. Download the intake manifold bracket. Install the upper timing sheathe assembly. Install the distributor. Install the rocker cover. Attach the emissions harness. Download the solenoid valves. Attach the oxygen sensor. Install the fuel lines. Install the canister hose. Download the oil cooler coolant hose. Install the spark plugs. Download the spark plug wires. Install the brake vacuum hose. Install the top radiator hose. Download the accessory journey belts. Install the accelerator cable. Fill the cooling system. Download the air cleaner assembly. Affix the an unfavorable battery cable. 3.0L Engine position the engine at TDC on the compression stroke. Correctly relieve the fuel system pressure. Disconnect the negative battery cable. Eliminate the air cleaner assembly. Drainpipe the cooling system. Eliminate the spark plug wires. Eliminate the fresh air duct assembly. Remove the cooling fan and radiator cowling. Remove the journey belts. Eliminate the air conditioning compresser idler pulley. If necessary, remove the compresser and also position it to the side. Remove the crankshaft pulley and also baffle plate. Eliminate the coolant bypass hose. Remove the top radiator hose. Eliminate the timing belt cover assembly retaining bolts. Remove the timing belt cover assembly and also gasket. Turn the crankshaft to align the adjustment marks the the pulleys. Eliminate the top idler pulley. Remove the time belt. If reusing the belt be sure to mark the direction that rotation. Disconnect and also plug canister, brake vacuum and also fuel hoses. If equipped through automatic transmission, disconnect the automatic transmission vacuum hose. Eliminate the 3-way soleniod valve assembly and disconnect all engine harness connector and also grounds. If equipped v automatic transmission, remove the dipstick. Disconnect the required vacuum hoses. Disconnect the accelerator linkage. Eliminate the distributor and also the EGR pipe. Eliminate the six expansion manifolds. Eliminate the O-rings indigenous the expansion manifolds and also purchase new ones. Eliminate the input manifold by loosening the retaining bolts in the proper sequence. Remove the cylinder head cover, gasket and also seal washers. Remove the center exhaust pipe insulator and pipe. Disconnect the exhaust manifold retaining bolts. Eliminate the exhaust manifold through insulator. Remove the seal plate.
Fig. 7: Cylinder head bolt removal sequence
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remove the cylinder head retaining bolts in the suitable sequence in 2 or 3 stages. Remove the cylinder head indigenous the vehicle. Once the cylinder head has actually been removed, it need to be cleaned and inspected before installing it onto the engine or being replaced. Refer to the "Engine Reconditioning" later in this section. Completely clean the cylinder head bolts. ~ the bolts room cleaned, measure up the size of every bolt and replace out of specifications bolts together required. Intake: 108mm Exhaust: 138mm Maximum Intake: 109mm Exhaust: 139mm inspect the oil regulate plug estimate at the cylinder block. Projection should be 0.53–0.57mm. If correct, use clean engine oil come a brand-new O-ring and position the on the regulate plug. To install: ar the brand-new cylinder head gasket on the left financial institution with the L mark facing up. Ar the new cylinder head gasket ~ above the right bank with the R mark encountering up. Install the cylinder onto the block. Tighten the head bolts in the complying with manner: coat the threads and also the seating deals with of the head bolts v clean engine oil.
Fig. 8: Cylinder head bolt tightening sequence
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torque the bolts in the appropriate sequence come 14 ft. Lbs. (19 Nm). Repaint a note on the head of every bolt. Making use of this note as a reference, tighten the bolts in the appropriate sequence an additional 90°. Repeat step d. install the seal plate. Download the exhaust manifold with insulator. Affix the exhaust manifold retaining bolts. Download the facility exhaust pipe insulator and pipe. Download the cylinder head cover, gasket and seal washers. Install the entry manifold by loosening the retaining bolts in the suitable sequence. Download the O-rings from the expansion manifolds. Download the six expansion manifolds. Download the distributor and the EGR pipe. If equipped v automatic transmission, install the dipstick. Attach the forced vacuum hoses. Attach the accelerator linkage. Download the 3-way soleniod valve assembly and also connect every engine harness connector and grounds. Affix the canister, brake vacuum and fuel hoses. If equipped with automatic transmission, affix the automatic transmission vacuum hose. Download the time belt. Install the time belt sheathe assembly and new gasket. Install the top radiator hose. Download the coolant bypass hose. Install the crankshaft pulley and also baffle plate. Download the compresser. Download the air conditioning compresser idler pulley. Download the accessory drive belts. Download the cooling fan and also radiator cowling. Download the fresh air duct assembly. Install the spark plug wires. Fill the cooling system. Download the air cleaner assembly. Attach the an unfavorable battery cable. 4.0L Engine relax fuel system pressure. Disconnect the an adverse battery cable. Drain the cooling device (engine cold) into a clean container and also save the coolant for reuse. fist when draining the coolant, save in mind the cats and also dogs space attracted by the ethylene glycol antifreeze, and also are quite likely to drink any that is left in one uncovered container or in puddles on the ground. This will certainly prove fatal in enough quantity. Constantly drain the coolant into a sealable container. Coolant must be reused unless it is contaminated or several years old. Disconnect the battery floor cable. Eliminate the air cleaner. Eliminate the upper and also lower input manifolds as described earlier. If the left cylinder head is gift removed: eliminate the accessory drive belt. Remove the air conditioning compressor. Remove the power steering pump and bracket assembly. Do NOT disconnect the hoses. Tie the assembly out of the way. Eliminate the spark plugs. If the best head is gift removed: eliminate the accessory drive belt. Eliminate the alternator and also bracket. Eliminate the EDIS ignition coil and bracket. Eliminate the spark plugs. remove the exhaust manifold(s). Eliminate the rocker eight covers as previously described. Eliminate the rocker pillar assembly. Eliminate the pushrods, keeping them in order for this reason they might be set up in their original locations. Loosen the cylinder head attaching bolts in reverse of the speak sequence, then eliminate the bolts and also discard them. They can not be re-used. Lift turn off the cylinder head(s). Remove and discard the old cylinder head gasket(s). Once the cylinder head has been removed, it need to be cleaned and also inspected prior to installing it onto the engine or gift replaced. Refer to the "Engine Reconditioning" later in this section. Come install: easy oil every bolt and stud bolt threads other than those specifying one-of-a-kind sealant. Position the new head gasket(s) top top the cylinder block, making use of the dowels because that alignment. The dowels have to be changed if damaged. NOTE: The cylinder head(s) and also intake manifold are torqued alternately and in sequence, to guarantee a correct fit and also gasket crush. position the cylinder head(s) on the block. Use a bead that RTV silicone gasket product to the mating joints the the head and also block at the 4 corners. Download the intake manifold gasket and again apply the sealer. NOTE: This sealer sets within 15 minutes, so job-related quickly! install the lower intake manifold and intsall the bolts and also nuts because that the manifold and also head(s). Tighten all fasteners finger-tight.
Fig. 9: Cylinder head bolt tightening succession
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Tighten the entry manifold fasteners, in sequence, come 36–72 inch lbs. (4–8 Nm). WARNING do not re-use the old head bolts. Constantly use new head bolts! torque the head bolts, in sequence, to 59 ft. Lbs. (80 Nm). Tighten the entry manifold fasteners, in sequence, to 6–11 ft. Lbs. (8–15 Nm). Tighten the head bolts, in sequence, second 80–85 levels tighter. 85 levels is a tiny less than 1⁄4 turn. 1⁄4 rotate would equal 90 degrees. Talk the entry manifold fasteners, in sequence, come 11–15 ft. Lbs. (15–20 Nm).; then, in sequence, come 15–18 ft. Lbs. (20–24 Nm). Dip every pushrod in heavy engine oil then install the pushrods in their initial locations. Install the rockerarm/shaft assembly(ies). Apply another bead that RTV sealer in ~ the 4 corners wherein the input manifold and heads meet. Download the rocker covers, using brand-new gaskets coated v sealer. Install the upper intake manifold. Download the exhaust manifold(s). Download the spark plugs and wires. If the left head to be removed, download the strength steering pump, compressor and drive belt. If the ideal head to be removed, install the EDIS coil and also bracket, alternator and bracket, and the journey belt. Download the air cleaner. To fill the cooling system. NOTE: in ~ this point, it"s a great idea to readjust the engine oil. Coolant contamination of the engine oil regularly occurs during cylinder head removal. affix the battery ground cable.


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Start the engine and check because that leaks.