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Cylinder Head

REMOVAL & INSTALLATION

2.4L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. 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.

  3. Properly relieve the fuel system pressure.
  4. Remove or disconnect the following:

  5. Rotate the crankshaft clockwise and align the timing mark on the camshaft sprocket with the timing mark on the cylinder head.
  6. 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.

  7. Mark the position of the rotor and distributor housing in relation to the cylinder head and remove the distributor.
  8. Remove or disconnect the following:

    To install:

    Fig. 2: Cylinder head bolt tightening sequence-2.4L engines

  9. Clean the cylinder head gasket mating surfaces.
  10. Install or connect the following:
  11. Tighten the bolts in the following sequence:
    1. Step 1: Torque the bolts in sequence to 58 ft. lbs. (78 Nm).
    2. Step 2: Loosen all bolts in sequence to 0 ft. lbs.
    3. Step 3: Torque the bolts in sequence to 14 ft. lbs. (20 Nm).
    4. Step 4: Turn the bolts an additional 90 degrees.
    5. Step 5: Turn an additional 90 degrees.
  12. Install or connect the following:
  13. Refill the cooling system.
  14. Start the engine and check for leaks. Check the ignition timing.
3.0L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Relieve the fuel system pressure.
  3. Drain the cooling system.
  4. Remove or disconnect the following:
  5. 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. Mark the timing belt in the direction of rotation for reinstallation purposes.
    3. 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. Remove or disconnect the following:

    To install:

    Fig. 3: Cylinder head bolt tightening sequence-3.0L engines

  7. Clean the gasket mounting surfaces.
  8. Install or connect the following:
  9. Be sure the camshaft and crankshaft sprocket timing marks are aligned.
  10. Turn the timing belt tensioner to the extreme counter-clockwise position and temporarily tighten the bolt.
  11. 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.
  12. Turn the crankshaft 2 turns in the normal direction of rotation and check the timing mark alignment.
  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. Install or connect the following:
  15. Refill the cooling system.
  16. Start the engine and check for leaks. Check the ignition timing.
3.5L Engine
  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. Relieve fuel system pressure.
  3. Drain the cooling system.
  4. 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.

  5. 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.

    To install:

    Fig. 4: Cylinder head bolt tightening sequence-3.5L engines

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

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