Cylinder Head Replacement
This article has been updated with TSB 99-06-01-016.
CYLINDER HEAD REPLACEMENT
Tools Required
J 28410 Gasket Remover
J 45059 Angle Meter
Removal Procedure
1. Remove the powertrain engine assembly. Refer to Engine Replacement. Removal and Replacement
2. The intake manifold. Refer to Intake Manifold Replacement. Service and Repair
3. The left side cam cover. Refer to Camshaft Cover Replacement. Camshaft Cover Replacement (Left)
4. The right side cam cover. Refer to Camshaft Cover Replacement. Camshaft Cover Replacement (Right)
5. The crankshaft balancer. Refer to Crankshaft Balancer Replacement. Service and Repair
6. The engine front cover. Refer to Engine Front Cover Replacement. Service and Repair
7. Align the timing marks.
8. Remove the chain tensioner from the timing chain for the cylinder head being removed.
9. Remove the cam sprockets from the head being removed. The timing chain remains in the chain case.
10. Remove the timing chain guides. Access to the retaining screws is through the plugs at the front of the cylinder head.
11. Remove the water crossover.
12. Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement. Exhaust Manifold Replacement - Left
13. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement. Exhaust Manifold Replacement - Right
Important: Do not reuse the head bolts after removal. New bolts have a 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.
14. Remove and discard the cylinder head bolts.
Important: With the camshafts remaining in the cylinder head some valves will be open at all times. For this reason the cylinder head cannot rest on a flat surface with the cylinder face down, or valve damage will result.
15. Remove the cylinder head gasket.
Notice: Carefully clean the aluminum gasket surfaces in order to prevent damage to the sealing surfaces. Use only plastic, wood, or dull gasket scrapers, such as J 28410. Follow the manufacturer's recommendations to dissolve gasket materials with chemical agents.
16. Clean the gasket surfaces.
17. Clean the combustion chambers.
18. Clean the head bolt threads in the cylinder block with a soft brush or the equivalent.
Caution: Wear safety glasses in order to avoid eye damage.
19. Clean the head bolt bosses in the cylinder head with compressed air.
Installation Procedure
1. Ensure all the cylinder head locating pins are securely mounted in the cylinder block deck face.
2. Make sure any old thread sealant material is removed from the cylinder head bolts holes in the cylinder block.
Important: Failure to remove all the old thread sealant material from the cylinder block could cause false torque readings.
3. Install a new right cylinder head gasket using the deck face locating pins for retention.
4. Install a new left cylinder head gasket using the deck face locating pins for retention.
5. Align the cylinder head with the deck face locating pins.
6. Place the cylinder head in position on the deck face.
Important: DO NOT reuse the old M11 cylinder head bolts.
7. Install new M11 cylinder head bolts (1) in the cylinder head.
8. Install the M6 cylinder head bolts (2) at the front of the cylinder head.
9. Repeat these procedures for the remaining cylinder head.
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.
10. Tighten the left cylinder head bolts in the sequence shown.
10.1. First Pass - Tighten the left cylinder head M11 cylinder head bolts to 40 Nm (30 lb ft ) in the sequence shown.
10.2. Second Pass - Tighten the left cylinder head M11 cylinder head bolts an additional 70 degrees in the sequence shown using the J 45059.
10.3. Third Pass - Repeat the sequence turning each bolt another 60 degrees.
10.4. Final Pass - Repeat the sequence again turning each bolt a final 60 degrees (total 190 degrees).
11. Tighten the M6 bolts at the front of the cylinder head to 12 Nm (106 lb in).
12. Tighten the right cylinder head bolts in the sequence shown.
12.1. First Pass - Tighten the right cylinder head M11 cylinder head bolts to 40 Nm (30 lb ft ) in the sequence shown.
12.2. Second Pass - Tighten the right cylinder head M11 cylinder head bolts an additional 70 degrees in the sequence shown using the J 45059.
12.3. Third Pass - Repeat the sequence turning each bolt another 60 degrees.
12.4. Final Pass - Repeat the sequence again turning each bolt a final 60 degrees (total 190 degrees).
13. Tighten the M6 bolts at the front of the cylinder head to 12 Nm (106 lb in).
14. Install the camshaft. Refer to Camshaft Replacement. Service and Repair
15. Set the camshaft timing. Refer to Setting Camshaft Timing. Setting Camshaft Timing
16. Install the camshaft guide bolt access hole plugs in the cylinder heads. The plugs should be seated and snug.
17. Install the engine front cover. Refer to Engine Front Cover Replacement. Service and Repair
18. Install the intake manifold. Refer to Intake Manifold Replacement. Service and Repair
19. Install the left side cam cover. Refer to Camshaft Cover Replacement. Camshaft Cover Replacement (Left)
20. Install the right side cam cover. Refer to Camshaft Cover Replacement. Camshaft Cover Replacement (Right)
21. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement. Service and Repair
22. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement. Exhaust Manifold Replacement - Right
23. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement. Exhaust Manifold Replacement - Left
24. Install the water crossover.
25. Install the powertrain assembly. Refer to Engine Replacement. Removal and Replacement