Cylinder Head Assembly: Service and Repair

Cylinder
Head
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures

Removal
1 Remove the cover and disconnect the battery ground cable.
For additional information, refer to Specifications [1][2]Specifications

WARNING: Make
sure to support the vehicle with axle stands.
2 Raise and support the vehicle.
3 Remove the fuel rail.
For additional information, refer to Fuel Rail Service and Repair
4 Remove the generator.
For additional information, refer to Generator - 3.2L Service and Repair
5 Remove both exhaust manifolds.
For additional information, refer to Exhaust Manifold Service and Repair
6 Remove the camshafts.
For additional information, refer to Camshafts Service and Repair




7 Release the fuel pipe.




8 Release the engine wiring harness clips.




9 Remove the spark plugs.





CAUTION: Mark the components to aid installation.

CAUTION: Extreme cleanliness must be exercised when handling these components.

10 Remove the 12 two-stage hydraulic lash adjusters.





CAUTION: Mark the components to aid installation.

CAUTION: Extreme cleanliness must be exercised when handling these components.

11 Remove the 12 tappets.









12 Remove and discard the 14 cylinder head bolts.

NOTE:
This step requires the aid of another technician.

13 Remove the cylinder head.





14 Remove and discard the cylinder head gasket.





NOTE:
Make sure that these components are installed to the noted removal position.
Remove the dowels.
Check that the cylinder block water jacket restrictors are installed.

Installation
1 Install the dowels.
2 Clean and inspect the cylinder head and cylinder block.




3 Check cylinder head face for distortion, across the center and from corner to corner.
For additional information, refer to Specifications [1][2]Mechanical Specifications

CAUTION: The head gasket must be installed over the cylinder block dowels.
4 Install a new cylinder head gasket.

CAUTION: Make sure that the component is correctly located on the locating dowels.

NOTE:
This step requires the aid of another technician.
5 Install the cylinder head.





CAUTION: Make sure that new cylinder head bolts are installed.

CAUTION: Take extra care not to damage the mating faces.

NOTE:
The cylinder head tightening process is carried out once to 45 Nm, then the bolts are loosened and the final torque and angle applied.

NOTE:
The cylinder head tightening process is carried out once to 45 Nm, then the bolts are loosened and the final torque and angle applied.
Tighten the cylinder head bolts in the sequence shown.
Torque to: 45 Nm
Check the cylinder head bolt torque in the sequence shown.
Torque to: 45 Nm
Tighten the cylinder head bolts in the sequence shown.
Torque to: 90 degree
Tighten the cylinder head bolts in the sequence shown.
Torque to: 180 degree





CAUTION: Make sure that the choke valves (1), (2) are in place.

CAUTION: Extreme cleanliness must be exercised when handling these components.

CAUTION: Make sure that these components are installed to the noted removal position.
6 Install the tappets.

CAUTION: Extreme cleanliness must be exercised when handling these components.

CAUTION: Make sure that these components are installed to the noted removal position.
7 Install the lash adjusters.
8 Install the engine wiring harness clips.
Torque to: 6 Nm
9 Install the spark plugs.
Torque to: 28 Nm

10 Secure the fuel line.
Torque to: 10 Nm

11 Install the camshafts.
For additional information, refer to Camshafts Service and Repair

12 Install the generator.
For additional information, refer to Generator - 3.2L Service and Repair

13 Install the fuel rail.
For additional information, refer to Fuel Rail Service and Repair

14 Install both exhaust manifolds.
For additional information, refer to Exhaust Manifold Service and Repair

15 Connect the battery ground cable and install the cover.
For additional information, refer to Specifications [1][2]Specifications