Cylinder Head Assembly: Service and Repair
Removal1. Remove the intake manifold.
2. Remove the engine sound insulator.
3. Remove the camshafts.
4. CAUTION: The shim and tappets are location-specific. Note the location so that they can be installed in their original locations or shims will have to be reselected during installation.
CAUTION: Do not use any means of marking the shims other than a permanent type marker. Any scratches or paint on the shims may result in incorrect lash adjustments and severe engine damage.
If necessary, remove the tappet bucket and shims.
5. Disconnect the clamp, remove the four bolts and the water outlet pipe.
6. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
7. Raise and support the vehicle.
8. Disconnect the Three-Way Catalytic (TWC) Converter from the exhaust manifolds.
9. Disconnect the EGR valve to exhaust manifold tube.
10. Lower the vehicle.
11. Remove the bolts from the rear of the cylinder head.
12. Remove the bolts.
13. Remove the RH bolts in the sequence shown.
14. Remove the RH cylinder head.
^ Discard the gasket.
15. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
Clean the sealing surfaces.
16. Remove the stud bolts from the rear of the cylinder head.
17. Remove the bolts.
18. Note: The lower rear bolt cannot be fully removed. This bolt must be retained above the decking surface with a rubber band to remove the LH cylinder head.
Remove the bolts in the sequence shown.
19. Remove the LH cylinder head.
^ Discard the gasket.
20. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
Clean the sealing surfaces.
21. Remove the RH exhaust manifold bolts.
^ Discard the gasket.
22. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
Clean the sealing surfaces.
23. Remove the LH exhaust manifold.
^ Discard the gasket.
24. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
Clean the sealing surfaces.
Installation
1. Install the LH exhaust manifold.
^ Install a new gasket.
2. Install the RH exhaust manifold.
^ Install a new gasket.
3. Note: The lower rear bolt cannot be installed with the cylinder head in place. Secure the bolt above deck height with a rubber band prior to cylinder head installation. Position the LH cylinder head.
Install a new gasket.
Left Side:
4. Install and tighten the bolts in five stages in the sequence shown.
^ Stage 1: Install finger-tight.
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 4: Tighten to 45 Nm (33 ft. lbs.) and an additional 90°.
^ Stage 5: Tighten an additional 90°.
5. Install the bolts on the rear of the cylinder head.
6. Install and tighten the bolts in two stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90°.
7. Position the RH cylinder head. Install a new gasket.
Right Side:
8. Install and tighten the bolts in five stages in the sequence shown.
^ Stage 1: Install finger-tight.
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 4: Tighten to 45 Nm (33 ft. lbs.) and an additional 90°.
^ Stage 5: Tighten an additional 90°.
9. Install the stud bolts on the rear of the cylinder head.
10. Install and tighten the bolts in two stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90°.
11. CAUTION: The shim and tappets are location-specific. They must be installed in their original locations or shims will have to be reselected during installation.
CAUTION: Do not use any means of marking the shims other than a permanent type marker. Any scratches or paint on the shims may result in incorrect lash adjustments and severe engine damage.
CAUTION: If a new cylinder head assembly is being installed, valve clearances must be adjusted or damage to the engine may occur.
Install the tappets and shims.
12. Raise the vehicle.
13. Connect the EGR valve to exhaust manifold tube.
14. Connect the TWC to the exhaust manifolds.
15. Lower the vehicle.
16. Connect the CHT sensor electrical connector.
17. Note: Make sure that the insulator is clear of the intake manifold sealing surfaces.
Install the engine sound insulator.
18. Install the water crossover and tighten the four bolts and connect the hose.
19. Install the camshafts.
20. Install the intake manifold.