Cylinder Head Assembly: Service and Repair

*** THIS ARTICLE INCLUDES REVISED UPDATES, FOR ADDITIONAL INFORMATION NOT INCLUDED HERE, REFER TO TSB #98-4-9, DATED MARCH 2, 1998 ***



REMOVAL AND INSTALLATION
1. Disconnect battery ground cable, then drain cooling system.
2. Remove air cleaner assembly, intake tube.
3. Remove drive belt.
4. If removing left cylinder head, proceed as follows:
a. Remove power steering pump and position aside, then remove oil fill cap.
b. Remove alternator and bracket.
5. If removing right cylinder head, proceed as follows:
a. Remove drive belt tensioner.
b. Remove PCV valve.
6. Remove intake manifolds.
7. Remove exhaust manifolds.
8. Remove rocker arm cover attaching bolts and the cover, note bolt and stud location for proper assembly.
9. Loosen rocker arm fulcrum attaching bolts enough to rotate rocker arm so pushrod can be removed.

NOTE: Keep pushrods in order so they can be installed in original position.

10. Loosen cylinder head bolts in multiple steps using same sequence used to tighten, then remove and discard cylinder head attaching bolts.
11. Remove cylinder head.
12. Reverse procedure to install, noting the following:
a. Ensure proper location of gasket and head on locating dowels, always use new cylinder head bolts.
b. Lightly oil all bolts except short cylinder head bolts.
c. Apply suitable sealer to short cylinder head bolts.

FWD 3.8L:

13. Reassemble and tighten the new head bolts to the following specifications:
Tighten all bolts in numerical sequence, as shown, in three steps as follows:

- 20 Nm (15 lb-ft)
- 40 Nm (30 lb-ft)
- 50 Nm (37 lb-ft)

Caution: Do not loosen all of the bolts at the same time. Work on one bolt at a time in the sequence shown. Failure to loosen bolts in proper sequence could cause cylinder head to warp.

14. In numerical sequence, retighten the bolts per the fallowing steps:

Long Bolts:

a. Loosen the long bolt and back out 2-3 turns.
b. Retighten the long bolt to 40-50 Nm (30-37 lb-ft).
c. Rotate the long bolt an additional 175°-185° (approximately 1/2 turn).
d. Go to the next bolt in sequence.

Short Bolts:

a. Loosen the short bolt and back out 2-3 turns.
b. Retighten the short bolt to 20-30 Nm (15-22 lb-ft).
c. Rotate the short bolt an additional 175°-185° (approximately 1/2 turn).
d. Go to the next bolt in sequence.

15. Seat each rocker arm fulcrum attaching bolt individually by first rotating crankshaft so that the matching lifter is on the base circle of the cam, then torque to 44 in lb After all fulcrum bolts have been seated then torque all fulcrum bolts to 19-25 ft lb.
16. Tighten valve cover bolts to 80-106 in lb.
17. Connect battery ground cable.
18. Bleed cooling system.