Mitsubishi Montero, Sport 1998-06

Cylinder Head

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
    CAUTION
    Some models covered by this manual may be equipped with an air bag. Whenever working near any of the Supplement Restraint System (SRS) components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS.

  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly, ducts and air intake hose
     
    Accelerator, and if equipped, kickdown cable
     
    Upper radiator hose
     
    Heater hoses
     
    Fuel lines and plug
     
    Power steering, if equipped unbolt the power steering pump from its brackets and position it to the side. Do not disconnect the power steering lines.
     
    Timing belt upper cover and valve cover
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Exhaust Gas Recirculation (EGR) connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    Evaporative Emission (EVAP) Purge Solenoid
     
    Engine Coolant Temperature (ECT) sensor and gauge connectors
     
    Front and injector wiring harness
     
    Camshaft Position (CMP) sensor
     
    Crankshaft Position (CKP) sensor
     
    Compactor connector
     
    Oil pressure switch connector
     
    Vacuum hoses
     
    Oil dipstick

    Click image to see an enlarged view

    Fig. Align the camshaft sprocket timing mark with the timing mark on the cylinder head-2.4L engines

     

  8.  
  9. Rotate the crankshaft clockwise and align the timing mark on the camshaft sprocket with the timing mark on the cylinder head.
  10.  
  11. Remove or disconnect the following:
    WARNING
    Do not rotate the crankshaft after the camshaft sprocket is removed from the camshaft. Secure the sprocket and timing belt so there is no slack in the belt. Be sure the sprocket does not become disengaged from the timing belt. If the engine is disturbed or the timing belt moved, the camshaft timing will have to be reset.



    Camshaft bolt
     
    Sprocket from the camshaft (with the timing belt attached) and allow it to rest on the lower cover. Secure the belt to the sprocket so that they do not become disengaged.
     



    Spark plug wires
     
    Distributor cap and wires
     

  12.  
  13. Mark the position of the rotor and distributor housing in relation to the cylinder head and remove the distributor.
  14.  
  15. Remove or disconnect the following:

    Exhaust pipe from the exhaust manifold
     
    Cylinder head bolts, starting from the outside and working inward
     
    Cylinder head from the engine
     
    Intake and exhaust manifolds from the cylinder head, if necessary
     

  16.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.4L engines

  1. Clean the cylinder head gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Intake and exhaust manifolds to the cylinder head, if removed
     
    New head gasket to the block and position the cylinder head assembly with all head bolts and washers.
     

  4.  
  5. Tighten the bolts in the following sequence:
    1. Step 1: Torque the bolts in sequence to 58 ft. lbs. (78 Nm).
    2.  
    3. Step 2: Loosen all bolts in sequence to 0 ft. lbs.
    4.  
    5. Step 3: Torque the bolts in sequence to 14 ft. lbs. (20 Nm).
    6.  
    7. Step 4: Turn the bolts an additional 90 degrees.
    8.  
    9. Step 5: Turn an additional 90 degrees.
    10.  

  6.  
  7. Install or connect the following:

    Camshaft sprocket to the camshaft. Torque bolt to 65 ft. lbs. (88 Nm).
     
    Distributor, aligning the marks made during removal
     
    Distributor cap and spark plug wires
     
    Power steering pump and adjust the belt tension
     
    Heater hoses and upper radiator hose
     
    Valve cover. Torque the bolts to 30 ft. lbs. (34 Nm).
     
    Upper timing belt cover. Torque the bolts to 95 inch lbs. (11 Nm).
     
    Fuel lines
     
    Accelerator and kickdown cable, if equipped
     
    MDP sensor connector
     
    EGR connector
     
    TP sensor connector
     
    IAC motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    EVAP Purge Solenoid
     
    ECT sensor and gauge connectors
     
    Front and injector wiring harness
     
    CMP sensor
     
    CKP sensor
     
    Compactor connector
     
    Oil pressure switch connector
     
    Oil dipstick
     
    Air cleaner assembly, ducts and air intake hose
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Start the engine and check for leaks. Check the ignition timing.
  12.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly, ducts and air intake hose
     
    Upper radiator hose
     
    Accessory drive belts
     
    Cooling fan and pulleys
     
    Air conditioning compressor, if equipped
     
    Power steering pump and mounting brackets and position them to the side, without disconnecting the lines.
     
    Timing belt covers
     

  8.  
  9. Remove the timing belt as follows:
    1. Rotate the crankshaft and bring the No. 1 piston to Top Dead Center (TDC) on the compression stroke. Align the camshaft and crankshaft sprocket timing marks.
    2.  
    3. Mark the timing belt in the direction of rotation for reinstallation purposes.
    4.  
    5. Loosen the timing belt tensioner bolt and turn the tensioner counterclockwise.
    6.  

  10.  


WARNING
Do not rotate the crankshaft or camshaft sprockets after the timing belt has been removed.

  1. Remove or disconnect the following:

    Timing belt
     
    Fuel lines and plug
     
    Wiring connectors, vacuum lines and hoses from the air intake plenum, intake manifold and cylinder head.
     
    Air intake plenum
     
    Intake manifold
     
    Exhaust manifold
     
    Camshaft sprocket bolt and camshaft sprocket, if necessary
     
    Alternator bracket and/or timing belt rear cover
     
    Oil dipstick, on left side only
     
    Crankshaft position (CKP) sensor on left side only
     
    Spark plug wires from the spark plugs
     
    Valve cover
     
    Cylinder head bolts starting from the outside and working inward
     
    Cylinder head from the engine
     

  2.  

To install:



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.0L engines

  1. Clean the gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head on the engine. Torque the cylinder head bolts in sequence using 3 even steps, to 80 ft. lbs. (108 Nm).
     
    Exhaust manifold
     
    Intake manifold and air intake plenum
     
    Fuel lines
     
    Wiring connectors, vacuum lines and hoses to the air intake plenum, intake manifold and cylinder head
     
    Valve cover
     
    Spark plug wires
     
    CKP sensor, if removed
     
    Oil dipstick, if removed
     
    Alternator bracket and/or timing belt rear cover
     
    Camshaft sprocket bolt and camshaft sprocket, if necessary
     

  4.  
  5. Be sure the camshaft and crankshaft sprocket timing marks are aligned.
  6.  
  7. Turn the timing belt tensioner to the extreme counter-clockwise position and temporarily tighten the bolt.
  8.  
  9. Install the timing belt in the original rotation direction. Loosen the timing belt tensioner bolt and allow the spring force of the tensioner to tension the belt.
  10.  
  11. Turn the crankshaft 2 turns in the normal direction of rotation and check the timing mark alignment.
  12.  
  13. If the timing is correct, tighten the tensioner bolt to 21 ft. lbs. (30 Nm). If the timing is incorrect, repeat the belt installation procedure.
  14.  
  15. Install or connect the following:

    Timing belt covers
     
    Alternator, alternator cover and alternator stay, if removed
     
    Air conditioning compressor
     
    Power steering pump with the brackets
     
    Pulleys. Torque the crankshaft pulley bolt to 134 ft. lbs. (181 Nm).
     
    Cooling fan
     
    Accessory drive belts
     
    Air cleaner assembly, ducts and air intake hose
     
    Upper radiator hose
     
    Negative battery
     

  16.  
  17. Refill the cooling system.
  18.  
  19. Start the engine and check for leaks. Check the ignition timing.
  20.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly, ducts and air intake hose
     
    Upper radiator hose
     
    Accessory drive belts
     
    Cooling fan and pulleys
     
    Air conditioning compressor, if equipped
     
    Power steering pump and mounting brackets and position them to the side, without disconnecting the lines.
     
    Timing belt covers
     

  8.  
  9. Remove the timing belt as follows:
    1. Rotate the crankshaft and bring the No. 1 piston to Top Dead Center (TDC) on the compression stroke. Align the camshaft and crankshaft sprocket timing marks.
    2.  
    3. Mark the timing belt in the direction of rotation for reinstallation purposes.
    4.  
    5. Loosen the timing belt tensioner bolt and turn the tensioner counterclockwise.
      WARNING
      Do not rotate the crankshaft or camshaft sprockets after the timing belt has been removed.

    6.  

  10.  
  11. Remove or disconnect the following:

    Timing belt
     
    Fuel lines and plug
     
    Wiring connectors, vacuum lines and hoses from the air intake plenum, intake manifold and cylinder head.
     
    Air intake plenum
     
    Intake manifold
     
    Exhaust manifold
     
    Camshaft sprocket bolt and camshaft sprocket, if necessary
     
    Alternator bracket and/or timing belt rear cover
     
    Oil dipstick, on left side only
     
    Crankshaft position (CKP) sensor on left side only
     
    Spark plug wires from the spark plugs
     
    Valve cover
     
    Cylinder head bolts starting from the outside and working inward
     
    Cylinder head from the engine
     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.0L engines

  1. Clean the gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head on the engine. Torque the cylinder head bolts in sequence using 3 even steps, to 80 ft. lbs. (108 Nm).
     
    Exhaust manifold
     
    Intake manifold and air intake plenum
     
    Fuel lines
     
    Wiring connectors, vacuum lines and hoses to the air intake plenum, intake manifold and cylinder head
     
    Valve cover
     
    Spark plug wires
     
    CKP sensor, if removed
     
    Oil dipstick, if removed
     
    Alternator bracket and/or timing belt rear cover
     
    Camshaft sprocket bolt and camshaft sprocket, if necessary
     

  4.  
  5. Be sure the camshaft and crankshaft sprocket timing marks are aligned.
  6.  
  7. Turn the timing belt tensioner to the extreme counter-clockwise position and temporarily tighten the bolt.
  8.  
  9. Install the timing belt in the original rotation direction. Loosen the timing belt tensioner bolt and allow the spring force of the tensioner to tension the belt.
  10.  
  11. Turn the crankshaft 2 turns in the normal direction of rotation and check the timing mark alignment.
  12.  
  13. If the timing is correct, tighten the tensioner bolt to 21 ft. lbs. (30 Nm). If the timing is incorrect, repeat the belt installation procedure.
  14.  
  15. Install or connect the following:

    Timing belt covers
     
    Alternator, alternator cover and alternator stay, if removed
     
    Air conditioning compressor
     
    Power steering pump with the brackets
     
    Pulleys. Torque the crankshaft pulley bolt to 134 ft. lbs. (181 Nm).
     
    Cooling fan
     
    Accessory drive belts
     
    Air cleaner assembly, ducts and air intake hose
     
    Upper radiator hose
     
    Negative battery
     

  16.  
  17. Refill the cooling system.
  18.  
  19. Start the engine and check for leaks. Check the ignition timing.
  20.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly, ducts and air intake hose
     
    Upper radiator hose
     
    Accessory drive belts
     
    Cooling fan and pulleys
     
    Air conditioning compressor, if equipped
     
    Power steering pump and mounting brackets and position them to the side, without disconnecting the lines.
     
    Timing belt covers
     

  8.  
  9. Remove the timing belt as follows:
    1. Rotate the crankshaft and bring the No. 1 piston to Top Dead Center (TDC) on the compression stroke. Align the camshaft and crankshaft sprocket timing marks.
    2.  
    3. Mark the timing belt in the direction of rotation for reinstallation purposes.
    4.  
    5. Loosen the timing belt tensioner bolt and turn the tensioner counterclockwise.
      WARNING
      Do not rotate the crankshaft or camshaft sprockets after the timing belt has been removed.

    6.  

  10.  
  11. Remove or disconnect the following:

    Timing belt
     
    Fuel lines and plug
     
    Wiring connectors, vacuum lines and hoses from the air intake plenum, intake manifold and cylinder head.
     
    Air intake plenum
     
    Intake manifold
     
    Exhaust manifold
     
    Camshaft sprocket bolt and camshaft sprocket, if necessary
     
    Alternator bracket and/or timing belt rear cover
     
    Oil dipstick, on left side only
     
    Crankshaft position (CKP) sensor on left side only
     
    Spark plug wires from the spark plugs
     
    Valve cover
     
    Cylinder head bolts starting from the outside and working inward
     
    Cylinder head from the engine
     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.0L engine

  1. Clean the gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head on the engine. Torque the cylinder head bolts in sequence using 3 even steps, to 80 ft. lbs. (108 Nm).
     
    Exhaust manifold
     
    Intake manifold and air intake plenum
     
    Fuel lines
     
    Wiring connectors, vacuum lines and hoses to the air intake plenum, intake manifold and cylinder head
     
    Valve cover
     
    Spark plug wires
     
    CKP sensor, if removed
     
    Oil dipstick, if removed
     
    Alternator bracket and/or timing belt rear cover
     
    Camshaft sprocket bolt and camshaft sprocket, if necessary
     

  4.  
  5. Be sure the camshaft and crankshaft sprocket timing marks are aligned.
  6.  
  7. Turn the timing belt tensioner to the extreme counter-clockwise position and temporarily tighten the bolt.
  8.  
  9. Install the timing belt in the original rotation direction. Loosen the timing belt tensioner bolt and allow the spring force of the tensioner to tension the belt.
  10.  
  11. Turn the crankshaft 2 turns in the normal direction of rotation and check the timing mark alignment.
  12.  
  13. If the timing is correct, tighten the tensioner bolt to 21 ft. lbs. (30 Nm). If the timing is incorrect, repeat the belt installation procedure.
  14.  
  15. Install or connect the following:

    Timing belt covers
     
    Alternator, alternator cover and alternator stay, if removed
     
    Air conditioning compressor
     
    Power steering pump with the brackets
     
    Pulleys. Torque the crankshaft pulley bolt to 134 ft. lbs. (181 Nm).
     
    Cooling fan
     
    Accessory drive belts
     
    Air cleaner assembly, ducts and air intake hose
     
    Upper radiator hose
     
    Negative battery
     

  16.  
  17. Refill the cooling system.
  18.  
  19. Start the engine and check for leaks. Check the ignition timing.
  20.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


CAUTION
The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     

  6.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



Air intake hoses
 
Air intake plenum and intake manifold
 
Exhaust manifold
 
Engine under cover
 
Radiator and shroud
 
Alternator
 
Cooling fan
 
Timing belt
 
Breather hose
 
Oil dipstick
 
Camshaft Position (CMP) sensor
 
Spark plug cable center cover and remove the spark plug cables
 
Valve cover
 
Intake camshaft sprocket
 
Rear timing belt cover
 
Ignition coil
 
Water hoses from the thermostat housing and the housing
 
Water inlet from the front head and discard O-ring
 
Water passage
 

  1. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward. Lift off the cylinder head assembly and remove the head gasket.
  2.  

To install:



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.5L engines

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.0012 in. (0.030mm), normally with 0.008 in. (0.203mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. (0.203mm) maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Install or connect the following:

    Cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Using 3 even steps, torque the head bolts in sequence, to 76-83 ft. lbs. (105-115 Nm).
     
    New O-ring and the water inlet to the front head
     
    New gaskets, thermostat housing and connect the hoses
     
    Water passage and new gaskets
     
    Ignition coil and center rear timing belt cover
     
    Intake camshaft sprocket. Use hex flange on camshaft to secure and tighten the retaining bolt to 65 ft. lbs. (90 Nm).
     
    New gasket and the valve cover. Torque the bolts to 84 inch lbs. (10 Nm).
     
    Spark plug cables and the center cover
     
    Oil dipstick
     
    CMP sensor
     
    Breather hose
     
    Radiator and shroud
     
    Timing belt
     
    Cooling fan
     
    Alternator
     
    Engine under cover
     
    Intake manifold and new gasket. Torque the nuts to 16 ft. lbs. (21 Nm).
     
    Air intake plenum and new gaskets. Torque the bolts to 13 ft. lbs. (18 Nm).
     
    Exhaust manifold and new gaskets. Torque the nuts to 22 ft. lbs. (29 Nm).
     
    Air intake hoses
     
    Negative battery cable
     

  6.  
  7. Change the engine oil and oil filter.
  8.  
  9. Refill the system with coolant.
  10.  
  11. Run the vehicle until the thermostat opens.
  12.  
  13. Once the vehicle has cooled, recheck the coolant level.
  14.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



    Negative battery cable
     



    Air intake hoses
     
    Air intake plenum and intake manifold
     
    Exhaust manifold
     
    Engine under cover
     
    Radiator and shroud
     
    Alternator
     
    Cooling fan
     
    Timing belt
     
    Breather hose
     
    Oil dipstick
     
    Camshaft Position (CMP) sensor
     
    Spark plug cable center cover and remove the spark plug cables
     
    Valve cover
     
    Intake camshaft sprocket
     
    Rear timing belt cover
     
    Ignition coil
     
    Water hoses from the thermostat housing and the housing
     
    Water inlet from the front head and discard O-ring
     
    Water passage
     

  8.  
  9. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward. Lift off the cylinder head assembly and remove the head gasket.
  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.5L engines

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.0012 in. (0.030mm), normally with 0.008 in. (0.203mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. (0.203mm) maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Install or connect the following:

    Cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Using 3 even steps, torque the head bolts in sequence, to 76-83 ft. lbs. (105-115 Nm).
     
    New O-ring and the water inlet to the front head
     
    New gaskets, thermostat housing and connect the hoses
     
    Water passage and new gaskets
     
    Ignition coil and center rear timing belt cover
     
    Intake camshaft sprocket. Use hex flange on camshaft to secure and tighten the retaining bolt to 65 ft. lbs. (90 Nm).
     
    New gasket and the valve cover. Torque the bolts to 84 inch lbs. (10 Nm).
     
    Spark plug cables and the center cover
     
    Oil dipstick
     
    CMP sensor
     
    Breather hose
     
    Radiator and shroud
     
    Timing belt
     
    Cooling fan
     
    Alternator
     
    Engine under cover
     
    Intake manifold and new gasket. Torque the nuts to 16 ft. lbs. (21 Nm).
     
    Air intake plenum and new gaskets. Torque the bolts to 13 ft. lbs. (18 Nm).
     
    Exhaust manifold and new gaskets. Torque the nuts to 22 ft. lbs. (29 Nm).
     
    Air intake hoses
     
    Negative battery cable
     

  6.  
  7. Change the engine oil and oil filter.
  8.  
  9. Refill the system with coolant.
  10.  
  11. Run the vehicle until the thermostat opens.
  12.  
  13. Once the vehicle has cooled, recheck the coolant level.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



    Negative battery cable
     



    Air intake hoses
     
    Air intake plenum and intake manifold
     
    Exhaust manifold
     
    Engine under cover
     
    Radiator and shroud
     
    Alternator
     
    Cooling fan
     
    Timing belt
     
    Breather hose
     
    Oil dipstick
     
    Camshaft Position (CMP) sensor
     
    Spark plug cable center cover and remove the spark plug cables
     
    Valve cover
     
    Intake camshaft sprocket
     
    Rear timing belt cover
     
    Ignition coil
     
    Water hoses from the thermostat housing and the housing
     
    Water inlet from the front head and discard O-ring
     
    Water passage
     

  8.  
  9. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward. Lift off the cylinder head assembly and remove the head gasket.
  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.5L engine

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.0012 in. (0.030mm), normally with 0.008 in. (0.203mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. (0.203mm) maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Install or connect the following:

    Cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Using 3 even steps, torque the head bolts in sequence, to 76-83 ft. lbs. (105-115 Nm).
     
    New O-ring and the water inlet to the front head
     
    New gaskets, thermostat housing and connect the hoses
     
    Water passage and new gaskets
     
    Ignition coil and center rear timing belt cover
     
    Intake camshaft sprocket. Use hex flange on camshaft to secure and tighten the retaining bolt to 65 ft. lbs. (90 Nm).
     
    New gasket and the valve cover. Torque the bolts to 84 inch lbs. (10 Nm).
     
    Spark plug cables and the center cover
     
    Oil dipstick
     
    CMP sensor
     
    Breather hose
     
    Radiator and shroud
     
    Timing belt
     
    Cooling fan
     
    Alternator
     
    Engine under cover
     
    Intake manifold and new gasket. Torque the nuts to 16 ft. lbs. (21 Nm).
     
    Air intake plenum and new gaskets. Torque the bolts to 13 ft. lbs. (18 Nm).
     
    Exhaust manifold and new gaskets. Torque the nuts to 22 ft. lbs. (29 Nm).
     
    Air intake hoses
     
    Negative battery cable
     

  6.  
  7. Change the engine oil and oil filter.
  8.  
  9. Refill the system with coolant.
  10.  
  11. Run the vehicle until the thermostat opens.
  12.  
  13. Once the vehicle has cooled, recheck the coolant level.
  14.  

3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


CAUTION
The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     

  6.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



Intake manifold
 
Timing belt
 
Front exhaust pipe
 
Water outlet pipe assembly and O-ring
 
Heater hose connections
 
Water passage assembly and gasket
 
Water pipe and O-ring
 
Breather hose
 
Spark plug wires; tag before disconnecting
 
Ignition coil
 
Oxygen (O2) sensor connector
 
Engine oil dipstick assembly and O-ring
 
Intake manifold plenum stay
 
Rocker cover
 
Camshaft Position (CMP) sensor connector
 

  1. Loosen the cylinder head mounting bolts in 3 steps, in the sequence shown. Lift off the cylinder head assembly and remove the head gasket.
  2.  


    Click image to see an enlarged view

    Fig. Loosen the cylinder head bolts in the proper sequence-3.8L engine


To install:

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.0012 in. (0.030mm), normally with 0.008 in. (0.203mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. (0.203mm) maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Install or connect the following:

    Cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Using 3 even steps, torque the head bolts in sequence, to 77-83 ft. lbs. (105-113 Nm) with a torque wrench and Special Tool No. MD998501.
     


    Click image to see an enlarged view

    Fig. The cylinder head bolts must be installed with the chamfered edge up and tighten in the proper sequence-3.8L engine

    Rocker cover
     
    Intake manifold plenum stay
     
    Engine oil dipstick assembly and O-ring
     
    O2 sensor connector
     
    Ignition coil
     
    Spark plug wires
     
    Breather hose
     
    Water pipe and O-ring
     
    Water passage assembly and gasket
     
    Heater hose connections
     
    Water outlet pipe assembly and O-ring
     
    Front exhaust pipe
     
    Timing belt
     
    Intake manifold
     
    Negative battery cable
     

  6.  
  7. Change the engine oil and oil filter.
  8.  
  9. Refill the system with coolant.
  10.  
  11. Run the vehicle until the thermostat opens.
  12.  
  13. Once the vehicle has cooled, recheck the coolant level.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



    Negative battery cable
     



    Intake manifold
     
    Timing belt
     
    Front exhaust pipe
     
    Water outlet pipe assembly and O-ring
     
    Heater hose connections
     
    Water passage assembly and gasket
     
    Water pipe and O-ring
     
    Breather hose
     
    Spark plug wires; tag before disconnecting
     
    Ignition coil
     
    Oxygen (O 2 ) sensor connector
     
    Engine oil dipstick assembly and O-ring
     
    Intake manifold plenum stay
     
    Rocker cover
     
    Camshaft Position (CMP) sensor connector
     

  8.  
  9. Loosen the cylinder head mounting bolts in 3 steps, in the sequence shown. Lift off the cylinder head assembly and remove the head gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-3.8L engine

  10.  

To install:

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.0012 in. (0.030mm), normally with 0.008 in. (0.203mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. (0.203mm) maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Install or connect the following:

    Cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward (see illustration). Using 3 even steps, torque the head bolts in sequence, to 77-83 ft. lbs. (105-113 Nm) with a torque wrench and Special Tool No. MD998501.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-3.8L engine

     
    Rocker cover
     
    Intake manifold plenum stay
     
    Engine oil dipstick assembly and O-ring
     
    O 2 sensor connector
     
    Ignition coil
     
    Spark plug wires
     
    Breather hose
     
    Water pipe and O-ring
     
    Water passage assembly and gasket
     
    Heater hose connections
     
    Water outlet pipe assembly and O-ring
     
    Front exhaust pipe
     
    Timing belt
     
    Intake manifold
     
    Negative battery cable
     

  6.  
  7. Change the engine oil and oil filter.
  8.  
  9. Refill the system with coolant.
  10.  
  11. Run the vehicle until the thermostat opens.
  12.  
  13. Once the vehicle has cooled, recheck the coolant level.
  14.  

 
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