Hyundai Cars 2006-2008

Cylinder Head

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Removal & Installation



Use fender covers to avoid damaging painted surfaces. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection. Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at Top Dead Center (TDC).

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Engine removal is required for this procedure.

  2.  
  3. Remove or disconnect the following:

    The negative battery connection
     
    The exhaust manifold
     
    The intake manifold
     
    The timing chain
     
    The water temperature control assembly
     
    The camshaft bearing cap
     
    The camshaft assembly
     

  4.  
  5. The cylinder head bolts, then remove cylinder head.
    1. Uniformly loosen and remove the 16 cylinder head bolts, in several passes, in the sequence shown.
    2.  
    3. Remove the 16 cylinder head bolts and plate washers.
      WARNING
      Head warpage or cracking could result from removing bolts in an incorrect order.

    4.  
    5. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.
      WARNING
      Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

    6.  

  6.  

To install:

Thoroughly clean all parts to be assembled. Always use a new head and manifold gasket. The cylinder head gasket is a metal gasket. Take care not to bend it. Rotate the crankshaft, set the No. 1 piston at TDC.

  1. Ensure the sealant locations on the cylinder head and cylinder block are free of engine oil or any debris.
  2.  
  3. Apply sealant on the cylinder block top face before assembling cylinder head gaskets.
    NOTE
    The part must be assembled within 5 minutes after sealant is applied. The bead width should be 0.08-0.12 inch (2-3mm). The sealant location: 0.04-0.06 inch (1.0-1.5mm) from block surface. Recommended sealant: Liquid sealant TB1217H.

  4.  
  5. Install the cylinder head. Remove any extruded sealant after assembling cylinder heads.
  6.  
  7. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
  8.  
  9. Install cylinder head bolts.
    1. Do not apply engine oil on the threads or under the heads of the cylinder head bolts.
    2.  
    3. Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.

      Step 1-Tightening torque: 28-30 ft. lbs. (37-41 Nm)
       
      Step 2-Tighten an additional: 120° plus or minus 2°
       
      Step 3-Tighten an additional: 90° plus or minus 2°
       

    4.  
    5. Tighten bolt (A) to: 14-17 ft. lbs. (19-24 Nm).
      NOTE
      Always use new cylinder head bolts.



      Click image to see an enlarged view

      Fig. Uniformly loosen/tighten and remove/install the 16 cylinder head bolts, in several passes, in the sequence shown



      Click image to see an enlarged view

      Fig. Tighten bolt (A) to 14-17 ft. lbs. (19-24 Nm)

    6.  

  10.  
  11. Install the Continuously Variable Valve Timing (CVVT) and camshaft sprocket. Tightening torque: 48-56 ft. lbs. (65-76 Nm).
    1. Install camshaft-inlet to dowel pin of CVVT assembly. At this time, do not install to oil hole of camshaft-inlet.
    2.  
    3. Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
    4.  
    5. Do not rotate the CVVT assembly when the camshaft is installed to the dowel pin of the CVVT assembly.
    6.  

  12.  
  13. Install the camshafts.
    1. Apply a light coat of engine oil on camshaft journals.
    2.  
    3. Assemble the key groove of camshaft rear side to the same level of head top surface.
    4.  
    5. Be careful to get the right bank, left bank, intake side, and exhaust side in the correct position before assembling.
    6.  

  14.  
  15. Install the camshaft bearing caps in the sequence shown:
    1. Step 1-Tightening torque: 48 inch lbs. (6 Nm).
    2.  
    3. Step 2-Tightening torque: 84-108 inch lbs. (10-12 Nm).
      WARNING
      Be careful to properly position the right bank, left bank, intake side, exhaust side, and front mark on the camshaft bearing caps while assembling.


      WARNING
      Rotate the crankshaft so as not to contact the valves to the pistons by positioning the pistons 0.3937 inch (10mm) below the top of the cylinder block.



      Click image to see an enlarged view

      Fig. Install the camshaft bearing caps in the sequence shown



      Click image to see an enlarged view

      Fig. Be careful to properly position the camshaft bearing caps according to its markings

    4.  

  16.  
  17. Install the water temperature control assembly.
  18.  
  19. Install the timing chain.
  20.  
  21. Check and adjust the valve clearance, as necessary.
  22.  
  23. Install the exhaust manifold.
  24.  
  25. Install the intake manifold.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Fill with engine coolant.
  30.  
  31. Start the engine and check for leaks.
  32.  
  33. Recheck the engine coolant level and oil level.

    Click image to see an enlarged view

    Fig. Exploded view of cylinder head and engine block



    Click image to see an enlarged view

    Fig. Exploded view of cylinder head and related components

  34.  

1.6L & 2.0L Engines

Specific to:

Hyundai Accent 2006-2008

Hyundai Elantra 2006-2008

Hyundai Tiburon 2006-2008

Engine removal is not required for this procedure. Use a fender cover to avoid damaging painted surfaces. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection. Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at Top Dead Center (TDC).

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the terminals from battery and remove the battery.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the undercover.
  8.  
  9. Drain the engine coolant. Remove the radiator cap to speed draining.
  10.  
  11. Remove the intake air hose and air cleaner assembly:
    1. Disconnect the breather hose from intake air hose.
    2.  
    3. Remove the intake air hose and air cleaner upper cover.
    4.  
    5. Disconnect the ECM connectors.
    6.  
    7. Remove the air cleaner element and air cleaner lower cover.
    8.  

  12.  
  13. Remove the battery tray.
  14.  
  15. Remove the upper radiator hose and lower radiator hose.
  16.  
  17. Remove the heater hoses.
  18.  
  19. Remove the fuel hose.
  20.  
  21. Remove the accelerator cable by loosening the lock-nut, then slip the cable end out of the throttle linkage.
  22.  
  23. Disconnect the Throttle Position Sensor (TPS) connector and the MAP sensor connector.
  24.  
  25. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold:
    1. Disconnect the rear oxygen sensor connector.
    2.  
    3. Disconnect the air conditioner compressor switch connector.
    4.  
    5. Disconnect the knock sensor connector.
    6.  
    7. Disconnect the injector connectors.
    8.  
    9. Remove the wire harness bracket.
    10.  
    11. Disconnect the Idle Speed Actuator (ISA) connector.
    12.  
    13. Disconnect the front oxygen sensor connector.
    14.  
    15. Disconnect the Crankshaft Position Sensor (CKP) connector.
    16.  
    17. Disconnect the Oil Control Valve (OCV) connector.
    18.  
    19. Disconnect the ignition coil connector.
    20.  
    21. Disconnect the ignition coil condenser connector.
    22.  
    23. Disconnect the Camshaft Position Sensor (CMP) connector.
    24.  
    25. Disconnect the ground cable.
    26.  
    27. Remove the wire harness bracket.
    28.  

  26.  
  27. Remove or disconnect the following:

    The hose of the Purge Control Solenoid Valve (PCSV) side
     
    The brake booster vacuum hose
     
    The power steering pump and fix the pump to vehicle with a wire
     
    The ignition coil
     
    The exhaust manifold
     
    The intake manifold
     
    The timing belt
     
    The cylinder head cover
     
    The camshaft sprocket
     
    The timing chain auto tensioner
     
    The camshaft bearing caps and camshafts
     
    The OCV
     
    The OCV filter
     
    The engine mounting support bracket fixing bolts
     

  28.  
  29. Remove the cylinder head bolts, then remove the cylinder head:
    1. Using an 8mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Head warpage or cracking could result from removing bolts in an incorrect order.
    2.  
    3. Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench. Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

      Click image to see an enlarged view

      Fig. Cylinder head torque/loosen sequence-1.6L & 2.0L engines



      Click image to see an enlarged view

      Fig. Exploded view of cylinder head and engine block-1.6L engine



      Click image to see an enlarged view

      Fig. Exploded view of cylinder head and related components-1.6L engine



      Click image to see an enlarged view

      Fig. Exploded view of cylinder head and related components-2.0L engine

    4.  

  30.  

To install:

Thoroughly clean all parts to be assembled. Always use a new cylinder head and manifold gasket. Always use a new cylinder head bolt. The cylinder head gasket is a metal gasket. Take care not to bend it. Rotate the crankshaft, set the No. 1 piston at TDC.

  1. Install the cylinder head gasket on the cylinder block. Be careful of the installation direction.
  2.  
  3. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
  4.  
  5. Install the cylinder head bolts:
    1. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
    2.  
    3. Using an 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.

      1.6L engine-Step 1: 22 ft. lbs. (29 Nm) plus 90°
       
      1.6L engine-Step 2: Release all bolts
       
      1.6L engine-Step 3: 22 ft. lbs. (29 Nm) plus 90°
       
      2.0L engine-M10 bolts Step 1: 18 ft. lbs. (25 Nm) plus 60°-65°
       
      2.0L engine-M10 bolts Step 2: Additional 60°-65°
       
      2.0L engine-M12 bolts Step 1: 22 ft. lbs. (29 Nm) plus 60°-65°
       
      2.0L engine-M12 bolts Step 2: Additional 60°-65°
       

    4.  

  6.  
  7. Install the engine mounting support bracket fixing bolts.
  8.  
  9. Install the OCV filter. Tightening torque: 30-37 ft. lbs. (40-50 Nm).
    NOTE
    Always use a new OCV filter gasket and keep the OCV filter clean.

  10.  
  11. Install the OCV. Tightening torque: 84-108 inch lbs. (10-12 Nm).
    NOTE
    Do not reuse the OCV when dropped. Keep the OCV clean. Do not hold the OCV sleeve during servicing. When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.

  12.  
  13. Install the camshafts:
    1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.

      Click image to see an enlarged view

      Fig. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket-1.6L engine

    2.  
    3. Install the camshaft and bearing caps.

      1.6L engine-Tightening torque: 108-120 inch lbs. (12-14 Nm).
       
      2.0L engine-Tightening torque: 120-132 inch lbs. (14-15 Nm)
       

    4.  
    5. Install the timing chain auto tensioner. Tightening torque: 72-84 inch lbs. (8-10 Nm).
    6.  

  14.  
  15. Using the SST (09221 - 21000), install the camshaft bearing oil seal.
  16.  
  17. Install the camshaft sprocket.
  18.  
  19. Install the cylinder head cover.
    1. Install the cylinder head cover gasket in the groove of the cylinder head cover.
      NOTE
      Before installing the cylinder head cover gasket, thoroughly clean the cylinder head cover and the groove. When installing, make sure the cylinder head cover gasket is seated securely in the corners of the recesses with no gap.

    2.  
    3. Apply liquid gasket to the head cover gasket at the corners of the recess.
      NOTE
      Use liquid gasket, Loctite® No. 5999. Check that the mating surfaces are clean and dry before applying liquid gasket. After assembly, wait at least 30 minutes before filling the engine with oil.

    4.  
    5. Install the cylinder head cover with bolts.

      Step 1: Pre-tighten all bolts by 36-48 inch lbs. (4-5 Nm)
       
      Step 2: Tighten by the specified torque 72-84 inch lbs. (8-10 Nm)
       

    6.  

  20.  
  21. Install or connect the following:

    The timing belt
     
    The intake manifold
     
    The exhaust manifold
     
    The ignition coil
     
    The power steering pump
     
    The brake booster hose
     
    The hose of the PCSV side
     

  22.  
  23. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold:

    The wire harness bracket
     
    The ground cable
     
    The CMP(Camshaft position sensor) connector
     
    The ignition coil condenser connector
     
    The ignition coil connector
     
    The OCV connector
     
    The CKP connector
     
    The front oxygen sensor connector
     
    The ISA connector
     
    The wire harness bracket
     
    The fuel injector connectors
     
    The knock sensor connector
     
    The air conditioner compressor switch connector
     
    The rear oxygen sensor connector
     

  24.  
  25. Install or connect the following:

    The TPS connector and the MAP sensor connector
     
    The accelerator cable
     
    The fuel hose
     
    The heater hoses
     
    The upper radiator hose(A) and lower radiator hose
     
    The battery tray
     
    The intake air hose and air cleaner assembly
     

  26.  
  27. Install the air cleaner element and air cleaner lower cover. Tightening torque: 72-84 inch lbs. (8-10 Nm).
  28.  
  29. Connect the ECM connectors.
  30.  
  31. Install the intake air hose and air cleaner upper cover.
  32.  
  33. Connect the breather hose to intake air hose.
  34.  
  35. Install the undercover.
  36.  
  37. Install the engine cover. Tightening torque: 36-48 inch lbs. (4-6 Nm).
  38.  
  39. Install the battery and connect the battery terminals.
  40.  
  41. Fill with engine coolant.
  42.  
  43. Start the engine and check for leaks.
  44.  
  45. Recheck engine coolant level and oil level.
  46.  

2.7L Engine

Specific to:

Hyundai Tiburon 2006-2008

Engine removal is not required for this procedure. Use a fender cover to avoid damaging painted surfaces. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection. Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at Top Dead Center (TDC).

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the side cover (A, B, C) and the engine cover (D).
  4.  
  5. Disconnect the battery terminal and the battery.

    Click image to see an enlarged view

    Fig. Remove the side cover and engine cover-2.7L engine

  6.  
  7. Remove the radiator drain plug and drain engine coolant. Remove the radiator cap to speed draining.
  8.  
  9. Remove the air cleaner assembly.
    1. Disconnect the Air Flow Sensor (AFS) connector.
    2.  
    3. Remove the breather hose from intake hose.
    4.  
    5. Remove the intake hose and air cleaner upper cover.
    6.  
    7. Remove the air cleaner lower cover.
    8.  

  10.  
  11. Remove the upper radiator hose and lower radiator hose.
  12.  
  13. Remove the heater hoses.
  14.  
  15. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold:

    Throttle position sensor (TPS) connector
     
    Idle speed actuator (ISA) connector
     
    Purge Control Solenoid Valve (PCSV) connector
     
    Knock sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    Engine ground line
     
    Heated oxygen sensor (Bank 2, Sensor 1) connector
     
    Engine temperature coolant sensor connector
     
    Ignition coil connector
     
    Crankshaft Position (CKP) sensor connector
     
    Heated oxygen sensor (Bank 1, Sensor 2) connector
     
    Fuel injector connectors
     

  16.  
  17. Remove or disconnect the following:

    The fuel inlet from the delivery pipe
     
    The Purge Control Solenoid Valve (PCSV) hose
     
    The brake booster vacuum hose
     
    The accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage
     
    The auto-cruise connector and the auto-cruise cable
     
    The PCV hose
     
    The intake manifold
     
    The power steering pump
     
    The exhaust manifold
     
    The timing belt
     
    The cylinder head covers
     
    The camshaft sprocket
     
    The camshaft bearing caps
     
    The camshafts
     
    The timing belt rear cover
     
    The water temperature control assembly and water pipe
     

  18.  
  19. Remove the cylinder head bolts, then remove the cylinder heads.
    1. Uniformly loosen and remove the 8 cylinder head bolts on each cylinder head in several passes and in the sequence shown, then repeat for the other side, as shown. Remove the 16 cylinder head bolts and plate washer.
      WARNING
      Head warpage or cracking could result from removing bolts in an incorrect order.

    2.  
    3. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.
      WARNING
      Be careful not to damage the contact surfaces of the cylinder head and cylinder block.



      Click image to see an enlarged view

      Fig. Uniformly loosen/tighten and remove/install the cylinder head bolts on each cylinder head in several passes and in the sequence shown-2.7L engine



      Click image to see an enlarged view

      Fig. Exploded view of cylinder head and engine block-2.7L engine



      Click image to see an enlarged view

      Fig. Exploded view of cylinder head and related components-2.7L engine

    4.  

  20.  

To install:

Thoroughly clean all parts to be assembled. Always use a new head gasket and manifold gasket. The cylinder head gasket is a metal gasket. Take care not to bend it. Rotate the crankshaft, set the No. 1 piston at TDC.

  1. Install the cylinder head gaskets on the cylinder block. Be careful of the installation direction.
  2.  
  3. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
  4.  
  5. Install cylinder head bolts:
    1. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
    2.  
    3. Install the plate washer to the cylinder head bolt.
    4.  
    5. Install and uniformly tighten the cylinder head bolts on each cylinder head in several passes and in the sequence shown, then repeat for the other side, as shown.
      NOTE
      If only 1 of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.



      Step 1: Torque bolts to 18 ft. lbs. (25 Nm)
       
      Step 2: Retighten the cylinder head bolts by 60° in the numerical order shown
       
      Step 3: Retighten the cylinder head bolts by 45° in the numerical order shown
       

    6.  

  6.  
  7. Install the water pipe and water temperature control assembly. Tightening torque: 11-5 ft. lbs. (15-20 Nm).
  8.  
  9. Install the timing belt rear cover. Tightening torque: 7-9 ft. lbs. (10-12 Nm).
  10.  
  11. Install the camshafts.
    1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.
    2.  
    3. Install the camshaft.
    4.  
    5. Install the camshaft bearing caps.
      NOTE
      Apply new engine oil to the thrust portion and journal of the camshafts. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.



      Tightening torque: M6 (38mm) bolt: 7-9 ft. lbs. (10-13 Nm)
       
      Tightening torque: M6 (50mm) bolt: 11-12 ft. lbs. (15-17 Nm)
       



      Click image to see an enlarged view

      Fig. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown-2.7L engine

    6.  

  12.  
  13. Using the SST (09214-21000), install the camshaft bearing oil seal.
  14.  
  15. Install the camshaft sprocket.
    1. Temporarily install the camshaft sprocket bolts.
    2.  
    3. Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket bolts. Tightening torque of camshaft sprocket bolt: 65-80 ft. lbs. (88-108 Nm).
    4.  

  16.  
  17. Install the semi-circular packing.
  18.  
  19. Install the cylinder head cover.
    1. Install the cylinder head cover gasket in the groove of the cylinder head cover.
      NOTE
      Before installing the head cover gasket, thoroughly clean the head cover gasket and the groove. When installing, make sure the head cover gasket is seated securely in the corners of the recesses with no gap.

    2.  
    3. Apply liquid gasket to the head cover gasket at the corners of the recess. Use liquid gasket, Loctite® No. 5699. Check that the mating surfaces are clean and dry before applying liquid gasket. After assembly, wait at least 30 minutes before filling the engine with oil.
    4.  
    5. Install the cylinder head covers with the 16 bolts. Uniformly tighten the bolts in several passes. Tightening torque: 6-7 ft. lbs. (8-10 Nm).
    6.  

  20.  
  21. Install or connect the following:

    The timing belt
     
    The exhaust manifold
     
    The power steering pump
     
    The intake manifold
     
    The PCV hose
     
    The auto-cruise connector and the auto- cruise cable
     
    The accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage
     
    The brake booster vacuum hose
     
    The PCSV hose
     
    The fuel inlet from delivery pipe
     
    The fuel injector connectors
     
    Heated oxygen sensor (Bank 1, Sensor 2) connector
     
    Crankshaft position sensor connector
     
    Ignition coil connector
     
    Engine temperature coolant sensor connector
     
    Heated oxygen sensor (Bank 2, Sensor 1) connector
     
    Engine ground line
     
    Camshaft position sensor connector
     
    Knock sensor connector
     
    Injector connector
     
    The PCSV connector
     
    Idle speed actuator connector
     
    Throttle position sensor connector
     

  22.  
  23. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
  24.  
  25. Install the heater hoses.
  26.  
  27. Install the upper radiator hose and lower radiator hose.
  28.  
  29. Install the air cleaner assembly.
    1. Install the air cleaner lower cover.
    2.  
    3. Install the intake hose and air cleaner upper cover.
    4.  
    5. Install the breather hose from intake hose.
    6.  
    7. Connect the AFS connector.
    8.  

  30.  
  31. Connect the battery terminal and the battery.
  32.  
  33. Fill with engine coolant.
  34.  
  35. Install the side cover and the engine cover.
  36.  
  37. Start the engine and check for leaks.
  38.  
  39. Recheck the engine coolant level and oil level.
  40.  

3.3L & 3.8L Engines

Specific to:

Hyundai Azera 2006-2008

Hyundai Sonata 2006-2008

Use a fender cover to avoid damaging painted surfaces. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection. Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at Top Dead Center (TDC).

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Engine removal is required for this procedure.

  2.  
  3. Remove or disconnect the following:

    The negative battery connection
     
    The exhaust manifold
     
    The intake manifold
     
    The timing chain
     
    The water temperature control assembly
     
    The camshaft bearing cap
     
    The camshaft assembly
     

  4.  
  5. The cylinder head bolts, then remove cylinder head.
    1. Uniformly loosen and remove the 16 cylinder head bolts, in several passes, in the sequence shown.
    2.  
    3. Remove the 16 cylinder head bolts and plate washers.
      WARNING
      Head warpage or cracking could result from removing bolts in an incorrect order.

    4.  
    5. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.
      WARNING
      Be careful not to damage the contact surfaces of the cylinder head and cylinder block.



      Click image to see an enlarged view

      Fig. Uniformly loosen/tighten and remove/install the 16 cylinder head bolts, in several passes, in the sequence shown-3.3L and 3.8L engines



      Click image to see an enlarged view

      Fig. Exploded view of cylinder head and engine block-3.3L and 3.8L engines



      Click image to see an enlarged view

      Fig. Exploded view of cylinder head and related components-3.3L and 3.8L engines

    6.  

  6.  

To install:

Thoroughly clean all parts to be assembled. Always use a new head and manifold gasket. The cylinder head gasket is a metal gasket. Take care not to bend it. Rotate the crankshaft, set the No. 1 piston at TDC.

  1. Ensure the sealant locations on the cylinder head and cylinder block are free of engine oil or any debris.
  2.  
  3. Apply sealant on the cylinder block top face before assembling cylinder head gaskets.
    NOTE
    The part must be assembled within 5 minutes after sealant is applied. The bead width should be 0.08-0.12 inch (2-3mm). The sealant location: 0.04-0.06 inch (1.0-1.5mm) from block surface. Recommended sealant: Liquid sealant TB1217H.

  4.  
  5. Install the cylinder head. Remove any extruded sealant after assembling cylinder heads.
  6.  
  7. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
  8.  
  9. Install cylinder head bolts.
    1. Do not apply engine oil on the threads or under the heads of the cylinder head bolts.
    2.  
    3. Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.

      Step 1-Tightening torque: 28-30 ft. lbs. (37-41 Nm)
       
      Step 2-Tighten an additional: 120° plus or minus 2°
       
      Step 3-Tighten an additional: 90° plus or minus 2°
       

    4.  
    5. Tighten bolt (A) to: 14-17 ft. lbs. (19-24 Nm).
      NOTE
      Always use new cylinder head bolts.



      Click image to see an enlarged view

      Fig. Uniformly loosen/tighten and remove/install the 16 cylinder head bolts, in several passes, in the sequence shown-3.3L and 3.8L engines



      Click image to see an enlarged view

      Fig. Tighten bolt (A) to 14-17 ft. lbs. (19-24 Nm)-3.3L and 3.8L engines

    6.  

  10.  
  11. Install the Continuously Variable Valve Timing (CVVT) and camshaft sprocket. Tightening torque: 48-56 ft. lbs. (65-76 Nm).
    1. Install camshaft-inlet to dowel pin of CVVT assembly. At this time, do not install to oil hole of camshaft-inlet.
    2.  
    3. Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
    4.  
    5. Do not rotate the CVVT assembly when the camshaft is installed to the dowel pin of the CVVT assembly.
    6.  

  12.  
  13. Install the camshafts.
    1. Apply a light coat of engine oil on camshaft journals.
    2.  
    3. Assemble the key groove of camshaft rear side to the same level of head top surface.
    4.  
    5. Be careful to get the right bank, left bank, intake side, and exhaust side in the correct position before assembling.
    6.  

  14.  
  15. Install the camshaft bearing caps in the sequence shown:
    1. Step 1-Tightening torque: 48 inch lbs. (6 Nm).
    2.  
    3. Step 2-Tightening torque: 84-108 inch lbs. (10-12 Nm).
      WARNING
      Be careful to properly position the right bank, left bank, intake side, exhaust side, and front mark on the camshaft bearing caps while assembling.


      WARNING
      Rotate the crankshaft so as not to contact the valves to the pistons by positioning the pistons 0.3937 inch (10mm) below the top of the cylinder block.



      Click image to see an enlarged view

      Fig. Install the camshaft bearing caps in the sequence shown-3.3L and 3.8L engines



      Click image to see an enlarged view

      Fig. Be careful to properly position the camshaft bearing caps according to its markings-3.3L and 3.8L engines

    4.  

  16.  
  17. Install the water temperature control assembly.
  18.  
  19. Install the timing chain.
  20.  
  21. Check and adjust the valve clearance, as necessary.
  22.  
  23. Install the exhaust manifold.
  24.  
  25. Install the intake manifold.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Fill with engine coolant.
  30.  
  31. Start the engine and check for leaks.
  32.  
  33. Recheck the engine coolant level and oil level.
  34.  

 
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