Removal and Installation
REMOVAL1. Perform fuel pressure release procedure before attempting any repairs.
2. Disconnect negative cable from remote jumper terminal.
3. Drain cooling system.
4. Remove accessory drive belts.
5. Remove the vibration dampener.
6. Remove exhaust cross-under pipe.
7. Remove the appropriate catalytic converter.
8. Remove upper and lower intake manifolds.
9. Remove cylinder head covers and timing chain cover.
10. Remove water outlet connector (Fig. 16).
11. Rotate crankshaft until crankshaft sprocket timing mark aligns with timing mark on oil pump housing.
12. Remove primary timing chain.
13. Remove camshaft bearing caps gradually in REVERSE sequence of installation (10-1) (Fig. 17).
14. Remove camshafts and valvetrain components from cylinder head (Fig. 18). Note component locations for re-installation in original locations.
CAUTION: Ensure cylinder head bolts 11-9 (Fig. 19) are removed before attempting the removal of cylinder head, as damage to cylinder head and/or block may occur.
15. Remove cylinder head bolts in reverse sequence of installation (Fig. 19) starting with bolts 11-9, then bolts 8-1.
16. Remove cylinder head(s).
17. Remove and discard cylinder head gasket.
18. Clean cylinder head and block sealing surfaces.
CLEANING
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the aluminum head sealing surface.
Clean all engine oil passages.
INSPECTION
1. Before cleaning, check for leaks, damage and cracks.
2. Clean cylinder head and oil passages.
3. Check cylinder head for flatness (Fig. 20).
4. Cylinder head must be flat within:
- Standard dimension = less than 0.05 mm (0.002 inch)
- Service Limit = 0.2 mm (0.008 inch)
- Grinding Limit = Maximum of 0.2 mm (0.008 inch) is permitted.
CAUTION: 0.20 mm (0.008 inch) MAX is a combined total dimension of the stock removal limit from cylinder head and block top surface (Deck) together.
INSTALLATION
NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced (Fig. 21)
Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt must be replaced (Fig. 21)
CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.
1. Clean sealing surfaces of cylinder head and block.
2. Install new head gasket over locating dowels.
3. Install cylinder head to block, assuring head is properly positioned over locating dowels.
4. Lubricate bolt threads with clean engine oil and install bolts.
5. Tighten bolts in sequence shown in (Fig. 22), using the following steps and torque values:
- Step 1: Bolts 1-8 to 48 Nm (35 ft. lbs.)
- Step 2: Bolts 1-8 to 75 Nm (55 ft. lbs.)
- Step 3: Bolts 1-8 to 75 Nm (55 ft. lbs.)
Do not use a torque wrench for the next step.
- Step 4: Bolts 1-8 to +90° Turn
- Step 5: Bolts 9-11 to 28 Nm (250 in. lbs.)
6. Install all valvetrain components and camshafts. Tighten camshaft bearing caps in sequence shown in (Fig. 23) to 12 Nm (105 in. lbs.).
7. Install timing chain and sprockets.
8. Install water outlet connector.
9. Install cylinder head covers.
10. Install timing chain cover and crankshaft vibration damper.
11. Install lower and upper intake manifolds.
12. Install catalytic converter.
13. Install exhaust cross-under pipe.
14. Install accessory drive belts.
15. Fill cooling system.
16. Connect negative cable to remote jumper terminal.