Cylinder Head Assemble. Chevrolet Joy 2008

For 1990-2009 cars

#### Tools Required

• | EN 46569 Valve Spring Compressor

• | EN 46570 (09916-38210) Valve Guide Reamer (11 mm or 0.4331 in)

• | EN 46598 (00916-58210) Valve Guide Installer

• | EN 46597 (00916-37320) Valve Guide Reamer (5 mm or 0.1969 in)

• | EN 46573 (09917-88220) Valve Guide Installer Attachment

• | EN 47518 (09916-48210) Valve Spring Compressor

• | OTC 1726 (KM-412) Engine Overhaul Stand

Important: Before installing the new valve guide into the cylinder head, ream guide hole with 11 mm reamer to remove burrs. Make sure that the guide hole cones to a complete roundness (1).

1. Make the valve guide hole using a EN 46570 .
2. Heat the cylinder head uniformly at a temperature 80-100°C (176-212°F) not to make the head deformed, and drive new valve guide completely into the hole with the tools the EN 46598 (1) and the EN 46573 (2).

Important: Do not reuse the valve guide once disassembled, replace it with the new oversized valve guide.

3. Peen and install new valve guide (3).
4. After installation, check the protruded part of the guide from the cylinder head (a).

Specifications

• | The valve guide oversize is 0.03 mm (0.0012 in).

• | The valve guide protrusion is 14 mm (0.5512 in).

5. Repair the valve guide bore with the EN 46597 .
6. Make the hole free from foreign material.
7. Install the valve spring seats (1).

Important: Do not reuse the disassembled oil seal and replace it with new one. When installing it, never tap or hit tool with a hammer or else. Install seal to guide only by pushing special tool with hand. Tapping or hitting tool may cause damage on seal.

8. Install new valve stem oil seal to the valve guide (2).

Important: After applying engine oil to seal and installing seal to the valve guide and make sure that seal is properly fixed to the valve guide.

Important: Before installing it, coat engine oil to the stem seals, valve guide bore and valve stem.

9. Install the valve to the valve guide (1).
10. Install the valve springs (2).
11. Each valve spring has top end, large-pitch end (4) , bottom end and small-pitch end (5). Be sure to position spring in place with its bottom end down to valve spring seat side (3).
12. Install the valve spring retainers (1).

Caution: Refer to Compressed Valve Spring Caution in the Preface section.

Important: Coat engine oil to the valve stem oil seals, the valve guide hole, and the valve stem.

13. Using the EN 46569 (1) with the EN 47518 (2), compress the valve springs (3).
14. Install the valve keeper (4).
15. Coat the engine oil to the camshaft front oil seal, the cam, and the camshaft journal.
16. Install the camshaft front oil seal to the housing hole (3).

Notice: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.

17. Install the camshaft to the cylinder head (2).

Notice: Refer to Fastener Notice in the Preface section.

18. Install the camshaft plate (1).

Tighten
Tighten the screw to 9-12 N·m (80-106 lb in).

19. Coat the engine oil to the rocker arms and the rocker arm shafts.

Important: Rocker arm shafts for the intake valves and the exhaust valves are different and their directions of installation are different.

20. Install the rocker arms and the rocker arm shafts (2).
21. Install the rocker arm springs and the short spring to the intake side of the No. 3 cylinder (1).

Tighten
Tighten the bolts to 9-12 N·m (80-106 lb in).

22. Install the spark plugs.
23. Install the exhaust manifold gasket and the exhaust manifold (2).
24. Install the bolts and nuts (1) in the sequent order as shown in the picture.

Tighten
Tighten the exhaust manifold nuts and bolts to 17-27 N·m (13-20 lb ft).

25. Install the intake manifold heat shield (2).

Tighten
Tighten the intake manifold heat shield bolts to 8-12 N·m (71-106 lb in).

26. Install the intake manifold gasket and the intake manifold (2).

Important: Before tightening the intake manifold nuts, first of all, tighten the intake manifold support bracket nut.

27. Install the intake manifold nuts in the sequent order.

Tighten

• | Tighten the intake manifold nuts to 15-19 N·m (11-14 lb ft).

• | Tighten the intake manifold support bracket nut to 15-19 N·m (11-14 lb ft).

28. Install the distributor case and distributor with the gasket (3).

Tighten

• | Tighten the distributor bolt to 9-12 N·m (80-106 lb in).

• | Tighten the distributor nuts to 9-12 N·m (80-106 lb in).

29. Install the intake manifold main bracket with the nuts and bolts (1).

Tighten

1. Tighten the bolts and the nut to 9-12 N·m (80-106 lb in).
2. Tighten the bolt to 18-22 N·m (13-16 lb ft).

30. Perform the following steps when repairing the pistons and crankshaft unit:

30.1. | Remove the engine and the transaxle. Refer to Engine Replacement .

30.2. | Remove the transaxle from the engine. Refer to Transmission Replacement .

30.3. | Remove the flywheel.

30.4. | Install the OTC 1726 to the engine assembly as the figure.

30.5. | Drain the engine oil from the engine.

30.6. | Remove the cylinder head. Refer to Cylinder Head Replacement .

30.7. | Remove the oil pump from the cylinder block. Refer to Oil Pump Replacement .