Cylinder Head Replacement

- Tools Required
- SA9102E Valve Seal Remover/Replacer





1. Clean all parts. Coat the three oil gallery plugs with Saturn P/N 21485277 (Loctite 242@ Threadlocker or equivalent) and install them using a standard driver, if removed.

NOTICE:
- Do not depress the spring cap too far as it will cause valve stem seal and valve stem damage.
- After each valve is installed, oil the valve guide with clean engine oil and stem before installing the valve stem seal. If a valve stem seal is removed, it must be discarded.





a. Install new valve stem seals using service tool SA9102E. Do not oil the seal's inner diameter where it contacts the guide.
b. Oil the valve stems and install the valves, springs, caps, and retainers.
2. Fill the hydraulic lash adjusters with clean engine oil using an oil squirt can, lubricate the lash adjuster body and install them in their proper locations.
3. Assemble rocker arms over lash adjusters and valve stems.

NOTICE: Dowel pin in each camshaft must be located at the 12 o'clock position during installation to prevent valve and piston damage.





4. Oil the camshafts (lobes and journals) and install each in the cylinder head with the dowel pin at the 12 o'clock position.

IMPORTANT: Camshafts are identified IN (intake manifold side of engine) and EX (exhaust side of engine). If camshafts are installed at the wrong location, the following will occur:

a. The oil baffles in the cam cover will interfere with the camshaft and the cam cover will not assemble properly. Noise will be evident upon engine operation.
b. DTC P0172 (System Rich) is likely to set.
c. Poor engine performance at throttle tip-in will be evident.

NOTICE: Fully tightening down one bearing cap at a time will break the camshaft and damage the cylinder head cam bearings surfaces or damage the cap bolt threads.





d. The forward bearing caps are used to control thrust; the camshafts must be positioned fully forward prior to their installation.
e. Install all the bearing caps on each camshaft with arrows pointed toward the camshaft sprockets. The camshaft bearing caps are numbered and have an I for intake side and an 15 for exhaust manifold side stamped on them. Tighten the caps down uniformly.
Torque: 14 Nm (124 inch lbs.)

NOTICE: Make sure all gasket surfaces are clean when installing manifolds and cylinder head assembly. Inspect intake manifold gasket for nicks, cuts or swelling. Replace if any of these conditions are found.





5. Install intake manifold. Tighten nuts in the following sequence:
Torque: 13 Nm (115 inch lbs.)
6. Install exhaust manifold using a new exhaust manifold gasket.

Torque: 13 Nm (115 inch lbs.)

6. Install exhaust manifold using a new exhaust manifold gasket.





IMPORTANT: In sequence, torque 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: 17 Nm (150 inch lbs.)