Removal and Installation
Cylinder Head
Material
Removal
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 engine damage can occur.
All engines
1. Disconnect the battery ground cable.
2. Drain the cooling system.
3. Remove the camshafts.
4. Remove the fuel injection supply manifold.
5. Remove the intake manifold.
2.0L engines
6. If equipped, disconnect the Secondary Air Injection (AIR) vacuum regulator electrical connector and vacuum hose.
7. If equipped, disconnect the hoses from the AIR control valve.
8. If equipped, disconnect the upper exhaust sensor electrical connector and retainer.
All engines
9. Remove the nuts and disconnect the catalytic converter from the muffler assembly.
- Remove and discard the gasket.
10. Remove the bolts and the catalytic converter support bracket.
11. NOTE: All 2.3L engines and some 2.0L engines are equipped with a heat shield that must be positioned aside to access the catalytic converter-to engine nuts.
If equipped, remove the four heat shield bolts and position the heat shield aside.
12. Disconnect the exhaust sensor electrical connectors.
13. Remove and discard the catalytic converter-to-engine nuts.
- Position aside the catalytic converter and support with mechanics wire.
- Remove and discard the catalytic converter gasket.
14. Disconnect the Exhaust Gas Recirculation (EGR) valve electrical connector.
15. Disconnect the coolant hoses from the coolant bypass.
16. Remove the bolts, coolant bypass and gasket.
- Discard the gasket.
17. Disconnect the EGR coolant hose.
18. Remove the bolts and the cylinder head.
- Discard the bolts.
19. Remove and discard the head gasket.
20. Inspect the cylinder head mating surfaces.
Installation
All engines
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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: 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.
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. Inspect the cylinder head for distortion.
3. Apply silicone gasket and sealant to the locations shown.
4. Install a new head gasket.
5. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation. Install new cylinder head bolts.
Tighten the bolts in the sequence shown in five stages.
1 Tighten the bolts to 5 Nm (44 inch lbs.).
2 Tighten the bolts to 15 Nm (11 ft. lbs.).
3 Tighten the bolts to 45 Nm (33 ft. lbs.).
4 Turn the bolts 90 degrees.
5 Turn the bolts an additional 90 degrees.
6. Install the EGR coolant hose.
7. Using a new gasket, install the coolant bypass.
8. Connect the coolant hoses onto the coolant bypass.
9. Connect the EGR valve electrical connector.
10. Clean and inspect the catalytic converter flange.
- Using a straightedge and a feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
11. Using a new gasket and nuts, install the catalytic converter.
12. Connect the exhaust sensor electrical connectors.
13. If equipped, install the heat shield and bolts.
14. Install the catalytic converter support bracket and bolts.
15. NOTE: Clean the mating surfaces of the muffler assembly and catalytic converter.
Using a new gasket and nuts, connect the catalytic converter and muffler assembly.
2.0L engines
16. If equipped, connect the upper exhaust sensor electrical connector and retainer.
17. If equipped, connect the hoses to the AIR control valve.
18. If equipped, connect the AIR vacuum regulator electrical connector and vacuum hose.
All engines
19. Install the intake manifold.
20. Install the fuel injector supply manifold.
21. Install the camshafts.
22. Connect the battery ground cable.
23. Fill and bleed the cooling system.