GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Cylinder Head

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REMOVAL & INSTALLATION



1.8L, 2.0L and 2.2L OHV Engines
1982-86 VEHICLES

See Figure 1

The engine should be overnight cold before removing the cylinder head.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system into a clean container; the coolant can be reused if it is still good.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Raise and safely support the vehicle using jackstands.
  10.  
  11. Remove the exhaust shield, then disconnect the exhaust pipe.
  12.  
  13. Disconnect the heater hose from the intake manifold.
  14.  
  15. Carefully lower the vehicle.
  16.  
  17. Unscrew the mounting bolts and remove the engine lift bracket (includes air management).
  18.  
  19. Remove (mark for correct installation) the distributor.
  20.  
  21. Disconnect the vacuum manifold at the alternator bracket.
  22.  
  23. Tag and detach the remaining vacuum lines at the intake manifold and thermostat.
  24.  
  25. Remove the air management pipe at the exhaust check valve.
  26.  
  27. Disconnect the accelerator linkage at the carburetor or T.B.I. unit, as applicable, and then remove the linkage bracket.
  28.  
  29. Tag and disconnect all necessary wires.
  30.  
  31. Detach the upper radiator hose at the thermostat.
  32.  
  33. Unfasten the bolt attaching the dipstick tube and hot water bracket.
  34.  
  35. Remove the idler pulley. Remove the A.I.R. and/or power steering pump drive belts.
  36.  
  37. For early model vehicles, unfasten the A.I.R. bracket-to-intake manifold bolt. If equipped with power steering, remove the air pump pulley, the A.I.R. through-bolt and the power steering adjusting bracket. Loosen the A.I.R. mounting bracket lower bolt so that the bracket will rotate.
  38.  
  39. If equipped with power steering, remove the power steering pump and lay aside with the lines still attached.
  40.  
  41. Disconnect and plug the fuel line(s) at the carburetor or TBI.
  42.  
  43. Remove the alternator with the wires attached and position aside. Remove the alternator brace from the head, then remove the upper mounting bracket.
  44.  
  45. Remove the rocker arm (valve) cover. Remove the rocker arms and pushrods.
  46.  
  47. Remove the cylinder head bolts in the reverse order given in the illustration. Remove the cylinder head with the carburetor or T.B.I. unit, intake and exhaust manifolds still attached.
  48.  



Click image to see an enlarged view

Fig. Fig. 1: This sequence MUST be followed when installing the cylinder head bolts - 1982-86 1.8L and 2.0L OHV engines

To install:
  1. To install, the gasket surfaces on both the head and the block must be clean of any foreign matter and free of any nicks or heavy scratches. Cylinder bolt threads in the block and the bolt must be clean.
  2.  
  3. Place a new cylinder head gasket in position over the dowel pins on the block. Carefully guide the cylinder head into position.
  4.  
  5. Coat the cylinder bolts with sealing compound and install them finger tight.
  6.  
  7. Using a torque wrench, tighten the cylinder head bolts as follows:
    1. 1982-85 vehicles: gradually tighten the bolts to 65-75 ft. lbs. (88-102 Nm) in the sequence shown in the illustration.
    2.  
    3. 1986 vehicles: gradually tighten the bolts to 70-73 ft. lbs. (95-95 Nm) in the sequence shown in the illustration.
    4.  

  8.  
  9. Install the rocker arms and pushrods and adjust the valve lash.
  10.  
  11. Install the cylinder head cover.
  12.  
  13. Install the alternator brace on the head, then fasten the upper mounting bracket.
  14.  
  15. Attach the wires, then install the alternator.
  16.  
  17. Connect the fuel line at the carburetor.
  18.  
  19. Install the A.I.R. bracket-to-intake manifold bolt. If equipped with power steering, install the air pump pulley, the A.I.R. through-bolt and the power steering adjusting bracket.
  20.  
  21. Install the idler pulley. Install the A.I.R. and/or power steering pump drive belts.
  22.  
  23. Install the bolt attaching the dipstick tube and hot water bracket.
  24.  
  25. Connect all wires, as tagged during removal.
  26.  
  27. Install the upper radiator hose at the thermostat.
  28.  
  29. Install the linkage bracket and connect the accelerator linkage at the carburetor or TBI.
  30.  
  31. Install the air management pipe at the exhaust check valve.
  32.  
  33. Connect the remaining vacuum lines at the intake manifold and thermostat.
  34.  
  35. Install the distributor.
  36.  
  37. Connect the vacuum manifold at the alternator bracket.
  38.  
  39. Install the engine lift bracket (includes air management).
  40.  
  41. Install the heater hose at the intake manifold.
  42.  
  43. Connect the exhaust pipe.
  44.  
  45. Install the exhaust shield.
  46.  
  47. Install the air cleaner.
  48.  
  49. Fill the cooling system.
  50.  
  51. Connect the negative battery cable, then start the engine and check for leaks.
  52.  

1987-91 VEHICLES

See Figures 2 and 3

The engine must be cold before removing the cylinder head. Always release the fuel pressure before starting repair.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly drain the cooling system into a suitable container.
  6.  
  7. Remove the TBI cover.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the exhaust shield. Disconnect the exhaust pipe.
  12.  
  13. Detach the heater hose from the intake manifold.
  14.  
  15. Remove the accelerator and TV cable bracket.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. Tag and disconnect the remaining vacuum lines at the intake manifold.
  20.  
  21. Disconnect the accelerator linkage at the TBI unit.
  22.  
  23. Tag and detach all necessary wires.
  24.  
  25. Unfasten the upper radiator hose at the thermostat.
  26.  
  27. Remove the serpentine belt.
  28.  
  29. Remove the power steering pump and lay aside with the fluid lines attached.
  30.  
  31. Make sure the fuel system pressure is released, then disconnect and plug the fuel lines.
  32.  
  33. Remove the alternator with the wires attached. Remove the rear alternator brace.
  34.  
  35. Remove the rocker arm (valve) cover. Remove the rocker arms and pushrods keeping all parts in order for correct installation.
  36.  
  37. Unfasten the cylinder head bolts. Remove the cylinder head with the TBI unit, intake and exhaust manifolds still attached.
  38.  



Click image to see an enlarged view

Fig. Fig. 2: Cylinder head bolt tightening sequence - 1987-89 2.0L OHV engines

To install:
  1. The gasket surfaces on both the head and the block must be clean of any foreign matter and free of any nicks or heavy scratches. Bolt threads in the block and the bolts must be clean.
  2.  
  3. Place a new cylinder head gasket in position over the dowel pins on the block. Carefully guide the cylinder head into position.
  4.  
  5. Coat the cylinder bolts with sealing compound and install them finger tight.
  6.  
  7. For 1987-89 vehicles, tighten the long bolts to 73-83 ft lbs. (99-113 Nm) and the short bolts to 62-70 ft lbs. (85-95 Nm), in the sequence shown in the illustration.
  8.  
  9. For 1990-91 vehicles, tighten the bolts twice, in the sequence shown in the accompanying figure. For the first pass, tighten the long bolts to 23 ft. lbs. (32 Nm) and the short bolts and stud to 22 ft. lbs. (29 Nm). Make a second pass, tightening the long bolts to 78 ft. lbs. (106 Nm) and the short bolts to 66 ft. lbs. (90 Nm).
  10.  



Click image to see an enlarged view

Fig. Fig. 3: Cylinder head bolt tightening sequence - 1990-91 2.2L OHV engines

  1. Install the pushrods and rocker arms, then install the rocker arm (valve) cover.
  2.  
  3. Install the alternator brace, connect the wires, then install the alternator.
  4.  
  5. Attach the fuel lines.
  6.  
  7. Install the power steering pump.
  8.  
  9. Install the serpentine belt.
  10.  
  11. Fasten the upper radiator hose at the thermostat.
  12.  
  13. Connect the wires as tagged during removal.
  14.  
  15. Attach the accelerator linkage at the throttle body.
  16.  
  17. Connect the vacuum lines at the intake manifold and thermostat.
  18.  
  19. Raise and safely support the vehicle.
  20.  
  21. Connect the heater hose to the intake manifold.
  22.  
  23. Install the accelerator and T.V. cable bracket.
  24.  
  25. Fasten the exhaust pipe, then carefully lower the vehicle.
  26.  
  27. Install the TBI cover.
  28.  
  29. Properly fill the cooling system, then connect the negative battery cable. Start the engine and check for leaks.
  30.  

1992-94 VEHICLES

See Figure 4

The engine must be cold before removing the cylinder head. Always release the fuel pressure before starting repair.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into an approved container.
  6.  
  7. Label and disconnect the vacuum lines.
  8.  
  9. Tag and detach the following electrical connections:

    Idle Air Control (IAC) valve
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    EVAP emission solenoid
     
    Fuel injector harness
     
    Exhaust Gas Recirculation (EGR) valve
     

  10.  
  11. Disconnect the accelerator linkage, T.V. cable, cruise control cable (if equipped), and the splash shield at the throttle body.
  12.  
  13. Remove the coolant reservoir (overflow or surge tank).
  14.  
  15. Remove the serpentine belt.
  16.  
  17. Unfasten the alternator rear brace, then remove the alternator.
  18.  
  19. Disconnect the power steering lines, then remove the pump.
  20.  
  21. Remove the serpentine drive belt tensioner.
  22.  
  23. Tag and disconnect the spark plug wires from the plugs.
  24.  
  25. Detach the EVAP canister purge line from beneath the manifold.
  26.  
  27. Disconnect the upper radiator hose from the thermostat.
  28.  
  29. Unfasten the throttle body cables from the bracket.
  30.  
  31. Remove the transaxle fill tube and level indicator.
  32.  
  33. Disconnect the coolant inlet hose on the cylinder head.
  34.  
  35. Detach and plug the fuel lines.
  36.  
  37. Disconnect the heater hose from the cylinder head.
  38.  
  39. Remove the intake manifold brace (located on the power steering bracket).
  40.  
  41. Remove the rocker arm (valve) cover. Remove the rocker arms and pushrods keeping all parts in order for correct installation.
  42.  
  43. Remove the spark plug wire bracket and the engine lift bracket.
  44.  
  45. Raise and safely support the vehicle.
  46.  
  47. Disconnect the exhaust pipe from the manifold. You may have to remove the oil filter to access, so don't forget to drain the crankcase first!
  48.  
  49. Carefully lower the vehicle.
  50.  
  51. Unfasten the cylinder head bolts, then remove the head.
  52.  

To install:
  1. The gasket surfaces on both the head and the block must be clean of any foreign matter and free of any nicks or heavy scratches. Bolt threads in the block and the bolts must be clean.
  2.  
  3. Place a new cylinder head gasket in position over the dowel pins on the block. Carefully guide the cylinder head into position. Install the cylinder head bolts finger tight.
  4.  
  5. Tighten the bolts, in the sequence shown in the accompanying figure, as follows:
    1. Long bolts: tighten to 46 ft. lbs. (63 Nm).
    2.  
    3. Short bolts: tighten to 43 ft. lbs. (58 Nm).
    4.  
    5. Tighten all bolts, in sequence, an additional angle of 90° using tool J 36660 or equivalent.

      Click image to see an enlarged view

      Fig. Fig. 4: Cylinder head bolt torque sequence for 1992-94 2.2L engines

    6.  

  6.  
  7. Install the engine lift bracket and the spark plug wire bracket.
  8.  
  9. Install the pushrods and rocker arms, then install the rocker arm (valve) covers.
  10.  
  11. Fasten the intake manifold brace to the power steering bracket.
  12.  
  13. Unplug, then connect the fuel lines.
  14.  
  15. Connect the coolant inlet hose onto the cylinder head.
  16.  
  17. Attach the upper radiator hose to the thermostat housing.
  18.  
  19. Connect the EVAP emission canister purge line under the manifold.
  20.  
  21. Attach the throttle body cables and bracket.
  22.  
  23. Install the transaxle level indicator and fill tube, secure with the retaining bolt.
  24.  
  25. Connect the spark plug wires, as tagged during removal.
  26.  
  27. Install the serpentine drive belt tensioner.
  28.  
  29. Install the power steering pump, then connect the fluid lines.
  30.  
  31. Install the alternator and rear brace.
  32.  
  33. Fasten the serpentine drive belt.
  34.  
  35. Install the coolant recovery reservoir (overflow or surge tank).
  36.  
  37. Route and connect the vacuum lines, as tagged during removal.
  38.  
  39. Attach the following electrical connectors:

    Idle Air Control (IAC) valve
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    EVAP emission solenoid
     
    Fuel injector harness
     
    Exhaust Gas Recirculation (EGR) valve
     

  40.  
  41. Install the air cleaner assembly.
  42.  
  43. Raise and safely support the vehicle.
  44.  
  45. Attach the exhaust pipe at the manifold. If necessary, install an oil filter.
  46.  
  47. Connect the heater hose to the cylinder head.
  48.  
  49. Carefully lower the vehicle.
  50.  
  51. Refill the crankcase and the coolant.
  52.  
  53. Connect the negative battery cable, then bleed the power steering system. For details, please refer to Suspension & Steering of this repair guide.
  54.  
  55. Start the engine and check for leaks.
  56.  

1.8L and 2.0L OHC Engines

See Figures 5 through 15

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove air cleaner or induction tube (turbo engines).
  6.  
  7. Drain cooling system.
  8.  
  9. Remove alternator and pivot bracket at camshaft carrier housing.
  10.  



Click image to see an enlarged view

Fig. Fig. 5: Remove the alternator and bracket from the camshaft carrier housing

  1. Remove power steering pump and bracket, then position aside.
  2.  
  3. Detach ignition coil electrical connections and remove coil.
  4.  
  5. Tag and disconnect spark plug wires and distributor cap and remove.
  6.  
  7. Remove throttle cable from bracket at intake manifold.
  8.  
  9. Disconnect throttle cable, downshift cable and T.V. cable from the throttle body assembly.
  10.  
  11. Detach the ECM connectors from throttle body assembly.
  12.  
  13. Remove vacuum brake hose at filter.
  14.  
  15. Disconnect inlet and return fuel lines at flex joints.
  16.  


CAUTION
The fuel lines are pressurized. Removal may cause fuel spray resulting in personal injury. Do not remove before bleeding the pressure from the fuel system. seeChapter 1for the procedure.

  1. Remove water pump bypass hose at intake manifold and water pump.
  2.  
  3. Disconnect ECM harness connectors at intake manifold.
  4.  
  5. Detach the heater hose from intake manifold.
  6.  
  7. Disconnect exhaust pipe at exhaust manifold. On turbo engines, disconnect the exhaust manifold at the turbo connection.
  8.  
  9. Disconnect breather hose at camshaft carrier.
  10.  
  11. Remove upper radiator hose.
  12.  
  13. Disconnect engine electrical harness and wires from thermostat housing.
  14.  
  15. Remove timing cover.
  16.  
  17. Remove timing probe holder.
  18.  
  19. Loosen water pump retaining bolts and remove timing belt.
  20.  
  21. Loosen camshaft carrier and cylinder head attaching bolts a little at a time, in the sequence shown in the accompanying figure.
  22.  



Click image to see an enlarged view

Fig. Fig. 6: Unfasten the camshaft carrier/cylinder head bolt in sequence



Click image to see an enlarged view

Fig. Fig. 7: Camshaft carrier and cylinder head bolt loosening sequence - 1.8L and 2.0L OHC engines

Camshaft carrier and cylinder head bolts should only be removed when engine is cold.



Click image to see an enlarged view

Fig. Fig. 8: Remove the retaining bolts, then ...

  1. Remove camshaft carrier assembly.
  2.  
  3. Remove cylinder head, intake manifold and exhaust manifold as an assembly. Remove and discard the gasket.
  4.  



Click image to see an enlarged view

Fig. Fig. 9: Remove the camshaft carrier/cylinder head, intake manifold and exhaust manifold as an assembly



Click image to see an enlarged view

Fig. Fig. 10: Remove and discard the cylinder head gasket

  1. The gasket surfaces on both the head and the block must be clean of any foreign matter and free of any nicks or heavy scratches. Bolt threads in the block and the bolts must be clean.
  2.  



Click image to see an enlarged view

Fig. Fig. 11: Carefully use a suitable scraper to clean the gasket mating surfaces

To install:
  1. Install a new cylinder head gasket in position on the block.
  2.  
  3. Apply a continuous bead of sealer to the cam carrier.
  4.  



Click image to see an enlarged view

Fig. Fig. 12: Apply a continuous bead of sealant to the camshaft carrier mating surface

  1. Install the cylinder head, reassembled with the intake and exhaust manifolds, if removed.
  2.  
  3. Position the camshaft carrier on the cylinder head and tighten the bolts, in the sequence in the accompanying figure, to the correct torque.
    1. Tighten all bolts in sequence to 18 ft. lbs. (25 Nm).
    2.  
    3. Tighten all bolts an additional 180° in 3 steps of 60° each.

      Click image to see an enlarged view

      Fig. Fig. 13: Tighten the cylinder head/camshaft carrier retaining bolts in sequence and to the proper torque specifications to avoid leakage, or other engine damage



      Click image to see an enlarged view

      Fig. Fig. 14: Camshaft carrier and cylinder head bolts tightening sequence - 1.8L and 2.0L OHC engines



      Click image to see an enlarged view

      Fig. Fig. 15: Tighten all bolts an additional 60°, three times (in sequence)

    4.  

  4.  
  5. Install timing belt.
  6.  
  7. Install timing probe holder.
  8.  
  9. Install timing cover.
  10.  
  11. Connect engine electrical harness and wires at thermostat housing.
  12.  
  13. Install upper radiator hose.
  14.  
  15. Connect breather hose at camshaft carrier.
  16.  
  17. Connect exhaust pipe at exhaust manifold. On turbo engines, connect the exhaust manifold at the turbo connection.
  18.  
  19. Connect heater hose at intake manifold.
  20.  
  21. Attach the ECM harness connectors at intake manifold.
  22.  
  23. Install water pump bypass hose at intake manifold and water pump.
  24.  
  25. Connect inlet and return fuel lines at flex joints.
  26.  
  27. Install vacuum brake hose at filter.
  28.  
  29. Attach the ECM connectors at throttle body assembly.
  30.  
  31. Connect throttle cable, downshift cable and T.V. cable at throttle body assembly.
  32.  
  33. Install throttle cable at bracket on intake manifold.
  34.  
  35. Connect the spark plug wires as tagged during removal, then install the distributor cap.
  36.  
  37. Attach the ignition coil electrical connections, then install the coil.
  38.  
  39. Install power steering pump and bracket.
  40.  
  41. Install alternator and pivot bracket on camshaft carrier housing.
  42.  
  43. Fill cooling system.
  44.  
  45. Install air cleaner or induction tube (turbo engines).
  46.  

2.8L and 3.1L Engines
1985-86 VEHICLES (LEFT SIDE)

See Figure 16

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Properly drain the cooling system, then carefully lower the vehicle.
  6.  
  7. Remove the intake and exhaust manifolds. For details, please refer to the procedures located earlier in this section.
  8.  
  9. Remove the oil level indicator tube.
  10.  
  11. Disconnect the wiring harness at the left head.
  12.  
  13. Remove the alternator bracket.
  14.  
  15. Loosen the rocker arm bolts until you are able to remove the pushrods, then remove the pushrods.
  16.  
  17. Unfasten the cylinder head retaining bolts, then remove the cylinder head.
  18.  

To install:
  1. Clean all gasket surfaces on the cylinder head, block and intake manifold and clean the bolt threads and bolts.
  2.  
  3. Place a new head gasket in position over the dowel pins with the words "This Side Up" facing upward.
  4.  
  5. Coat the cylinder head bolts with sealer and tighten them to 77 ft. lbs. (104 Nm) in the sequence shown in the accompany figure.
  6.  



Click image to see an enlarged view

Fig. Fig. 16: Cylinder head bolt tightening sequence - 1985-86 2.8L engines

  1. Install the pushrods, making sure the lower ends are in the lifter seats, and loosely retain with the rocker arms.
  2.  
  3. Install the intake manifold and gaskets.
  4.  
  5. Install the exhaust manifold.
  6.  
  7. Attach the wiring harness.
  8.  
  9. Install the oil level indicator.
  10.  
  11. Install the alternator bracket.
  12.  
  13. Fill the cooling system.
  14.  
  15. Adjust the drive belt and the valve lash.
  16.  
  17. Connect the negative battery cable, then start the engine and check for leaks.
  18.  

1985-86 VEHICLES (RIGHT SIDE)

See Figure 16

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the cooling system, then lower the vehicle.
  6.  
  7. If equipped, remove the cruise control servo bracket.
  8.  
  9. Remove the intake and exhaust manifolds. For details, please refer to the procedure earlier in this section.
  10.  
  11. Tag and disconnect the spark plug wires, then remove the plugs.
  12.  
  13. Loosen the rocker arm bolts and remove the pushrods.
  14.  
  15. Unfasten the cylinder head bolts, then remove the cylinder head.
  16.  

To install:
  1. Clean all gasket surfaces on the cylinder head, block and intake manifold and clean the bolt threads and bolts.
  2.  
  3. Place a new head gasket in position over the dowel pins with the words "This Side Up" facing upward. Position the cylinder head.
  4.  
  5. Coat the cylinder head bolts with sealer, then tighten to 77 ft. lbs. (104 Nm), in the sequence shown in the accompanying figure.
  6.  
  7. Install the pushrods in the lifter seats and loosely retain with the rocker arms.
  8.  
  9. Install the intake manifold and gaskets.
  10.  
  11. If equipped, install the cruise control servo bracket.
  12.  
  13. Install the spark plugs, then connect the wires as tagged during removal.
  14.  
  15. Install the exhaust manifold.
  16.  
  17. Fill the cooling system.
  18.  
  19. Connect the negative battery cable, then start the vehicle and check for leaks.
  20.  

1987-93 VEHICLES (LEFT SIDE)

See Figure 17

  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Properly drain the cooling system.
  4.  
  5. Remove the rocker arm (valve) cover.
  6.  
  7. Remove the intake manifold as outlined earlier in this section.
  8.  
  9. Disconnect the exhaust crossover at the right exhaust manifold.
  10.  
  11. Remove the oil level indicator tube bracket.
  12.  
  13. Loosen the rocker arms nuts enough to remove the pushrods, then remove the pushrods.
  14.  
  15. Starting with the outer bolts, remove the cylinder head bolts. Remove the cylinder head with the exhaust manifold.
  16.  
  17. Clean and inspect the surfaces of the cylinder head, block and intake manifold. Clean the threads in the block and the threads on the bolts.
  18.  

To install:
  1. Align the new gasket over the dowels on the block with the note "This Side Up" facing the cylinder head.
  2.  
  3. Position the cylinder head and exhaust manifold crossover assembly on the engine.
  4.  
  5. Coat the cylinder head bolts with a proper sealer and install the bolts hand tight.
  6.  
  7. Tighten the bolts, in the correct sequence, to 33 ft. lbs. (45 Nm), then rotate an additional 90° ( 1 / 4 turn).
  8.  
  9. Install the pushrods in the same order they were removed.
  10.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Install the rocker arms. The correct rocker arm torque is 14-20 ft. lbs. (19-27 Nm).
  2.  
  3. Install the intake manifold using a new gasket and following the correct sequence, tighten the bolts to the correct specification.
  4.  
  5. The remainder of the installation is the reverse of the removal.
  6.  



Click image to see an enlarged view

Fig. Fig. 17: Cylinder head bolt tightening sequence - 1987-94 2.8L and 3.1L engines

1987-93 VEHICLES (RIGHT SIDE)

See Figure 17

  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Disconnect the exhaust manifold from the exhaust pipe.
  6.  
  7. Carefully lower the vehicle. Disconnect the exhaust manifold from the cylinder head and remove the manifold.
  8.  
  9. Remove the rocker cover, then remove the intake manifold. For details, please refer to the procedure located in this section.
  10.  
  11. Loosen the rocker arms enough so the pushrods can be removed. Note the position of the pushrods for assembly.
  12.  
  13. Starting with the outer bolts, unfasten the cylinder head bolts and remove the cylinder head.
  14.  
  15. Clean and inspect the surfaces of the cylinder head, engine block and intake manifold. Clean the threads in the engine block and the threads on the cylinder head bolts.
  16.  

To install:
  1. Align the new gasket on the dowels on the engine block with the note "This Side Up" facing the cylinder head.
  2.  
  3. Position the cylinder head on the engine. Coat the head bolts with a proper sealer. Install and tighten the bolts hand tight.
  4.  
  5. Tighten the bolts, in sequence, to 33 ft. lbs. (45 Nm), then rotate an additional 90° ( 1 / 4 turn).
  6.  
  7. Install the pushrods in the same order as they were removed.
  8.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Install the rocker arms. The correct rocker arm torque is 14-20 ft. lbs. (1987-88), 18 ft. lbs. (1989-92).
  2.  
  3. Install the intake manifold using a new gasket. Following the correct sequence, torque the bolts to the proper specification.
  4.  
  5. The remainder of the installation is the reverse of the removal.
  6.  
  7. Connect the negative battery cable, then start the engine and check for leaks.
  8.  

1994 VEHICLES (LEFT SIDE)

See Figure 17

On these 3.1L engines, an "Idle Learn" procedure must be performed which requires the use of a scan tool.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the battery and the air cleaner assembly.
  4.  
  5. Properly drain and recover the cooling system.
  6.  
  7. Detach the O 2 sensor connector.
  8.  
  9. Disconnect the exhaust crossover pipe from the exhaust manifold.
  10.  
  11. Remove the rocker arm covers, as outlined earlier in this section.
  12.  
  13. Remove the intake manifold and plenum.
  14.  
  15. Remove the exhaust crossover, then remove the left exhaust manifold.
  16.  
  17. Remove the oil level indicator.
  18.  
  19. Tag and disconnect the spark plug wires at the left cylinder head.
  20.  
  21. Loosen the rocker arms nuts enough to remove the pushrods, then remove the pushrods.
  22.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Starting with the outer bolts, unfasten the cylinder head bolts and remove the cylinder head.
  2.  
  3. Clean and inspect the surfaces of the cylinder head, engine block and intake manifold. Clean the threads in the engine block and the threads on the cylinder head bolts.
  4.  

To install:
  1. Align the new gasket on the dowels on the engine block with the note "This Side Up" facing the cylinder head.
  2.  
  3. Position the cylinder head on the engine. Coat the head bolts with a proper sealer. Install and tighten the bolts hand tight.
  4.  
  5. Tighten the bolts, in sequence, to 33 ft. lbs. (45 Nm), then rotate an additional 90° ( 1 / 4 turn).
  6.  
  7. Install the pushrods in the same order as they were removed. Make sure they seat properly in the lifters. Tighten the rocker arm nuts.
  8.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Install the intake manifold and plenum.
  2.  
  3. Install the rocker arm covers.
  4.  
  5. Install the oil level indicator.
  6.  
  7. Install the left exhaust manifold.
  8.  
  9. Attach the O 2 sensor connector.
  10.  
  11. Connect the exhaust crossover pipe to the exhaust manifolds.
  12.  
  13. Install the battery and air cleaner assembly.
  14.  
  15. Fill the cooling system, then connect the negative battery cable.
  16.  

On the 3.1L engine, a Tech 1® scan tool is needed to perform the "Idle Learn" procedure.

  1. For the 3.1L engine perform the following "Idle Learn" procedure;
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle in park or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  2.  
  3. Start the engine and check for leaks.
  4.  

1994 VEHICLES (RIGHT SIDE)

See Figure 17

On these 3.1L engines, an "Idle Learn" procedure must be performed which requires the use of a scan tool.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Properly drain and recover the cooling system.
  6.  
  7. Detach the O 2 sensor connector.
  8.  
  9. Disconnect the exhaust crossover pipe from the exhaust manifold.
  10.  
  11. Remove the right exhaust manifold.
  12.  
  13. Remove the rocker arm covers, as outlined earlier in this section.
  14.  
  15. Remove the intake manifold and plenum.
  16.  
  17. Loosen the rocker arms nuts enough to remove the pushrods, then remove the pushrods.
  18.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Starting with the outer bolts, unfasten the cylinder head bolts and remove the cylinder head.
  2.  
  3. Clean and inspect the surfaces of the cylinder head, engine block and intake manifold. Clean the threads in the engine block and the threads on the cylinder head bolts.
  4.  

To install:
  1. Align the new gasket on the dowels on the engine block with the note "This Side Up" facing the cylinder head.
  2.  
  3. Position the cylinder head on the engine. Coat the head bolts with a proper sealer. Install and tighten the bolts hand tight.
  4.  
  5. Tighten the bolts, in sequence, to 33 ft. lbs. (45 Nm), then rotate an additional 90° ( 1 / 4 turn).
  6.  
  7. Install the pushrods in the same order as they were removed. Make sure they seat properly in the lifters. Tighten the rocker arm nuts.
  8.  

Intake pushrods are marked orange and are 6 in. (152.4mm) long. Exhaust pushrods are marked blue and are 63/8in. (161.9mm) long.

  1. Install the intake manifold and plenum.
  2.  
  3. Install the rocker arm covers.
  4.  
  5. Install the right exhaust manifold.
  6.  
  7. Attach the O 2 sensor connector.
  8.  
  9. Connect the exhaust crossover pipe to the exhaust manifolds.
  10.  
  11. Install the air cleaner assembly.
  12.  
  13. Fill the cooling system, then connect the negative battery cable.
  14.  

On the 3.1L engine, a Tech 1® scan tool is needed to perform the "Idle Learn" procedure.

  1. For the 3.1L engine perform the following "Idle Learn" procedure;
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle in park or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  2.  
  3. Start the engine and check for leaks.
  4.  

 
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