2/18/2017 Cylinder Head Assembly Service and Repair, Removal and Replacement: Cylinder Head

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1 Cylinder Head 1/17

2 RH Splash Shield Accessory Drive Belt, Thermostat Housing and Fuel Rail 2/17

3 RH Accessory Drive and Timing Drive Components 3/17

4 LH Accessory Drive and Timing Drive Components 4/17

5 LH Spark Plug Wires, Oil Level Indicator and Tube and Ground Strap 5/17

6 6/17

7 Removal Both sides 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting. 2. Drain the engine cooling system. For additional information, refer to Cooling System &/or Engine Block Heater. 3. Remove the intake manifold. For additional information, refer to Intake Manifold See: Intake Manifold > Removal and Replacement > Intake Manifold See: Intake Manifold. 4. Remove the cooling fan shroud. For additional information, refer to Cooling System &/or Engine Block Heater. 5. Remove the roller followers. For additional information, refer to Camshaft Roller Follower See: Rocker Arm Assembly > Removal and Replacement > Camshaft Roller Follower. 6. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt. 7. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 8. NOTE: The coolant bypass hose will be removed with the thermostat housing. Move the coolant bypass hose clamp off the coolant pump outlet. 7/17

8 9. Remove the 3 bolts and the thermostat housing and coolant bypass hose. 10. Remove the 4 bolts and the fuel rail and fuel injector assembly. 11. If equipped, remove the nut and position the A/C hose bracket aside. 12. NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crankshaft sensor speed wheel and incorrect timing of the engine. NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block. This positions the engine at Top Dead Center (TDC). Install the Crankshaft TDC Timing Tool. RH side 13. Disconnect the generator electrical connections and detach the wiring harness retainers. 14. Remove the bolt and the accessory drive belt tensioner. 15. Remove the 3 bolts and the generator bracket assembly. 16. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 17. Detach the 2 wiring harness retainers and position the wiring harness aside. - Remove and discard the 2 retainers. 18. Remove the 5 pushpins and the RH inner fender splash shield. 19. Remove the RH hydraulic timing chain tensioner. 20. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold - RH See: Exhaust Manifold > Removal and Replacement > Exhaust Manifold - RH See: Exhaust System. 8/17

9 Replacement > Exhaust Manifold - RH See: Exhaust System. 21. Remove the bolt and position the wiring harness bracket aside. 22. Install the Camshaft Sprocket Holding Tool and the Adapter for Tighten to 10 Nm (89 lb-in). 23. NOTE: The RH camshaft sprocket is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt. Using the Torque Wrench Extension and the Camshaft Sprocket Nut Socket, remove the RH camshaft bolt. 24. Remove the RH timing drive cassette upper bolt. 25. NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head. NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain. 9/17

10 LH side 26. Remove the 4 bolts and position the power steering and A/C compressor bracket aside. 27. Remove the bolt and detach the wiring harness from the LH cylinder head. 28. Remove the bolt and the oil level indicator tube. 29. NOTICE: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. Mark the spark plug locations before removing them. Using the Spark Plug Wire Remover, disconnect the LH spark plug wires from the LH spark plugs and remove the ignition coil. 30. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold - LH See: Exhaust Manifold > Removal and Replacement > Exhaust Manifold - LH See: Exhaust System. 31. Remove the bolt and detach the ground strap. 32. Remove the LH side hydraulic timing chain tensioner. 33. Install the Camshaft Sprocket Holding Tool and the Adapter for Tighten the top clamp bolts to 10 Nm (89 lb-in). 10/17

11 34. Remove the LH camshaft sprocket bolt. 35. Remove the LH timing drive cassette upper bolt. 36. NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head. NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block. Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain. Both sides 37. NOTICE: To avoid damage to the timing chain cassette, an assistant will be required to help lift the cylinder head from the vehicle. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused. Remove the cylinder heads. - Remove the 10 cylinder head bolts in the sequence shown. Discard all bolts. - Remove and discard the head gasket. 11/17

12 38. 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. Clean the cylinder head gasket surfaces with metal surface cleaner. 39. 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. Installation Both sides 1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed. 2. Position the cylinder head gasket on the block. RH side 3. NOTICE: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused. Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages. - Stage 1: Tighten to 12 Nm (106 lb-in). - Stage 2: Tighten to 25 Nm (18 lb-ft). 4. Install 2 new 8-mm bolts. - Tighten to 32 Nm (24 lb-ft). 12/17

13 5. Tighten the eight 12-mm bolts in the sequence shown in 2 stages. - Stage 1: Tighten 90 degrees. - Stage 2: Tighten an additional 90 degrees. 6. NOTE: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Remove the rubber band. Install the camshaft sprocket and bolt. 7. Install the RH timing drive cassette upper bolt. - Tighten to 10 Nm (89 lb-in). 8. Position the wiring harness bracket and install the bolt. - Tighten to 28 Nm (21 lb-ft). 9. Install the RH exhaust manifold. For additional information, refer to Exhaust Manifold - RH See: Exhaust Manifold > Removal and Replacement > Exhaust Manifold - RH See: Exhaust System. 10. Install the RH inner fender splash shield and the 5 pushpins. 11. Install 2 new wiring harness retainers and attach the wiring harness. 12. Connect the CKP sensor electrical connector. 13. Position the generator bracket and install the 3 bolts. - Tighten to 42 Nm (31 lb-ft). 14. Position the accessory drive belt tensioner and install the bolt. - Tighten to 47 Nm (35 lb-ft). 13/17

14 15. Connect the generator electrical connectors and install the nut. Attach the wiring harness retainers. - Tighten to 12 Nm (106 lb-in). LH side 16. NOTICE: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused. Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages. - Stage 1: Tighten to 12 Nm (106 lb-in). - Stage 2: Tighten to 25 Nm (18 lb-ft). 17. Install 2 new 8-mm bolts. - Tighten to 32 Nm (24 lb-ft). 14/17

15 18. Tighten the eight 12-mm bolts in the sequence shown in 2 stages. - Stage 1: Tighten 90 degrees. - Stage 2: Tighten an additional 90 degrees. 19. NOTE: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Remove the rubber band. Install the camshaft sprocket and bolt. 20. Install the LH timing drive cassette upper bolt. - Tighten to 12 Nm (106 lb-in). 21. Position the ground strap and install the bolt. - Tighten to 25 Nm (18 lb-ft). 22. Install the LH exhaust manifold. For additional information, refer to Exhaust Manifold - LH See: Exhaust Manifold > Removal and Replacement > Exhaust Manifold - LH See: Exhaust System. 23. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots. Position the ignition coil in the engine compartment and connect the spark plug wires to the LH spark plugs. 24. Install the oil level indicator tube and bolt. - Tighten to 10 Nm (89 lb-in). 25. Attach the wiring harness to the LH cylinder head and install the bolt. - Tighten to 10 Nm (89 lb-in). 26. Position the power steering and A/C compressor bracket and install the 4 bolts. - Tighten to 42 Nm (31 lb-ft). Both sides 27. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt. 15/17

16 28. NOTE: The LH and RH camshafts must be retimed when either camshaft is disturbed. NOTE: Install the hydraulic chain tensioners during camshaft timing. Time the camshafts. For additional information, refer to Camshaft Timing See: Camshaft, Engine > Procedures > Camshaft Timing. 29. NOTE: Inspect the thermostat housing O-ring seal. Install a new O-ring seal if necessary. Position the thermostat housing, making sure the bypass hose is connected to the coolant pump, and install the 3 bolts. - Tighten to 11 Nm (97 lb-in). 30. Position the bypass hose clamp. 31. Connect the ECT sensor electrical connector. 32. Position the fuel rail and fuel injector assembly and install the 4 bolts. - Tighten to 23 Nm (17 lb-ft). 33. Connect the spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction. 34. Install the roller followers. For additional information, refer to Camshaft Roller Follower See: Rocker Arm Assembly > Removal and Replacement > Camshaft Roller Follower. 35. Install the cooling fan shroud. For additional information, refer to Cooling System &/or Engine Block Heater. 36. Install the intake manifold. For additional information, refer to Intake Manifold See: Intake Manifold > Removal and Replacement > Intake Manifold See: Intake Manifold. 37. Fill and bleed the engine cooling system. For additional information, refer to Cooling System &/or Engine Block Heater. 16/17

17 2017 ALLDATA, LLC. All Rights Reserv ed. (Version ) 17/17

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