Cylinder Head

Removal & Installation

2.3L Engine

To Remove:

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. Properly discharge the A/C system.
5. Disconnect the battery ground cable.

   CAUTION
   Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, crankshaft sprocket, and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. Because of this, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before loosening or removing the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur.

6. Remove the camshafts and the exhaust manifold.
7. Remove the fuel injector supply manifold and spacers.
8. Remove the positive crankcase ventilation (PCV) hose clips.
9. Disconnect the EGR tube and the ground strap.
10. Disconnect the engine coolant temperature sender unit and the exhaust gas recirculation (EGR) valve electrical connectors.
11. Disconnect the EGR coolant hose and remove it from the hose bracket.
12. Disconnect the coolant bypass hose.
13. Remove the bolts and the cylinder head, then discard the bolts.
14. Remove and discard the head gasket.
15. Inspect the cylinder head mating surfaces.

To Install:

CAUTION
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These items will cause scratches and gouges, which create leak paths.

1. Clean the cylinder head gasket surfaces with metal surface cleaner.
2. Apply silicone gaskets and sealant.

   RTV sealer application-2.3L cylinder head

3. Install a new head gasket.

   NOTE: New cylinder head bolts must be installed because they are torque-to-yield and mustn’t be reused.

   NOTE: Lubricate the cylinder head bolts with clean engine oil.

4. Install the cylinder head and new bolts. Tighten the bolts as indicated below:
   • Step 1: Tighten the bolts to 44 in-lb (5 Nm).
   • Step 2: Tighten the bolts to 11 ft-lb (15 Nm).
   • Step 3: Tighten the bolts to 33 ft-lb (45 Nm).
   • Step 4: Turn the bolts 90 degrees (1/4 turn).
   • Step 5: Turn the bolts an additional 90 degrees (1/4 turn).

   Head bolt torque sequence-2.3L

5. Connect the coolant bypass hose.
6. Connect the EGR coolant hose.
7. Connect the engine coolant temperature sender unit and the EGR valve electrical connectors.
8. Connect the EGR tube and the ground strap.
   • Torque large bolt to 41 ft-lb (55 Nm)
   • Torque small bolt to 89 in-lb (10 Nm).
9. Install the PCV hose clips.
10. Install the fuel injector supply manifold spacers with the manifold.
11. Install the exhaust manifold.
12. Install the camshafts.
13. Recharge the A/C system.
14. Fill the cooling system.
15. Connect the battery ground cable.