Removal and Replacement
Cylinder Head
Degas Bottle
Engine Mount
Camshafts
Cylinder Head
Removal
NOTICE: 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 is also unfastened if the pulley bolt is loosened. 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.
NOTICE: 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.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.
2. Release the fuel system pressure. For additional information, refer to Fuel System - General Information Service and Repair.
3. Check the valve clearance. For additional information, refer to Valve Clearance Check Adjustments.
4. Drain the engine cooling system. For additional information, refer to Engine Cooling Service and Repair.
5. Disconnect the degas bottle-to-radiator hose from the degas bottle.
6. Remove the nut and bolt and position the degas bottle to access the lower degas bottle hose.
7. Disconnect the lower degas bottle hose and remove the degas bottle.
8. Remove the generator. For additional information, refer to Charging System Service and Repair.
9. Remove the fuel supply rail. For additional information, refer to Fuel Charging and Controls - 2.5L Fuel Rail.
10. Remove the intake manifold. For additional information, refer to Intake Manifold Service and Repair.
11. Remove the exhaust manifold. For additional information, refer to Exhaust Manifold Removal and Replacement.
12. Remove the bolt and the engine mount damper from the engine mount bracket.
13. Remove the bolt and the ground wire from the engine mount bracket.
14. Remove the engine mount bracket bolt.
15. Install the Engine Lifting Brackets and a suitable length of chain to the threaded hole in the LH side of the engine block.
16. Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in).
17. Remove the nut, 2 bolts and the engine mount.
18. Lower the engine 25 mm (0.98 in).
19. Remove the 2 nuts and the engine mount bracket.
20. Remove the timing drive components. For additional information, refer to Timing Drive Components Removal and Replacement.
21. Remove the Camshaft Alignment Plate.
22. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
23. Remove the bolt and the Variable Camshaft Timing (VCT) solenoid.
24. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTE: Mark the location and orientation of each camshaft bearing cap.
Remove the camshafts from the engine.
- Loosen the camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps.
- Remove the bolts and the camshaft bearing caps.
- Remove the camshafts.
25. NOTE: 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.
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.
Remove and inspect the valve tappets. For additional information, refer to Engine System - General Information Valve Tappet Inspection.
26. Disconnect the upper radiator hose, coolant bypass hose and heater hose from the engine coolant outlet.
27. Disconnect the EGR valve electrical connector.
28. Disconnect the coolant hose from the EGR valve.
29. Remove the 10 bolts and the cylinder head.
- Discard the bolts.
- Discard the cylinder head gasket.
Installation
1. NOTICE: 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.
NOTICE: 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 in the following sequence.
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. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to Engine System - General Information Cylinder Head Distortion Cylinder Block Distortion.
4. Apply silicone gasket and sealant to the locations shown.
5. Install a new cylinder head gasket.
6. NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. New cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages:
- Stage 1: Tighten to 7 Nm (62 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Turn 90 degrees.
- Stage 5: Turn an additional 90 degrees.
7. Connect the coolant hose to the EGR valve.
8. Connect the EGR valve electrical connector.
9. Connect the upper radiator hose, coolant bypass hose and heater hose to the engine coolant outlet.
10. NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.
11. NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position 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 in their original locations and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
- Stages 1: Tighten the camshaft bearing cap bolts until finger-tight.
- Stages 2: Tighten to 7 Nm (62 lb-in).
- Stages 3: Tighten to 16 Nm (142 lb-in).
12. Install the Camshaft Alignment Plate.
13. Install the VCT solenoid and bolt.
- Tighten to 10 Nm (89 lb-in).
14. Install the timing drive components. For additional information, refer to Timing Drive Components Removal and Replacement.
15. Install the engine mount bracket and the 2 nuts.
- Tighten to 103 Nm (76 lb-ft).
16. Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in).
17. Install the engine mount, nut and 2 bolts.
- Tighten to 55 Nm (41 lb-ft).
18. Lower the engine 25 mm (0.98 in).
19. Install the engine mount bracket bolt.
- Tighten to 115 Nm (85 lb-ft).
20. Install the ground wire-to-engine mount bracket and bolt.
- Tighten to 10 Nm (89 lb-in).
21. Install the engine mount damper and the bolt.
- Tighten to 23 Nm (17 lb-ft).
22. Install the exhaust manifold. For additional information, refer to Exhaust Manifold Removal and Replacement.
23. Install the intake manifold. For additional information, refer to Intake Manifold Service and Repair.
24. Install the fuel supply rail. For additional information, refer to Fuel Charging and Controls - 2.5L Fuel Rail.
25. Install the generator. For additional information, refer to Charging System Service and Repair.
26. Connect the lower degas bottle hose to the degas bottle.
27. Install the degas bottle and the nut and bolt.
- Tighten to 9 Nm (80 lb-in).
28. Connect the degas bottle-to-radiator hose.
29. Fill and bleed the engine cooling system. For additional information, refer to Engine Cooling Service and Repair.