How to remove cylinder head of 1.6 GA engine?

Details here on Page 94

11. Following the tightening sequence shown in
Figure 15, torque the fasteners in 1/2 turn increments and in two stages to the specifications.
Torque the fasteners to 1/2 the given torque, then
torque them to their final specifications:
a. Cylinder head nuts (1-4, Figure 15): 50 N•m
(37 ft.-lb.).
b. Cylinder head cap nut (5, Figure 15): 35 N•m
(26 ft.-lb.).
c. Cylinder head bolts (6 and 7, Figure 15): 20
N•m (15 ft.-lb.).
12. If the cylinder has also been reinstalled, torque
the cylinder bolts (A and B, Figure 23) to 10 N•m
(89 in.-lb.). One of the bolts sits in a recess (B, Fig-
ure 23) in the cylinder block.
13. If removed, install the locating pin (B, Figure
21) into the camshaft

Engine Lower End Torque Specifications - V star 1100

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Yamaha V star 1100 Manual Online: Engine Lower End Torque Specifications. Item N•m Alternator cover bolts 10 Connecting rod nuts 48 Crankcase stud 10 mm 20 ...

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  Cylinder Head Removal - Yamaha V star 1100 Owner's Manual

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  Yamaha V star 1100 Manual Online: Cylinder Head Removal. The procedures for removing the rear (Figure 3) and front (Figure 4) cylinder heads are nearly ...
  
  
  videos that might help
  
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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.

below are the instruction you well need to remove head .....good luck Removal Procedure

1. Remove the air cleaner element.
2. Remove the air cleaner outlet resonator. .
3. Remove the powertrain control module (PCM) and engine wire harness bracket and related hoses and connections.
4. Remove the generator.
5. Remove the intake manifold.
6. Remove the exhaust manifold. Do not remove the exhaust pipe from the manifold. Only have the manifold pushed off to the side of the engine.
7. Position the A/C line out of the way towards the front of the vehicle.
8. Disconnect the following cross-vehicle engine wiring harness connectors:
• Engine coolant temperature sensor • Manifold absolute pressure (MAP) sensor • Ignition coils • Harness clamps at power steering pump • Wiring harness fastener at the right front inner fender • Throttle body • Camshaft sensors • Camshaft actuators • Fuel rail • Heated oxygen sensor (HO2S)
9. Set aside the cross-vehicle engine wiring harness on the left side of the vehicle.
10. Remove the camshaft cover.
    
11. Partially drain the cooling system.


12. Before performing one of the top dead center (TDC) procedures, break loose both the exhaust and intake camshaft sprocket bolts. Use a 25 mm (1 in) open end wrench on the camshaft hexes to hold the camshaft from turning. DO NOT remove the bolts.
13. Perform one of the following methods for the service timing procedure.
    
14. First Method--Rotate the engine clockwise by hand to TDC on the compression stroke by using a piston TDC indicator tool and/or dial indicator in the number 1 cylinder.
    
15. First Method (continued)--The TDC indicator tool graduation marks on the shaft should note top of the piston stroke.
    
16. First Method (continued)--When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats.
    
17. Second Method--Rotate the crankshaft in the engine rotational direction clockwise until the number 1 piston is at TDC on the compression stroke. The word Delphi on the exhaust camshaft position actuator will be parallel with the cylinder head to cam cover mating surface. When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats. A 0.005 inch feeler gauge should not slide under the straight edge (1).
    
18. Use a white paint pen or equivalent to place a reference mark on the harmonic balancer to the front cover for alignment purposes.
19. Lower the vehicle.
Important: If the timing is correct (TDC compression stroke number 1 cylinder), the camshaft flats will be in the up position.
Install J 44221 to the back of the camshafts.

20. Remove the upper timing chain guide to the cylinder head.
    
21. Clean the timing chain and gears with brake cleaner or suitable solvent. Use a white paint pen or equivalent to place a reference mark on both timing gear sprockets and the timing chain to mark location prior to disassembly. It is recommended that the paint marks be in the 12 o'clock position.


22. Install EN-48464 . It is important to install the tool with the proper orientation and to ensure that it is seated square against the timing chain and against the timing cover center bolt.



23. The narrow ramp of the wedge tool needs to be placed so that it faces the timing chain.
24. The wedge tool should be lightly seated using a couple of very light taps with a small plastic or brass hammer. The wedge tool will be fully seated against the tensioner after it moves about 25 mm (1 in).
25. Once the tool is correctly installed, unscrew the handle and remove the handle


26. Remove both upper cylinder head access hole plugs from the front of the cylinder head.
27. Remove the 1 long and 2 short cylinder head bolts next to the exhaust and intake timing chain tensioner shoes and discard the bolts.
28. Remove both upper timing chain tensioner shoe bolts.
29. Remove the exhaust and the intake camshaft sprocket bolts. Discard the bolts.



30. Carefully remove the exhaust and intake camshaft sprockets with the timing chain from the exhaust and intake camshafts. The illustration shows the exhaust camshaft sprocket already removed.



31. Remove the sprockets from the chain, tie a piece of mechanic's wire on the timing chain and let it drop.



32. Before removing the cylinder head bolts, use a drift punch and hammer to shock the bolts. This will ensure that the cylinder head bolts will not strip out the threads in the engine block or break. If a bolt breaks during engine disassembly, EN-47702 is available to assist in the removal of the remaining bolt segment.
    
33. Remove the cylinder head bolts. Discard the bolts.
    
34. Remove the cylinder head.
35. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.
    
36. Remove the cylinder head gasket.
Discard the gasket.

37. Remove all remaining gasket material from the engine block.
38. Inspect the cylinder head gasket mating surface on the engine block.
39. Clean and inspect the cylinder head.
40. Disassemble the cylinder head if necessary.

Fig. 1: Cylinder head bolt tightening sequence for all 4-cylinder engines


1. Clean the cylinder head bolts and the threads in the block. Make sure the bolts turn freely in the block.
2. Install a new head gasket on the engine block. Make sure the camshaft sprocket timing marks are still aligned, as set during the removal procedure. Install the cylinder head.
3. Lubricate the bolt threads and seat surfaces with clean engine oil and install them. Torque the bolts in 2-3 steps to 56-60 ft. lbs. (75-81 Nm) in the proper sequence.

Hope helps.

Cylinder Head REMOVAL & INSTALLATION 2.3L Engine

1. Properly relieve the fuel system pressure.
2. Disconnect the negative battery cable, then drain cooling system into a suitable container.
3. Detach the heater inlet and throttle body heater hoses from water outlet. If accessible at this time, disconnect the upper radiator hose from the water outlet.
4. Remove the exhaust manifold. For details, please refer to the procedure located in this section.
5. Remove the intake (camshaft housing for SOHC) and exhaust (DOHC only) camshaft housings.
6. Unfasten the oil fill tube bolt/screw then remove the oil fill cap and level indicator assembly. Pull the oil fill tube upward to unseat from block.
7. Label and disengage the injector harness electrical connector.
8. Detach the throttle body-to-air intake duct.
9. Tag and disconnect the power brake vacuum hose from the throttle body.
10. Remove the throttle cable bracket.
11. Remove the throttle body from the intake manifold with the electrical harness and throttle cable attached and position the assembly aside.
12. Tag and disconnect the MAP sensor vacuum hose from the intake manifold, then remove the intake manifold brace.
13. Detach the electrical connectors from the MAP sensor, IAT sensor and the EVAP canister purge solenoid.
14. If not already done, detach the upper (inlet) radiator hose from the water outlet.
15. Disengage the coolant temperature sensor connector(s).
16. Unfasten the cylinder head bolts in reverse order of the installation sequence shown in the accompanying figures.
17. Lift the cylinder head from the engine block. Remove and discard the gasket. Inspect the oil flow check valve for freedom of movement.
18. Using a suitable solvent, thoroughly clean and dry all bolts, bolt holes and mating surfaces. Inspect the head bolts for any damage and replace, if necessary. If using a scraper to clean the old gasket material from the mating surfaces, use only a plastic or wood one, NOT a metal scraper. Do NOT allow any debris to fall into the engine! To install:
    
19. Place a new cylinder head gasket on the cylinder block, then carefully position the cylinder head in place.
20. Sparingly coat the head bolt threads with clean engine oil, then allow the oil to drain off before installing.
21. On 1988-89 engines, install and tighten the cylinder head bolts, in sequence, as follows:
    • Step 1 - Tighten all head bolts in sequence to 26 ft. lbs. (35 Nm)
    • Step 2 - Using a torque angle meter, tighten the short bolts an additional 80°and the long bolts an additional 90°in sequence Fig. 5: Cylinder head bolt tightening sequence - 1988-89 2.3L engine
      
22. On 1990-91 engines, tighten the cylinder head bolts, in sequence, as follows:
    • Step 1 - Tighten all head bolts in sequence to 26 ft. lbs. (35 Nm)
    • Step 2 - Using a torque angle meter, tighten the short bolts an additional 100°and the long bolts an additional 110°in sequence Fig. 6: Cylinder head bolt tightening sequence - 1990-91 2.3L engine
      
23. On 1992 engines, tighten the cylinder head bolts, in sequence, as follows:
    • Step 1 - Tighten, in sequence, head bolts 1-6 to 26 ft. lbs. (35 Nm), 7-8 to 15 ft. lbs. (20 Nm) and 9-10 to 22 ft. lbs. (30 Nm).
    • Step 2 - Tighten all head bolts, in sequence, an additional 90°using J 36660 or equivalent
    • Step 3 - In sequence, loosen each bolt one turn, then immediately re-tighten to the specified torque
    • Step 4 - After completing step 3 on all 10 bolts, tighten each bolt, in sequence, an additional 90° Fig. 7: Cylinder head bolt tightening sequence - 1992 2.3L engine
      
24. On 1993-95 vehicles, tighten the cylinder head bolts to the specifications shown in the accompanying figures. Fig. 8: Cylinder head bolt tightening sequence and specifications - 1993 2.3L engine
    Fig. 9: Cylinder head bolt tightening sequence and specifications - 1994-95 2.3L engine
    
25. Engage the coolant temperature sensor electrical connector(s).
26. Connect the upper radiator hose to the water outlet.
27. Install the intake manifold bracket.
28. Attach the following electrical connections: MAP sensor, IAT sensor, and the purge solenoid.
29. Using a new gasket, install the throttle body to the intake manifold.
30. Install the accelerator control cable bracket.
31. Connect the throttle body-to-air intake duct.
32. Install the oil fill tube and level indicator.
33. Install the camshaft housing(s).
34. Install the exhaust manifold. For details, please refer to the procedure located in this section.
35. Connect the heater inlet and throttle body heater hoses to the water outlet.
36. Fill all fluids to their proper levels.
37. Connect the battery cable, start the engine and check for leaks.

Cylinder Head Removal & Installation 5.7L Engine To Remove:

1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove the air cleaner assembly.
4. Remove the upper radiator hose.
5. Remove both heater hoses.
6. Disconnect spark plug wires at distributor cap.
7. Remove distributor cap.
8. Remove the coolant bypass hose from the water pump.
9. Remove the drive belt. NOTE: It is not necessary to evacuate the A/C refrigerant.
   
10. Remove the A/C compressor from the mounting bracket and set it aside.
11. Remove the wiring bracket from the rear of the cylinder head.
12. Disconnect the accessory bracket and slide forward.
13. Remove the upper and lower intake manifold.
14. Remove the exhaust manifolds.
15. Remove the valve rocker arms and pushrods.
16. Remove the power steering pump pulley.
17. Disconnect the electrical connector from the power steering pump.
18. Remove nuts attaching the power steering pump to the engine.
19. Remove power steering pump mounting bracket bolts and nut.
20. Slide power steering pump/bracket assembly forward and remove stud.
21. Set power steering pump/bracket assembly aside.
22. Disconnect the wiring bracket from rear of the right cylinder head.
23. Remove the generator.
24. Remove the oil indicator tube bracket bolt.
25. Remove the generator mounting bracket.
26. Remove the sixteen cylinder head bolts.
27. Remove cylinder heads and gaskets.
28. Clean all sealing surfaces.

To Install:
Right Side NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
NOTE: Do not use any type of sealant on the cylinder head gasket (unless specified).

1. Clean the cylinder head bolt holes with a thread chaser and compressed air.
2. Check the cylinder head locating pins for proper installation.
3. Place a new cylinder head gasket over the engine block dowel pins.
4. Install the cylinder head to the engine block.
5. Apply sealant (GM P/N 12346004 or equivalent) to cylinder head bolt threads.
6. Install the cylinder head bolts.
   
   
7. Tighten the cylinder head bolts in sequence on the first pass.
   • Torque to: 22 ft. lbs. (30 Nm)
8. Using a torque angle meter, tighten the long bolts (1, 2, 5, 6, 9, 10 and 13) on the second pass in sequence to 75°.
9. Using a torque angle meter, tighten the medium bolts (14 and 17) on the second pass in sequence to 65°.
10. Using a torque angle meter, tighten the short bolts (3, 4, 7, 8, 11, 12, 15 and 16) on the second pass in sequence to 55°.
11. Install the valve rocker arms and pushrods.
12. Install the generator mounting bracket stud.
    • Torque to: 15 ft. lbs. (20 Nm)
13. Loosely assemble the generator mounting bracket over the stud.
14. Install all nuts and bolts finger tight.
    • Torque to: 30 ft. lbs. (41 Nm)
15. Install the generator.
16. Install the oil indicator tube bracket bolt.
17. Install the exhaust manifold.
18. Install the lower intake manifold.
19. Install the valve rocker arm covers.
20. Install the wiring bracket to the rear of the cylinder head.
21. Connect the accessory bracket.
22. Install the A/C compressor.
23. Install the drive belt.
24. Install the distributor cap.
25. Connect the spark plug wires to the distributor cap.
26. Install both heater hoses.
27. Install the upper radiator hose.
28. Install the air cleaner assembly.
29. Refill the engine coolant.
30. Connect the negative battery cable.

Left Side To Install:
NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
NOTE: Do not use any type of sealant on the cylinder head gasket (unless specified).
NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
NOTE: Do not use any type of sealant on the cylinder head gasket (unless specified).

1. Clean the cylinder head bolt holes with a thread chaser and compressed air.
2. Check the cylinder head locating pins for proper installation.
3. Place a new cylinder head gasket over the engine block dowel pins.
4. Install the cylinder head to the engine block.
5. Apply sealant (GM P/N 12346004 or equivalent) to cylinder head bolt threads.
6. Install the cylinder head bolts.
   
   
7. Tighten the cylinder head bolts in sequence on the first pass.
   • Torque to: 22 ft. lbs. (30 Nm)
8. Using a torque angle meter, tighten the long bolts (1, 2, 5, 6, 9, 10 and 13) on the second pass in sequence to 75°.
9. Using a torque angle meter, tighten the medium bolts (14 and 17) on the second pass in sequence to 65°.
10. Using a torque angle meter, tighten the short bolts (3, 4, 7, 8, 11, 12, 15 and 16) on the second pass in sequence to 55°.
11. Install the valve rocker arms and pushrods.
12. Install the power steering pump mounting bracket stud.
    • Torque to: 15 ft. lbs. (20 Nm)
13. Loosely assemble the mounting bracket over the stud.
14. Install all nuts and bolts finger tight.
    • Torque to: 30 ft. lbs. (41 Nm)
15. Install the power steering pump pulley.
16. Connect the electrical connector to the power steering pump.
17. Install the exhaust manifold.
18. Install the lower intake manifold.
19. Install the valve rocker arm covers.
20. Install the wiring bracket to the rear of the cylinder head.
21. Connect the accessory bracket.
22. Install the A/C compressor.
23. Install the drive belt.
24. Install the distributor cap.
25. Connect the spark plug wires to the distributor cap.
26. Install both heater hoses.
27. Install the upper radiator hose.
28. Install the air cleaner assembly.
29. Refill the engine coolant.
30. Connect the negative battery cable.

Check this procedure...

1. Tighten the first design cylinder head bolts as follows:
   1. M11 bolts 1st pass: in sequence to 22 ft. lbs. (30 Nm).
   2. M11 bolts 2nd pass: in sequence + 90 degrees.
   3. M11 bolts (1,2,3,4,5,6,7,8): + 90 degrees.
   4. M11 bolts (9 and 10): + 50 degrees.
   5. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      
2. Tighten the second design cylinder head bolts as follows:
   1. M11 bolts (1-10) 1st pass: in sequence to 22 ft. lbs. (30 Nm).
   2. M11 bolts (1-10) 2nd pass: in sequence + 90 degrees.
   3. M11 bolts (1-10): + 70 degrees.
   4. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

Fig. Cylinder head bolt tightening sequence-4.8L, 5.3L and 6.0L engines (click for zoom)


Install the cylinder head bolts in sequence to 22 ft. lbs. (30 Nm). The bolts must be tightened once, then be tightened again in sequence in the following order:

1. Step 1: Short length bolt: (3, 4, 7, 8, 11, 12, 15, 16), plus 55 degrees.
2. Step 2: Medium length bolt: (14, 17), plus 65 degrees.
3. Step 3: Long length bolts: (1, 2, 5, 6, 9, 10, 13), plus 75 degrees.

Fig. Cylinder head bolt tightening sequence-5.0L and 5.7L engines

REMOVAL & INSTALLATION

1C-LTC and 2CL-TC Engines
(see Figures 1 and 2)

1. Disconnect the negative battery cable. Remove and label all electrical wiring, connectors and vacuum hoses necessary to gain removal clearance.

Fig. 1: Loosen and remove the cylinder head cover retaining nuts

1. Disconnect the PCV hose.
2. Remove the six nuts and seal washers from the cylinder head cover. Loosen them in a crisscross pattern.
3. Remove the cylinder head cover and the cover gasket from the cylinder head. Discard the gasket and replace with a new one.
   

To install:

1. With a wire brush or gasket scraper, remove all the old gasket material from the cylinder head and the cylinder head cover gasket surfaces.
2. When the cylinder head surfaces are free and clean, apply beads of sealant to the cylinder head in the locations shown in the accompanying illustration.

Fig. 2: Be sure to apply sealant on the cylinder head prior to cover installation

1. Install the new gasket in the cover. Make sure that the gasket seats evenly.
2. Place the cover with the gasket onto the cylinder head.
3. Install the six nuts and seal washers. Tighten the nuts to 65 inch lbs. (8 Nm).
4. Connect the PCV hose. Connect all removed vacuum hoses, connectors and electrical wiring. Connect the negative battery cable.
5. Start the engine and inspect for oil leaks. Repair any leaks as necessary.

Hope this help (remember comment and rated this).

300M, Concorde, Intrepid, LHS, 1998-2004 - Cylinder Head
Removal & Installation
2.7L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Properly relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   NOTE Place shop rags in the openings to prevent debris from entering the engine.
   Negative battery cable Accessory drive belts Crankshaft damper Intake plenum, lower intake manifold and exhaust manifold Valve and timing chain covers Coolant connections for the cylinder heads
5. Rotate the crankshaft until the crankshaft timing mark aligns with the timing mark on the oil pump.
   WARNING Be sure the head bolts 9-11 are removed before attempting to remove the cylinder head, the head and/or block may be damaged.
   Primary timing chain Camshaft bearing caps, gradually, in the reverse order of the tightening sequence Camshafts Cylinder head bolts in reverse order of installation starting with bolts 11-9, then 8-1 Cylinder head(s)

To install:




Fig. Camshaft bolt tightening sequence-2.7L engine



Fig. Cylinder head bolt tightening sequence-2.7L engine

1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean the oil passages thoroughly.
2. Place a new head gasket on the cylinder block over the locating dowels.
3. Inspect the cylinder head bolts for necking (stretching) by holding a straightedge against the threads of each bolt. If all of the threads are not contacting the straightedge, the bolt should be replaced. New head bolts are recommended.
   WARNING Due to the cylinder head bolt torque method used, it is imperative that the bolt threads be inspected for necking (stretching) prior to installation. If the threads are necked down, the bolt should be replaced. Failure to do so may result in parts failure or damage.
4. Lubricate the bolt threads with clean engine oil, then install them.
5. Torque the head bolts in the sequence shown in the illustration, utilizing the following steps and tightening values:
   1. Step 1: bolts 1 through 8: 35 ft. lbs. (48 Nm).
   2. Step 2: bolts 1 through 8: 55 ft. lbs. (75 Nm).
   3. Step 3: bolts 1 through 8: 55 ft. lbs. (75 Nm).
   4. Step 4: bolts 1 through 8: plus 90 degree turn using a torque angle meter.
   5. Step 5: bolts 9 through 11: 21 ft. lbs. (28 Nm).
      
   
   
6. Install or connect the following:
   Camshafts, timing chain and sprockets Water connections to the cylinder head Valve and timing chain covers Crankshaft damper and torque the center bolt to 125 ft. lbs. (170 Nm) Lower intake manifold and intake plenum Exhaust manifolds Accessory drive belts Negative battery cable
7. Fill the cooling system to the proper level.
8. Start the vehicle, check for leaks and repair if necessary.

continue...

there r no locks to the cylinder just to pluck it off carefully...........may be two locks can be present it just got tightened because it may be not used so far..............just twist a while and u will open it easily......