Crossfire 2006-2008

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil
  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Mass Air Flow (MAF) sensor
     
    Radiator and radiator fan
     
    Camshaft position sensor
     
    Intake manifold
     
    Cylinder head cover
     
    Exhaust pipes from exhaust manifold
     

  10.  
  11. Rotate the crankshaft so that the crankshaft timing mark aligns with the 40 degree After Top Dead Center (ATDC) mark on the front cover as shown. Grooves in the camshafts must be toward the inside of the wedge.

    Click image to see an enlarged view

    Fig. Crankshaft timing mark set to 40 degrees ATDC

  12.  
  13. Lock the camshafts in place with Camshaft Locking Plates 9104 and 9105.

    Click image to see an enlarged view

    Fig. Camshaft locking plate

  14.  
  15. Remove the timing chain tensioner as shown.

    Click image to see an enlarged view

    Fig. Removing timing chain tensioner

  16.  
  17. Use a cable tie and secure the timing chain the camshaft sprocket.

    Click image to see an enlarged view

    Fig. Securing timing chain to camshaft sprocket

  18.  
  19. Remove the camshaft sprockets.
  20.  
  21. Remove the camshaft locking plate tools.
  22.  
  23. Loosen and remove the camshaft bearing cap bolts in the sequence shown.
  24.  
  25. Remove the rocker arms and the camshafts.
  26.  
  27. Remove the cylinder head bolts in the sequence shown.
  28.  
  29. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt removal sequence



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence

  30.  

To install:

Click image to see an enlarged view

Fig. Examine the head bolts for signs of stretching

  1. Check the cylinder head bolts for signs of stretching. If length exceeds 5.67 inches (144 mm), replace bolts as necessary.
  2.  
  3. Lubricate the threads of the bolts with clean engine oil.
  4.  
  5. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows:
    1. Step 1: 7 ft. lbs. (10 Nm)
    2.  
    3. Step 2: 22 ft. lbs. (30 Nm)
    4.  
    5. Step 3: rotate bolts 90 degrees clockwise
    6.  
    7. Step 4: rotate bolts 90 degrees clockwise
    8.  
    9. Step 5: Bolts 9 and 10 to 7-15 ft. lbs. (10-20 Nm)

      Click image to see an enlarged view

      Fig. Cylinder head bolt torque sequence

    10.  

  6.  
  7. Install the rocker arms and the camshafts.
  8.  
  9. Install the camshaft bearing cap bolts in the sequence shown. Tighten the bolts to 11 ft. lbs. (15 Nm), plus an additional 90 degrees.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt torque sequence

  10.  
  11. Lock the camshafts in place with Camshaft Locking Plates 9104 and 9105.
  12.  
  13. Install the camshaft sprockets. Tighten the bolts to 37 ft. lbs. (50 Nm), plus an additional 90 degrees.
  14.  
  15. Remove cable tie from timing chain.
  16.  
  17. Install the timing chain tensioner. Tighten the bolt to 59 ft. lbs. (80 Nm).
  18.  
  19. Remove camshaft locking plates
  20.  
  21. Ensure crankshaft is set to 40 degrees ATDC
  22.  
  23. Install or connect the following:

    Exhaust pipes to manifold. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Cylinder head covers. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Intake manifold.
     
    Ignition coils
     
    Accessory drive belt
     
    Camshaft position sensor
     
    Radiator and radiator fan
     
    Mass Air Flow (MAF) sensor
     
    Air intake assembly
     
    Negative battery cable
     

  24.  
  25. Fill and bleed the cooling system.
  26.  
  27. Fill the engine with oil.
  28.  
  29. Start the engine and check for leaks.
  30.  

 
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