Mercedes-Benz Cars 2000-05

Cylinder Head 1

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Removal & Installation




NOTE
Use care to ensure that the valve timing is not disturbed.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Hoses and wires
     
    Camshaft cover
     
    Throttle linkage
     
    Camshaft sprocket nuts
     

  6.  
  7. Mark the chain, sprocket and cam for ease of assembly. Remove the sprocket and chain and wire it aside. Unbolt the manifolds and exhaust header pipe and set them aside.
  8.  


NOTE
Be sure the chain is securely wired so it will not slide into the engine.

  1. Remove or disconnect the following:

    Cylinder head bolts in the reverse order of the illustrated sequence.
     
    Cylinder head
     

  2.  
  3. Clean all gasket material from the sealing surfaces. Be sure the cylinder head locating dowels are positioned in the engine block.
  4.  


WARNING
All Diesel engines utilize cylinder head stretch bolts. These bolts undergo a permanent stretch each time they are tightened. When a maximum length is reached, they must be replaced with new bolts. Before tightening the head bolts on these engines, refer to the illustration for the specific length of the bolts.



Click image to see an enlarged view

Fig. Be sure to replace bolts that are beyond maximum length-Diesel engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-Diesel engine

To install:

  1. Install the cylinder head and gasket. Torque the cylinder head bolts in sequence as follows:
    1. Step 1: 11 ft. lbs. (15 Nm).
    2.  
    3. Step 2: 20 ft. lbs. (35 Nm).
    4.  
    5. Step 3: + 90 degrees.
    6.  
    7. Step 5: wait 10 minutes.
    8.  
    9. Step 6: + additional 90 degrees.
    10.  

  2.  
  3. Install or connect the following:

    Manifolds and exhaust header pipe. Torque the pipe fasteners to 24 ft. lbs. (34 Nm).
     
    Sprocket and chain
     
    Camshaft sprocket nuts
     
    Trowel linkage
     
    Camshaft cover
     
    Hoses and wires
     
    Coolant
     
    Negative battery cable
     

  4.  

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

    Negative battery cable
     

  4.  
  5. Drain and recycle the engine coolant.

    Engine cooling fan and clutch
     
    Fan shroud
     

  6.  


NOTE
The fan clutch is equipped with right-hand thread.

  1. Place a guard plate behind the radiator/condenser to protect it from damage during removal and installation.

    Engine cover
     
    Air cleaner housing, resonance pipe and body
     

  2.  
  3. Properly relieve the fuel system pressure.

    Fuel line
     
    Ignition coils
     
    Cylinder head covers
     

  4.  


NOTE
The intake manifold system must not be disassembled.



Intake manifold
 
Vacuum switchover valve
 
Camshaft Position (CMP) sensor
 

  1. Lock the automatic belt tensioner by rotating the tensioner counterclockwise until a 5mm drift or pin fits through the tensioner.

    Serpentine belt
     
    Heater hose at left cylinder head
     
    Driver side fender liner
     
    Exhaust support bracket
     
    Power steering pump and position it aside leaving the hoses attached
     
    Exhaust system from the exhaust manifolds
     

  2.  
  3. Rotate the engine clockwise to position the crankshaft 40 degrees after top dead center.
  4.  


WARNING
The engine must not be rotated backward.

  1. Lock the camshafts using the Camshaft Locking tools 112 589 00 32 00 and 112 589 01 32 00.
  2.  
  3. Remove or disconnect the following:

    Generator, then the timing chain tensioner
     
    Oil filter housing and heat exchanger
     
    Camshaft gears and attach them to the chain with a cable tie
     
    Camshaft bearing bridges
     
    Timing case-to-cylinder head bolts
     

  4.  
  5. Loosen and remove the cylinder head bolts in stages following the illustrated sequence.

    Cylinder head off the engine block
     
    All gasket material from the sealing surfaces of the cylinder head and engine block. Be careful not to gouge or scratch the surface of the aluminum head. Be sure the cylinder head locating dowels are positioned in the engine block. Clean and dry the head bolt holes using compressed air.
     

  6.  
  7. Measure the length of the cylinder head bolt shafts, new bolt length is 5.57 inches (141.5mm) and the maximum permissible length is 5.69 inches (144.5mm). Replace bolts that measure greater than the maximum permissible length.
  8.  


    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head accessory components-3.2 and 3.7L engines shown; 4.3L and 5.0L engines similar



    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head removal-3.2 and 3.7L engines shown; 4.3L and 5.0L engines similar



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-3.2 and 3.7L engines



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-4.3L and 5.0L engines


To install:



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.2 and 3.7L engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-4.3L and 5.0L engines

  1. Clean the head bolt threads, then apply clean engine oil to the thread and head contact surfaces.
  2.  
  3. Install the cylinder head to the engine block and tighten the head bolts according to sequence as follows:
    1. Step 1. 96 inch lbs. (10 Nm).
    2.  
    3. Step 2. 22 ft. lbs. (30 Nm).
    4.  
    5. Step 3. 90 degrees.
    6.  
    7. Step 4. additional 90 degrees.
    8.  

  4.  
  5. Install or connect the following:

    Timing case-to-cylinder head bolts and tighten to 15 ft. lbs. (20 Nm)
     
    Camshaft bearing bridges
     
    Camshaft gear and tighten the mounting bolt to 37 ft. lbs. (50 Nm) plus an additional 90 degrees. Check the basic camshaft position and adjust if necessary.
     
    Timing chain tensioner with a new gasket and tighten to 59 ft. lbs. (80 Nm)
     
    Generator
     

  6.  
  7. Remove the camshaft locking plates.

    Exhaust system to the manifolds and tighten the mounting nuts to 15 ft. lbs. (20 Nm)
     
    Heater hose to the cylinder head
     
    Power steering pump
     
    Serpentine belt and remove the locking pin
     
    CMP sensor
     
    Vacuum switchover valve
     
    Intake manifold
     
    Cylinder head covers and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Ignition coils and tighten the mounting bolts to 70 inch lbs. (8 Nm)
     
    Fuel pipe
     
    Air cleaner housing, resonance pipe and body
     
    Engine cover
     

  8.  
  9. Remove the guard plate from the radiator/condenser.

    Fan shroud, then the cooling fan
     

  10.  
  11. Fill the engine with coolant.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Read fault memory, encode the radio and normalize the power windows.
  16.  
  17. Start the vehicle and check for leaks.
  18.  


NOTE
Use care to ensure that the valve timing is not disturbed.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Hoses and wires
     
    Camshaft cover
     
    Throttle linkage
     
    Camshaft sprocket nuts
     

  6.  
  7. Mark the chain, sprocket and cam for ease of assembly. Remove the sprocket and chain and wire it aside. Unbolt the manifolds and exhaust header pipe and set them aside.
    NOTE
    Be sure the chain is securely wired so it will not slide into the engine.

  8.  
  9. Remove or disconnect the following:

    Cylinder head bolts in the reverse order of the illustrated sequence.
     
    Cylinder head
     

  10.  
  11. Clean all gasket material from the sealing surfaces. Be sure the cylinder head locating dowels are positioned in the engine block.
    WARNING
    All Diesel engines utilize cylinder head stretch bolts. These bolts undergo a permanent stretch each time they are tightened. When a maximum length is reached, they must be replaced with new bolts. Before tightening the head bolts on these engines, refer to the illustration for the specific length of the bolts.



    Click image to see an enlarged view

    Fig. Be sure to replace bolts that are beyond maximum length-Diesel engines

  12.  

To install:

  1. Install the cylinder head and gasket. Torque the cylinder head bolts in sequence as follows:

    11 ft. lbs. (15 Nm)
     
    20 ft. lbs. (35 Nm)
     
    + 90 degrees
     
    wait 10 minutes
     
    + additional 90 degrees
     

  2.  
  3. Install or connect the following:

    Manifolds and exhaust header pipe. Torque the pipe fasteners to 24 ft. lbs. (34 Nm)
     
    Sprocket and chain
     
    Camshaft sprocket nuts
     
    Trowel linkage
     
    Camshaft cover
     
    Hoses and wires
     
    Coolant
     
    Negative battery cable
     

  4.  

1.8L And 2.3L (111) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust system and bracket at transmission
     
    Thermostat housing cover
     
    Air intake tubes
     
    Electrical connectors
     
    Coolant hose (3) at the rear of the cylinder head
     
    Intake manifold (19). Position it aside.
     
    Crankcase breather hose
     
    Manifold bracket (2)
     
    Valve cover
     
    Thermostat housing
     
    Cylinder head front cover
     
    Heated (HO2S) sensor connector
     
    Engine and transmission dipstick guide tubes (7) (8)
     

  6.  
  7. Position crankshaft to 20-30 degrees After Top Dead Center (ATDC) for cylinder No. 1.
  8.  
  9. Lock the camshafts (75 and 78) with locking pins (01) and matchmark the timing chain to the sprockets.
  10.  
  11. Remove or disconnect the following:

    Chain tensioner (14)
     
    Chain guide rail in the cylinder head
     
    Exhaust camshaft sprocket (76)
     
    Intake camshaft sprocket (74)
     

  12.  
  13. Install the cylinder head removal bracket (16) and remove the guide rail pin (11), using a threaded extractor.

    Timing chain housing bolts (A)
     
    Cylinder head bolts in the reverse order of the illustrated tightening sequence
     

  14.  


CAUTION
Never use a prybar between the head and block.

  1. Remove the cylinder head and clean all gasket material from the sealing surfaces. Be sure the cylinder head locating dowels are positioned correctly in the engine block.
  2.  
  3. Inspect length of the cylinder head bolt shaft. New bolt length is 102mm and the maximum permissible length is 105mm. Replace bolts that measure greater than the maximum permissible length.
  4.  

To install:



Click image to see an enlarged view

Fig. Exploded view of the cylinder head accessory components-1.8L and 2.3L (111) engines



Click image to see an enlarged view

Fig. Exploded view of the cylinder head mounting-1.8L and 2.3L (111) engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-1.8L and 2.3L (111) engines


NOTE
The head gasket is not watertight until the engine has reached operating temperature. Do not pressure test the cooling system until the engine has reached operating temperature.

  1. Verify the Top Dead Center (TDC) position of the No. 1 cylinder. Clean the head bolt threads and apply clean engine oil to the thread and head contact surfaces.
  2.  
  3. Install or connect the following:

    Head gasket and cylinder head. Torque the head bolts using the illustrated sequence to 41 ft. lbs. (55 Nm) plus 90 degrees, then an additional 90 degrees.
     
    Timing chain housing bolts
     
    Guide rail pin
     

  4.  
  5. Remove the cylinder head removal bracket.

    Intake and exhaust camshaft sprockets
     
    Guide rail
     
    Chain tensioner
     

  6.  
  7. Remove the camshaft locking pins and verify timing mark alignment.

    Engine oil and transmission dipstick guide tubes
     
    HO2S sensor
     
    Cylinder head front cover
     
    Thermostat housing
     
    Valve cover
     
    Cylinder head coolant hose
     
    Crankcase breather hose
     
    Intake manifold
     
    Electrical connectors
     
    Thermostat housing cover and air intake tubes
     
    Exhaust system and bracket
     
    Coolant
     
    Negative battery cable
     

  8.  

2.2L And 2.3L (111) Engines

NOTE
Cylinder head tightening illustrations are located in Section 1 of this manual. The illustrations follow the Torque Charts.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust system and bracket at transmission
     
    Thermostat housing cover
     
    Air intake tubes
     
    Electrical connectors
     
    Coolant hose (3) at the rear of the cylinder head
     
    Intake manifold (19). Position it aside
     
    Crankcase breather hose
     
    Manifold bracket (2)
     
    Valve cover
     
    Thermostat housing
     
    Cylinder head front cover
     
    HO 2 S sensor connector
     
    Engine and transmission dipstick guide tubes (7) (8)
     

  6.  
  7. Position crankshaft to 20-30 degrees ATDC for cylinder No. 1.
  8.  
  9. Lock the camshafts (75 and 78) with locking pins (01) and matchmark the timing chain to the sprockets.
  10.  
  11. Remove or disconnect the following:

    Chain tensioner (14)
     
    Chain guide rail in the cylinder head
     
    Exhaust camshaft sprocket (76)
     
    Intake camshaft sprocket (74)
     

  12.  
  13. Install the cylinder head removal bracket (16) and remove the guide rail pin (11), using a threaded extractor.
  14.  
  15. Remove or disconnect the following:
    CAUTION
    Never use a prybar between the head and block.



    Timing chain housing bolts (A)
     
    Cylinder head bolts in the reverse order of the illustrated tightening sequence
     

  16.  
  17. Remove the cylinder head and clean all gasket material from the sealing surfaces. Be sure the cylinder head locating dowels are positioned correctly in the engine block.
  18.  
  19. Inspect length of the cylinder head bolt shaft. New bolt length is 102mm and the maximum permissible length is 105mm. Replace bolts that measure greater than the maximum permissible length.
  20.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the cylinder head accessory components-2.2L and 2.3L (111) engines



Click image to see an enlarged view

Fig. Exploded view of the cylinder head mounting-2.2L and 2.3L (111) engines


NOTE
The head gasket is not watertight until the engine has reached operating temperature. Do not pressure test the cooling system until the engine has reached operating temperature.

  1. Verify the TDC position of the No. 1 cylinder. Clean the head bolt threads and apply clean engine oil to the thread and head contact surfaces.
  2.  
  3. Install or connect the following:

    Head gasket and cylinder head. Torque the head bolts using the illustrated sequence to 41 ft. lbs. (55 Nm) plus 90 degrees, then an additional 90 degrees
     
    Timing chain housing bolts
     
    Guide rail pin
     

  4.  
  5. Remove the cylinder head removal bracket.
  6.  
  7. Install or connect the following:

    Intake and exhaust camshaft sprockets
     
    Guide rail
     
    Chain tensioner
     

  8.  
  9. Remove the camshaft locking pins and verify timing mark alignment.
  10.  
  11. Install or connect the following:

    Engine oil and transmission dipstick guide tubes
     
    HO 2 S sensor
     
    Cylinder head front cover
     
    Thermostat housing
     
    Valve cover
     
    Cylinder head coolant hose
     
    Crankcase breather hose
     
    Intake manifold
     
    Electrical connectors
     
    Thermostat housing cover and air intake tubes
     
    Exhaust system and bracket
     
    Coolant
     
    Negative battery cable
     

  12.  


NOTE
Cylinder head tightening illustrations are located in Section 1 of this manual. The illustrations follow the Torque Charts.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust system and bracket at transmission
     
    Thermostat housing cover
     
    Air intake tubes
     
    Electrical connectors
     
    Coolant hose (3) at the rear of the cylinder head
     
    Intake manifold (19). Position it aside
     
    Crankcase breather hose
     
    Manifold bracket (2)
     
    Valve cover
     
    Thermostat housing
     
    Cylinder head front cover
     
    HO 2 S sensor connector
     
    Engine and transmission dipstick guide tubes (7) (8)
     

  6.  
  7. Position crankshaft to 20-30 degrees ATDC for cylinder No. 1.
  8.  
  9. Lock the camshafts (75 and 78) with locking pins (01) and matchmark the timing chain to the sprockets.
  10.  
  11. Remove or disconnect the following:

    Chain tensioner (14)
     
    Chain guide rail in the cylinder head
     
    Exhaust camshaft sprocket (76)
     
    Intake camshaft sprocket (74)
     

  12.  
  13. Install the cylinder head removal bracket (16) and remove the guide rail pin (11), using a threaded extractor.
  14.  
  15. Remove or disconnect the following:
    CAUTION
    Never use a prybar between the head and block.



    Timing chain housing bolts (A)
     
    Cylinder head bolts in the reverse order of the illustrated tightening sequence
     

  16.  
  17. Remove the cylinder head and clean all gasket material from the sealing surfaces. Be sure the cylinder head locating dowels are positioned correctly in the engine block.
  18.  
  19. Inspect length of the cylinder head bolt shaft. New bolt length is 102mm and the maximum permissible length is 105mm. Replace bolts that measure greater than the maximum permissible length.
  20.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the cylinder head accessory components-2.2L and 2.3L (111) engines



Click image to see an enlarged view

Fig. Exploded view of the cylinder head mounting-2.2L and 2.3L (111) engines


NOTE
The head gasket is not watertight until the engine has reached operating temperature. Do not pressure test the cooling system until the engine has reached operating temperature.

  1. Verify the TDC position of the No. 1 cylinder. Clean the head bolt threads and apply clean engine oil to the thread and head contact surfaces.
  2.  
  3. Install or connect the following:

    Head gasket and cylinder head. Torque the head bolts using the illustrated sequence to 41 ft. lbs. (55 Nm) plus 90 degrees, then an additional 90 degrees
     
    Timing chain housing bolts
     
    Guide rail pin
     

  4.  
  5. Remove the cylinder head removal bracket.
  6.  
  7. Install or connect the following:

    Intake and exhaust camshaft sprockets
     
    Guide rail
     
    Chain tensioner
     

  8.  
  9. Remove the camshaft locking pins and verify timing mark alignment.
  10.  
  11. Install or connect the following:

    Engine oil and transmission dipstick guide tubes
     
    HO 2 S sensor
     
    Cylinder head front cover
     
    Thermostat housing
     
    Valve cover
     
    Cylinder head coolant hose
     
    Crankcase breather hose
     
    Intake manifold
     
    Electrical connectors
     
    Thermostat housing cover and air intake tubes
     
    Exhaust system and bracket
     
    Coolant
     
    Negative battery cable
     

  12.  

2.6L, 2.8L And 3.2L (112) And 4.3L, 5.0L And 5.5L (113) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure and drain the engine coolant. Place a guard plate behind the radiator/condenser to protect it from damage.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fan clutch, fan and shroud
     
    Engine cover
     
    Air cleaner housing, resonance pipe and body
     
    Fuel line
     
    Ignition coils
     
    Cylinder head covers
     

  6.  


NOTE
The intake manifold system must not be disassembled.



Intake manifold
 
Vacuum switchover valve
 
Camshaft Position (CMP) sensor
 

  1. Lock the Automatic belt tensioner by rotating the tensioner counterclockwise until a 5mm drift or pin fits through the tensioner, and then remove the serpentine belt.
  2.  
  3. Remove or disconnect the following:

    Power steering pump and position it aside leaving the hoses attached
     
    Serpentine belt
     
    Heater hose at the firewall
     
    Exhaust system
     

  4.  
  5. Rotate the engine clockwise to position the crankshaft 40 degrees After Top Dead Center (ATDC).
  6.  


WARNING
The engine must not be rotated backwards.

  1. Lock the camshafts using camshaft locking tools.
  2.  
  3. Remove or disconnect the following:

    Generator
     
    Timing chain tensioner
     
    Camshaft gears. Attach to the chain with a cable tie.
     
    Camshaft bearing bridges
     
    Camshafts
     
    Timing case-to-cylinder head bolts
     
    Cylinder head bolts in the reverse order of the illustrated tightening sequence
     

  4.  


CAUTION
Never use a prybar between the head and block.

  1. Remove the cylinder head and clean all gasket material from the sealing surfaces. Be sure the cylinder head locating dowels are positioned in the engine block.
  2.  
  3. Inspect length of the cylinder head bolt shaft. New bolt length is 141.5mm and the maximum permissible length is 144.5mm. Replace bolts that measure greater than the maximum permissible length.
  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head accessory components-2.6L, 2.8L and 3.2L (112) shown: 4.3L, 5.0L and 5.5L (113) engines similar



    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head removal-2.6L, 2.8L and 3.2L (112) shown: 4.3L, 5.0L and 5.5L (113) engines similar



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-2.6L, 2.8L and 3.2L (112) engines



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-4.3L, 5.0L and 5.5L (113) engines


To install:

  1. Clean the head bolt threads and apply clean engine oil to the thread and head contact surfaces.
  2.  
  3. Install the cylinder head gasket and head. Torque the head bolts according to the illustrated sequence as follows:
    1. Step 1: 15 ft. lbs. (20 Nm).
    2.  
    3. Step 2: 37 ft. lbs. (50 Nm).
    4.  
    5. Step 3: 60-70 degrees.
    6.  
    7. Step 4: Additional 60-70 degrees.
    8.  

  4.  
  5. Install or connect the following:

    Timing case-to-cylinder head bolts and torque to 15 ft. lbs. (20 Nm)
     
    Camshafts
     
    Camshaft bearing bridges
     
    Camshaft gear. Torque the mounting bolt to 37 ft. lbs. (50 Nm) plus an additional 90 degrees.
     
    Timing chain tensioner with new gasket. Torque to 59 ft. lbs. (80 Nm).
     
    Generator
     

  6.  
  7. Remove the camshaft locking plates.

    Exhaust system. Torque mounting nuts to 15 ft. lbs. (20 Nm).
     
    Heater hose
     
    Power steering pump
     
    Serpentine belt
     
    CMP sensor
     
    Vacuum switchover valve
     
    Intake manifold
     
    Cylinder head covers. Torque the bolts to 88 inch lbs. (10 Nm).
     
    Ignition coils. Torque the mounting bolts to 70 inch lbs. (8 Nm).
     
    Fuel line
     
    Air cleaner housing, resonance pipe and body
     
    Engine cover
     
    Fan clutch, fan and shroud
     

  8.  
  9. Remove the guard plate from the radiator/condenser.
  10.  
  11. Fill the cooling system, connect the negative battery cable, start the engine and check for leaks.
  12.  

2.8L, 3.2L And 3.6L (104) Engine

NOTE
Cylinder head tightening illustrations are located in Section 1 of this manual. The illustrations follow the Torque Charts.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure and drain the engine coolant.
  4.  
  5. Position the No. 1 cylinder at TDC.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Coolant hoses
     
    Upper timing cover
     

  8.  
  9. Matchmark the camshaft sprocket to the timing chain, and remove the pin (1) for the timing chain guide with a threaded extractor.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Be sure the chain is securely wired so it will not slide into the engine.



    Guide sprocket (left-hand thread)
     
    Bearing assembly
     
    Timing chain from the camshaft sprockets. Wire the chain aside
     

  12.  
  13. Remove or disconnect the following:

    Vacuum hoses and electrical connectors
     
    Exhaust system
     
    Secondary air injection pipe if equipped
     
    Dipstick tube support bracket
     
    Crankcase breather hose
     
    Fuel lines
     
    Dipstick tube
     
    Throttle, kickdown and cruise control cables
     

  14.  
  15. Loosen the head bolts in stages in the reverse order of the illustrated sequence.
    CAUTION
    Never use a prybar between the head and the block.

  16.  
  17. Remove the cylinder head and clean all gasket material from the sealing surfaces. Be sure the cylinder head locating dowels are positioned correctly in the engine block.
  18.  
  19. Inspect length of the cylinder head bolt shaft. New bolt length is 6.30 inches (160mm), and the maximum permissible length is 6.44 inches (163.5mm). Replace bolts that measure greater than the maximum permissible length.
  20.  

To install:


NOTE
The head will not be watertight until the engine reaches operating temperature. Do not pressure test the cooling system until the engine has reached operating temperature.



Click image to see an enlarged view

Fig. Cylinder head gasket identification-2.8L 3.2L and 3.6L (104) Engines

  1. Rotate the camshafts so that the bottom edge of the holes in the camshaft flange, are level with the top edge of the cylinder head.

    Click image to see an enlarged view

    Fig. Verify the correct position of the camshafts for cylinder head installation using a 4mm pin (1)-2.8L 3.2L and 3.6L (104) Engines

  2.  
  3. Verify the TDC position of the No. 1 cylinder. Clean the head bolt threads, and then apply clean engine oil to the thread and head contact surfaces.
  4.  
  5. Install the head gasket and cylinder head.
  6.  
  7. Torque the head bolts using the illustrated sequence to 41 ft. lbs. (55 Nm) plus 90 degrees, then an additional 90 degrees.
  8.  
  9. Install or connect the following:

    Timing chain and upper timing chain guide
     
    Timing chain guide pin
     
    Guide sprocket and bearing assembly. Torque the bolt to 26 ft. lbs. (35 Nm)
     
    Throttle, kickdown and cruise control cables
     
    Fuel lines
     
    Crankcase breather hose
     
    Oil dipstick tube
     
    Secondary air injection pipe if equipped
     
    Exhaust system
     
    Vacuum hoses and electrical connectors
     
    Coolant hoses
     
    Coolant
     
    Negative battery cable
     

  10.  


NOTE
Cylinder head tightening illustrations are located in Section 1 of this manual. The illustrations follow the Torque Charts.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure and drain the engine coolant.
  4.  
  5. Position the No. 1 cylinder at TDC.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Coolant hoses
     
    Upper timing cover
     

  8.  
  9. Matchmark the camshaft sprocket to the timing chain, and remove the pin (1) for the timing chain guide with a threaded extractor.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Be sure the chain is securely wired so it will not slide into the engine.



    Guide sprocket (left-hand thread)
     
    Bearing assembly
     
    Timing chain from the camshaft sprockets. Wire the chain aside
     

  12.  
  13. Remove or disconnect the following:

    Vacuum hoses and electrical connectors
     
    Exhaust system
     
    Secondary air injection pipe if equipped
     
    Dipstick tube support bracket
     
    Crankcase breather hose
     
    Fuel lines
     
    Dipstick tube
     
    Throttle, kickdown and cruise control cables
     

  14.  
  15. Loosen the head bolts in stages in the reverse order of the illustrated sequence.
    CAUTION
    Never use a prybar between the head and the block.

  16.  
  17. Remove the cylinder head and clean all gasket material from the sealing surfaces. Be sure the cylinder head locating dowels are positioned correctly in the engine block.
  18.  
  19. Inspect length of the cylinder head bolt shaft. New bolt length is 6.30 inches (160mm), and the maximum permissible length is 6.44 inches (163.5mm). Replace bolts that measure greater than the maximum permissible length.
  20.  

To install:


NOTE
The head will not be watertight until the engine reaches operating temperature. Do not pressure test the cooling system until the engine has reached operating temperature.



Click image to see an enlarged view

Fig. Cylinder head gasket identification-2.8L 3.2L and 3.6L (104) Engines

  1. Rotate the camshafts so that the bottom edge of the holes in the camshaft flange, are level with the top edge of the cylinder head.

    Click image to see an enlarged view

    Fig. Verify the correct position of the camshafts for cylinder head installation using a 4mm pin (1)-2.8L 3.2L and 3.6L (104) Engines

  2.  
  3. Verify the TDC position of the No. 1 cylinder. Clean the head bolt threads, and then apply clean engine oil to the thread and head contact surfaces.
  4.  
  5. Install the head gasket and cylinder head.
  6.  
  7. Torque the head bolts using the illustrated sequence to 41 ft. lbs. (55 Nm) plus 90 degrees, then an additional 90 degrees.
  8.  
  9. Install or connect the following:

    Timing chain and upper timing chain guide
     
    Timing chain guide pin
     
    Guide sprocket and bearing assembly. Torque the bolt to 26 ft. lbs. (35 Nm)
     
    Throttle, kickdown and cruise control cables
     
    Fuel lines
     
    Crankcase breather hose
     
    Oil dipstick tube
     
    Secondary air injection pipe if equipped
     
    Exhaust system
     
    Vacuum hoses and electrical connectors
     
    Coolant hoses
     
    Coolant
     
    Negative battery cable
     

  10.  

3.2L (104) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure and drain the engine coolant.
  4.  
  5. Position the No. 1 cylinder at Top Dead Center (TDC).
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Coolant hoses
     
    Upper timing cover
     

  8.  
  9. Matchmark the camshaft sprocket to the timing chain, and remove the pin (1) for the timing chain guide with a threaded extractor.

    Guide sprocket (left-hand thread)
     
    Bearing assembly
     
    Timing chain from the camshaft sprockets and wire the chain aside
     

  10.  


NOTE
Be sure the chain is securely wired so it will not slide into the engine.



Vacuum hoses and electrical connectors
 
Exhaust system
 
Secondary air injection pipe, if equipped
 
Dipstick tube support bracket
 
Crankcase breather hose
 
Fuel lines
 
Dipstick tube
 
Throttle, kickdown and cruise control cables
 

  1. Loosen the head bolts in stages in the reverse order of the tightening sequence.
  2.  


CAUTION
Never use a prybar between the head and the block.

  1. Remove the cylinder head and clean all gasket material from the sealing surfaces. Be sure the cylinder head locating dowels are positioned correctly in the engine block.
  2.  
  3. Inspect length of the cylinder head bolt shaft. New bolt length is 6.30 inches (160mm), and the maximum permissible length is 6.44 inches (163.5mm). Replace bolts that measure greater than the maximum permissible length.
  4.  

To install:



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.2L (104) engines


NOTE
The head will not be watertight until the engine reaches operating temperature. Do not pressure test the cooling system until the engine has reached operating temperature.



Click image to see an enlarged view

Fig. Cylinder head gasket identification-3.2L (104) Engines

  1. Rotate the camshafts so that the bottom edge of the holes in the camshaft flange, are level with the top edge of the cylinder head.
  2.  
  3. Verify the TDC position of the No. 1 cylinder. Clean the head bolt threads, and then apply clean engine oil to the thread and head contact surfaces.
  4.  
  5. Install the head gasket and cylinder head.
  6.  
  7. Torque the head bolts using the illustrated sequence to 41 ft. lbs. (55 Nm) plus 90 degrees, then an additional 90 degrees.
  8.  
  9. Install or connect the following:

    Timing chain and upper timing chain guide
     
    Timing chain guide pin
     
    Guide sprocket and bearing assembly. Torque the bolt to 26 ft. lbs. (35 Nm).
     
    Throttle, kickdown and cruise control cables
     
    Fuel lines
     
    Crankcase breather hose
     
    Oil dipstick tube
     
    Secondary air injection pipe, if equipped
     
    Exhaust system
     
    Vacuum hoses and electrical connectors
     
    Coolant hoses
     
    Coolant
     
    Negative battery cable
     

  10.  


    Click image to see an enlarged view

    Fig. Verify the correct position of the camshafts for cylinder head installation using a 4mm pin (1)-3.2L (104) Engines


 
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