GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Cylinder Head

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REMOVAL & INSTALLATION



2.0L Engine

See Figures 1, 2, 3 and 4

Cylinder head gasket replacement is necessary if camshaft carrier/cylinder head bolts are loosened. The head bolts should only be loosened when the engine is cold and should NEVER be reused.

  1. Properly relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant into a suitable container. Remove the induction tube.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the serpentine belt.
  2.  
  3. Remove the alternator and bracket.
  4.  
  5. Remove the ignition coil.
  6.  
  7. Matchmark the rotor to the distributor housing and the distributor housing to the cam carrier. Remove the distributor and tag and disconnect the spark plug wires. Refer to Engine Electrical of this information for distributor removal.
  8.  
  9. Tag and disconnect all cables from the intake manifold, throttle body and downshift cable.
  10.  
  11. Label and detach all electrical connections from the throttle body and intake manifold.
  12.  
  13. Tag and disconnect all vacuum lines and hoses from the following components:

    Brake booster
     
    Intake manifold and water pump (coolant and heater hoses)
     
    Breather from the camshaft carrier
     
    Upper radiator hose
     

  14.  
  15. Disengage the exhaust manifold-to-turbo connection.
  16.  
  17. Unfasten the oxygen sensor electrical connector.
  18.  
  19. Detach and plug the fuel lines.
  20.  
  21. Label and disconnect the wiring at the engine harness and thermostat housing.
  22.  
  23. Remove the timing belt and rear cover. For details, please refer to the procedure later in this section.
  24.  
  25. Make sure the engine is cold, then loosen the cam carrier/cylinder head bolts gradually in sequence.
  26.  



Click image to see an enlarged view

Fig. Fig. 1: When loosening the cylinder head/cam carrier bolts, make sure follow this sequence-2.0L engine

  1. Remove camshaft carrier, rocker arms and valve lifters/lash compensators.
  2.  
  3. Remove cylinder head with the intake and exhaust manifolds as an assembly. Remove the head gasket.
  4.  

To install:
  1. Thoroughly clean and dry the mating surfaces and bolt holes. Apply a continuous 1 /8 inch (3mm) bead of RTV sealant to the sealing surface of camshaft carrier.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Apply a continuous 1/8 inch (3mm) bead of RTV sealant to the sealing surface of camshaft carrier

When installing the cylinder head, you MUST use a new gasket and new head bolts!

  1. Install a new head gasket and position the head on the engine block. Tighten the new head bolts in sequence as follows:

    Step 1-Tighten to 18 ft. lbs. (25 Nm)
     
    Step 2-Using a torque angle meter, tighten an additional 60°
     
    Step 3-Tighten to 120° (another additional 60°)
     
    Step 4-Tighten to 180° (a third additional 60°)
     

  2.  



Click image to see an enlarged view

Fig. Fig. 3: To help prevent leakage, follow this sequence when tightening the new head bolts-2.0L engine



Click image to see an enlarged view

Fig. Fig. 4: Schematic of the torque degrees needed for proper bolt tightening

  1. Install the rear cover and timing belt.
  2.  
  3. Connect all wiring to the engine harness and thermostat housing.
  4.  
  5. Attach the exhaust manifold-to-turbo connection and engage the oxygen sensor wiring.
  6.  
  7. Connect the vacuum lines and/or hoses to the components previously removed from.
  8.  
  9. Attach all electrical connections to the throttle body and intake manifold.
  10.  
  11. Fasten all the fuel lines.
  12.  
  13. Connect all cables to the intake manifold bracket, throttle body, and downshift cable.
  14.  
  15. Install the distributor and spark plug wires, aligning the matchmarks.
  16.  
  17. Install the ignition coil.
  18.  
  19. Install the alternator and bracket.
  20.  
  21. Connect the induction tube.
  22.  
  23. Fill all fluids to their proper levels.
  24.  
  25. Connect the battery cable, start the engine and check for leaks.
  26.  
  27. After the engine has reached normal operation temperature (thermostat is open), tighten all head bolts, in sequence, another 30-50°. Shut the engine off.
  28.  

2.3L Engine

See Figures 5 through 9

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable, then drain cooling system into a suitable container.
  4.  
  5. Detach the heater inlet and throttle body heater hoses from water outlet. If accessible at this time, disconnect the upper radiator hose from the water outlet.
  6.  
  7. Remove the exhaust manifold. For details, please refer to the procedure located in this section.
  8.  
  9. Remove the intake (camshaft housing for SOHC) and exhaust (DOHC only) camshaft housings.
  10.  
  11. Unfasten the oil fill tube bolt/screw then remove the oil fill cap and level indicator assembly. Pull the oil fill tube upward to unseat from block.
  12.  
  13. Label and disengage the injector harness electrical connector.
  14.  
  15. Detach the throttle body-to-air intake duct.
  16.  
  17. Tag and disconnect the power brake vacuum hose from the throttle body.
  18.  
  19. Remove the throttle cable bracket.
  20.  
  21. Remove the throttle body from the intake manifold with the electrical harness and throttle cable attached and position the assembly aside.
  22.  
  23. Tag and disconnect the MAP sensor vacuum hose from the intake manifold, then remove the intake manifold brace.
  24.  
  25. Detach the electrical connectors from the MAP sensor, IAT sensor and the EVAP canister purge solenoid.
  26.  
  27. If not already done, detach the upper (inlet) radiator hose from the water outlet.
  28.  
  29. Disengage the coolant temperature sensor connector(s).
  30.  
  31. Unfasten the cylinder head bolts in reverse order of the installation sequence shown in the accompanying figures.
  32.  
  33. Lift the cylinder head from the engine block. Remove and discard the gasket. Inspect the oil flow check valve for freedom of movement.
  34.  
  35. Using a suitable solvent, thoroughly clean and dry all bolts, bolt holes and mating surfaces. Inspect the head bolts for any damage and replace, if necessary. If using a scraper to clean the old gasket material from the mating surfaces, use only a plastic or wood one, NOT a metal scraper. Do NOT allow any debris to fall into the engine!
  36.  

To install:
  1. Place a new cylinder head gasket on the cylinder block, then carefully position the cylinder head in place.
  2.  
  3. Sparingly coat the head bolt threads with clean engine oil, then allow the oil to drain off before installing.
  4.  
  5. On 1988-89 engines, install and tighten the cylinder head bolts, in sequence, as follows:

    Step 1-Tighten all head bolts in sequence to 26 ft. lbs. (35 Nm)
     
    Step 2-Using a torque angle meter, tighten the short bolts an additional 80° and the long bolts an additional 90° in sequence
     

  6.  



Click image to see an enlarged view

Fig. Fig. 5: Cylinder head bolt tightening sequence-1988-89 2.3L engine

  1. On 1990-91 engines, tighten the cylinder head bolts, in sequence, as follows:

    Step 1-Tighten all head bolts in sequence to 26 ft. lbs. (35 Nm)
     
    Step 2-Using a torque angle meter, tighten the short bolts an additional 100° and the long bolts an additional 110° in sequence
     

  2.  



Click image to see an enlarged view

Fig. Fig. 6: Cylinder head bolt tightening sequence-1990-91 2.3L engine

  1. On 1992 engines, tighten the cylinder head bolts, in sequence, as follows:

    Step 1-Tighten, in sequence, head bolts 1-6 to 26 ft. lbs. (35 Nm), 7-8 to 15 ft. lbs. (20 Nm) and 9-10 to 22 ft. lbs. (30 Nm).
     
    Step 2-Tighten all head bolts, in sequence, an additional 90° using J 36660 or equivalent
     
    Step 3-In sequence, loosen each bolt one turn, then immediately re-tighten to the specified torque
     
    Step 4-After completing step 3 on all 10 bolts, tighten each bolt, in sequence, an additional 90°
     

  2.  



Click image to see an enlarged view

Fig. Fig. 7: Cylinder head bolt tightening sequence-1992 2.3L engine

  1. On 1993-95 vehicles, tighten the cylinder head bolts to the specifications shown in the accompanying figures.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: Cylinder head bolt tightening sequence and specifications-1993 2.3L engine



Click image to see an enlarged view

Fig. Fig. 9: Cylinder head bolt tightening sequence and specifications-1994-95 2.3L engine

  1. Engage the coolant temperature sensor electrical connector(s).
  2.  
  3. Connect the upper radiator hose to the water outlet.
  4.  
  5. Install the intake manifold bracket.
  6.  
  7. Attach the following electrical connections: MAP sensor, IAT sensor, and the purge solenoid.
  8.  
  9. Using a new gasket, install the throttle body to the intake manifold.
  10.  
  11. Install the accelerator control cable bracket.
  12.  
  13. Connect the throttle body-to-air intake duct.
  14.  
  15. Install the oil fill tube and level indicator.
  16.  
  17. Install the camshaft housing(s).
  18.  
  19. Install the exhaust manifold. For details, please refer to the procedure located in this section.
  20.  
  21. Connect the heater inlet and throttle body heater hoses to the water outlet.
  22.  
  23. Fill all fluids to their proper levels.
  24.  
  25. Connect the battery cable, start the engine and check for leaks.
  26.  

2.4L Engine

See Figures 10, 11 and 12

Tools required to remove and install the cylinder head on this engine are as follows; a torque angle meter, spark plug wire remover, and engine support fixture and engine lift hook. In this procedure the GM supplied tool number will be offered if needed.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the throttle body-to-air cleaner duct.
  6.  
  7. Disconnect the heater inlet and throttle body heater hoses from the water outlet.
  8.  
  9. Disconnect the power brake vacuum hose from the throttle body.
  10.  
  11. Separate the following electrical connections:

    MAP sensor
     
    Intake Air Temperature (IAT) sensor
     
    EVAP canister purge solenoid
     
    Camshaft position sensor
     

  12.  
  13. Remove the alternator stud-ended bolt.
  14.  
  15. Remove the intake manifold brace and manifold. Refer to the procedure earlier in this section.
  16.  
  17. Install the alternator stud-ended bolt.
  18.  
  19. Attach the engine support fixture J 28467-400 and the lift hook J 28467-A or their equivalents to support the engine.
  20.  
  21. Remove the exhaust manifold as outlined earlier in this section.
  22.  
  23. Disconnect the ignition coil and module assembly wiring. Remove the coil and module assembly-to-camshaft housing bolts, then lift the assembly straight up and extract from the engine.
  24.  

If necessary, use a plug wire removal tool J 36011 or equivalent if the wires are stuck to the spark plugs. Twist then pull up on the connector to remove.

  1. Disengage the camshaft position sensor wiring.
  2.  
  3. Unbolt and set aside the power steering pump. Make sure when you remove the lines that you plug them to keep from fluid spewing.
  4.  
  5. Tag and plug all vacuum lines at the fuel pressure regulator. Label and remove the fuel injector harness wiring.
  6.  
  7. Slide the fuel line retaining clamp from the bracket on top of the intake camshaft housing.
  8.  
  9. Unbolt the fuel injector rail-to-camshaft housing.
  10.  
  11. Remove the fuel rail from the cylinder head. Refer to Fuel System .
  12.  



Click image to see an enlarged view

Fig. Fig. 10: Removing the fuel rail and pipes-2.4L engine

  1. Disconnect the timing chain housing at the intake camshaft housing, but do not remove it from the vehicle.
  2.  
  3. Disengage the oil pressure switch electrical wiring.
  4.  
  5. On automatics, unbolt and extract the transaxle fluid level indicator tube assembly from the exhaust camshaft cover and place it aside.
  6.  

Any time the camshaft housing-to-cylinder head bolts are loosened or removed, the camshaft housing-to-cylinder head gasket must be replaced.

  1. Unbolt and remove the intake camshaft housing-to-cylinder head. User the reverse of the tightening procedure when loosening the camshaft housing-to-cylinder head retaining bolts.
  2.  

Turn the camshaft housing upside down as soon as it is removed from the cylinder head. The lifter will fall out of the camshaft housing if it is not turned upside down. The lifter can be damaged if they fall out and hit a hard surface.

  1. Remove the intake housing and gasket.
  2.  
  3. Remove the exhaust camshaft housing-to-cylinder head bolts. Use the reverse order of the tightening sequence when loosening the camshaft housing-to-cylinder head bolts.
  4.  
  5. Remove the camshaft housing and gasket, refer to the Camshaft procedure later in this section.
  6.  
  7. Separator the upper radiator hose from the coolant outlet.
  8.  
  9. Disconnect the engine coolant temperature sensor wiring.
  10.  
  11. Remove the cylinder head-to-block bolts in sequence. Refer to the illustration.
  12.  


WARNING
Cylinder head warpage or cracking could result from removing the bolts in the incorrect order.

  1. Lift the cylinder head from the block, and place the head on wooden blocks on a bench.
  2.  

If the head is hard to separate from the block, pry between the head and block with a flat-bladed tool to separate. Be careful not to damage the contact surfaces of the cylinder head or block.

  1. Using a razor blade gasket scraper, clean the surface of the cylinder head and mating surface of the block. Be sure to remove all traces of gasket.
  2.  

Do not use an abrasive pad to clean the head or block surfaces. An abrasive pad may cause damage to the components.


CAUTION
Protect your eyes from the flying dirt particles when using high pressured air.

  1. Clean and inspect the cylinder head if reusing the same one.
  2.  

To install:
  1. Place a new head gasket on the cylinder block.
  2.  

Do not use any sealant on the head or block surfaces.

  1. Place the cylinder head on top of the block over the dowels. The dowels will allow you to place the head in the appropriate position for seating purposes.
  2.  
  3. Sparingly apply clean engine oil to the threads and the bottom of the flange of the new head bolts and allow the oil to drain before installing each one.
  4.  



Click image to see an enlarged view

Fig. Fig. 11: Cylinder head bolt tightening sequence-2.4L engine

  1. Insert and tighten the head bolts in sequence to specifications.

    Bolts 1 through 8-40 ft. lbs. (65 Nm)
     
    Bolts 9 through 10-30 ft. lbs. (40 Nm)
     
    Then turn each bolt an additional 90° in sequence
     

  2.  

Roll the camshaft housing right side up as it is installed onto the cylinder head. The lifters can be damaged if they fall out and hit a hard surface.

  1. Install the camshaft housing, gasket and bolts, but do not tighten at this time.
  2.  
  3. Install the exhaust camshaft housing, gasket and bolts, but do not tighten at this time.
  4.  
  5. Apply pipe sealant or equivalent to the camshaft housing retaining bolt threads. Using a torque angle meter install the bolts and tighten in sequence to 11 ft. lbs. (15 Nm) on the first pass then plus an additional 90° turn on the second pass. Refer to the illustrations.
  6.  



Click image to see an enlarged view

Fig. Fig. 12: Tightening the camshaft housing-to-cylinder head bolts-2.4L engine

  1. Install the timing chain housing and chain, refer to the procedure later in this section.
  2.  
  3. Uncover the fuel injectors and install new O-ring seals. Lubricate the seals with engine oil.
  4.  
  5. Attach the fuel rail to the camshaft housing and secure the bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Install the fuel line retaining clamp and retainer to the bracket on the top of the camshaft housing.
  8.  
  9. Attach the vacuum line to the pressure regulator.
  10.  
  11. Attach the fuel injector harness wiring to each injector. Be sure each harness is on the proper injector.
  12.  
  13. Attach the camshaft position sensor wiring.
  14.  
  15. Attach the power steering pump. Refer to Drive Train .
  16.  
  17. Connect the oil pressure switch wiring harness.
  18.  
  19. Bolt the transaxle fluid level tube to the exhaust camshaft cover.
  20.  
  21. Reinstall all spark plugs. Make sure they are in the same ports they were removed from. Now is a good time to inspect and replace them as needed.
  22.  
  23. Install the ignition coil and module wiring.
  24.  
  25. Attach all spark plug boots assembles that may have been stuck to a plug back onto the coil and module.
  26.  
  27. Locate the coil and module and place it over the spark plugs and push straight down to secure.
  28.  
  29. Clean any loose lubricant that may have come off of the bolts attaching the coil/module assembly.
  30.  
  31. Apply new sealant onto the ignition coil and module cover assembly-to-camshaft housing bolts. Tighten the bolts to 16 ft. lbs. (22 Nm).
  32.  
  33. Remove the engine support fixture and hook.
  34.  
  35. Remove the alternator stud bolt.
  36.  
  37. Install the intake manifold and gasket, refer to the procedure earlier in this section.
  38.  
  39. Install the intake manifold brace.
  40.  
  41. Reinstall the alternator stud bolt.
  42.  
  43. Attach all wiring still disconnected and hoses.
  44.  
  45. Install the exhaust manifold, throttle body and air cleaner.
  46.  
  47. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks. Top off coolant level if necessary.
  48.  
  49. Connect the negative battery cable.
  50.  

2.5L Engine

See Figure 13

  1. Relieve the fuel system pressure.
  2.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant into a suitable container.
  4.  
  5. For 1986-88 vehicles, raise and safely support the vehicle, then disconnect the exhaust pipe from the manifold. Detach the oxygen sensor connector, then carefully lower the vehicle.
  6.  
  7. For 1989-91 vehicles, remove the exhaust manifold. For details, please refer to the procedure located in this section.
  8.  
  9. Remove the oil level indicator (dipstick) tube from the cylinder head.
  10.  
  11. Remove the air cleaner assembly.
  12.  
  13. Label and disconnect the electrical wiring, throttle linkage and fuel lines at the rail from the throttle body assembly.
  14.  
  15. Disconnect the heater hose from the intake manifold.
  16.  
  17. Tag and detach the wiring connections from the intake manifold and cylinder head.
  18.  
  19. Remove the alternator or alternator bracket for access.
  20.  
  21. If equipped with a top-mounted A/C compressor, remove the compressor and lay it aside.
  22.  
  23. If equipped with power steering, remove the upper bracket from the power steering pump.
  24.  
  25. Disconnect the radiator hoses from the engine.
  26.  
  27. Remove the rocker arm (valve) cover. Label and remove the rocker arms and pushrods.
  28.  
  29. Unfasten the cylinder head bolts in reverse order of the installation sequence (shown in the accompanying figures), then lift the cylinder head from the engine compartment. Remove and discard the gasket.
  30.  

To install:
  1. Thoroughly clean and dry all bolts, bolt holes and mating surfaces. Inspect the head bolts for any damage and replace if necessary.
  2.  
  3. Install a new head gasket over the dowel pins in the block, then carefully position the cylinder head in place. Secure the head by installing the mounting bolts finger-tight.
  4.  
  5. On 1986-87 vehicles, tighten the cylinder head bolts in sequence as follows:

    Step 1-Tighten all bolts, in sequence, to 18 ft. lbs. (25 Nm)
     
    Step 2-Repeat sequence, tightening to 22 ft. lbs. (30 Nm), except front bolt/stud (No. 9 in illustration)
     
    Step 3-Tighten front bolt/stud (No. 9 in illustration) to 29 ft. lbs. (40 Nm)
     
    Step 4-Using a torque angle meter, tighten all bolts, except No. 9, an additional 120°
     
    Step 5-Tighten No. 9 an additional 120°
     

  6.  



Click image to see an enlarged view

Fig. Fig. 13: Cylinder head bolt tightening sequence-1986-91 2.5L

  1. On 1988-91 vehicles, tighten the cylinder head bolts in sequence as follows:

    Step-Tighten all bolts, in sequence, to 18 ft. lbs. (25 Nm)
     
    Step 2-Repeat sequence, tightening to 26 ft. lbs. (35 Nm), except front bolt/stud (No. 9 in illustration)
     
    Step 3-Tighten front bolt/stud (No. 9 in figure) to 18 ft. lbs. (25 Nm)
     
    Step 4-Using a torque angle meter, tighten all bolts in sequence an additional 90°
     

  2.  
  3. Install the pushrods and rocker arms in their original positions.
  4.  
  5. Using a new gasket, install the rocker arm (valve) cover.
  6.  
  7. Connect the radiator hoses. Install the power steering pump and upper bracket.
  8.  
  9. If removed, install the air conditioning compressor.
  10.  
  11. Install the alternator and/or bracket, if removed.
  12.  
  13. Attach the electrical wiring connectors to the intake manifold and the cylinder head.
  14.  
  15. Install the heater hose to the intake manifold.
  16.  
  17. Connect the electrical wiring, throttle linkage and fuel lines at fuel rail to the throttle body assembly.
  18.  
  19. Install the oil level indicator tube to the cylinder head.
  20.  
  21. For 1986-88 vehicles, raise and safely support the vehicle, then connect the exhaust pipe to the manifold, then attach the oxygen sensor connector. Carefully lower the vehicle.
  22.  
  23. For 1989-91 vehicles, install the exhaust manifold. For details, please refer to the procedure located in this section.
  24.  
  25. Install the air cleaner assembly.
  26.  
  27. Adjust all belt tensions and fill all fluids to their proper levels.
  28.  
  29. Connect the battery cable, start the engine and check for leaks.
  30.  

3.0L and 3.3L Engines

See Figures 14 through 19

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable
  4.  
  5. Drain the coolant into a suitable container.
  6.  
  7. Detach the mass air flow sensor and the air intake duct.
  8.  
  9. Remove ignition module and wiring.
  10.  
  11. Remove the serpentine drive belt, the alternator and bracket.
  12.  
  13. Label and detach all necessary vacuum lines and electrical connections.
  14.  
  15. Remove the fuel lines, the fuel rail and tag and disconnect the spark plug wires.
  16.  
  17. Remove the heater/radiator hoses from the throttle body and intake manifold. Remove the cooling fan and the radiator.
  18.  
  19. Remove the intake manifold. Refer to the procedure located in this section.
  20.  
  21. Remove the rocker arm (valve) covers. Label and remove the rocker arms, pedestals and pushrods.
  22.  
  23. Remove the left side exhaust manifold.
  24.  
  25. Remove the power steering pump.
  26.  
  27. Remove the oil dipstick and dipstick tube.
  28.  
  29. Remove the left side head bolts in reverse order of the installation sequence and lift the left cylinder head from the engine.
  30.  
  31. Raise and safely support the vehicle.
  32.  
  33. Unfasten the right exhaust manifold-to-engine bolts, then remove the right exhaust manifold.
  34.  
  35. Carefully lower the vehicle.
  36.  
  37. Remove the right cylinder head-to-engine bolts in reverse of the installation sequence and lift the right cylinder head from the engine.
  38.  



Click image to see an enlarged view

Fig. Fig. 14: Loosen cylinder head bolts with a breaker bar in the reverse of installation tightening sequence-3.0L and 3.3L engines



Click image to see an enlarged view

Fig. Fig. 15: Removing the cylinder head from the engine block-1986 3.0L engine shown

  1. Remove and discard the cylinder head gasket(s).
  2.  



Click image to see an enlarged view

Fig. Fig. 16: Whenever you remove the cylinder head, replace the gasket

To install:
  1. Thoroughly clean and dry all bolts, bolt holes and mating surfaces. Inspect the head bolts for any damage and replace if necessary.
  2.  



Click image to see an enlarged view

Fig. Fig. 17: Use a suitable scraper to clean the head-to-block mating surfaces. Placing clean rags in the engine block will prevent debris from falling in the block

  1. Place a new head gasket to the block, then carefully position the cylinder head in place.
  2.  
  3. On the 3.0L engine, tighten the cylinder head bolts, in sequence, as follows:

    Step 1-Tighten to 25 ft. lbs. (34 Nm)
     
    Step 2-Using a torque angle meter, tighten an additional 90°
     
    Step 3-Tighten another additional 90°, to a maximum of 60 ft. lbs. (81 Nm)
     

  4.  



Click image to see an enlarged view

Fig. Fig. 18: Cylinder head bolt tightening sequence-3.0L and 3.3L engines

  1. On the 3.3L engine, tighten the cylinder head bolts, in sequence, as follows:

    Step 1-Tighten to 35 ft. lbs. (47 Nm)
     
    Step 2-Using a torque angle meter, tighten an additional 130°
     
    Step 3-Tighten the 4 center bolts an additional 30°
     

  2.  



Click image to see an enlarged view

Fig. Fig. 19: When tightening the head bolts, always use a torque wrench

  1. Install the intake manifold. For details, please refer to the procedure located in this section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Install the exhaust manifold.
  6.  
  7. Carefully lower the vehicle.
  8.  
  9. Install the power steering pump. Install the dipstick and dipstick tube.
  10.  
  11. Using new gaskets, install the valve covers.
  12.  
  13. Install the rocker arms, pedestals and bolts. Tighten pedestal bolts to 43 ft. lbs. (58 Nm) for the 3.0L engine or 28 ft. lbs. (38 Nm) for the 3.3L engine.
  14.  
  15. Install the intake manifold assembly.
  16.  
  17. Connect the heater and radiator hoses to the throttle body and intake manifold.
  18.  
  19. Install the cooling fan and the radiator.
  20.  
  21. Attach the fuel lines, the fuel rail and the spark plug wires.
  22.  
  23. Engage all vacuum lines and electrical connections.
  24.  
  25. Install the serpentine drive belt, the alternator and bracket.
  26.  
  27. Install the ignition module and wiring.
  28.  
  29. Connect the mass air flow sensor and the air intake duct.
  30.  
  31. Fill all fluids to their proper levels.
  32.  
  33. Connect the battery cable, start the engine and check for leaks.
  34.  

3.1L Engine

See Figure 20


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

LEFT SIDE (FRONT)
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Disconnect the top half of the air cleaner assembly, then remove the throttle body air inlet duct.
  8.  
  9. Remove the exhaust crossover pipe heat shield and crossover pipe.
  10.  
  11. Disconnect the spark plug wires from spark plugs and looms then route the wires out of the way.
  12.  
  13. Remove the rocker arm (valve) covers.
  14.  
  15. Remove upper intake plenum and lower intake manifold.
  16.  
  17. Remove the left side exhaust manifold.
  18.  
  19. Remove oil level indicator tube.
  20.  

When removing the valve train components they must be kept in order for installation in the same locations they were removed from.

  1. Remove rocker arms nut, rocker arms, balls and pushrods.
  2.  
  3. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket.
  4.  

To install:
  1. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
  2.  
  3. Place the cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP are showing.
  4.  
  5. Coat the bolt threads lightly with sealer, then install finger-tight.
  6.  
  7. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
  8.  
  9. Install the pushrods, rocker arms, balls and rocker arm nuts in their proper locations. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the lower intake manifold and upper intake plenum.
  12.  
  13. Install the rocker arm (valve) covers.
  14.  
  15. Install the oil level indicator tube. Insert the dipstick.
  16.  
  17. Connect the spark plug wires to spark plugs and looms.
  18.  
  19. Install the left side exhaust manifold.
  20.  
  21. Install the exhaust crossover pipe and heat shield.
  22.  
  23. Refill the cooling system.
  24.  
  25. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
  26.  
  27. Connect negative battery cable.
  28.  
  29. Start vehicle and verify that there are no leaks.
  30.  



Click image to see an enlarged view

Fig. Fig. 20: Cylinder head mounting and bolt tightening sequence-3.1L engine

RIGHT CYLINDER HEAD (REAR)

CAUTION
Fuel Injection systems remain under pressure, even after the engine has been turnedOFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the top half of the air cleaner assembly and remove the throttle body air inlet duct.
  8.  
  9. Remove the exhaust crossover pipe heat shield and crossover pipe.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Detach the Oxygen (O 2 ) sensor connector.
  14.  
  15. Disconnect the exhaust pipe from the exhaust manifold.
  16.  
  17. Remove the right side exhaust manifold.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Disconnect the spark plug wires from spark plugs and wire looms and route the wires out of the way.
  22.  
  23. Remove the rocker arm (valve) covers.
  24.  
  25. Remove upper intake plenum and lower intake manifold.
  26.  

When removing the valve train components they must be kept in order for installation in the same locations they were removed from.

  1. Remove rocker arms nut, rocker arms, balls and pushrods.
  2.  
  3. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket.
  4.  

To install:
  1. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
  2.  
  3. Place the cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP showing.
  4.  
  5. Coat the bolt threads lightly with sealer, then install finger-tight.
  6.  
  7. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
  8.  
  9. Install the pushrods loosely retained with the rocker arm assemblies. Make sure all pushrods are in the correct locations. Coat the ends of the pushrods with prelube. The intake rods are marked yellow and are 5 3 /4 inch long. The exhaust pushrods are marked green and 6 inches long. balls and rocker arm nuts. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the lower intake manifold and upper intake plenum.
  12.  
  13. Install the rocker arm (valve) covers.
  14.  
  15. Connect the spark plug wires to spark plugs and wire looms.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Install the exhaust manifold.
  20.  
  21. Connect the exhaust pipe to the exhaust manifold.
  22.  
  23. Carefully lower the vehicle.
  24.  
  25. Connect the Oxygen (O 2 ) sensor wiring.
  26.  
  27. Install the exhaust crossover pipe and heat shield.
  28.  
  29. Refill the cooling system.
  30.  
  31. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
  32.  
  33. Connect negative battery cable.
  34.  
  35. Start vehicle and verify that there are no leaks.
  36.  

 
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