Cylinder Head Replacement
CYLINDER HEAD AND GASKET REPLACEMENTTOOLS REQUIRED
- J 38122A Crankshaft Pulley Holder
- J 43405 Engine Support Fixture Adaptor
- J 44811 Accessory Belt Tensioner Unloader
- J 45027 Timing Chain Tensioner Unloader
- J 45122 Engine Support Adapter
- SA9105E Engine Three Bar Fixture
- SA9127E Gauge Bar Set
REMOVAL
1. Disconnect negative battery cable.
2. Disconnect Intake Air Temperature (IAT) sensor connector.
3. Loosen clamp at air cleaner assembly.
4. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
5. Loosen clamp at throttle body assembly.
6. Disconnect PVC fresh air vent hose at cam cover.
7. Remove outlet resonator/duct assembly.
8. Remove air cleaner assembly hold-down bolt.
9. Remove air cleaner assembly.
10. Remove ignition module bolts.
11. Remove ignition module assembly.
12. Disconnect ECM electrical connector and ground at ECM.
13. Remove oil level indicator bolt to manifold.
14. Disconnect electrical connector at throttle body.
15. Disconnect electrical connector at fuel injector harness and attachment at bottom of intake manifold.
16. Disconnect electrical connector at purge solenoid and MAP sensor.
17. Disconnect vacuum hose at brake booster.
18. Disconnect coolant pipe bracket bolts to front of cylinder head.
19. Disconnect degas hose at clamp at cylinder head and unclip from fuel rail. Position away from cam cover assembly.
20. Disconnect ground strap at rear of cam cover assembly.
21. Relieve fuel system pressure.
22. Disconnect Gauge Bar Set SA9127E after pressure has been relieved.
23. Disconnect fuel rail bracket and bolt at rear of cam cover.
CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING TO COLLECT FUEL. PLACE CLOTH IN AN APPROVED CONTAINER.
NOTICE: An open-end wrench must be used to support the fuel line-to-rail connection during loosening/tightening to avoid damaging the fuel rail assembly.
24. While supporting the fuel rail assembly with an open-end wrench, loosen transfer line fitting at fuel rail.
25. Position fuel line away from cam cover assembly.
26. Remove cam cover assembly bolts.
27. Remove cam cover assembly.
NOTICE: To avoid valve to piston contact, No. 1 piston must be positioned at approximately 60 degrees Before Top Dead Center (BTDC). Pistons are properly positioned when diamond shaped hole on intake camshaft sprocket is located at 12 o'clock.
IMPORTANT: To rotate camshaft(s), use a 24 mm open-end wrench on camshaft flats. Camshaft(s) should be rotated in a clockwise direction only (facing camshaft sprockets from passenger side of vehicle).
28. Locate the No. l piston to approximately 60 degrees before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove spark plugs. This will ease rotation effort.
29. Remove upper timing chain guide.
IMPORTANT: The timing chain tensioner must be removed to unload chain tension before timing chain is removed. If it is not removed, the timing chain may bind and be difficult to remove.
30. Remove timing chain tensioner.
31. Remove fixed timing chain guide access plug.
32. Using a magnetic socket, remove upper fixed guide bolt.
33. Install Engine Three Bar Fixture SA9105E set up for SUV application. (Also, use Engine Support Adapter J45122 with long hooks from Engine Support Fixture Adaptor J43405).
34. Remove right-hand engine mount-to-bracket bolts.
35. Remove right-hand mount assembly nuts.
36. Remove right-hand engine mount assembly.
37. Remove right-hand mount bracket.
38. Remove right-hand engine mount bracket.
39. Raise vehicle on hoist.
40. Remove right wheel and splash shield.
IMPORTANT: Do not rest engine assembly on oil pan plug on side of oil pan near crankshaft pulley or an oil leak may result.
41. Install block of wood (1x2x4) between oil pan and cradle.
42. Install Accessory Belt Tensioner Unloader J44811 tool.
43. Remove accessory drive belt.
44. Remove tensioner bolt. To remove bolt, an access hole has been provided through the inner and outer engine rail.
45. Remove tensioner assembly.
46. Install Crankshaft Pulley Holder J38122A.
IMPORTANT: The crankshaft balancer pulley bolt head and washer assembly prevents oil leakage at center of pulley. Do not damage sealing surfaces. If pulley cannot be removed by pulling with hand, use a three jaw puller.
47. Remove crankshaft balancer pulley bolt and pulley. Discard pulley bolt.
NOTICE: To avoid damage to the front cover assembly, do not pry against cover.
48. Remove front cover assembly bolts.
49. Remove lower water pump assembly bolt.
50. Remove front cover assembly and gasket.
51. Remove adjustable guide bolt.
52. Remove lower fixed guide bolt.
53. Remove fixed guide.
54. Drain coolant system.
55. Remove upper radiator hose from cylinder head.
56. Remove exhaust manifold pipe to manifold nuts.
57. Disconnect electrical connectors at front and rear oxygen sensors.
58. Remove down pipe to intermediate pipe nuts.
59. Remove down pipe assembly.
60. Lower vehicle.
NOTICE: The camshaft sprocket bolts are torque-to-yield bolts and are not reusable. They must be replaced when removed.
61. Use a 24 mm wrench to hold camshaft assembly while removing the exhaust sprocket bolt. Discard bolt.
62. Remove exhaust sprocket.
63. Remove adjustable guide through the top of cylinder head.
NOTICE: The camshaft sprocket bolts are torque-to-yield bolts and are not reusable. They must be replaced when removed.
64. Use a 24 mm wrench to hold camshaft assembly while removing intake sprocket bolt. Discard bolt.
65. Remove intake sprocket.
66. Remove timing chain assembly through top of cylinder head.
67. Remove timing chain drive sprocket from crankshaft.
NOTICE: Replace timing chain guides if wear exceeds 1.12 mm (0.045 inch).
68. Inspect timing chain guide for wear.
69. Inspect timing chain and sprockets for signs of excessive wear, chipping, or seizure to links on chain.
70. Install floor jack with block of wood and support engine at center of oil pan.
71. Remove engine three bar engine support fixture.
72. Remove cylinder head bolts using loosening sequence.
73. With assistance, remove cylinder head from block with exhaust and intake manifold attached.
INSTALLATION
NOTICE: Set crankshaft to 60 degrees before Top-Dead-Center (TDC) to prevent valves to piston contact.
1. Transfer all components (intake manifold, plugs, etc.) if new cylinder head is being installed.
2. Set crankshaft to 60 degrees before top dead center.
3. Install cylinder head gasket placing OPEN facing up.
IMPORTANT: Always use new cylinder head bolts.
4. With assistance, install cylinder head, aligning it onto cylinder head dowels.
5. Lightly apply clean engine oil to threads and to bottom side of flange of head bolts. Allow oil to drain before installing.
6. Install and torque cylinder head bolts in sequence.
Torque:
Cylinder Head Bolts: 30 N.m (22 ft. lbs.) + 155 degrees
7. Coat front cylinder head crankcase bolts with Permatex Threadlocker Blue P/N 21485278 or equivalent.
Torque:
Cylinder Head Front Chaincase Bolts: 35 N.m (26 ft. lbs.)
8. Position exhaust camshaft with offset slot to 2 o'clock position.
9. Position intake camshaft with offset slot to 11 o'clock position.
10. Install timing chain drive sprocket to crankshaft.
11. Using dampener, rotate crank so that mark on timing chain drive sprocket is at 5 o'clock position.
12. Assemble chain to intake camshaft sprocket aligning copper link to INT diamond timing mark on camshaft sprocket.
NOTICE: When lowering timing chain into cylinder head, rotate assembly 90 degrees to allow chain to fall between cylinder block bosses, then rotate assembly back so that camshaft sprocket is facing forward.
13. Lower assembly through chain housing opening on top of cylinder head. Use care to make sure that chain goes around both sides of cylinder block bosses.
NOTICE: The crankshaft sprocket timing mark will be at approximately 5 o'clock position.
14. Route chain around crankshaft sprocket and align silver link to timing mark.
NOTICE: The camshaft sprocket bolts are torque-to-yield bolts and are not reusable. They must be replaced when removed.
15. Install intake camshaft sprocket with chain in proper position to camshaft. Rotate intake camshaft using a 24 mm wrench on flats on camshaft until camshaft aligns with sprocket.
16. Install new intake camshaft sprocket bolt and finger tighten.
IMPORTANT: With timing chain aligned to crankshaft sprocket mark, the crankshaft can be rotated slightly to eliminate slack from the fixed side of timing chain. Be sure that marks are properly aligned.
IMPORTANT: Make sure crankshaft marks and camshaft marks aligns with colored links.
17. Install adjustable timing chain guide through opening at top of cylinder head and install chain guide bolt.
Torque:
Timing Chain Guide (Adjustable) Bolt: 10 N.m (89 inch lbs.)
18. Install exhaust camshaft sprocket loosely on exhaust camshaft with timing mark on sprocket aligned with silver link.
19. Install new camshaft sprocket bolt loosely.
20. Align exhaust camshaft sprocket with chain in proper position to camshaft. Rotate exhaust clockwise using a 24 mm wrench on flats on camshaft until camshaft aligns with sprocket.
21. Verify that all colored links are aligned with appropriate intake (1), crankshaft sprocket (2), and exhaust marks.
22. Verify crankshaft sprocket timing mark is at 5 o'clock.
23. If marks are not correct you must repeat timing procedure.
24. Install fixed timing chain guide and bolts.
Torque:
Timing Chain (Fixed) Bolts: 10 N.m (89 inch lbs.)
25. Apply thread sealant Permatex Thread Pipe Sealant (or equivalent) compound to thread. Install fixed guide bolt access hole plug.
Torque:
Timing Chain Guide Bolt Access Hole Plug: 40 N.m (30 ft. lbs.)
26. Install upper timing chain guide and bolts.
Torque:
Timing Chain Guide (Upper) Bolts: 10 N.m (89 inch lbs.)
NOTICE: Use a 24 mm wrench to support the camshaft while applying torque to camshaft sprocket bolt. Do not torque camshaft bolts against timing chain, as it may damage timing chain.
27. Tighten intake and exhaust camshaft sprocket bolts while holding camshaft with 24 mm wrench.
Torque:
Camshaft Sprocket Bolts: 85 N.m (63 ft. lbs.)+ 30 degrees
NOTICE: There is 1st and 2nd tensioner and guide assembly. A 2nd design tensioner assembly (notched style) should be used only with a 2nd design adjustable guide.
28. Measure timing chain tensioner assembly from end to end. A new tensioner should be supplied in a fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 inch) (a) from end-to-end. A tensioner in the active state will measure 85 mm (3.35 inch) (a) from end-to-end. If the tensioner is not in a compressed state, perform the following steps:
28.1. Hole the flat end of tensioner piston with Timing Chain Tensioner Unloader J45027.
28.2. Using timing chain tensioner unloader J45027, rotate piston clockwise slightly at which resistance will be felt and will collapse and lock in.
28.3. At this point tensioner should measure approximately 72 mm (2.83 inch) (a) from end-to-end. If tensioner does not read 72 mm, repeat this procedure.
29. Remove all thread material from timing chain tensioner hole.
30. Install timing chain tensioner.
Torque:
Timing Chain Tensioner: 75 N.m (55 ft. lbs.)
31. Timing chain tensioner is released by compressing it 2 mm (0.079 inch) which will release locking mechanism in ratchet. Tensioner can be released by one of two methods:
If engine has less than 48,279 km (30,000 miles) tensioner can be released by starting engine. This method cannot be used on engine with over 30,000 miles or cam chain may jump teeth on cam sprockets.
If engine has over 48,279 km (30,000 miles) on it use a suitable tool with a rubber tip on the end. Feed tool down through cam drive to rest on cam chain, giving a sharp jolt diagonally downward to release tensioner.
32. Raise vehicle if necessary.
33. Install new front cover gasket.
34. Install front cover assembly.
35. Install front cover assembly bolts.
Torque:
Front Cover-to-Block Bolts: 25 N.m (18 ft. lbs.)
36. Install front cover water pump bolt.
Torque:
Water Pump Bolts: 25 N.m (18 ft. lbs.)
37. Lubricate front seal and sealing surface of pulley with clean motor oil.
38. Install balancer pulley onto crankshaft indexing keyway. Use care to properly align flats on balancer pulley with flats on oil pump drive in front cover assembly.
39. Install crankshaft damper pulley.
40. Install new crankshaft balancer pulley bolt with washer assembly.
41. Install crankshaft pulley holder J38122.
Torque:
Crankshaft Pulley Bolt: 100 N.m (74 ft. lbs.) + 75 degrees
42. Install accessory drive belt tensioner.
Torque:
Drive Belt Tensioner Bolt: 50 N.m (37 ft. lbs.)
43. Route belt around alternator and A/C compressor.
44. Install accessory drive belt tool J39914 onto tensioner and unload spring tension from tensioner while positioning belt.
45. Release tensioner and remove tool.
46. Position manifold down pipe with gasket onto flange studs.
47. Install exhaust manifold pipe to exhaust manifold nuts.
Torque:
Exhaust Manifold Pipe to Exhaust Manifold Nuts: 30 N.m (22 ft. lbs.)
48. Attach electrical harnesses at bottom intake manifold.
49. Position oil level indicator into oil pan assembly.
50. Install oil level indicator tube bolt.
Torque:
Oil Level Indicator-to-Manifold Bolt: 11 N.m (89 inch lbs.)
51. Remove oil drain plug and drain oil.
Torque:
Oil Drain Plug: 25 N.m (18 ft. lbs.)
52. Lower vehicle.
53. Remove oil filter and install new oil filter.
54. Fill engine with oil.
Torque:
Oil Filter Cap: 25 N.m (18 ft. lbs.)
55. Install right-hand engine bracket and bolts.
Torque:
Engine Mount Bracket-to-Engine Bolts: 90 N.m (66 ft. lbs.)
56. Install right-hand engine mount onto body side rail studs.
57. Install right hand engine mount to body nuts.
Torque:
Engine Mount-to-Body Nuts: 110 N.m (81 ft. lbs.)
58. Install right-hand engine mount to engine mount bracket bolts.
Torque:
Engine Mount-to-Engine Mount Bracket Bolts: 55 N.m (41 ft. lbs.)
59. Remove support wood between engine cradle and oil pan.
60. Install right engine inner splash shield.
61. Install right wheel and hand-tighten wheel nuts.
62. Tighten wheel nuts.
Torque:
Wheel Nuts: 125 N.m (92 ft. lbs.)
63. Visually inspect camshaft cover gasket for signs of leakage. Camshaft cover gasket is reusable if not damaged.
64. Assemble camshaft cover and gasket using care to make sure that gasket is located in retaining groove on camshaft cover.
65. Install cover on cylinder head and tighten bolts.
Torque:
Camshaft Cover Bolts: 10 N.m (89 inch lbs.)
66. Position engine harness and install fasteners at cam cover.
67. Connect throttle body connector.
68. Attach ECM ground and ECM connector.
69. Connect fuel injector harness.
70. Connect upper radiator hose.
71. Connect brake booster hose at booster.
72. Connect EVAP purge hose and connector.
73. Connect oxygen sensors at exhaust manifold.
74. Re-position fuel line assembly.
NOTICE: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging fuel rail assembly.
75. Install transfer line fitting at fuel to fuel rail.
Torque:
Transfer Line Fitting-to-Fuel Rail: 10 N.m (89 inch lbs.)
76. Connect fuel rail bracket and bolt to cylinder head.
Torque:
Fuel Line Bracket Bolt: 10 N.m (89 inch lbs.)
77. Connect ground strap to camshaft cover assembly.
Torque:
Camshaft Cover Ground Strap Bolts: 10 N.m (89 inch lbs.)
78. Connect degas hose and attach to fuel rail.
79. Connect coolant pipe bracket bolts to cylinder head.
Torque:
Coolant Pipe Bracket Bolt: 10 N.m (89 inch lbs.)
80. Install spark plugs (if removed).
Torque:
Spark Plugs: 20 N.m (15 ft. lbs.)
81. Install ignition module assembly to cam cover and hand-tighten retaining bolts.
Torque:
Ignition Module-to-Camshaft Cover Bolts: 8 N.m (71 inch lbs.)
82. Install air cleaner assembly and bolt.
Torque:
Air Cleaner-to-Support Bracket Bolt: 10 N.m (89 inch lbs.)
83. Install outlet resonator/duct assembly into position.
84. Connect PCV fresh air vent hose assembly.
85. Tighten clamp at throttle body assembly.
86. Position outlet resonator/duct assembly up with support bracket and install push-pin.
87. Tighten clamp at air cleaner assembly.
88. Connect Intake Air Temperature (IAT) sensor connector.
89. Install coolant.
90. Connect negative battery cable.
Torque:
Battery Terminal Bolt: 17 N.m (13 ft. lbs.)
91. Start vehicle and inspect for leaks.