Removal and Replacement

Cylinder Head













Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley 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 tools, otherwise severe engine damage can occur.

1. Disconnect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

2. Remove the camshafts. For additional information, refer to Camshafts Camshafts.

3. Remove the exhaust manifold. For additional information, refer to Exhaust Manifold Removal and Replacement.

4. Remove the fuel rail. For additional information, refer to Fuel Charging and Controls - 2.3L Fuel Rail.

5. Remove the coolant hose retainer clip, the stud bolt and the ground cable.

6. Remove the EGR tube from the cylinder head.

7. Disconnect the EGR valve electrical connector.

8. Disconnect the EGR coolant hose and remove it from the hose bracket.

9. Disconnect the coolant bypass hose.

10. Remove the cylinder block coolant drain plug.

11. Remove the 10 bolts and the cylinder head.
- Discard the bolts.

12. Remove and discard the head gasket.

13. 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.

NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. 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 surfaces 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 remaining 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.

14. 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 and Cylinder Block Distortion.

Installation

1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.

2. 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, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.

NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the locations shown.





3. Install a new cylinder head gasket.

4. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

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 the 10 new bolts. Tighten the bolts in the sequence shown, in 5 stages.

- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 15 Nm (133 lb-in).

- Stage 3: Tighten to 45 Nm (33 lb-ft).

- Stage 4: Tighten an additional 90 degrees.

- Stage 5: Tighten an additional 90 degrees.





5. Install the cylinder block coolant drain plug.
- Tighten to 55 Nm (41 lb-ft).

6. Connect the coolant bypass hose.

7. Connect the EGR coolant hose.

8. Connect the EGR valve electrical connector.

9. Connect the EGR tube to the cylinder head.
- Tighten to 55 Nm (41 lb-ft).

10. Position the ground strap and install the stud bolt to the cylinder head.
- Tighten to 10 Nm (89 lb-in).

11. Install the coolant hose retainer clip.

12. Install the fuel rail. For additional information, refer to Fuel Charging and Controls - 2.3L Fuel Rail.

13. Install the exhaust manifold. For additional information, refer to Exhaust Manifold Removal and Replacement.

14. Install the camshafts. For additional information, refer to Camshafts Camshafts.

15. Connect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.