Removal and Replacement
Cylinder Head
Cylinder Head (View 1 of 3)
Cylinder Head (View 2 of 3)
Cylinder Head (View 3 of 3)
Removal
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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 the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
NOTICE: 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.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Check the valve clearance. For additional information, refer to Valve Clearance Check Adjustments.
4. Remove the degas bottle.
5. Remove the catalytic converter.
6. Remove the generator.
7. Remove the fuel supply rail.
8. Remove the intake manifold. For additional information, refer to Intake Manifold Service and Repair.
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 radio frequency interference capacitor from the engine mount bracket.
12. Remove the engine mount bracket bolt.
13. Install the Engine Lifting Brackets and a suitable length of chain to the threaded hole in the LH side of the engine block.
14. Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in).
15. Remove the nut, 2 bolts and the engine mount.
16. Lower the engine 25 mm (0.98 in).
17. Remove the 2 nuts and the engine mount bracket.
18. Remove the timing drive components. For additional information, refer to Timing Drive Components Removal and Replacement.
19. Remove the Camshaft Alignment Plate.
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. NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTE: Mark the location and orientation of each camshaft bearing cap.
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. NOTICE: 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 Emission (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 Engine Coolant Temperature (ECT) electrical connector.
27. Disconnect the EGR valve electrical connector.
28. Disconnect the coolant hose from the EGR valve.
Vehicles with AIR
29. Remove the 2 bolts and position the AIR valve bracket aside.
All vehicles
30. Remove the 10 bolts and the cylinder head.
- Discard the bolts.
Installation
All vehicles
1. NOTICE: 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.
NOTICE: 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 in the following sequence.
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. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
3. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
4. Apply silicone gasket and sealant to the locations shown.
5. Install a new head gasket.
6. NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. New cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages:
- Stage 1: Tighten to 7 Nm (62 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Turn 90 degrees.
- Stage 5: Turn an additional 90 degrees.
Vehicles with AIR
7. Position AIR valve bracket and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
All vehicles
8. Connect the coolant hose to the EGR valve.
9. Connect the EGR valve electrical connector.
10. Connect the ECT electrical connector.
11. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
12. Attach the EVAP tube bundle retaining clip retaining clip.
13. NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.
14. NOTICE: 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 in their original location and orientation. Tighten the 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 lb-in).
- Stages 3: Tighten to 16 Nm (142 lb-in).
15. Install the Camshaft Alignment Plate.
16. Install the VCT solenoid and bolt.
- Tighten to 10 Nm (89 lb-in).
17. Install the timing drive components. For additional information, refer to Timing Drive Components Removal and Replacement.
18. Install the engine mount bracket and the 2 nuts.
- Tighten to 103 Nm (76 lb-ft).
19. Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in).
20. Install the engine mount, nut and 2 bolts.
- Tighten to 55 Nm (41 lb-ft).
21. Lower the engine 25 mm (0.98 in).
22. Install the engine mount bracket bolt.
- Tighten to 115 Nm (85 lb-ft).
23. Install the radio frequency interference capacitor and bolt to the engine mount bracket.
- Tighten to 10 Nm (89 lb-in).
Vehicles with AIR
24. Install the AIR pump and the 3 bolts.
- Tighten to 30 Nm (22 lb-ft).
25. Connect the AIR pump electrical connector.
All vehicles
26. Install the intake manifold. For additional information, refer to Intake Manifold Service and Repair.
27. Install the fuel supply rail.
28. Install the generator.
29. Install the catalytic converter.
30. Install the degas bottle.
31. Fill and bleed the engine cooling system.