Removal and Installation
CYLINDER HEADREMOVAL
1. Perform fuel pressure release procedure before attempting any repairs.
2. Disconnect negative cable from battery (1).
3. Raise vehicle on hoist.
4. Drain cooling system.
5. Remove accessory drive belt (5).
6. Remove the vibration damper.
7. Disconnect camshaft position sensor (2), and coolant temperature sensor (1) connectors.
8. Remove upper intake manifold.
9. Disconnect coils (3), capacitors, and injector connectors (2).
10. Reposition harness out of the way.
11. Disconnect fuel feed line (1).
12. Remove lower intake manifold.
13. Remove cylinder head covers.
14. Remove coolant outlet (3).
15. Remove timing chain cover (4).
16. Rotate crankshaft until crankshaft sprocket timing mark aligns with timing mark on oil pump housing (2).
17. Remove primary timing chain (7).
18. Remove upper primary timing chain guides (10).
19. Remove camshaft bearing caps gradually in the sequence shown.
20. Remove camshafts (3 & 10) and valvetrain components from cylinder head. Note component locations for reinstallation in original locations.
21. For left cylinder head removal: Remove fastener securing engine oil dipstick tube to cylinder head. Remove engine oil dipstick tube. Remove generator.
22. For right cylinder head removal:
^ Remove cylinder head ground strap.
^ Disconnect EGR valve electrical connector and remove EGR valve from head.
CAUTION: Ensure cylinder head bolts 1 - 3 are removed before attempting the removal of cylinder head, as damage to cylinder head and/or block may occur.
23. Remove cylinder left head bolts (2) and right head bolts (1) in sequence shown.
24. Remove cylinder head(s).
25. Remove and discard cylinder head gasket.
26. Clean cylinder head and block sealing surfaces.
CLEANING
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the aluminum head sealing surface.
Clean all engine oil passages.
INSPECTION
1. Before cleaning, check for leaks, damage and cracks.
2. Clean cylinder head and oil passages.
3. Check cylinder head for flatness.
4. Cylinder head must be flat within:
Standard dimension = less than 0.05 mm (0.002 inch.)
Service Limit = 0.2 mm (0.008 inch.)
Grinding Limit = Maximum of 0.2 mm (0.008 inch.) is permitted.
CAUTION: 0.20 mm (0.008 inch) MAX is a combined total dimension of the stock removal limit from cylinder head and block top surface (Deck) together.
INSTALLATION
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 must be replaced
Necking can be checked by holding a straight edge against the threads (3). If all the threads do not contact the scale (2), the bolt must 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 for left head (2) and right head (1), 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. For left cylinder head installation:
^ Install engine oil dipstick tube.
^ Install generator.
7. For right cylinder head Installation:
^ Install cylinder head ground strap.
^ Install EGR valve (if equipped).
8. Install all valvetrain components and camshafts. Tighten camshaft bearing caps in sequence shown to 12 Nm (105 inch lbs.).
9. Install primary timing chain (7), guides (2,5,10) and sprockets (9).
10. Install coolant outlet (3).
11. Install lower intake manifold.
12. Install cylinder head covers.
13. Connect camshaft position sensor (2) and coolant temperature sensor (1) connectors.
14. Install timing chain cover.
15. Install crankshaft vibration damper.
16. Install upper intake manifold.
17. Connect oil pressure sensor (1) connector.
18. Install accessory drive belt (5).
19. Fill cooling system.
20. Connect negative battery (1) cable.
21. Start engine and check for leaks.