Cylinder Head Assembly: Service and Repair
This article has been updated with bulletin No: 99-06-01-016.
Cylinder Head Replacement
Fig. 9 Chain Guide Access Plug Removal:
Cylinder Head Bolt Tightening Sequence:
REMOVE OR DISCONNECT
1. Engine assembly.
2. The following subassemblies:
- Intake manifold.
- Cam covers.
- Harmonic balancer.
- Front cover.
- Oil pump.
3. Chain tensioner from timing chain for cylinder head being removed. Align all timing marks first!
4. Cam sprockets from head being removed. Timing chain remains in chain case.
5. Timing chain guides. Access to retaining screws is through plugs at front of cylinder head.
6. Water crossover.
7. Exhaust manifold.
8. Cylinder head bolts. Discard bolts.
NOTE: Do not reuse head bolts after removal. New bolts have special coating used for bolt retention after installation. This coating remains in the cylinder block threads after removal so proper cleaning of the cylinder block threads is important.
9. Cylinder head and gasket.
10. Clean the gasket surfaces and combustion chambers.
- Head bolt threads in cylinder block with soft brush or equivalent.
- Head bolt bosses in cylinder head with compressed air.
CAUTIONS:
- With camshafts remaining in cylinder head some valves will be open at all times. For this reason cylinder head cannot rest on a flat surface with cylinder face down, or valve damage will result.
- Caution must be exercised when cleaning aluminum gasket surfaces to prevent damage to the sealing surfaces. Use only plastic, wood, or dull gasket scrapers such as J-28410. Chemical agents to dissolve gasket materials can also be used effectively by following the manufacturers recommendations.
INSTALL OR CONNECT
1. New cylinder head gasket.
2. Cylinder head.
3. 10 new M11 and 3 M6 head bolts.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
4. Tighten the left cylinder head bolts in the sequence shown.
4.1. First Pass - Tighten the left cylinder head M11 cylinder head bolts to 40 Nm (30 lb ft ) in the sequence shown.
4.2. Second Pass - Tighten the left cylinder head M11 cylinder head bolts an additional 70 degrees in the sequence shown using the J 45059.
4.3. Third Pass - Repeat the sequence turning each bolt another 60 degrees.
4.4. Final Pass - Repeat the sequence again turning each bolt a final 60 degrees (total 190 degrees).
5. Tighten the M6 bolts at the front of the cylinder head to 12 Nm (106 lb in).
6. Tighten the right cylinder head bolts in the sequence shown.
6.1. First Pass - Tighten the right cylinder head M11 cylinder head bolts to 40 Nm (30 lb ft ) in the sequence shown.
6.2. Second Pass - Tighten the right cylinder head M11 cylinder head bolts an additional 70 degrees in the sequence shown using the J 45059.
6.3. Third Pass - Repeat the sequence turning each bolt another 60 degrees.
6.4. Final Pass - Repeat the sequence again turning each bolt a final 60 degrees (total 190 degrees).
7. Three M6 bolts to 12 Nm (106 lbs in).
8. Camshafts.
9. Set camshaft timing.
10. Camshaft guide bolt access hole plugs in cylinder heads. Plugs should be seated and snug.
11. The following sub assemblies:
- Cam covers.
- Oil pump.
- Front cover.
- Harmonic balancer.
- Intake manifold.
- Water crossover.
12. Exhaust manifold and tighten nuts to 30 Nm (22 lbs ft). Tighten the manifold bolts to 25 Nm (18 lbs ft).
13. Engine assembly.