Cylinder Head Assembly: Service and Repair

Cylinder Head Replacement

Removal Procedure





1. Remove the fuel pump fuse.

2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.

Caution:
Refer to Battery Disconnect Caution Battery Disconnect Caution in Cautions and Notices.

3. Disconnect the negative battery cable.

4. Drain the engine coolant. Refer to Cooling System Draining and Filling (2.5L) Service and Repair.

5. Drain the engine oil.

6. Drain the transaxle oil.





7. Drain the power steering oil.

8. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.

9. Remove the engine assembly. Refer to Engine Replacement Removal and Replacement.

10. Remove the timing chain. Refer to Camshaft Timing Chain and Sprocket Replacement Service and Repair.

11. Remove the intake manifold support bracket.





12. Remove the power steering pump.





13. Remove the alternator. Refer to Generator Replacement (2.5L) Removal and Replacement.

14. Remove the upper pad bracket bolts and the upper pad bracket.





15. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement Service and Repair in Engine Controls-2.5L.

16. Remove the EGR pipes. Refer to Exhaust Gas Recirculation Valve Pipe Replacement (Exhaust) Exhaust Gas Recirculation Valve Pipe Replacement (Exhaust)Exhaust Gas Recirculation Valve Pipe Replacement (Intake) Exhaust Gas Recirculation Valve Pipe Replacement (Intake) in Engine Controls-2.5L.

17. Remove the EGR adapter.





18. Remove the heater pipe.

19. Remove the exhaust manifold. Refer to Exhaust Manifold Removal 1. Exhaust Manifold Removal.

20. Remove the exhaust manifold gasket.

21. Remove the camshaft position (CMP) sensor. Refer to Camshaft Position Sensor Replacement Service and Repair in Engine Controls-2.5L.

22. Remove the engine coolant temperature (ECT) sensor. Refer to Engine Coolant Temperature Sensor Replacement Service and Repair in Engine Controls-2.5L.

23. Remove the coolant outlet port.





Notice:
Use extreme care when removing the cylinder head to prevent any engine oil , dirt, or coolant from entering the engine. Damage to the engine could result.

24. Remove the cylinder head bolts in sequence shown and the cylinder head.

25. Remove the cylinder head gasket.

26. Remove the liquid gasket.

Installation Procedure





1. Clean the contact surfaces between the cylinder head and the cylinder block.

2. Install the dowel pins.





3. Apply the RTV sealer Loctite(R) 5900-M8585, GM P/N 12346286 or Canadian P/N 10953472 on the surface of the cylinder block (1) as shown in the illustration.

4. Install the cylinder head gasket.

5. Apply the RTV sealer Loctite(R) 5900-M8585, GM P/N 12346286 or Canadian P/N 10953472 on the upper surface of the cylinder head gasket (1) as shown in the illustration.





6. Install the cylinder head.

Notice:
Refer to Fastener Notice Fastener Notice in Cautions and Notices.

7. Tighten the cylinder head bolts gradually and in the sequence shown.

Tighten the cylinder head bolts to 20 Nm (15 lb ft). After finishing the initial tightening, tighten all the cylinder head bolts to 25 Nm (18 lb ft) and turn the bolts another 2 turns of 70 degrees.





8. Install the coolant outlet port.

Tighten the coolant outlet port retaining bolts to 10 Nm (89 lb in).

9. Install the ECT sensor. Refer to Engine Coolant Temperature Sensor Replacement Service and Repair in Engine Controls-2.5L.

10. Instal the CMP sensor. Refer to Camshaft Position Sensor Replacement Service and Repair in Engine Controls-2.5L.

11. Discard the used exhaust manifold gasket and replace with a new one.

12. Install the exhaust manifold. Refer to Exhaust Manifold Removal 1. Exhaust Manifold Removal.

13. Install the heater pipe.





14. Install the EGR adapter.

Tighten the EGR adapter retaining bolts to 20 Nm (15 lb ft).

15. Install the EGR pipes. Refer to Exhaust Gas Recirculation Valve Pipe Replacement (Exhaust) Exhaust Gas Recirculation Valve Pipe Replacement (Exhaust)Exhaust Gas Recirculation Valve Pipe Replacement (Intake) Exhaust Gas Recirculation Valve Pipe Replacement (Intake) in Engine Controls-2.5L.

16. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement Service and Repair in Engine Controls-2.5L.





17. Install the upper pad bracket.

Tighten the upper pad bracket bolts to 45 Nm (33 lb ft).

18. Install the alternator. Refer to Generator Replacement (2.5L) Removal and Replacement.





19. Install the power steering pump.

Tighten the power steering pump retaining bolts to 25 Nm (18 lb ft).





20. Install the intake manifold support bracket.

Tighten the intake manifold support bracket bolt to 25 Nm (18 lb ft).





21. Install the timing chain and the timing chain cover. Refer to Camshaft Timing Chain and Sprocket Replacement Service and Repair.

22. Install the engine assembly. Refer to Engine Replacement Removal and Replacement.

23. Install the fuel pump fuse.

24. Connect the negative battery cable.

25. Refill the crankcase with engine oil.

26. Refill the engine coolant system. Refer to Cooling System Draining and Filling (2.5L) Service and Repair.

27. Fill and bleed the power steering system Refer to Power Steering System Bleeding Power Steering System Bleeding in Power Steering System.

28. Refill the A/C System. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.