GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Cylinder Head

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REMOVAL & INSTALLATION



2.2L Engine

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Cylinder head bolt tightening sequence-2.2L engine

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this repair guide.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Properly drain the engine cooling system into a suitable container.
  8.  
  9. Tag and disconnect the vacuum lines and electrical connectors from the intake manifold and cylinder head.
  10.  
  11. Detach the control cables from the throttle body and remove the cable bracket at the throttle body and rocker arm cover.
  12.  
  13. Remove the serpentine belt and belt tensioner.
  14.  
  15. Tag and disconnect the spark plug wires, then lay them out of the way.
  16.  
  17. Disconnect the canister purge lines under the manifold.
  18.  
  19. Detach the upper radiator hose from the engine.
  20.  
  21. Disconnect the upper and lower heater hoses from the intake manifold.
  22.  
  23. Detach the coolant inlet hose from the cylinder head.
  24.  
  25. Remove the intake manifold brace from the power steering pump bracket.
  26.  
  27. Disconnect and cap the fuel lines at the quick connects.
  28.  

When removing valve train components, they must be kept in order for installation in the same locations they were removed from.

  1. Remove the rocker arm cover, rocker arm nuts, rocker arms and pushrods.
  2.  
  3. Remove the engine oil fill tube.
  4.  

Removal of the intake and exhaust manifolds from the vehicle should not be necessary. However, if additional room is needed, remove them.

  1. Remove the engine lift brackets.
  2.  
  3. Unfasten the cylinder head retaining bolts, then remove the cylinder head from the vehicle. Remove and discard the gasket and thoroughly clean all mating surfaces. Clean the threads on the cylinder head bolts and the block threads.
  4.  

To install:
  1. Place a new cylinder head gasket inPosition over the dowel pins on the block. Carefully guide the cylinder head into position.
  2.  
  3. Install all the cylinder head bolts finger-tight. New replacement bolts are recommended. The long bolts go into bolt positions 1, 4, 5, 8 and 9. The short bolts are inPositions 2, 3, 6 and 7. The stud is in position 10.
  4.  
  5. Tighten the bolts in the sequence shown in the accompanying figure. Tighten the long bolts to 23 ft. lbs. (32 Nm) and the short bolts and stud to 22 ft. lbs. (29 Nm). Make a final pass over all bolts, tightening each an additional 90 degrees ( 1 / 4 -turn) using a torque angle meter.
  6.  
  7. Install the engine lift brackets. Tighten the front bracket bolt to 41 ft. lbs. (55 Nm) and the rear bracket bolt to 32 ft. lbs (43 Nm).
  8.  
  9. If applicable, install the intake and exhaust manifolds to the cylinder head.
  10.  
  11. Install the oil fill tube.
  12.  
  13. Install the pushrods, rocker arms, rocker arm ball and tighten the rocker arm nuts to 22 ft. lbs. (30 Nm).
  14.  
  15. Position the rocker arm cover and secure with the retaining bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  16.  
  17. Uncap and connect the fuel lines to the fuel rail.
  18.  
  19. Install the intake manifold brace.
  20.  
  21. Attach the coolant hose to the cylinder head.
  22.  
  23. Connect the upper and lower heater hoses to the intake manifold.
  24.  
  25. Attach the upper radiator hose.
  26.  
  27. Connect the canister purge hose under the intake manifold.
  28.  
  29. Attach the spark plug wires, as tagged during removal.
  30.  
  31. Install the serpentine belt tensioner and tighten the mounting bolt to 37 ft. lbs. (50 Nm). Install the serpentine belt.
  32.  
  33. Connect the control cables to the intake manifold bracket and throttle body lever.
  34.  
  35. Attach the vacuum lines and electrical connectors to the intake manifold and cylinder head.
  36.  
  37. Install the air cleaner assembly.
  38.  
  39. An oil and filter change is recommended since coolant can get into the oil system during cylinder head service.
  40.  
  41. Connect the negative battery cable.
  42.  
  43. Refill and bleed the cooling system. Start the engine and verify proper engine operation.
  44.  

2.3L Engine

See Figures 2 and 3



Click image to see an enlarged view

Fig. Fig. 2: Cylinder head retaining bolt tightening sequence-2.3L engine



Click image to see an enlarged view

Fig. Fig. 3: Camshaft housing cover bolt tightening sequence-2.3L engine

  1. Disconnect the negative battery cable. Properly relieve the fuel system pressure as outlined in Fuel System of this repair guide.
  2.  
  3. Properly drain the cooling system into a suitable container.
  4.  
  5. Disconnect the heater inlet and throttle body heater hoses from the water inlet.
  6.  
  7. Remove the exhaust manifold, as outlined earlier in this information.
  8.  
  9. Remove the intake and exhaust camshaft housing.
  10.  
  11. Remove the oil fill cap, tube and retainer. Pull the tube up and out of the block.
  12.  
  13. Disconnect and move the fuel injector harness.
  14.  
  15. Release the fuel system pressure.
  16.  
  17. Remove the throttle body and air inlet tube with the hoses and cables still connected. Position the assembly out of the way.
  18.  
  19. Remove the power brake booster hose and throttle cable bracket.
  20.  
  21. Remove the MAP sensor vacuum hose and all electrical connectors from the intake manifold and cylinder head.
  22.  
  23. Remove the radiator inlet hose and coolant sensor connectors.
  24.  
  25. In the reverse order of installation, remove the cylinder head-to-block retaining bolts.
  26.  
  27. Gently tap the outer edges of the cylinder head with a rubber hammer to dislodge the head gasket. Do not pry a screwdriver between the 2 surfaces.
  28.  
  29. Remove the cylinder head and intake manifold as an assembly.
  30.  

To install:
  1. Clean all gasket mating surfaces with a plastic scraper and solvent. Remove all dirt from the bolts with a wire brush.
  2.  
  3. Clean and inspect the oil flow check valve but do not remove the valve.
  4.  
  5. Check the cylinder head mating surface for flatness using a straight-edge and a feeler gauge. Resurface the head, if the warpage exceeds 0.010 in. (0.25mm).
  6.  
  7. Check to see if the dowel pins are installed properly, and replace if necessary.
  8.  

To avoid damage, install new spark plugs after the cylinder head has been installed on the engine. In the mean time, plug the holes to prevent dirt from entering the combustion chamber during reinstallation.

  1. Do not use any sealing compounds on the new cylinder head gasket. Match the new gasket with the old one to ensure a perfect match.
  2.  
  3. Install the cylinder head and camshaft housing covers.
  4.  
  5. Tighten all bolts to 26 ft. lbs. (35 Nm) plus an additional 100ºfor bolts No. 7 and 9. Tighten an additional 110ºfor all bolts except No. 7 and 9.
  6.  
  7. Install the throttle body heater hoses, upper radiator hose and intake manifold bracket.
  8.  
  9. Attach the cylinder head and intake manifold electrical connectors and vacuum hoses.
  10.  
  11. Install the throttle body-to-intake manifold with a new gasket. Install the throttle cable, MAP sensor vacuum hose and air cleaner duct.
  12.  
  13. Lubricate the new oil fill tube O-ring and install the fill tube. Make sure the tube is fully seated in the block.
  14.  
  15. Install the exhaust manifold, as outlined earlier in this information.
  16.  
  17. Fill the radiator with the specified amount of engine coolant.
  18.  
  19. Recheck all procedures to ensure completion of repair.
  20.  
  21. Connect the negative battery cable, start the engine and check for fluid leaks.
  22.  

2.5L Engine

See Figure 4



Click image to see an enlarged view

Fig. Fig. 4: Cylinder head bolt tightening sequence-2.5L engine

  1. Properly relieve the fuel system pressure as outlined in Fuel System .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the exhaust pipe and oxygen sensor.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Remove the oil level indicator tube and auxiliary ground cable.
  14.  
  15. Remove the air cleaner assembly.
  16.  
  17. Label and disconnect the vacuum hoses.
  18.  
  19. Detach the fuel injection wiring connectors, throttle linkage and fuel lines.
  20.  
  21. Disconnect the heater hose from the intake manifold.
  22.  
  23. Tag and detach the wiring connectors from the manifold and cylinder head.
  24.  
  25. Remove the vacuum hoses, serpentine belt and alternator bracket.
  26.  
  27. Disconnect the radiator hoses.
  28.  
  29. Remove the rocker arm cover, as outlined earlier in this information.
  30.  
  31. Loosen the rocker arm nuts and move the rocker arms to the side enough to remove the pushrods.
  32.  
  33. Mark each pushrod and remove from the engine.
  34.  

Mark each valve component to ensure that they are replaced in the same location as removed.

  1. Unfasten the cylinder head bolts.
  2.  
  3. Tap the sides of the cylinder head with a plastic hammer to dislodge the gasket. Remove the cylinder head with the intake and exhaust manifold still attached.
  4.  
  5. If the cylinder head has to be serviced or replaced, remove the intake manifold, exhaust manifold and remaining hardware.
  6.  

To install:
  1. Before installing, clean the gasket surfaces of the head and block.
  2.  
  3. Check the cylinder head for warpage using a straight-edge.
  4.  
  5. Match up the old head gasket with the new one to ensure the holes are exact. Install a new gasket over the dowel pins in the cylinder block.
  6.  
  7. Install the cylinder head in place over the dowel pins.
  8.  
  9. Coat the cylinder head bolt threads with sealing compound and install finger-tight.
  10.  
  11. Tighten the cylinder head bolts, in sequence, as follows:
    1. Tighten all bolts to 18 ft. lbs. (24 Nm).
    2.  
    3. Tighten bolts A through J, except I, to 26 ft. lbs. (35 Nm).
    4.  
    5. Tighten bolt I to 18 ft. lbs. (24 Nm). turn).
    6.  

  12.  
  13. Install the pushrods, rocker arms and nuts (or bolts) in the same location as removed. Tighten the nuts (or bolts) to 24 ft. lbs. (32 Nm).
  14.  
  15. Install the rocker arm cover, as outlined earlier in this information.
  16.  
  17. Install the radiator hoses, alternator bracket and serpentine belt.
  18.  
  19. Connect all intake manifold and cylinder head wiring.
  20.  
  21. Attach the vacuum hoses and heater hose at manifold.
  22.  
  23. Install the wiring, throttle linkage and fuel lines to the throttle body assembly.
  24.  
  25. Install the oil level indicator tube-to-exhaust manifold.
  26.  
  27. Install the air cleaner assembly and refill the cooling system.
  28.  
  29. Raise and safely support the vehicle.
  30.  
  31. Install the exhaust pipe and oxygen sensor.
  32.  
  33. Carefully lower the vehicle. Properly fill the cooling system with the correct type and amount of coolant.
  34.  
  35. Connect the negative battery cable. Start the engine and check for leaks.
  36.  

2.8L and 1989-91 3.1L Engine

See Figure 5



Click image to see an enlarged view

Fig. Fig. 5: Cylinder head bolt tightening sequence-2.8L and 3.1L engines

LEFT SIDE
  1. Relieve the fuel system pressure, as outlined in Fuel System of this repair guide. Disconnect the negative battery cable.
  2.  
  3. Properly drain the cooling system into a suitable container.
  4.  
  5. Remove the rocker arm (valve) cover, as outlined earlier in this information.
  6.  
  7. Remove the intake manifold from the vehicle, as outlined earlier in this information.
  8.  
  9. Remove the exhaust crossover pipe.
  10.  
  11. Remove the left side exhaust manifold, as outlined earlier in this information.
  12.  
  13. Disconnect the oil level indicator tube bracket.
  14.  
  15. Loosen the rocker arms nuts, turn the rocker arms and remove the pushrods. Intake and exhaust pushrods are different lengths and are color coded for identification; intake pushrods are marked orange and exhaust pushrods are marked blue in color.
  16.  

Be sure to keep the parts in order for installation purposes.

  1. Tag and disconnect the spark plug wires from the spark plugs.
  2.  
  3. Unfasten the cylinder head-to-engine bolts; start with the outer bolts and work toward the center. Remove the cylinder head with the exhaust manifold as an assembly.
  4.  

To install:
  1. Clean the gasket mounting surfaces. Inspect the surfaces of the cylinder head, block and intake manifold for damage and/or warpage. Clean the threaded holes in the block and the cylinder head bolt threads.
  2.  
  3. Use new gaskets, align the new cylinder head gasket over the dowels on the block with the note THIS SIDE UP facing the cylinder head.
  4.  
  5. Install the cylinder head and exhaust manifold crossover assembly on the engine.
  6.  
  7. Using GM sealant 1052080 or equivalent, coat the cylinder head bolts and install the bolts hand-tight.
  8.  
  9. Using the correct sequence, tighten the bolts to 33 ft. lbs. (45 Nm). After all bolts are tightened to 33 ft. lbs. (45 Nm), rotate the torque wrench another 90° or 1 / 4 turn. This will apply the correct torque to the bolts.
  10.  
  11. Install the left exhaust manifold.
  12.  
  13. Connect the plug wires to the spark plugs.
  14.  
  15. Install the pushrods in the same order that they were removed. Tighten the rocker arm nuts to 14-20 ft. lbs. (19-27 Nm).
  16.  
  17. Install the intake manifold using a new gasket and following the correct sequence, tighten the bolts to the correct specification.
  18.  
  19. Install the oil level indicator tube and install the rocker cover. Install the air inlet tube and spark plug wires.
  20.  
  21. Reinstall engine strut bracket and exhaust manifold.
  22.  
  23. Connect the negative battery cable. Refill the cooling system. Start the engine and check for leaks.
  24.  

RIGHT SIDE
  1. Disconnect the negative battery cable. Properly drain the cooling system into a suitable container.
  2.  
  3. Relieve the fuel system pressure, as outlined in Fuel System of this repair guide.
  4.  
  5. Remove the air cleaner assembly. Remove the torque strut from the engine.
  6.  
  7. Raise and safely support the vehicle. Remove the exhaust manifold-to-exhaust pipe bolts and separate the pipe from the manifold.
  8.  
  9. Carefully lower the vehicle. Remove the coolant recovery tank.
  10.  
  11. Remove the exhaust manifold-to-cylinder head bolts and the manifold.
  12.  
  13. Remove exhaust crossover heat shield and crossover pipe at right exhaust manifold.
  14.  
  15. Tag and disconnect right side spark plug wires at cylinder head.
  16.  
  17. Remove the rocker arm cover. Remove the intake manifold-to-cylinder head bolts and the intake manifold.
  18.  
  19. Loosen the rocker arms nuts, turn the rocker arms and remove the pushrods. Intake and exhaust pushrods are different lengths and are color coded for identification; intake pushrods are marked orange and exhaust pushrods are marked blue in color.
  20.  

Be sure to keep the components in order for reassembly purposes.

  1. Remove the cylinder head-to-engine bolts, starting with the outer bolts and working toward the center of the cylinder head.
  2.  

To install:
  1. Clean the gasket mounting surfaces. Inspect the parts for damage and/or warpage. Clean the engine block threaded holes and the cylinder head bolt threads.
  2.  
  3. Place a new cylinder head gasket on the engine block dowels with the note THIS SIDE UP facing the cylinder head.
  4.  
  5. Using GM sealant 1052080 or equivalent, coat the cylinder head bolts and install the bolts hand-tight.
  6.  
  7. Using the tightening sequence, tighten the bolts to 33 ft. lbs. (45 Nm). After all bolts are torqued to 33 ft. lbs. (45 Nm), rotate the torque wrench another 90° or 1 / 4 turn. This will apply the correct torque to the bolts.
  8.  
  9. Install the pushrods in the same order as they were removed. Tighten the rocker arm nuts to 14-20 ft. lbs. (19-27 Nm).
  10.  
  11. Follow the tightening sequence, use a new gasket and install the intake manifold.
  12.  
  13. Connect the spark plug wires to cylinder head.
  14.  
  15. Install the right side exhaust crossover pipe, heat shield and manifold.
  16.  
  17. Connect the exhaust pipe to the manifold.
  18.  
  19. Install the oil level indicator tube and install the rocker cover. Install the air inlet tube.
  20.  
  21. Install the coolant recovery tank. Refill the cooling system.
  22.  
  23. Connect the negative battery cable. Start the engine, allow it to reach normal operating temperatures and check for leaks.
  24.  

1992-93 3.1L Engine

See Figures 5, 6, 7 and 8

LEFT SIDE


Click image to see an enlarged view

Fig. Fig. 6: Unfasten the cylinder head bolts, then remove the head



Click image to see an enlarged view

Fig. Fig. 7: Remove and discard the cylinder head gasket



Click image to see an enlarged view

Fig. Fig. 8: Use a suitable scraper to thoroughly clean the gasket mating surfaces

  1. Relieve the fuel system pressure, as outlined in Fuel System of this repair guide. Disconnect the negative battery cable.
  2.  
  3. Properly drain the cooling system into a suitable container.
  4.  
  5. Remove the intake manifold from the vehicle, as outlined earlier in this information.
  6.  
  7. Remove the exhaust crossover pipe.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the oil filter and adapter.
  12.  
  13. If equipped, position the oil cooler aside.
  14.  
  15. Carefully lower the vehicle.
  16.  
  17. Unbolt the A/C compressor, if equipped, and position it aside.
  18.  
  19. Remove the radiator hose clamp at the water pump, then disconnect the hose.
  20.  
  21. Remove the A/C (if equipped) and torque strut mounting bracket.
  22.  
  23. Tag and disconnect the plug wires from the spark plugs.
  24.  
  25. Remove the left side exhaust manifold, as outlined earlier in this information.
  26.  
  27. Remove the vacuum pipe nut.
  28.  
  29. Unfasten the cylinder head-to-engine bolts; start with the outer bolts and work toward the center. Remove the cylinder head and gasket. Discard the gasket.
  30.  

To install:
  1. Clean the gasket mounting surfaces. Inspect the surfaces of the cylinder head, block and intake manifold for damage and/or warpage. Clean the threaded holes in the block and the cylinder head bolt threads.
  2.  
  3. Use new gaskets, align the new cylinder head gasket over the dowels on the block with the note THIS SIDE UP facing the cylinder head.
  4.  
  5. Install the cylinder head and exhaust manifold crossover assembly on the engine.
  6.  
  7. Using GM sealant 1052080 or equivalent, coat the cylinder head bolts and install the bolts hand-tight.
  8.  
  9. Using the correct sequence, tighten the bolts to 33 ft. lbs. (45 Nm). After all bolts are tightened to 33 ft. lbs. (45 Nm), use tool J36660, or equivalent torque wrench to rotate the bolts another 90° or 1 / 4 turn. This will apply the correct torque to the bolts.
  10.  
  11. Install the vacuum pipe nut.
  12.  
  13. Install the left exhaust manifold.
  14.  
  15. Connect the plug wires to the spark plugs.
  16.  
  17. Install the A/C and torque strut mounting bracket.
  18.  
  19. Attach the radiator hose to the water pump and secure with the clamp.
  20.  
  21. If equipped, position the A/C compressor and install the retaining bolts.
  22.  
  23. Raise and safely support the vehicle.
  24.  
  25. Install the exhaust crossover pipe.
  26.  
  27. Install the intake manifold, using a new gasket, as outlined earlier in this information.
  28.  
  29. Connect the negative battery cable. Refill the cooling system. Start the engine and check for leaks.
  30.  

RIGHT SIDE
  1. Relieve the fuel system pressure, as outlined in Fuel System of this repair guide.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly drain the cooling system into a suitable container.
  6.  
  7. Remove the intake manifold and gasket, as outlined earlier in this information.
  8.  
  9. Raise and safely support the vehicle. Remove the exhaust manifold-to-exhaust pipe bolts and separate the pipe from the manifold.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Remove the exhaust crossover pipe nuts to the right exhaust manifold.
  14.  
  15. Rotate the engine forward, as outlined earlier in this information.
  16.  
  17. If equipped, remove the secondary air injection pipe.
  18.  
  19. Detach the oxygen sensor electrical connector.
  20.  
  21. Unfasten the cylinder head retaining bolts, then remove the cylinder head and gasket. Discard the gasket.
  22.  

To install:
  1. Clean the gasket mounting surfaces. Inspect the parts for damage and/or warpage. Clean the engine block threaded holes and the cylinder head bolt threads.
  2.  
  3. Place a new cylinder head gasket on the engine block dowels with the note THIS SIDE UP facing the cylinder head.
  4.  
  5. Using GM sealant 1052080 or equivalent, coat the cylinder head bolts and install the bolts hand-tight.
  6.  
  7. Using the correct sequence, tighten the bolts to 33 ft. lbs. (45 Nm). After all bolts are tightened to 33 ft. lbs. (45 Nm), use tool J36660, or equivalent torque wrench to rotate the bolts another 90° or 1 / 4 turn. This will apply the correct torque to the bolts.
  8.  
  9. Attach the oxygen sensor electrical connector.
  10.  
  11. If equipped, install the secondary air injection pipe.
  12.  
  13. Rotate the engine back to its original location.
  14.  
  15. Fasten the exhaust crossover pipe nuts to the right exhaust manifold.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Connect the exhaust pipe at the rear exhaust manifold.
  20.  
  21. Carefully lower the vehicle.
  22.  
  23. Install the intake manifold, as outlined earlier in this information.
  24.  
  25. Refill the cooling system.
  26.  
  27. Connect the negative battery cable. Start the engine, allow it to reach normal operating temperatures and check for leaks.
  28.  

1994-96 3.1L Engine

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. Properly drain the engine cooling system into a suitable container.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the engine oil into a suitable container, then carefully lower the vehicle.
  8.  
  9. Remove the upper and lower intake manifolds, as outlined earlier in this information.
  10.  
  11. Remove the valve rocker arm and pushrod assemblies. Make sure to keep all components in order for installation purposes.
  12.  
  13. Remove the exhaust crossover pipe assembly.
  14.  
  15. Remove the engine mount strut and A/C compressor bracket.
  16.  
  17. Oil level indicator tube assembly.
  18.  
  19. Tag and disconnect the spark plug wires, then remove the spark plugs.
  20.  
  21. Unfasten the cylinder head retaining bolts and screws, then remove the cylinder head and gasket from the vehicle. Discard the gasket.
  22.  

To install:
  1. Clean the gasket mounting surfaces. Inspect the parts for damage and/or warpage. Clean the engine block threaded holes and the cylinder head bolt threads.
  2.  
  3. Place a new cylinder head gasket on the engine block dowels with the note THIS SIDE UP facing the cylinder head.
  4.  
  5. Using GM sealant 1052080 or equivalent, coat the cylinder head bolts and install the bolts hand-tight.
  6.  
  7. Using the correct sequence, tighten the bolts to 33 ft. lbs. (45 Nm). After all bolts are tightened to 33 ft. lbs. (45 Nm), use tool J36660, or equivalent torque wrench to rotate the bolts another 90° or 1 / 4 turn. This will apply the correct torque to the bolts.
  8.  
  9. Install the spark plugs and connect the plug wires.
  10.  
  11. Install the oil level indicator tube assembly.
  12.  
  13. Install the engine mount strut and A/C compressor bracket.
  14.  
  15. Install the exhaust crossover pipe assembly.
  16.  
  17. Install the valve rocker arm and pushrod assemblies.
  18.  
  19. Install the lower and upper intake manifold assemblies.
  20.  
  21. Refill the crankcase with engine oil. Refill the cooling system.
  22.  
  23. Connect the negative battery cable, then start the engine and check for proper operation.
  24.  

LEFT SIDE (FRONT)

See Figures 9 and 10

Click image to see an enlarged view

Fig. Fig. 9: Cam carrier with lifter hold-down hoses inPosition-3.4L engine



Click image to see an enlarged view

Fig. Fig. 10: Cylinder head bolt tightening sequence-3.4L engine

  1. Properly relieve the fuel system pressure as outlined in Fuel System .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain cooling system into a suitable container.
  6.  
  7. Remove the intake manifold, as outlined earlier in this information.
  8.  
  9. Remove left side cam carrier as follows:
    1. Disconnect oil/air breather hose from cam carrier cover. Tag and detach the spark plug wires from plugs and remove rear spark plug wire cover.
    2.  
    3. Remove cam carrier cover bolts and lift the cover OFF. Remove gasket and O-rings from cover.
    4.  
    5. Remove secondary timing belt by removing secondary timing belt actuator and tensioner assembly and sliding belt from pulleys. in. (5.5mm) fuel line hose for the intake valves.
    6.  
    7. Remove exhaust crossover pipe and torque strut.
    8.  
    9. Remove torque strut bracket at engine.
    10.  
    11. Unfasten the cam carrier mounting bolts and nuts and remove the cam carrier.
    12.  
    13. Remove cam carrier gasket from cylinder head.
    14.  

  10.  
  11. On vehicles equipped with a manual transaxle, remove the front air hose.
  12.  
  13. Remove the right side cooling fan.
  14.  
  15. Remove exhaust manifold mounting bolts, then remove the manifold.
  16.  
  17. Remove oil level indicator tube bolt and tube.
  18.  
  19. Detach the electrical connector from temperature sending unit.
  20.  
  21. Unfasten the cylinder head bolts, then remove the cylinder head. Remove and discard the gasket.
  22.  

To install:
  1. Clean the gasket mounting surfaces. Inspect the parts for damage and/or warpage.
  2.  
  3. Clean the engine block threaded holes and the cylinder head bolt threads. Remove oil from threaded holes in block.
  4.  
  5. Install new cylinder head gasket to block with tabs between cylinders facing up.
  6.  
  7. Install cylinder head and bolts and tighten in proper sequence. Tighten the bolts to 33 ft. lbs. (45 Nm) plus an additional 90 degree ( 1 / 4 ) turn using tool J 36660 or equivalent torque angle meter.
  8.  
  9. Attach electrical connector to coolant temperature sending unit.
  10.  
  11. Install oil level tube and bolt. Tighten to 89 inch lbs. (10 Nm).
  12.  
  13. Install exhaust manifold and nuts. Tighten to 116 inch lbs. (13 Nm).
  14.  
  15. Install the front air pipe, if equipped with a manual transaxle.
  16.  
  17. Install the right side cooling fan.
  18.  
  19. Install cam carrier following these steps:
    1. Install new gasket on cam carrier to cylinder mounting surface. -38613 or equivalent, to carrier assembly.
    2.  
    3. Install cam carrier to cylinder head. Install mounting bolts and nuts. Torque bolts and nuts to 18 ft. lbs. (25 Nm).
    4.  
    5. Remove lifter hold-down hoses and cam hold-down tool.
    6.  
    7. Install torque strut bracket to engine and install torque strut.
    8.  
    9. Install engine crossover pipe.
    10.  
    11. Install secondary timing belt and cam carrier cover.
    12.  

  20.  
  21. Install the intake manifold.
  22.  
  23. Refill fluid levels as required. Connect the negative battery cable.
  24.  
  25. Start the engine and check for fluid leaks.
  26.  

RIGHT SIDE (REAR)
  1. Relieve the fuel system pressure as outlined in Fuel System of this repair guide.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain cooling system into a suitable container.
  6.  
  7. Remove intake manifold, as outlined earlier in this information.
  8.  
  9. Remove right side cam carrier as follows:
    1. Remove intake plenum and right timing belt cover.
    2.  
    3. Tag and disconnect the right spark plug wires.
    4.  
    5. Remove air/oil separator hose at cam carrier cover.
    6.  
    7. Remove cam carrier cover bolts and lift of cover. Remove gasket and O-rings from cover.
    8.  
    9. Remove secondary timing belt by removing secondary timing belt actuator and tensioner assembly and sliding belt from pulleys. in. (5.5mm) fuel line hose for the intake valves.
    10.  
    11. Remove exhaust crossover pipe and torque strut.
    12.  
    13. Remove torque strut bracket at engine. Remove front engine lift hook.
    14.  
    15. Unfasten the cam carrier mounting bolts and nuts and remove the cam carrier.
    16.  
    17. Remove cam carrier gasket from cylinder head.
    18.  

  10.  
  11. Raise and support vehicle safely.
  12.  
  13. Remove front exhaust pipe at manifold.
  14.  
  15. If equipped with a manual transaxle, remove the rear air hose from air pipe.
  16.  
  17. Carefully lower the vehicle and detach the electrical connector from the oxygen sensor.
  18.  
  19. Remove rear timing belt tensioner bracket.
  20.  
  21. Unfasten the cylinder head bolts, then remove the cylinder head. Remove and discard the gasket.
  22.  

To install:
  1. Clean the gasket mounting surfaces. Inspect the parts for damage and/or warpage.
  2.  
  3. Clean the engine block threaded holes and the cylinder head bolt threads. Remove oil from threaded holes in block.
  4.  
  5. Install new cylinder head gasket to block with tabs between cylinders facing up.
  6.  
  7. Install cylinder head and bolts and tighten in proper sequence. Tighten the bolts to 33 ft. lbs. (45 Nm) plus an additional 90 degree ( 1 / 4 )turn using tool J 36660 or equivalent torque angle meter.
  8.  
  9. Install rear timing belt tensioner bracket.
  10.  
  11. Attach the electrical connector to oxygen sensor.
  12.  
  13. Raise the vehicle and support safely.
  14.  
  15. Connect rear air hose to air pipe for vehicles with a manual transaxle.
  16.  
  17. Install front exhaust pipe to the manifold. Carefully lower the vehicle.
  18.  
  19. Install the cam carrier following these steps:
    1. Install a new gasket on cam carrier to cylinder mounting surface.
    2.  
    3. Install cam hold-down tool J-38613 or equivalent, to carrier assembly.
    4.  
    5. Install the cam carrier to the cylinder head. Install mounting bolts and nuts. Tighten the bolts and nuts to 18 ft. lbs. (26 Nm).
    6.  
    7. Remove the lifter hold-down hoses and cam hold-down tool.
    8.  
    9. Install the torque strut bracket to engine and install torque strut.
    10.  
    11. Install the engine crossover pipe and engine lift hook.
    12.  
    13. Install the secondary timing belt and cam carrier cover.
    14.  
    15. Connect the spark plug wires and install the cover.
    16.  

  20.  
  21. Install the intake manifold, as outlined earlier in this information.
  22.  
  23. Refill fluid levels as required. Connect the negative battery cable.
  24.  
  25. Start vehicle and check for fluid leaks.
  26.  

3.8L Engine

See Figure 11



Click image to see an enlarged view

Fig. Fig. 11: Cylinder head bolt torque sequence-3.8L engine

LEFT SIDE (FRONT)
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable and remove the air cleaner assembly.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove the intake manifold, as outlined earlier in this information.
  8.  
  9. Remove the valve covers, then remove the rocker arm assemblies.
  10.  
  11. Detach the torque strut from the bracket at cylinder head.
  12.  
  13. Disconnect the vacuum line from the transaxle.
  14.  
  15. Remove the left exhaust manifold, as outlined earlier in this information.
  16.  
  17. Tag and disconnect the spark plug wires and remove the spark plugs.
  18.  
  19. Remove the alternator front mount bracket and ignition module with the bracket.
  20.  
  21. Unfasten the cylinder head bolts and remove the cylinder head. Remove and discard the gasket.
  22.  
  23. Clean all gasket mating surfaces and the cylinder head bolt holes in the block.
  24.  

To install:
  1. Place the cylinder head gasket on the engine block dowels with the note THIS SIDE UP facing the cylinder head and the arrow facing the front of the engine.
  2.  
  3. Install the cylinder head bolts and tighten as follows:
    1. Tighten the cylinder head bolts, in sequence, to 35 ft. lbs. (47 Nm).
    2.  
    3. Rotate each bolt 130º, in sequence.
    4.  
    5. Rotate the center 4 bolts an additional 30º, in sequence.
    6.  

  4.  
  5. Install the rocker arm assemblies and valve covers.
  6.  
  7. Install the intake and exhaust manifolds.
  8.  
  9. Install the alternator front mount bracket and ignition module with bracket.
  10.  
  11. Install the spark plugs and connect the wires, as tagged during removal.
  12.  
  13. Install the torque strut to the bracket, at the head and tighten to 41 ft. lbs. (55 Nm).
  14.  
  15. Fill the cooling system with the proper type and amount of coolant.
  16.  
  17. Connect the negative battery cable and install the air cleaner assembly.
  18.  
  19. Start the engine and check for proper operation.
  20.  

RIGHT SIDE (REAR)
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable and remove the air cleaner assembly.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Disconnect the exhaust crossover pipe.
  8.  
  9. Remove the intake manifold, as outlined earlier in this information.
  10.  
  11. Raise and support the vehicle safely.
  12.  
  13. Disconnect the front exhaust pipe from the manifold.
  14.  
  15. Remove the valve covers, as outlined earlier in this information.
  16.  
  17. Remove the belt tensioner pulley.
  18.  
  19. Disconnect the heater hose from the engine.
  20.  
  21. Remove the power steering pump mounting bracket and lay the pump to aside. DO NOT disconnect the fluid lines.
  22.  
  23. Tag and disconnect the the spark plug wires and remove the spark plugs.
  24.  
  25. Disconnect the exhaust manifold and leave in place.
  26.  
  27. Detach the electrical connection from the oxygen sensor.
  28.  
  29. Remove the rocker arm assemblies.
  30.  
  31. Unfasten the cylinder head bolts and remove the cylinder head. Remove and discard the gasket.
  32.  
  33. Clean all gasket mating surfaces and the cylinder head bolt holes in the block.
  34.  

To install:
  1. Place the cylinder head gasket on the engine block dowels with the note THIS SIDE UP facing the cylinder head and the arrow facing the front of the engine.
  2.  
  3. Install the cylinder head bolts and tighten as follows:
    1. Tighten the cylinder head bolts, in sequence, to 35 ft. lbs. (47 Nm).
    2.  
    3. Rotate each bolt 130º, in sequence.
    4.  
    5. Rotate the center 4 bolts an additional 30º, in sequence.
    6.  

  4.  
  5. Attach the electrical connection to the oxygen sensor.
  6.  
  7. Install the exhaust manifold and intake manifold, as outlined earlier in this information.
  8.  
  9. Install the rocker arm assemblies and the valve cover(s).
  10.  
  11. Install the spark plugs and connect the wires, as tagged during removal.
  12.  
  13. Install the power steering pump bracket and tighten the bolts to 37 ft. lbs. (50 Nm).
  14.  
  15. Install the belt tensioner pulley.
  16.  
  17. Fasten the heater hose to the engine.
  18.  
  19. Connect the exhaust crossover pipe.
  20.  
  21. Raise and support the vehicle safely.
  22.  
  23. Attach the front exhaust pipe to the manifold, then carefully lower the vehicle.
  24.  
  25. Fill the cooling system with the proper type and amount of coolant.
  26.  
  27. Connect the negative battery cable and install the air cleaner assembly.
  28.  
  29. Start the engine and check for proper operation.
  30.  

CLEANING AND INSPECTION



See Figure 12

Click image to see an enlarged view

Fig. Fig. 12: Clean the combustion chamber using a drill-mounted wire brush


CAUTION
To avoid personal injury ALWAYS wear safety glasses when using a power drill and wire brush.

  1. With the valves installed to protect the valve seats, remove carbon deposits from the combustion chambers and valve heads with a drill-mounted wire brush. Be careful not to damage the cylinder head gasket surface. If the head is to be disassembled, proceed to Step 3. If the head is not to be disassembled, proceed to Step 2.
  2.  
  3. Remove all dirt, oil and old gasket material from the cylinder head with solvent. Clean the bolt holes and the oil passage. Be careful not to get solvent on the valve seals as the solvent may damage them. If available, dry the cylinder head with compressed air. Check the head for cracks or other damage, and check the gasket surface for burrs, nicks and flatness. If you are in doubt about the head's serviceability, consult a reputable automotive machine shop.
  4.  
  5. Remove the valves, springs and retainers, then clean the valve guide bores with a valve guide cleaning tool. Remove all dirt, oil and old gasket material from the cylinder head with solvent. Clean the bolt holes and the oil passage.
  6.  
  7. Remove all deposits from the valves with a wire brush or buffing wheel. Inspect the valves as described later in this information.
  8.  
  9. Check the head for cracks using a dye penetrant in the valve seat area and ports, head surface and top. Check the gasket surface for burrs, nicks and flatness. If you are in doubt about the head's serviceability, consult a reputable automotive machine shop.
  10.  

If the cylinder head was removed due to an overheating condition and a crack is suspected, do not assume that the head is not cracked because a crack is not visually found. A crack can be so small that it cannot be seen by eye, but can pass coolant when the engine is at operating temperature. Consult an automotive machine shop that has testing equipment to make sure the head is not cracked.

RESURFACING



See Figures 13 and 14

Whenever the cylinder head is removed, check the flatness of the cylinder head gasket surface as follows:

  1. Make sure all dirt and old gasket material has been cleaned from the cylinder head. Any foreign material left on the head gasket surface can cause a false measurement.
  2.  



Click image to see an enlarged view

Fig. Fig. 13: Checking the cylinder head for flatness diagonally across the head surface



Click image to see an enlarged view

Fig. Fig. 14: Checking the cylinder head for flatness straight across the head surface

  1. Place a straightedge straight across and diagonally across the gasket surface of the cylinder head (in the positions shown in the figures). Using feeler gauges, determine the clearance at the center of the straightedge.
  2.  
  3. If the surfaces are "out of flat'' by more than 0.005 in. (0.127mm) the surface should be milled.
  4.  
  5. If warpage exceeds 0.010 in. (0.25mm) then the cylinder head should likely be replaced. Contact a reputable machine shop for machining service and recommendations.
  6.  

When resurfacing the cylinder head(s) on V-type engines, the intake manifold mounting position is altered and must be corrected by machining a proportionate amount from the intake manifold flange.

 
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