Spark

Cylinder Head Replacement — with CH-49290

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Open the bonnet.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Drain the cooling system. Refer to Cooling System Draining and Filling .
4. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement .
5. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement .
6. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement .
7. Remove the ignition coil. Refer to Ignition Coil Replacement .
8. Remove the camshaft cover. Refer to Camshaft Cover Replacement .
9. Remove thermostat housing. Refer to Engine Coolant Thermostat Replacement .
10. Remove the water pump. Refer to Water Pump Replacement .
11. Remove the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement .
12. Raise the vehicle.
13. Remove the sump. Refer to Sump Replacement .
14. Remove the drive belt. Refer to Drive Belt Replacement .
15. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
16. Remove the generator. Refer to Generator Replacement .
17. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

18. Assemble the CH-49290 engine support tool (1) according to the details provided in the SPX installation manual.
19. Install the torque support (2) to the engine.
20. Support the CH-904 base frame on a jack.
21. Support the CH-49290 engine support tool on the CH-904 base frame.




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly.

22. Install the CH-49290 engine support tool (1) according to the details provided in the SPX installation manual.



23. Remove the 4 engine mount bolts (1, 3) and 2 nuts (2).
24. Remove the engine mount (4).
25. Remove the engine front cover. Refer to Engine Front Cover and Oil Pump Removal .
26. Remove the timing chain. Refer to Camshaft Timing Chain Replacement and Adjustment .
27. Remove the intake, exhaust camshaft. Refer to Camshaft Replacement .
28. Remove the cylinder head. Refer to Cylinder Head Removal .

1. Clean the sealing surfaces and remove all remains of dirt and old gasket material.
2. Install the new cylinder head gasket.

Caution: Refer to Fastener Caution in the Preface section.




3. Install the new cylinder head bolts (1), with washers (2) and tighten the bolt (1) to 22 N·m + 82° (16 lb ft + 82°).
4. Install the camshaft. Refer to Camshaft Replacement .
5. Install the timing chain. Refer to Camshaft Timing Chain Replacement and Adjustment .
6. Install the engine front cover. Refer to Engine Front Cover and Oil Pump Installation .



7. Install the engine mount (4).
8. Tighten the engine mount to engine retaining bolt (3) and nuts (2) to 58 N·m (42 lb ft).
9. Tighten the engine mount to body retaining bolt (1) to 50 N·m (37 lb ft).
10. Raise the vehicle.



11. Remove the CH-49290 engine support tool (1)
12. Remove the CH-49290 engine support tool from the CH-904 base frame .
13. Remove the CH-904 base frame from the jack.



14. Disassemble the CH-49290 engine support tool (1).
15. Remove the torque support (2) from the engine
16. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
17. Install the generator. Refer to Generator Replacement .
18. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
19. Install the drive belt. Refer to Drive Belt Replacement .
20. Install the oil pan. Refer to Sump Replacement .
21. Lower the vehicle.
22. Install the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement .
23. Install the water pump. Refer to Water Pump Replacement .
24. Install the thermostat housing . Refer to Engine Coolant Thermostat Replacement .
25. Install the camshaft cover. Refer to Camshaft Cover Replacement .
26. Install the ignition coil. Refer to Ignition Coil Replacement .
27. Install the exhaust manifold. Refer to Exhaust Manifold Replacement .
28. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement .
29. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement .
30. Refill the cooling system. Refer to Cooling System Draining and Filling .
31. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
32. Close the bonnet.