Cylinder Head Assembly: Service and Repair

Cylinder Head





Material

Removal
1. Disconnect the battery ground cable.
2. Drain the cooling system.

3. 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.

CAUTION: 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 you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe damage can occur.

Remove the camshafts.
4. Remove the catalytic converter.
5. Remove the fuel injection supply manifold.
6. Remove the intake manifold.





7. Remove the fuel injection supply manifold spacers.





8. Disconnect the exhaust gas recirculation (EGR) vacuum regulator electrical connector.





9. Remove the hoses from the air control valve.





10. Disconnect the EGR valve electrical connector.





11. Remove the coolant hoses from the coolant bypass.





12. Remove the coolant bypass.
1. Remove the coolant bypass lower hose.
2. Remove the coolant bypass bolts and the coolant bypass.





13. Disconnect the EGR coolant hose.





14. Disconnect the radio interference capacitor.





15. Remove the bolts and the cylinder head.
^ Discard the bolts.





16. Remove and discard the head gasket.
17. Inspect the cylinder head mating surfaces.

Installation

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 which make leak paths.

Clean the cylinder head gasket surfaces with metal surface cleaner.





2. Apply silicone gasket and sealant to the locations shown.





3. Install a new head gasket.





4. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

NOTE: Lubricate the cylinder head bolts with clean engine oil.

Install the cylinder head and new bolts. Tighten the bolts in the sequence shown in five stages.
^ Stage 1: Tighten the bolts to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten the bolts to 15 Nm (11 ft. lbs.).
^ Stage 3: Tighten the bolts to 45 Nm (33 ft. lbs.).
^ Stage 4: Turn the bolts 90 degrees.
^ Stage 5: Turn the bolts an additional 90 degrees.





5. Connect the radio interference capacitor electrical connector.





6. Install the EGR coolant hose.





7. Install the coolant bypass.
1. Install the coolant bypass and the bolts.
2. Install the coolant bypass lower hose.





8. Install the coolant hoses onto the coolant bypass.





9. Connect the EGR valve electrical connector.





10. Install the air control valve hoses.





11. Connect the EGR vacuum regulator electrical connector.





12. Install the fuel injector supply manifold spacers.
13. Install the intake manifold.
14. Install the fuel injector supply manifold.
15. Install the catalytic converter.
16. Install the camshafts.
17. Connect the battery ground cable.
18. Fill and bleed the cooling system.