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Cylinder Head Installation - Yamaha XVS650 Service Manual

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Yamaha XVS650 Manual Online: Cylinder Head Installation. Rear cylinder head 1.1nstall: • Nuts (cylinder head) (M10:1 ....4) • Bolts (cylinder head) (M8:5-7) ...

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NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

REMOVAL
1. Drain engine coolant from radiator and cylinder block by removing the drain plugs.
2. Remove the intake manifold.
3. Remove exhaust manifold.
4. Remove camshafts.
5. Remove valve tappets from cylinder head, then support front of engine with wood block between crankshaft pulley and front subframe.
6. Remove righthand engine lifting eye bolt, then righthand engine lifting eye.
7. Remove power steering pump mounting bracket and cylinder head support bracket.
8. Remove camshaft timing belt tensioner pulley and front cover from front of cylinder head.
9. Remove water thermostat housing from cylinder head as follows:
a. Raise and support vehicle.
b. Disconnect crankcase ventilation tube from positive crankcase ventilation valve.
c. Disconnect upper radiator hose and radiator overflow hose from water hose connection.
d. Remove water outlet connection bolts and water hose connection from water thermostat housing.
e. Remove water thermostat and seal from water thermostat, then seal from water thermostat housing. Inspect seals for damage and replace if necessary.
10. Remove ignition coil bracket from cylinder head as follows:
a. Disconnect fuel charging wiring or engine control sensor wiring from ignition coil, then ignition wires by squeezing locking tabs and twisting while pulling upward.
b. Remove ignition coil bolts or screws, then coil.
c. Remove ignition coil bracket.

Fig. 11 Cylinder head bolt removal sequence


11. Remove spark plugs from cylinder head, then cylinder head bolts in sequence. Discard cylinder head bolts.
12. Remove cylinder head and head gasket from cylinder block.
13. If necessary, remove lefthand engine lifting eye from cylinder head.
14. Inspect cylinder head and cylinder block, then replace components as required.

INSTALLATION
1. Reverse procedure to install, noting following:
a. Clean cylinder head intake manifold, valve cover and cylinder head gasket surfaces. Ensure flatness of cylinder head and cylinder block gasket surfaces meets specifications.

Fig. 12 Cylinder head bolt tightening sequence



b. Torque new cylinder head bolts in sequence, first to 15-22 ft lb, then to 30-37 ft lb. Finally tighten all bolts an additional 90-120° in the same sequence.

1. Clean the cylinder gasket surfaces on the engine block.
2. Inspect the dowel pins (cylinder head locator) for proper installation.
3. Clean the cylinder head gasket surfaces on the cylinder head.
4. Place the NEW cylinder head gasket in position over the dowel pins (cylinder head locator).The cylinder head gasket is not directional and may be installed using either side facing the engine block.
5. Install the cylinder head to the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
   
Install the cylinder head bolts.

6. Tighten the bolts in the sequence shown in the image below on the first pass to 30 [n-m] (22 lb ft).


7. Use a torque angle meter in order to tighten the cylinder head bolts in sequence on the final pass. Tighten:
   
   • Tighten the long bolts (1, 2, 5, 6, 9, 10, and 13) on the final pass in sequence to 75 degrees.
   • Tighten the medium bolts (14 and 17) on the final pass in sequence to 65 degrees.
   • Tighten the short bolts (3, 4, 7, 8, 11, 12, 15, and 16) on the final pass in sequence to 55 degrees.


8. Measure the NEW spark plugs for the proper gap.Adjust the spark plug gap if necessary.
   Specification:
   Spark plug gap to 1.52 mm (0.060 in)
9. Install the NEW spark plugs. Tighten:
   
   • Tighten the spark plugs for a USED cylinder head to 15 [n-m] (11 lb ft).
   • Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 [n-m] (22 lb ft).


10. If reusing the engine coolant temperature (ECT) gauge sensor, apply sealant GM P/N 12346004 to the threads of the ECT gauge sensor.
11. Install the ECT gauge sensor.Tighten:
    Tighten the ECT gauge sensor to 20 [n-m] (15 lb ft).
    

Quote:





Originally Posted by norvelplagbao52

1993 saturn sl2 1.9 dohc cylinder head torque
specs and sequence
Cylinder head bolt
tightening procedure:
CYLINDER HEAD BOLT TIGHTENING SEQUENCE:

INTAKE
SIDE
8 4 1 5 9

7 3 2 6 10
EXHAUST SIDE

In sequence,
torque the cylinder head bolts. Torque: 30 Nm (22 ft-lbs).
In sequence,
torque all bolts. Torque: 50 Nm (37 ft-lbs)
In sequence, turn each bolt an
additional 90 degrees.





Originally Posted by norvelplagbao52

1993 saturn sl2 1.9 dohc cylinder head torque
specs and sequence
Cylinder head bolt
tightening procedure:
CYLINDER HEAD BOLT TIGHTENING SEQUENCE:

INTAKE
SIDE
8 4 1 5 9

7 3 2 6 10
EXHAUST SIDE

In sequence,
torque the cylinder head bolts. Torque: 30 Nm (22 ft-lbs).
In sequence,
torque all bolts. Torque: 50 Nm (37 ft-lbs)
In sequence, turn each bolt an
additional 90 degrees.

Engine oil going to radiator is a cylinder head problem.
Either
1. Cylinder head gasket burnt
2. Cylinder head bolts not tight enough
3. Cylinder head cracked
4 Cylinder head warped.

Remove cyliner head and pressure test it for cracks. If cracked replace unless someone near you can repair effectively. If not then skim and you might as well do a complete cylinder head service ie valves, stem seals etc. Put back head with new gasket and torque correctly and be surprised with the results.

To install:

Fig. Cylinder head bolt torque sequence-3.8L engine

1. Install the new cylinder head gasket with the arrow pointing to the front of the engine.
2. Install the cylinder head.
3. Install NEW cylinder head bolts. Torque the bolts in sequence, as follows:
   1. Step 1: 37 ft. lbs. (50 Nm).
   2. Step 2: Plus 120 degree turn.

To install:

Fig. Tighten the cylinder head bolts using the following sequence-31L and 3.4L engines

1. Install the cylinder head with a new gasket.
2. Apply thread sealer to the head bolts.
3. Tighten the cylinder head bolts to 37 ft. lbs. (50 Nm) plus an additional 90 degree turn.

1.8 liter..NOTE: Lubricate the cylinder head bolts using the specified engine oil.

Install the cylinder head bolts. Tighten the cylinder head bolts in 2 or 3 steps in the sequence shown to 76-81 Nm (56-60 lb-ft).


1.9 liter
Apply a light coating of engine oil to the threads of the new cylinder head bolts. Install the new cylinder head bolts to the cylinder head. Following the sequence shown below, tighten the cylinder head bolts to 40-60 Nm (30-44 lb-ft). Loosen all cylinder head bolts approximately two turns, then retighten the cylinder head bolts to 60 Nm (44 lb-ft) following the sequence shown. After tightening, turn all bolts 90 degrees, in the same sequence. Complete bolt tightening by turning them an additional 90 degrees, in the same sequence.

3.4L Engine To Remove:

1. Remove the lower intake manifold.
2. Remove the exhaust crossover pipe.
3. If removing the right cylinder head, remove the catalytic converter from exhaust manifold.
4. If removing the left cylinder head, remove the engine oil dipstick and tube.
5. Remove the rocker arms and pushrods.
6. Remove and discard the cylinder head bolts.
7. Remove the cylinder head.
8. Clean the mating surfaces on the following items:
   • Cylinder head
   • Cylinder block
   • Intake manifold
9. Clean the cylinder block bolt threads.

NOTE: During disassembly, keep the valve train components together for proper location during assembly.
To Install:
NOTE: Coat the cylinder head bolt threads using thread sealer.

1. If removed, install the following components:
   • Exhaust manifold
   • Accessory studs
   • Spark plugs
2. Place the cylinder head gasket in position over the dowel pins. Ensure that the THIS SIDE UP note is showing.
3. Install the cylinder head. Cylinder head torque sequence ’99-‘00
   
   Cylinder head torque sequence ’01-05
   
   
4. Install the new cylinder head bolts.
   • Tighten the cylinder head bolts a first pass to 44 ft lb (60 Nm).
5. Tighten the cylinder head bolts in sequence an additional 95 degrees.
6. Install the intake gasket.
7. Install the pushrods and rocker arms.
8. Raise and support the vehicle.
9. Install the catalytic converter and dipstick tube and indicator if removed.
10. Lower the vehicle.
11. Install the exhaust crossover pipe.
12. Install the intake manifolds.
13. Connect negative battery cable.
14. Fill the cooling system.

here is the troque spec for the cylinder heads.

Cylinder Head Bolt

• First Pass

60 N·m
44 lb ft

• Final Pass

95 degrees
Cylinder Head Bolt

• First Pass

60 N·m
44 lb ft

• Final Pass

95 degrees


Cylinder Head Bolt

• First Pass

60 N·m
44 lb ft

• Final Pass

95 degrees
first pass 44 ftlbs
second pass 95 degrees

The cylinder head is a crucial part of all combustion engines, and cylinder head cracking can result in catastrophic damage to the engine. In some cases, cylinder head cracking may result in such severe injury to the engine that it must be replaced. As a result, most motorists try to prevent cylinder head cracking, as an ounce of prevention in this case is worth many pounds of cure. The causes of cylinder head cracking are all relatively simple and easy to prevent, except in the case of mechanical parts failure through no fault of the operator. The cylinder head, used in combination with a head gasket, seals the cylinders of the car, along with other parts associated with them. The cylinder head is customized for the vehicle, and has very precisely milled surfaces to provide a smooth and flush fit with all connecting parts. In the case of a minor crack, the cylinders may lose compression and misfire. Major cracks can cause severe damage to the cylinders of the engine. For this reason, when replacing either the cylinder head or the head gasket, make sure that you are using the correct parts, including bolts, for the job. Even a brand new car can experience cylinder head cracking if parts have been installed incorrectly or if there are weaknesses in the metal. Especially in the case of a vehicle which is still under warranty, drivers should contest the cylinder head cracking with the dealer. Be certain to inspect any vehicle before you purchase to check for weak spots in the metal or incorrectly installed components. This includes the cylinder head gasket, because improper installation of this vital part can cause cylinder head cracking. Cylinder head cracking has become more common as car manufacturers use mixed metals in their engines. Many vehicles, for example, have a solid cast iron engine block but an aluminum cylinder head. These two metals expand at different rates, and this can lead to cylinder head cracking. The most common cause of cylinder head cracking is overheating. When a vehicle overheats, it puts stress on all of its metal components, including the cylinder head, which is often at the center of the heat. This can cause the head gasket to fail, which may lead to cylinder head cracking as the components warp and pressure begins to leak. All drivers should properly maintain their vehicles to prevent overheating. Many drivers mistakenly pour cool water into the radiator when their vehicles overheat, in an attempt to bring the temperature down. This is not a good idea, because the rapid temperature change will cause cylinder head cracking due to thermal stress. In a case where the cylinder head survives overheating, the driver may inadvertently destroy it by trying to do good. To prevent overheating, make sure that your radiator is filled and in good condition, with a tightly sealed cap. Check to be certain that your engine thermostat is in good working order, and accurately reflecting the temperature. Make sure that you have no leaky belts or stretched hoses, and that the fan is working effectively. If your car does overheat, stop, turn off the engine, and allow it to cool completely before adding water. Cylinder head cracking can also be caused by localized hot spots in the engine, which usually represent a failure in some portion of the cooling system. Always make sure that hot spots are addressed, particularly if your head gasket has failed and required replacement recently. Hot spots are often caused by uneven expansion of engine parts, leaky hoses, and pre-ignition in the cylinders of the engine. If your car has overheated, check the cylinder head and gasket for signs of cracking or warping. If the cylinder head has warped even slightly out a flush state, it will cause cylinder head cracking. In this case, the head gasket may need to be replaced and the cylinder head should be ground even again before it cracks. Thanks for using FiXya - a FiXya rating is appreciated!