Cylinder Head Assembly: Service and Repair

REMOVAL
1. Perform fuel pressure release procedure before attempting any repairs.
2. Disconnect negative cable from remote jumper terminal.
3. Drain cooling system and remove A/C and accessory drive belts. Refer to Cooling System.
4. Remove crankshaft damper.
5. Remove intake plenum and lower intake manifold.
6. Remove cylinder head cover and timing chain cover.

Figure 45-Water Outlet Connector:

7. Remove water outlet connector. Refer to Cooling System.
8. Rotate crankshaft until crankshaft sprocket timing mark aligns with timing mark on oil pump housing.
9. Remove primary timing chain.

Figure 48 Camshaft Bearing Cap Tightening Sequence:

10. Remove camshaft bearing caps gradually in reverse sequence of installation.
11. Remove camshafts from cylinder head.

Figure 47 Cylinder Head Tightening Sequence:

CAUTION: Ensure cylinder head bolts 11 - 9 are removed before attempting the removal of cylinder head as damage to cylinder head and/or block may occur.

12. Remove cylinder head bolts in reverse sequence of installation starting with bolts 11 - 9, then bolts 8 - 1.

13. Remove cylinder head(s).

INSTALLATION

Figure 46-Checking Cylinder Head Bolts For Stretching(Necking):

NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.

Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced.

CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.

1. Clean sealing surfaces of cylinder head and block.
2. Install new head gasket over locating dowels.
3. Install cylinder head to block, assuring head is properly positioned over locating dowels.
4. Lubricate bolt threads with clean engine oil and install bolts.
5. Tighten bolts in sequence shown in , using the following steps and torque values:
- Step 1: Bolts 1 - 8 to 48 Nm (35 ft. lbs.)
- Step 2: Bolts 1 - 8 to 75 Nm (55 ft. lbs.)
- Step 3: Bolts 1 - 8 to 75 Nm (55 ft. lbs.)
- Step 4: Bolts 1 - 8 to +90° Turn Do not use a torque wrench for this step.
- Step 5: Bolts 9 - 11 to 28 Nm (250 inch lbs.)

6. Install camshafts.
7. Install timing chain and sprockets.
8. Install water outlet connector. Refer Cooling System.
9. Install cylinder head covers.
10. Install timing chain cover and crankshaft damper
11. Install lower intake manifold and intake plenum.
12. Install A/C and accessory drive belts. Refer to Cooling System.
13. Fill cooling system. Refer to Cooling System.
14. Connect negative cable to remote jumper terminal.