Cylinder Head
Cylinder HeadSpecial Tool(s):
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.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction.
3. Check the valve clearance.
4. Remove the degas bottle. For additional information, refer to Cooling System.
5. Remove the catalytic converter. For additional information, refer to Catalytic Converter.
6. Remove the generator. For additional information, refer to Alternator.
7. Remove the fuel supply rail. For additional information, refer to Fuel Delivery and Air Induction.
8. Remove the intake manifold.
Vehicles with secondary air injection (AIR)
9. Disconnect the secondary air injection (AIR) pump electrical connector.
10. Remove the 3 bolts and position the AIR pump aside.
All vehicles
11. Remove the bolt and the ground wire from the engine mount bracket.
12. Remove the engine mount bracket bolt.
13. Install the special tool and a suitable length of chain to the threaded hole in the LH side of the engine block.
14. Install the special.
^ Using the special tool, lift the engine 25 mm (0.98 inch).
15. Remove the nut, 2 bolts and the engine mount.
16. Lower the engine 25 mm (0.98 inch).
17. Remove the 2 nuts and the engine mount bracket.
18. Remove the timing drive components.
19. Remove the special tool.
20. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
21. Remove the bolt and the variable camshaft timing (VCT) solenoid.
22. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
Remove the camshafts from the engine.
^ Loosen the camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps.
^ Remove the bolts and the camshaft bearing caps.
^ Remove the camshafts.
23. CAUTION: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
Remove and inspect the valve tappets.
24. Detach the retaining clip and position the evaporative emissions (EVAP) tube bundle aside.
25. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
26. Disconnect the engine coolant temperature sensor (ECT) electrical connector.
27. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
28. Disconnect the coolant hose from the EGR valve.
Vehicles with secondary air injection (AIR)
29. Remove the 2 bolts and position AIR valve bracket aside.
All vehicles
30. Remove the 10 bolts and the cylinder head.
^ Discard the bolts.
Installation
All vehicles
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 10 new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages:
^ Stage 1: Tighten to 7 Nm (62 inch lbs.).
^ Stage 2: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 3: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 4: Turn 90 degrees.
^ Stage 5: Turn an additional 90 degrees.
Vehicles with secondary air injection (AIR)
6. Position AIR valve bracket and install the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
All vehicles
7. Connect the coolant hose to the EGR valve.
8. Connect the EGR valve electrical connector.
9. Connect the ECT electrical connector.
10. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
11. Attach the EVAP tube bundle retaining clip retaining clip.
12. NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.
13. CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
Install the camshafts and bearing caps. Tighten the camshaft bearing caps in the sequence shown in 3 stages:
^ Stages 1: Tighten the camshaft bearing cap bolts until finger tight.
^ Stages 2: Tighten to 7 Nm (62 inch lbs.).
^ Stages 3: Tighten to 16 Nm (12 ft. lbs.).
14. Install the special tool.
15. Install the VCT solenoid and bolt.
^ Tighten to 10 Nm (89 inch lbs.).
16. Install the timing drive components.
17. Install the engine mount bracket and the 2 nuts.
^ Tighten to 103 Nm (76 ft. lbs.).
18. Using the special too, lift the engine 25 mm (0.98 inch).
19. Install the engine mount, nut and 2 bolts.
^ Tighten to 55 Nm (41 ft. lbs.).
20. Lower the engine 25 mm (0.98 inch).
21. Install the engine mount bracket bolt.
^ Tighten to 115 Nm (85 ft. lbs.).
22. Install the ground wire and bolt to the engine mount bracket.
^ Tighten to 10 Nm (89 inch lbs.).
Vehicles with secondary air injection (AIR)
23. Install the AIR pump and the 3 bolts.
^ Tighten to 30 Nm (22 ft. lbs.).
24. Connect the AIR pump electrical connector.
All vehicles
25. Install the intake manifold.
26. Install the fuel supply rail. For additional information, refer to Fuel Delivery and Air Induction.
27. Install the generator. For additional information, refer to Alternator.
28. Install the catalytic converter. For additional information, refer to Catalytic Converter.
29. Install the degas bottle. For additional information, refer to Cooling System.
30. Fill and bleed the engine cooling system. For additional information, refer to Cooling System.