Cylinder Head

Cylinder Head





Material








Removal

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the engine cooling system.
3. Remove the camshafts.
4. Remove the intake manifold.
5. Remove the catalytic converter.
6. Disconnect the radio ignition interference capacitor electrical connector.
7. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
8. Disconnect the EGR coolant hose from the EGR valve.
9. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
10. Remove the bolts and the and the cylinder head.
^ Discard the bolts.

Installation

1. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. Inspect the cylinder head for distortion.





3. Apply silicone gasket and sealant to the locations shown.
4. Install a new head gasket.





5. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

NOTE: Lubricate the bolts with clean engine oil prior to installation. Install new cylinder head bolts.

Tighten the bolts in the sequence shown in 5 stages:
1. Tighten to 5 Nm (44 inch lbs.).
2. Tighten to 15 Nm (11 ft. lbs.).
3. Tighten to 45 Nm (33 ft. lbs.).
4. Turn 90 degrees.
5. Turn an additional 90 degrees.

6. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
7. Connect the EGR coolant hose to the EGR valve.
8. Connect the exhaust gas recirculation (EGR) valve electrical connector.
9. Connect the radio ignition interference capacitor electrical connector.
10. Install the catalytic converter.
11. Install the intake manifold.
12. Install the camshafts.
13. Fill and bleed the engine cooling system.