Cylinder Head Removal and Installation

This article has been updated with bulletin No: 99-06-01-016.



TOOL REQUIRED
^ J 28410 Gasket Remover

REMOVAL





1. Remove the engine.
2. Remove the following subassemblies:
^ The intake manifold.
^ The left side cam cover.
^ The right side cam cover.
^ The crankshaft balancer.
^ The engine front cover.
3. Align the timing marks.
4. Remove the chain tensioner from the timing chain for the cylinder head being removed.
5. Remove the cam sprockets from the head being removed. The timing chain remains in the chain case.
6. Remove the timing chain guides. Access to the retaining screws is through the plugs at the front of the cylinder head.
7. Remove the water crossover.
8. Remove the left exhaust manifold. See Exhaust System.
9. Remove the right exhaust manifold. See Exhaust System.

CAUTION: Do not reuse the head bolts after removal. New bolts have a special coating used for bolt retention after installation. This coating remains in the cylinder block threads after removal so proper cleaning of the cylinder block threads is important.

10. Remove and discard the cylinder head bolts.

CAUTION: With the camshafts remaining in the cylinder head some valves will be open at all times. For this reason the cylinder head cannot rest on a flat surface with the cylinder face down, or valve damage will result.

11. Remove the cylinder head gasket.

CAUTION: Carefully clean the aluminum gasket surfaces in order to prevent damage to the sealing surfaces. Use only plastic, wood, or dull gasket scrapers, such as Gasket Remover. Follow the manufacturer's recommendations to dissolve gasket materials with chemical agents.

12. Clean the gasket surfaces.
13. Clean the combustion chambers.
14. Clean the head bolt threads in the cylinder block with a soft brush or the equivalent.

WARNING: Wear safety glasses In order to avoid eye damage.

15. Clean the head bolt bosses in the cylinder head with compressed air.

INSTALLATION
1. Install the new cylinder head gasket.
2. Install the cylinder head.
3. Install ten new M11 and three M6 head bolts. The M6 bolts can be reused.









4. The torque specification and sequence for the cylinder head bolts (1--10) using J 36660-A is:
a. First Pass 40 Nm (30 lb. ft.).
b. Second Pass 70 Degrees.
c. Third Pass 60 Degrees.
d. Fourth Pass 60 Degrees (190 Degrees total).
e. The 3 front M6 cylinder head bolts 12 Nm (106 lb. in.).
5. Install the camshaft.
6. Set the camshaft timing.
7. Install the camshaft guide bolt access hole plugs in the cylinder heads. The plugs should be seated and snug.
8. Install the engine front cover.
9. Install the intake manifold.
10. Install the left side cam cover.
11. Install the right side cam cover.
12. Install the crankshaft balancer.
13. Install the right exhaust manifold. See Exhaust System.
14. Install the left exhaust manifold.
15. Install the water crossover.
16. Install the powertrain assembly. See Powertrain Management.