Disconnect the negative battery cable.
Drain and recycle the engine coolant.
Drain and recycle the engine oil.
Properly relieve the fuel system pressure.
Disconnect the air duct from the throttle body.
Disconnect the intake manifold braces from the rear of the engine.
Remove the exhaust manifold.
Remove the alternator and all related brackets.
Remove the distributor assembly.
Using a block of wood, set a jack under the aluminum oil pan and remove the passenger's side engine mount.
Remove the cylinder head cover.
Remove the timing chain and camshaft sprockets.
The lower timing chain should not be disengaged from the crankshaft sprocket.
Remove the camshafts.
The valve train components must be reassembled in their original positions. Be sure to note their locations.
Loosen the cylinder head bolts in the illustrated order.
A warped or cracked cylinder head could result from loosening in incorrect order. The cylinder head bolts should be loosened in two or three steps.
Remove the cylinder head and intake manifold as an assembly.
Remove the cylinder head gasket.
Clean the gasket mating surfaces thoroughly.
Inspect both the engine block and cylinder head for damage.
Install a new cylinder head gasket. Ensure that the proper side of the gasket is facing up. Each gasket manufacturer will have a slightly different way of telling which side is up. Read the manufacturer's instructions carefully.
Install the cylinder head and temporarily tighten the cylinder head bolts. This is necessary to avoid damaging the cylinder head gasket. Be sure to install washers between the bolts and cylinder head.
Install the upper timing chain and cover.
Tighten the cylinder head bolts in the proper sequence to the following torque specifications:
A.Tighten all the bolts to 22 ft. lbs. (29 Nm).
B.Tighten all the bolts to 10 ft. lbs. (79 Nm).
C.Loosen all the bolts completely.
D.Tighten all the bolts to 18-25 ft. lbs. (25-34 Nm).
E.Turn all the bolts 86-91 degrees clockwise.If an angle wrench is not available, tighten all the bolts to 6-13 ft. lbs. (75-84 Nm).
Install the camshafts.
Install the timing chain and sprockets.
Install the cylinder head cover.
Install the passenger's side engine mount and lower the engine.
Install the distributor assembly.
Install the alternator and all related brackets.
Install the exhaust manifold.
Install the intake manifold braces.
Connect the air duct to the throttle body.
Refill and bleed the cooling system.
Refill the engine with the proper grade and viscosity of engine oil.
Connect the negative battery cable.
Start the engine and make the necessary adjustments.
Check for proper operation and leaks.
Monday, September 21st, 2009 AT 9:58 PM