Pickup 1997

Cylinder Head

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Removal & Installation



When installing sliding parts such as rocker arms, camshafts and oil seals, be sure to apply clean engine oil on their friction surfaces. When tightening the cylinder head or rocker shaft bolts, apply clean engine oil to the bolt threads and seat surfaces.

After completing this procedure, allow the rocker cover-to-cylinder head rubber plugs to dry for 30 minutes before starting the engine. This will allow the liquid gasket sealer to cure properly.

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    If working near and/or around the SRS system and components, be sure to disable the SRS system. After disabling the system wait three minutes or more before servicing the vehicle. Disconnect the air bag module connector.



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    Fig. Air bag module connector location



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    Fig. Fuel pump fuse location

  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the cooling system. Be sure to properly dispose of used coolant.
  8.  
  9. Remove the drive belt(s).
  10.  
  11. Drain the engine oil. Be sure to properly dispose of used oil.
  12.  
  13. Tag and disconnect all vacuum hoses, water hoses, fuel tubes and wiring harnesses necessary to gain access to the cylinder head.
  14.  
  15. Disconnect the EGR tube at the exhaust manifold.
  16.  
  17. Disconnect the air induction hose.
  18.  
  19. Detach the accelerator bracket. If necessary, mark the position and remove the accelerator cable wire end from the throttle drum.
  20.  
  21. Remove the intake manifold.

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    Fig. Intake manifold and related components

  22.  
  23. Unplug the exhaust gas sensor, then remove the exhaust cover and exhaust pipe at the exhaust manifold connection. Remove the exhaust manifold from the cylinder head.

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    Fig. Exhaust system and related components-2WD



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    Fig. Exhaust system and related components-4WD

  24.  
  25. Remove the rocker cover. If it sticks to the cylinder head, tap the cover with a rubber mallet. Be careful not to strike the rocker arms when removing the rocker arm cover.
  26.  

After removing the rocker cover, matchmark the timing chain and the camshaft sprocket with paint or chalk. If this is done, it will not be necessary to locate the factory timing marks.

  1. Remove the spark plugs to protect them from damage.
  2.  

The spark plug leads may already be marked; however, it would be wise to mark them yourself.

  1. Set the No. 1 cylinder piston at TDC on its compression stroke. This piston will be at TDC when the timing pointer is aligned with the red timing mark on the crankshaft pulley.
  2.  
  3. Before removing the camshaft sprocket, it will be necessary to wedge the chain in place so that it will not fall down into the front cover. The factory procedure is to wedge the timing chain in place with a wooden wedge, as illustrated. The problem with this procedure is that it may allow the chain tensioner to move out far enough to cock itself against the chain. If this happens, you'll find that the chain won't go back over the sprocket after you've reinstalled the sprocket. In this case, you'll have to remove the front cover and push the tensioner back. After you've wedged the chain, unbolt the camshaft sprocket and remove it.

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    Fig. Timing chain retaining tool installation

  4.  
  5. Working from both ends in, loosen the cylinder head bolts in steps and remove them. Remove the bolts securing the cylinder head to the front cover assembly.
  6.  

The cylinder head bolts should be loosened in two or three steps in the correct order to prevent head warpage or cracking.

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Fig. Cylinder head loosening sequence

  1. Loosen and remove the cylinder head bolts a little at a time in the correct sequence. Lift the cylinder head off the engine block. It may be necessary to tap the head lightly with a rubber mallet to loosen it.

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    Fig. Cylinder head and related components

  2.  

To install:


NOTE
Be sure to use new fasteners, as required.



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Fig. Camshaft knock pin positioning



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Fig. Apply liquid sealant to the cylinder head plugs



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Fig. Press the rubber plug into the cylinder head



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Fig. Cylinder head plug positioning

  1. Thoroughly clean the cylinder block and head surfaces, and check both for warpage.
  2.  
  3. Fit the new head gasket. Don't use sealant. Install the cylinder head assembly. Make sure that no open valves are in the way of raised pistons, and never rotate the crankshaft or camshaft separately because of possible damage which might occur to the valves.
  4.  
  5. Confirm that the No. 1 piston is at TDC on its compression stroke as follows: Align the timing mark with the red (0 degree) mark on the crankshaft pulley. Make sure the distributor rotor head is set at No. 1 on the distributor cap. Confirm that the knock pin on the camshaft is set at the top position.
  6.  
  7. Install the cylinder head and torque the head bolts in sequence and to specification.

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    Fig. Cylinder head torque sequence

  8.  

Do not rotate the crankshaft and camshaft separately, or valves will hit the tops of the pistons.

  1. Remove the wedge from the timing chain. Position the timing chain on the camshaft sprocket by aligning each matchmark. Install the camshaft sprocket to the camshaft.
  2.  
  3. Hold the camshaft sprocket stationary, and tighten the sprocket bolt to specification.
  4.  
  5. Install the front cover-to-cylinder head retaining bolts. Torque bolts to specification.

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    Fig. Front cover and related components

  6.  
  7. Clean and regap the spark plugs, then install them in the cylinder head. Do not over torque the spark plugs.
  8.  
  9. Install the intake manifold and collector assembly with new gaskets.
  10.  
  11. Install the exhaust manifold with new gaskets.
  12.  
  13. Apply liquid gasket to the rubber plugs, then install the plugs in their correct location in the cylinder head. The seating surface of the rubber plugs must be clean and dry, and the plugs should be installed within 5 minutes of the sealant application. After the sealant is applied and the rubber plugs are in place, rock the plugs back and forth a few times to distribute the sealant evenly. Wipe the excess sealant from the cylinder head with a clean rag.
  14.  
  15. Install the rocker cover with a new gasket.
  16.  
  17. Attach the accelerator bracket and cable, if removed.
  18.  
  19. Attach all vacuum hoses, water hoses, fuel tubes and electrical connections that were removed to gain access to the cylinder head.
  20.  
  21. Reconnect the air induction hose.
  22.  
  23. Install the spark plugs wires in their correct location.
  24.  
  25. Install the power steering brackets, idler pulley, and power steering pump.
  26.  
  27. Install and adjust the drive belts.
  28.  
  29. Fill the engine with the proper grade and type engine oil.
  30.  
  31. Fill and bleed the cooling system, and connect the negative battery cable.
  32.  
  33. Make all the necessary engine adjustments.
  34.  
  35. Using the CONSULT-III diagnostic tool, or equivalent, perform the SRS self diagnostic test and any reconnect/relearn procedures, as required.
  36.  

 
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