Cylinder Head
Cylinder HeadSpecial Tool(s):
Material:
Removal
CAUTION: 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 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 bolt. 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.
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.
All engines
1. Release the fuel system pressure.
2. Remove the battery tray.
3. Drain the cooling system.
4. Check the valve clearance.
5. Remove the nuts and disconnect the catalytic converter from the exhaust assembly.
^ Remove and discard the gasket.
6. Remove the 2 bolts and the catalytic converter support bracket from the engine.
7. NOTE: All 2.3L engines and some 2.0L engines are equipped with a heat shield that must be positioned aside to access the catalytic converter-to-engine nuts.
If equipped, remove the 4 heat shield bolts and position the heat shield aside.
8. Disconnect the exhaust sensor electrical connectors.
9. Remove and discard the catalytic converter-to-engine nuts.
^ Position aside the catalytic converter and support with mechanic's wire.
^ Remove and discard the catalytic converter gasket.
10. Remove the generator.
11. Remove the fuel injection supply manifold.
12. Remove the intake manifold.
13. Remove the timing drive components.
14. Remove the special tool.
15. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
16. 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 sequence, one turn at a time.
^ Repeat the first step until all tension is released from the camshaft bearing caps.
^ Remove the camshaft bearing caps.
^ Remove the camshafts.
17. 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.
Remove the valve tappets.
18. 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.
Inspect the valve tappets.
2.0L engines
19. If equipped, disconnect the secondary air injection (AIR) vacuum regulator electrical connector and vacuum hose.
20. If equipped, disconnect the hoses from the AIR control valve.
21. If equipped, disconnect the upper exhaust sensor electrical connector and retainer.
All engines
22. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
23. Disconnect the coolant hoses from the coolant bypass.
24. Remove the 4 bolts, coolant bypass and gasket.
^ Discard the gasket.
25. Disconnect the EGR coolant hose.
26. Remove the bolts and the cylinder head.
^ Discard the bolts.
27. Remove and discard the head gasket.
28. Inspect the cylinder head mating surfaces.
Installation
All engines
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. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
3. Inspect the cylinder head for distortion.
4. Apply silicone gasket and sealant to the locations shown.
5. Install a new head gasket.
6. 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.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 3: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 4: Turn 90°.
^ Stage 5: Turn an additional 90°.
7. Install the EGR coolant hose.
8. Using a new gasket, install the coolant bypass and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
9. Connect the coolant hoses onto the coolant bypass.
10. Connect the EGR valve electrical connector.
11. Clean and inspect the catalytic converter flange.
^ Using a straightedge and a feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
12. Using a new gasket and 7 nuts, install the catalytic converter.
^ Tighten to 55 Nm (41 ft. lbs.).
13. Connect the exhaust sensor electrical connectors.
14. NOTE: All 2.3L engines and some 2.0L engines are equipped with a heat shield that must be positioned aside to access the catalytic converter-to engine nuts.
If equipped, position the heat shield and install the 4 heat shield bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
15. Install the catalytic converter support bracket and the 2 bolts to the engine.
^ Tighten to 47 Nm (35 ft. lbs.).
2.0L engines
16. If equipped, connect the upper exhaust sensor electrical connector and retainer.
17. If equipped, connect the hoses to the AIR control valve.
18. If equipped, connect the AIR vacuum regulator electrical connector and vacuum hose.
All engines
19. NOTE: Lubricate the valve tappets with clean engine oil.
Install the valve tappets in their original positions.
20. CAUTION: Install the camshafts with the alignment notches in the camshafts lined up so the camshaft alignment plate can be installed. Make sure the lobes on the No. 1 cylinder are in the same position at noted in the removal procedure. Failure to follow this procedure 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 bolts in the sequence shown in 3 stages.
^ Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until the cam is fully seated.
^ Stage 2: Tighten the bolts to 7 Nm (62 inch lbs.).
^ Stage 3: Tighten the bolts to 16 Nm (12 ft. lbs.).
21. Install the timing drive components.
22. Install the intake manifold.
23. Install the fuel injector supply manifold.
24. Install the generator.
25. Connect the radio interference capacitor electrical connector.
26. Install the dual cooling fans and connect the electrical connectors.
27. Install the battery tray.
28. Drain the engine oil and change the filter.
^ Tighten the plug to 28 Nm (21 ft. lbs.).
29. Fill the engine with clean engine oil.
30. Fill and bleed the cooling system.
31. Fill the power steering system.