Mazda Car 2002-04

Cylinder Head 2

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Removal & Installation



2.3L (L3) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing chain.
  6.  
  7. Remove the ignition coil.
  8.  
  9. Unbolt the alternator and move it aside with the connectors still attached.
  10.  
  11. Remove the front exhaust pipe.
  12.  
  13. Remove the intake manifold.
  14.  
  15. Disconnect the following components:

    Upper radiator hose
     
    Water and heater hose
     

  16.  
  17. Support the engine using an engine jack and attachment as shown in the illustration.

    Click image to see an enlarged view

    Fig. Support the engine using an engine jack and attachment as shown-Mazda 6 models

  18.  
  19. Remove the oil control valve.
  20.  
  21. Remove the camshafts.
    NOTE
    The cylinder head and camshaft caps are numbered and must be reassembled in their original locations. When removing a when removed, keep the caps with the cylinder head they were removed from, do not switch the caps.

  22.  
  23. Loosen the cylinder head bolts using 2-3 passes in the sequence illustrated.
  24.  
  25. Once all the bolts have been removed, remove the cylinder head and gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-Mazda 3 models

  26.  

To install:

  1. If reusing old bolts, which is not recommended; measure the length of each head bolt at the locations illustrated. If any bolt exceeds 5.717-5.740 inch (145.2-145.8mm) replace the bolt.

    Click image to see an enlarged view

    Fig. Measure the length of each head bolt at the locations illustrated, if reusing the old bolts. If any bolt exceeds 5.717-5.740 inch (145.2-145.8mm) replace the bolt-Mazda 3 models



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-Mazda 6 with the 2.3L (L3) engine

  2.  
  3. Install a new cylinder head gasket.
  4.  
  5. Install the cylinder head.
  6.  
  7. Apply clean engine oil to the bolt threads and seating faces.
  8.  
  9. Install new cylinder head bolts and torque in 2-3 steps, in sequence as follows:
    1. Step 1: Tighten the bolts in sequence to 27-97 inch lbs. (3-11 Nm).
    2.  
    3. Step 2: Tighten the bolts in sequence to 9.5-12.5 ft. lbs. (13-17 Nm).
    4.  
    5. Step 3: Tighten the bolts in sequence to 32-34.5 ft. lbs. (43-47 Nm).
    6.  
    7. Step 4: Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 85-92 degrees.
    8.  
    9. Step 5: Turn each bolt, in sequence, 85-92 degrees.
    10.  

  10.  
  11. Install the camshafts and caps in their original positions.
  12.  
  13. Install the remaining components in the reverse order of removal.
  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Change the oil and filter.
  18.  
  19. Run the engine and check for proper operation.
  20.  

2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen (O 2 S) sensor connectors
     
    Exhaust pipe-to-manifold nuts and lower the exhaust pipes
     
    Right-hand 3-way catalytic converter
     
    Compressor (supercharger)
     
    Intake manifold
     
    Timing belt covers and timing belt
     
    Spacer and O-ring from the front of the camshaft
     
    Ignition coils
     
    Cylinder head cover mounting bolts, in 5-6 steps, using the reverse of the tightening sequence
     
    Cylinder head cover
     
    Camshaft sprockets
     

  8.  
  9. Turn the camshafts so the knock pins are aligned with the marks on the camshaft caps. This will reduce the pressure on the adjustment shims.
  10.  
  11. Note the markings on the camshaft caps prior to removal, so they can be reinstalled in the same positions. The right-hand (rear) caps are marked with numbers and the left-hand (front) caps are marked with letters.
  12.  
  13. Loosen the front camshaft cap bolts in sequence, in 5-6 steps. Remove the front camshaft caps. Remove the remaining camshaft cap bolts in the proper sequence. Remove the caps, being sure to remove the thrust caps last. Do not damage the cylinder head thrust bearing support.
  14.  
  15. Remove or disconnect the following:

    Camshafts and oil seals
     
    Lifters and adjustment shims
     

  16.  
  17. Identify and mark each lifter as it is removed so it can be reinstalled in the same position.
  18.  
  19. Remove or disconnect the following:

    Lower radiator hose
     
    Water inlet pipe
     
    Compressor bracket
     
    Alternator bracket bolt to gain additional clearance
     
    Rubber insulator from the left-hand cylinder head
     

  20.  
  21. Temporarily install the No. 3 engine mount, which was removed with the timing belt, to support the engine.
  22.  
  23. Remove or disconnect the following:

    Engine support device
     
    Cylinder head bolts, in 2-3 steps, by the reversing order of the torque sequence
     
    Cylinder heads
     
    Oil control plug O-rings
     

  24.  
  25. Clean all gasket mating surfaces. Inspect the cylinder head for damage, cracks, and water and oil leakage. Check the head gasket surface for distortion using a straightedge and feeler gauge. Maximum allowable distortion is 0.004 in. (0.10mm).
  26.  

To install:

  1. Apply clean engine oil to the O-rings, and install them onto the oil control plugs.
  2.  
  3. Position new head gaskets on the cylinder block. The gaskets cannot be interchanged between sides and are marked R and L for right and left side.
  4.  
  5. Install the cylinder heads.
  6.  
  7. Apply clean engine oil to the threads of new cylinder head bolts and install. Torque the bolts in 2-3 steps, in sequence, to 17-19 ft. lbs. (23-26 Nm).
  8.  
  9. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 90 degrees. Again, turn each bolt, in sequence, an additional 90 degrees.
  10.  
  11. Install the rubber insulator onto the left-hand cylinder head.
  12.  
  13. Fit the knock sensor harness into the drill hole on the cylinder block. Pass the harness under the rubber insulator.
  14.  
  15. Install or connect the following:

    Engine support device and remove the No. 3 engine mount
     
    Alternator bracket bolt. Torque the bolt to 12-16 ft. lbs. (16-22 Nm)
     
    Compressor bracket. Torque the bolts to 14-18 ft. lbs. (19-25 Nm)
     
    Water inlet pipe. Torque the bolts to 14-18 ft. lbs. (19-25 Nm)
     
    Lower radiator hose
     
    Lifters in their original positions by lubricating them with engine oil. Verify that they move smoothly in their bore
     
    New oil seals on the camshafts
     

  16.  
  17. Apply clean engine oil to the camshaft lobes, journals and supports.
  18.  
  19. Install or connect the following:

    Camshafts so the gear marks align
     
    Thrust caps. Torque the bolts, in 5-6 steps, until they are fully seated on the cylinder head
     

  20.  
  21. Apply silicone sealant, at a thickness of 0.06-0.09 in. (1.5-2.5mm), to the cylinder head surface in the area forward of the camshaft gear cavity.
  22.  
  23. Install or connect the following:

    Remaining camshaft caps in their original positions. Torque the caps, in sequence, in 5 equal steps, with the final step being 100-125 inch lbs. (11-14 Nm)
     
    New camshaft oil seal lubricated with engine oil. Tap the seal in evenly with a Seal Installer tool 49 F401 337A with a final protrusion of 0-0.02 in. (0-0.5mm). Tap in a new blind cap
     
    Camshaft sprockets. Torque the bolts to 91-103 ft. lbs. (123-140 Nm)
     

  24.  
  25. Measure and adjust the valve clearances.
  26.  
  27. Remove any sealant and gasket material from the cylinder head cover contact surfaces.
  28.  
  29. Apply silicone sealant to the cylinder head in the area adjacent to the front and rear camshaft caps.
  30.  
  31. Install or connect the following:

    Cylinder head cover using a new gasket. Torque the bolts in 5-6 steps, in sequence, to 44-78 inch lbs. (5-9 Nm)
     
    Distributor using a new O-ring
     
    Ignition coils
     
    Spacer using a new O-ring. Torque the bolt to 14-18 ft. lbs. (19-25 Nm)
     
    Timing belt and timing belt cover
     
    Intake manifold
     
    Compressor (supercharger)
     
    Right-hand 3-way catalytic converter
     
    Exhaust pipes to the manifolds. Torque the nuts to 28-38 ft. lbs. (38-51 Nm)
     
    O 2 S connectors
     
    Negative battery cable
     

  32.  
  33. Fill and bleed the coolant system.
  34.  
  35. Run the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head and related components-2.3L engine

  36.  

2.5L (Kl) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Front exhaust pipe
     
    Air cleaner assembly
     
    Intake manifold
     
    Fuel hose
     
    Cylinder head cover
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt.
     
    Upper radiator hose
     
    Number 3 engine mount bracket
     
    Seal plate
     
    Water outlet
     
    Camshaft
     
    Alternator stay
     

  10.  
  11. Temporarily install the Number 3 engine mount to support the engine.

    Cylinder head bolts by loosening them, in 2-3 steps, in the sequence illustrated
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.5L (KL) engines

     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head gasket positioning-2.5L (KL) engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.5L (KL) engines

  1. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     

  2.  
  3. Apply clean engine oil to the bolt threads and seating faces.
  4.  
  5. Install new cylinder head bolts and torque in 2-3 steps, in sequence, to 17-19 ft. lbs. (23-26 Nm). If reusing old bolts, which is not recommended; make sure the maximum length of the bolt is 5.217 inch (132.5mm). The standard length of the bolt should be 5.166-5.188 inch (131.2-131.8mm).
  6.  
  7. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 85-95 degrees. Again, turn each bolt, in sequence, an additional 85-95 degrees.
  8.  
  9. Support the engine assembly with a suitable lifting device and remove the number 3 mount.
  10.  
  11. Install or connect the following:

    Alternator stay
     
    Camshaft
     
    Water outlet
     
    Seal plate
     
    Number 3 engine mount bracket
     
    Upper radiator hose
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while tightening the pulley bolt to 90-97 ft. lbs. (123-132 Nm).
     
    Cylinder head cover
     
    Fuel hose
     
    Intake manifold
     
    Air cleaner assembly
     
    Front exhaust pipe
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Change the oil and filter.
  16.  
  17. Run the engine and check for proper operation.
  18.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Air cleaner assembly
     
    Spark plug wires
     
    Distributor
     
    Intake manifold
     
    Upper radiator hose
     
    Water outlet
     
    Number 3 engine mount bracket
     
    Seal plate
     
    Front exhaust pipe
     
    Alternator stay
     
    Cylinder head cover
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt.
     
    Camshaft
     

  10.  
  11. Temporarily install the Number 3 engine mount to support the engine.

    Cylinder head bolts by loosening them, in 2-3 steps, in the sequence illustrated
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.5L (KL) engines

     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head gasket positioning-2.5L (KL) engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.5L (KL) engines

  1. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     

  2.  
  3. Apply clean engine oil to the bolt threads and seating faces.
  4.  
  5. Install new cylinder head bolts and torque in 2-3 steps, in sequence, to 17-19 ft. lbs. (23-26 Nm). If reusing old bolts, which is not recommended; make sure the maximum length of the bolt is 5.217 inch (132.5mm). The standard length of the bolt should be 5.166-5.188 inch (131.2-131.8mm).
  6.  
  7. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 85-95 degrees. Again, turn each bolt, in sequence, an additional 85-95 degrees.
  8.  
  9. Support the engine assembly with a suitable lifting device and remove the number 3 mount.
  10.  
  11. Install or connect the following:

    Camshaft
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while tightening the pulley bolt to 90-97 ft. lbs. (123-132 Nm).
     
    Cylinder head cover
     
    Alternator stay
     
    Front exhaust pipe
     
    Seal plate
     
    Number 3 engine mount bracket
     
    Water outlet
     
    Upper radiator hose
     
    Intake manifold
     
    Distributor and spark plug wires
     
    Air cleaner assembly
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Change the oil and filter.
  16.  
  17. Run the engine and check for proper operation.
  18.  

2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Identify each lifter as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in an oil-filled, sealed container.



    Negative battery cable
     
    Fresh air duct and the air cleaner assembly
     
    Battery, if additional clearance space is needed.
     
    Accelerator cable
     
    Wiring harness from the cylinder heads
     
    Fuel, heater and vacuum hoses

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head assemblies-2.5L engine

     
    Intake manifold
     
    Distributor
     
    Ventilation pipe from the left cylinder head cover
     
    Cylinder head covers
     
    Timing belt covers and the timing belt
     
    Camshafts
     
    3 bolts and the seal plate from the front of the engine
     
    Upper radiator hose
     
    Oxygen (O 2 S) sensor connectors
     
    Exhaust pipe-to-manifold nuts and lower the pipes
     
    Hydraulic lifters
     



    Cylinder head bolts, in 2-3 steps, in the reverse order of the torque sequence
     
    Cylinder heads
     

  8.  
  9. Clean all gasket mating surfaces. Inspect the cylinder head for damage, cracks, and water and oil leakage. Check the head gasket surface for distortion using a straightedge and feeler gauge. Maximum allowable distortion is 0.004 in. (0.10mm).
  10.  

To install:

  1. Position new head gaskets on the cylinder block. The gaskets cannot be interchanged between sides and are marked R and L for right and left side.
  2.  
  3. Install the cylinder heads.
  4.  
  5. Apply clean engine oil to the threads of new cylinder head bolts and install. Torque the cylinder head bolts in 2-3 steps, in sequence, to 17-19 ft. lbs. (23-26 Nm).
  6.  
  7. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 90 degrees. Again, turn each bolt, in sequence, an additional 90 degrees.
  8.  
  9. Install or connect the following:

    Lifters in their original positions lubricated with engine oil. Be sure they move freely in the bores
     
    Camshafts
     
    Exhaust pipes to the manifolds. Torque the nuts to 41 ft. lbs. (55 Nm)
     
    O 2 S connectors
     
    Timing belt and timing belt covers
     

  10.  
  11. Apply sealant to the cylinder head surface in the area of the front and rear camshaft caps.
  12.  
  13. Install or connect the following:

    Cylinder head covers using new gaskets. Torque the bolts in 5-6 steps, in sequence, to 44-78 inch lbs. (5-9 Nm)
     
    Intake manifold using new gaskets. Torque the bolts to 14-18 ft. lbs. (19-25 Nm)
     
    Distributor using a new O-ring lubricated with engine oil. Hand-tighten the mounting bolts
     
    Vacuum, heater and fuel hoses
     
    Wiring harness to the cylinder heads
     
    Accelerator cable, adjust as necessary
     
    Battery, if removed
     
    Air cleaner assembly and the fresh air duct
     
    Negative battery cable
     

  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Adjust the ignition timing and idle speed.
  18.  
  19. Run the engine and check for proper operation.
  20.  

3.0L (Aj) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the water pump.
  10.  
  11. Remove the timing chain.
  12.  
  13. Support the engine using an engine jack and attachment.
  14.  
  15. Remove the water bypass tube stud bolt and bolt and disconnect the tube from the cylinder head.
  16.  
  17. Remove the camshaft(s).
  18.  
  19. Remove the rocker arm(s).
  20.  
  21. Remove the camshafts.
    NOTE
    If removing the right hand cylinder head and camshaft caps, remove thrust caps 1R and 5R first. Do not loosen any of the other cap bolts until the thrust caps are removed or you could damage the thrust caps. If removing the left hand cylinder head and camshaft caps, remove thrust caps 1L and 6L first. Do not loosen any of the other cap bolts until the thrust caps are removed or you could damage the thrust caps.

  22.  
  23. Loosen the camshaft caps using 7-8 passes in sequence after first removing the thrust caps to allow the camshafts to be slowly raised. Keep the caps in the order they were removed so they are re-installed in their original positions.
  24.  
  25. Loosen the cylinder head bolts using 2-3 passes in the sequence illustrated.
  26.  
  27. Once all the bolts have been removed, remove the cylinder head and gasket.

    Click image to see an enlarged view

    Fig. If removing the right hand camshaft caps, remove thrust caps 1R and 5R first-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Loosen the right hand camshaft caps using 7-8 passes in this sequence after first removing the thrust caps-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. If removing the left hand camshaft caps, remove thrust caps 1L and 6L first-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Loosen the left hand camshaft caps using 7-8 passes in this sequence after first removing the thrust caps-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-Mazda 6 with the 3.0L (AJ) engine

  28.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-Mazda 6 with the 3.0L (AJ) engine

  1. Install a new head gasket and the cylinder head.
  2.  
  3. Lubricate the cylinder head bolt threads.
  4.  
  5. Torque the cylinder head bolts in the proper sequence as follows:
    1. Step 1: Tighten the bolts in sequence 24-28 ft. lbs. (32-38 Nm).
    2.  
    3. Step 2: Tighten the bolts in sequence an additional 85-95 degrees.
    4.  
    5. Step 3: Loosen the bolts in sequence one full turn.
    6.  
    7. Step 4: Tighten the bolts in sequence 24-28 ft. lbs. (32-38 Nm).
    8.  
    9. Step 5: Tighten the bolts in sequence an additional 85-95 degrees.
    10.  
    11. Step 6: Tighten the bolts in sequence an additional 85-95 degrees.
    12.  

  6.  
  7. Install the camshafts in their original positions.
  8.  
  9. Install the left hand camshaft as follows:
    1. Place the crankshaft keyway at the 11 O-clock position by rotating the crankshaft clockwise.
    2.  
    3. Install the camshaft and the caps in their original positions and hand tighten the bolts.
    4.  
    5. Position the mark on the intake camshaft to the 9 O-clock position as illustrated.
    6.  
    7. Position the mark on the exhaust camshaft to the 12 O-clock position.
    8.  
    9. Install the timing chain.
      NOTE
      Tighten the camshaft journal thrust caps last to avoid damaging the thrust caps.

    10.  
    11. Tighten the camshaft caps using several passes to 71-106 inch lbs. (8-12 Nm). After adjust the camshaft endplay using the thrust caps 1L and 6L, tighten the remaining caps.

      Click image to see an enlarged view

      Fig. When installing the left hand camshaft place the crankshaft keyway at the 11 O-clock position-Mazda 6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Install the left hand camshaft and position the mark on the intake camshaft to the 9 O-clock and the exhaust camshaft to the 12 O-clock position-Mazda 6 with the 3.0L (AJ) engine

    12.  

  10.  
  11. Install the right hand camshaft as follows:
    1. Install the camshaft and the caps in their original positions and hand tighten the bolts.
    2.  
    3. Place the crankshaft keyway at the 3 O-clock position.
    4.  
    5. Position the mark on the exhaust camshaft to the 12 O-clock position by rotating the crankshaft clockwise.
    6.  
    7. Position the mark on the intake camshaft to the 3 O-clock position as illustrated.
    8.  
    9. Install the timing chain.
      NOTE
      Tighten the camshaft journal thrust caps last to avoid damaging the thrust caps.

    10.  
    11. Tighten the camshaft caps using several passes to 71-106 inch lbs. (8-12 Nm). After adjust the camshaft endplay using the thrust caps 1R and 5R, tighten the remaining caps.

      Click image to see an enlarged view

      Fig. When installing the right hand camshaft place the crankshaft keyway at the 3 O-clock position-Mazda 6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Install the right hand camshaft and position the mark on the intake camshaft to the 3 O-clock and the exhaust camshaft to the 12 O-clock position-Mazda 6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Right side camshaft cap torque sequence-Mazda 6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Left side camshaft cap torque sequence-Mazda 6 with the 3.0L (AJ) engine

    12.  

  12.  
  13. Install the water bypass tube.
  14.  
  15. Remove the engine jack and attachment.
  16.  
  17. Install the water pump.
  18.  
  19. Fill the cooling system.
  20.  
  21. Fill and bleed the cooling system.
  22.  
  23. Change the oil and filter.
  24.  
  25. Run the engine and check for proper operation.
  26.  

Mazdaspeed6
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing chain.
  6.  
  7. Unbolt the alternator and move it aside with the connectors still attached.
  8.  
  9. Remove the front exhaust pipe.
  10.  
  11. Remove the intake manifold.
  12.  
  13. Disconnect the following components:

    Upper radiator hose
     
    Water and heater hose
     

  14.  
  15. Support the engine using an engine jack and attachment as shown in the illustration.
  16.  
  17. Remove the oil control valve.
  18.  
  19. Remove the camshafts.
    NOTE
    The cylinder head and camshaft caps are numbered and must be reassembled in their original locations. When removing a when removed, keep the caps with the cylinder head they were removed from, do not switch the caps.

  20.  
  21. Loosen the cylinder head bolts using 2-3 passes in the sequence illustrated.
  22.  
  23. Once all the bolts have been removed, remove the cylinder head and gasket.
  24.  

To install:

  1. If reusing old bolts, which is not recommended; measure the length of each head bolt at the locations illustrated. If any bolt exceeds 5.700-5.720 inch (144.7-145.3mm) replace the bolt.
  2.  
  3. Install a new cylinder head gasket.
  4.  
  5. Install the cylinder head.
  6.  
  7. Apply clean engine oil to the bolt threads and seating faces.
  8.  
  9. Install new cylinder head bolts and torque in 2-3 steps, in sequence as follows:
    1. Step 1: Tighten the bolts in sequence to 27-97 inch lbs. (3-11 Nm).
    2.  
    3. Step 2: Tighten the bolts in sequence to 9.6-12.5 ft. lbs. (13-17 Nm).
    4.  
    5. Step 3: Tighten the bolts in sequence to 32-34.6 ft. lbs. (43-47 Nm).
    6.  
    7. Step 4: Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 88-92 degrees.
    8.  
    9. Step 5: Turn each bolt, in sequence, 88-92 degrees.
    10.  

  10.  
  11. Install the camshafts and caps in their original positions.
  12.  
  13. Install the remaining components in the reverse order of removal.
  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Change the oil and filter.
  18.  
  19. Run the engine and check for proper operation.
  20.  

 
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