Page 1522 of 5267
21. Raise the vehicle.
22. Install the exhaust pipe onto the left exhaust manifold.
23. Lower the vehicle.
24. Connect the negative cable to the battery.
25. Start the engine and check for leaks.
Page 1526 of 5267
COVER-CYLINDER HEAD
DESCRIPTION
The cylinder head covers (1,2) are made of glass re-
enforced thermoset plastic, and are not interchangable
from side-to-side.
REMOVAL
1. Disconnect negative cable from battery.
2. Remove the resonator assemble and air inlet hose.
3. Disconnect injector connectors and un-clip the
injector harness.
4. Route injector harness in front of cylinder head
cover.
5. Disconnect the left side breather tube and remove
the breather tube.
6. Remove the cylinder head cover mounting bolts
(1).
7. Remove cylinder head cover (1) and gasket.
NOTE: The gasket may be used again, providing
no cuts, tears, or deformation has occurred.
Page 1527 of 5267
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
1. Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
2. Install cylinder head cover (2).
3. Tighten cylinder head cover bolts (1) and double
ended studs to 12 Nꞏm (105 in. lbs.).
4. Install left side breather and connect breather tube.
5. Connect injector electrical connectors and injector
harness retaining clips.
6. Install the resonator and air inlet hose.
7. Connect negative cable to battery.
Page 1531 of 5267

ARM-VALVE ROCKER
DESCRIPTION
The rocker arms are steel stampings with an integral roller bearing. The rocker arms incorporate a 2.8 mm (0.11
inch) oil hole in the lash adjuster socket for roller and camshaft lubrication.
REMOVAL
NOTE: Disconnect the battery negative cable to
prevent accidental starter engagement.
1. Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
2. For rocker arm removal on cylinder No. 4, Rotate
the crankshaft until cylinder No. 1 is at BDC intake
stroke.
3. For rocker arm removal on cylinder No. 1, Rotate
the crankshaft until cylinder No. 1 is at BDC com-
bustion stroke.
4. For rocker arm removal on cylinders No. 3 and No.
5, Rotate the crankshaft until cylinder No. 1 is at
TDC exhaust stroke.
5. For rocker arm removal on cylinders No. 2 and No.
6, Rotate the crankshaft until cylinder No. 1 is at
TDC ignition stroke.
6. Using special tool 8516 Rocker Arm Remover (2) ,
press downward on the valve spring, remove
rocker arm.
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
1. For rocker arm installation on cylinders No. 4,
Rotate the crankshaft until cylinder No. 1 is at BDC
intake stroke.
2. For rocker arm installation on cylinder No. 1,
Rotate the crankshaft until cylinder No. 1 is at BDC
combustion stroke.
3. For rocker arm installation on cylinders No. 3 and
No. 5, Rotate the crankshaft until cylinder No. 1 is
at TDC exhaust stroke.
4. For rocker arm installation on cylinders No. 2 and
No. 6, Rotate the crankshaft until cylinder No. 1 is
at TDC ignition stroke.
5. Using special tool 8516 (2) press downward on the
valve spring, install rocker arm.
Page 1536 of 5267

HEAD-CYLINDER-RIGHT
DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER
A tappet-like noise may be produced from several items. Check the followingitems.
1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be
spongy.
2. Insufficient running time after rebuilding cylinder head. Low speed runningupto1hourmayberequired.
3. Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has
reached normal operating temperature.
4. Low oil pressure.
5. The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris.
6. Airingestedintooilduetobrokenorcrackedoilpumppickup.
7. Worn valve guides.
8. Rocker arm ears contacting valve spring retainer.
9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system.
10. Oil leak or excessive cam bore wear in cylinder head.
11. Faulty lash adjuster.
a. Check lash adjusters for sponginess while installed in cylinder head and cam on camshaft at base circle.
Depress part of rocker arm over adjuster. Normal adjusters should feel firm when pressed quickly. When pressed
very slowly, lash adjusters should collapse.
b. Remove suspected lash adjusters, and replace.
c. Before installation, make sure adjusters are full of oil. This can be verified by little plunger travel when lash
adjuster is depressed quickly.
REMOVAL
REMOVAL RIGHT CYLINDER HEAD
1. Disconnect battery negative cable.
2. Raise the vehicle on a hoist.
3. Disconnect the exhaust pipe at the right side
exhaust manifold.
4. Drain the engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
5. Lower the vehicle.
6. Remove the intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
7. Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
8. Remove the fan shroud (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL).
9. Remove oil fill housing from cylinder head.
10. Remove accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
11. Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark (2).
Page 1542 of 5267

12. Remove Special Tool 8429 (1).
13. Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
14. Install the crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION). Tighten damper bolt 175 Nꞏm
(130 Ft. Lbs.).
15. Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
16. Install the fan shroud (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
17. Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
18. Install the intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
19. Install oil fill housing onto cylinder head.
20. Refill the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
21. Raise the vehicle.
22. Install the exhaust pipe onto the right exhaust manifold.
23. Lower the vehicle.
24. Reconnect battery negative cable.
25. Start the engine and check for leaks.
Page 1548 of 5267

COVER - CYLINDER HEAD
REMOVAL
1. Disconnect battery negative cable.
2. Remove air cleaner assembly, resonator assembly and air inlet hose.
3. Drain cooling system, below the level of the heater hoses (Refer to 7 - COOLING - STANDARD PROCEDURE).
4. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
5. Remove air conditioning compressor retaining bolts and move compressortotheleft.
6. Remove heater hoses.
7. Disconnect injector and ignition coil connectors.
8. Disconnect and remove positive crankcase ventilation (PCV) hose.
9. Remove oil fill tube.
10. Un-clip injector and ignition coil harness and move away from cylinderhead cover.
11. Remove right rear breather tube and filter assembly.
12. Remove cylinder head cover retaining bolts.
13. Remove cylinder head cover.
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severedamagetocoversmay
occur.
NOTE: The gasket may be used again, provided no cuts, tears, or deformationhas occurred.
1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Tighten cylinder head cover bolts and double ended studs to 12 Nꞏm (105 in.lbs).
3. Install right rear breather tube and filter assembly.
4. Connect injector, ignition coil electrical connectors and harness retaining clips.
5. Install the oil fill tube.
6. Install PCV hose.
7. Install heater hoses.
8. Install air conditioning compressor retaining bolts.
9. Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
10. Fill Cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
11. Install air cleaner assembly, resonator assembly and air inlet hose.
12. Connect battery negative cable.
Page 1549 of 5267

ROCKER ARM - VALVE
DESCRIPTION
The rocker arms are steel stampings with an integral roller bearing. The rocker arms incorporate a 0.5 mm oil hole
in the lash adjuster socket for roller and camshaft lubrication.
REMOVAL
NOTE: Disconnect the battery negative cable to
prevent accidental starter engagement.
1. Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
2. For rocker arm removal on cylinder No. 4, Rotate
the crankshaft until cylinder No. 1 is at BDC intake
stroke.
3. For rocker arm removal on cylinder No. 1, Rotate
the crankshaft until cylinder No. 1 is at BDC com-
bustion stroke.
4. For rocker arm removal on cylinders No. 3 and No.
5, Rotate the crankshaft until cylinder No. 1 is at
TDC exhaust stroke.
5. For rocker arm removal on cylinders No. 2 and No.
6, Rotate the crankshaft until cylinder No. 1 is at
TDC ignition stroke.
6. Using special tool 8516 Rocker Arm Remover (2) ,
press downward on the valve spring, remove
rocker arm.