Aurora 2001-2003

Cylinder Head

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Removal & Installation



3.5L Engine
Left (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the crankcase and the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Coolant crossover pipe
     
    Left exhaust manifold
     
    Camshaft cover
     

  6.  
  7. Install a holding tool on the camshafts to hold them in position.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Be sure to keep the rocker arms and lifters in order so they can be installed in their original locations.



    Camshaft primary chain
     
    Camshafts from the left cylinder head
     
    Rocker arms and valve lifters
     



    M6 bolts from the front of the cylinder head, note the location of the longer bolt
     
    M11 cylinder head bolts
     
    Cylinder head
     

  10.  

To install:

Click image to see an enlarged view

Fig. Front cylinder head bolt torque sequence-3.5L (VIN H) engine

  1. Install the cylinder head with a new gasket.
  2.  
  3. Install new M11 bolts and M6 bolts.
  4.  
  5. Torque the M11 bolts in sequence to:
    1. Step 1: 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: 100 degree turn.
    4.  
    5. Step 3: 100 degree turn.
    6.  

  6.  
  7. Torque the long M6 bolt to 22 ft. lbs. (30 Nm).
  8.  
  9. Torque both shorter M6 bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Install or connect the following:

    Lifters
     
    Rocker arms
     
    Camshafts
     
    Primary chain
     

  12.  
  13. Remove the timing chain holding tool.
  14.  
  15. Install or connect the following:

    Camshaft covers. Torque the bolts to 80 inch lbs. (9 Nm).
     
    Exhaust manifold. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Coolant crossover pipe. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Intake manifold. Torque the bolts to 62 inch lbs. (7 Nm).
     
    New oil filter
     
    Negative battery cable
     

  16.  
  17. Refill the crankcase.
  18.  
  19. Refill the cooling system.
  20.  
  21. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Camshaft holding fixture J-42038-3.5L engine

  22.  

Right (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the crankcase and the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Do not remove the rear exhaust manifold. Detach it from the cylinder head and the connection from the front manifold; then, move it aside.



    Negative battery cable
     
    Intake manifold
     
    Coolant crossover pipe
     



    Rear exhaust manifold from the cylinder head and front manifold
     
    Camshaft cover
     

  6.  
  7. Install a holding tool on the camshafts to hold them in position.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Keep the rocker arms and lifters in order so they can be installed in their original positions.



    Primary camshaft chain
     
    Right side camshafts
     
    Rocker arms and lifters
     



    Engine Coolant Temperature (ECT) sensor from the cylinder head
     
    M6 bolts from the front of the cylinder head, note the location of the longer bolt
     
    M11 cylinder head bolts
     
    Cylinder head
     

  10.  

To install:

Click image to see an enlarged view

Fig. Rear cylinder head bolt torque sequence-3.5L (VIN H) engine

  1. Install the cylinder head with a new gasket.
  2.  
  3. Install new M11 bolts.
  4.  
  5. Install M6 bolts in the front of the cylinder head.
  6.  
  7. Tighten the M11 bolts in sequence using the following steps:
    1. Step 1: 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: 100 degree turn.
    4.  
    5. Step 3: 100 degree turn.
    6.  

  8.  
  9. Torque the long M6 bolt to 22 ft. lbs. (30 Nm).
  10.  
  11. Torque both short M6 bolts to 106 inch lbs. (12 Nm).
  12.  
  13. Install or connect the following:

    ECT sensor. Torque the sensor to 15 ft. lbs. (20 Nm).
     
    Lifters and rocker arms in their original positions
     
    Camshafts
     
    Primary chain
     
    Camshaft covers. Torque the bolts to 80 inch lbs. (9 Nm).
     
    Exhaust manifold on the cylinder head. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Coolant crossover pipe. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Intake manifold. Torque the bolts to 62 inch lbs. (7 Nm).
     
    New oil filter
     
    Negative battery cable
     

  14.  
  15. Refill the crankcase.
  16.  
  17. Refill the cooling system.
  18.  
  19. Start the engine and check for leaks.
  20.  

4.0L Engine

LEFT SIDE

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Exhaust manifold
     
    Alternator
     
    Water crossover
     
    Intake manifold
     
    Camshaft cover
     
    Front cover
     
    Secondary camshaft drive chain
     
    Power steering hose retaining bolt from the head
     
    Cylinder head
     

  4.  

To install:

Click image to see an enlarged view

Fig. Left cylinder head bolt torque sequence-2001-02 4.0L models

  1. Install the cylinder head with a new gasket.
  2.  
  3. Install new M11 head bolts and M6 head bolts.
  4.  
  5. Torque the M11 bolts in sequence as follows:
    1. Step 1: 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: 70 degree turn.
    4.  
    5. Step 3: 60 degree turn.
    6.  
    7. Step 4: 60 degree turn.
    8.  

  6.  
  7. Torque the M6 bolts to 106 inch lbs. (12 Nm).
  8.  
  9. Install or connect the following:

    Power steering hose retaining bolt. Torque the bolt to 37 ft. lbs. (50 Nm).
     
    Secondary camshaft drive chain
     
    Front cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Camshaft cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Intake manifold. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Water crossover. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Exhaust manifold. Torque the bolts to 18 ft. lbs. (25 Nm). RIGHT SIDE
     

  10.  
  11. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  12.  
  13. Remove or disconnect the following:

    Exhaust manifold
     
    Water crossover
     
    Intake manifold
     
    Camshaft cover
     
    Front cover
     
    Secondary camshaft drive chain
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Ground wire from the head
     
    Front and rear transmission braces from the head
     
    Cylinder head
     

  14.  

To install:

Click image to see an enlarged view

Fig. Right cylinder head bolt torque sequence-2001-02 4.0L models

  1. Install the cylinder head with a new gasket.
  2.  
  3. Install new M11 head bolts and M6 head bolts.
  4.  
  5. Torque the M11 head bolts in sequence as follows:
    1. Step 1: 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: 70 degree turn.
    4.  
    5. Step 3: 60 degree turn.
    6.  
    7. Step 4: 60 degree turn.
    8.  

  6.  
  7. Torque the M6 head bolts to 106 inch lbs. (12 Nm).
  8.  
  9. Install or connect the following:

    Front and rear transmission braces to the head. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    ECT electrical connector
     
    Ground wire to the head. Torque the nut to 13 ft. lbs. (17 Nm).
     
    Secondary camshaft drive chain
     
    Front cover. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Camshaft cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Intake manifold. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Water crossover. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Exhaust manifold. Torque the bolts to 22 ft. lbs. (30 Nm).
     

  10.  

Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Exhaust manifold
     
    Alternator
     
    Water crossover
     
    Intake manifold
     
    Camshaft cover
     
    Front cover
     
    Secondary camshaft drive chain
     
    Power steering hose retaining bolt from the head
     
    Cylinder head
     

  4.  

To install:

Click image to see an enlarged view

Fig. Left cylinder head bolt torque sequence-4.0L models

  1. Install the cylinder head with a new gasket.
  2.  
  3. Install new M11 head bolts and M6 head bolts.
  4.  
  5. Torque the M11 bolts in sequence as follows:
    1. Step 1: 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: 70 degree turn.
    4.  
    5. Step 3: 60 degree turn.
    6.  
    7. Step 4: 60 degree turn.
    8.  

  6.  
  7. Torque the M6 bolts to 106 inch lbs. (12 Nm).
  8.  
  9. Install or connect the following:

    Power steering hose retaining bolt. Torque the bolt to 37 ft. lbs. (50 Nm).
     
    Secondary camshaft drive chain
     
    Front cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Camshaft cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Intake manifold. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Water crossover. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Exhaust manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     

  10.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Exhaust manifold
     
    Water crossover
     
    Intake manifold
     
    Camshaft cover
     
    Front cover
     
    Secondary camshaft drive chain
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Ground wire from the head
     
    Bolt securing the exhaust crossover pipe to the cylinder head
     
    Front and rear transmission braces from the head
     
    Cylinder head
     

  4.  

To install:

Click image to see an enlarged view

Fig. Right cylinder head bolt torque sequence-4.0L models

  1. Install the cylinder head with a new gasket.
  2.  
  3. Install new M11 head bolts and M6 head bolts.
  4.  
  5. Torque the M11 head bolts in sequence as follows:
    1. Step 1: 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: 70 degree turn.
    4.  
    5. Step 3: 60 degree turn.
    6.  
    7. Step 4: 60 degree turn.
    8.  

  6.  
  7. Torque the M6 head bolts to 106 inch lbs. (12 Nm).
  8.  
  9. Install or connect the following:

    Front and rear transmission braces to the head. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    ECT electrical connector
     
    Ground wire to the head. Torque the nut to 13 ft. lbs. (17 Nm).
     
    Bolt securing the exhaust crossover pipe to the cylinder head. Torque the bolt to 18 ft. lbs. (25 Nm).
     
    Secondary camshaft drive chain
     
    Front cover. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Camshaft cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Intake manifold. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Water crossover. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Exhaust manifold. Torque the bolts to 22 ft. lbs. (30 Nm).
     

  10.  

 
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