Montana SV6 (2006), Relay, Terraza, Uplander (2005-2007)

Cylinder Head

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the lower intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
  8.  
  9. Remove the valve rocker arms and the pushrods. For additional information, refer to the following section, -Rocker Arms, Removal & Installation.-
  10.  
  11. Remove the exhaust crossover pipe. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  12.  
  13. For the left cylinder head, remove the oil level indicator tube.
  14.  
  15. Remove the spark plug wires from the spark plugs.
  16.  
  17. Remove the spark plugs.
  18.  
  19. For the right side cylinder head, remove the alternator. For additional information, refer to the following section, -Alternator, Removal & Installation.-
  20.  
  21. Remove the appropriate side exhaust manifold. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  22.  
  23. Remove the cylinder head bolts and discard.
  24.  
  25. Remove the cylinder head.
  26.  
  27. Remove the cylinder head gasket.
  28.  
  29. Clean and inspect the cylinder head and the gasket mating surfaces.
  30.  

To install:

  1. Install a new cylinder head gasket over the alignment pins.
  2.  
  3. Install the cylinder head over the locator pins and the gasket.
  4.  
  5. Install the new cylinder head bolts. Tighten the bolts, in the sequence shown, to 44 ft. lbs. (60 Nm).
  6.  
  7. Use the angle tool, J 45059, or suitable angle measuring device, to rotate the bolts in sequence an additional 95 degrees.
  8.  
  9. Install the exhaust manifold. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  10.  
  11. Install the spark plugs. Torque the spark plugs to 15 ft. lbs. (20 Nm), if using a new cylinder head, or to 11 ft. lbs. (15 Nm), if using an existing head.
  12.  
  13. For the right side cylinder head, install the alternator. For additional information, refer to the following section, -Alternator, Removal & Installation.-
  14.  
  15. Install the spark plug wires to the spark plugs.
  16.  
  17. For the left side cylinder head, install the oil level indicator tube.
  18.  
  19. Install the exhaust crossover pipe. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  20.  
  21. Install the valve rocker arms and pushrods. For additional information, refer to the following section, -Rocker Arms, Removal & Installation.-
  22.  
  23. Install the lower intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
  24.  
  25. Fill the crankcase with engine oil.
  26.  
  27. Fill the cooling system.
  28.  
  29. Start the engine and inspect for leaks.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-3.5L and 3.9L engines



    Click image to see an enlarged view

    Fig. Cylinder head gasket installation

  30.  

3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the lower intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
  8.  
  9. Remove the exhaust crossover pipe. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  10.  
  11. If removing the left side cylinder head, remove the oil dipstick tube.
  12.  
  13. Remove the spark plugs.
  14.  
  15. Remove the and discard the cylinder head bolts.
  16.  
  17. Remove the cylinder head.
  18.  

To install:

  1. Clean and inspect the cylinder head and the gasket mating surfaces.
  2.  
  3. Install the spark plugs to the cylinder head.

    Click image to see an enlarged view

    Fig. Head gaskets are specific for right hand and left hand applications, and also must be installed with the correct side facing up. Note the markings (1) on the head gaskets for proper installation.

  4.  
  5. Install a new cylinder head gasket.
  6.  
  7. Install the cylinder head on to the locator pins on the engine block. Install the cylinder head bolts finger tight.
  8.  
  9. Tighten the bolts, in the sequence shown, to 44 ft. lbs. (60 Nm).
  10.  
  11. Use the angle tool, J 45059, or suitable angle measuring device, to rotate the bolts in sequence an additional 95 degrees.
  12.  
  13. Install the oil dipstick tube, if removed.
  14.  
  15. Install the exhaust crossover pipe. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  16.  
  17. Install the lower intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
  18.  
  19. Refill the engine with oil to the correct level.
  20.  
  21. Refill the cooling system to the correct level.
  22.  
  23. Start the engine and check for leaks.
  24.  

 
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