Buick Encore: Cylinder head replacement

Cylinder head replacement - Removal Procedure

Special Tools

• EN-470-B Angular Torque Wrench
• EN-955 Fixing Pin
• EN-953-A Fixing Tool

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the turbocharger. Refer to Turbocharger Replacement.
3. Remove the intake manifold. Refer to Intake Manifold Replacement.
4. Remove the water outlet. Refer to Water Outlet Replacement (LUJ, LUV) .
5. Remove the camshaft position actuator solenoid valve intake and exhaust. Refer to Camshaft Position Actuator Solenoid Valve Replacement .
6.  Adjust the engine to TDC. Refer to Camshaft Timing Chain Inspection

Fig. 72: Timing Chain Tensioner Plug

7. Remove the timing chain tensioner plug (1) from the engine front cover.

Fig. 73: Hexagonal Wrench Rotation Direction

NOTE: Remove and reinstall the EN-953-A fixing tool for this step.

8. Install a wrench (1) on the cast hexagonal portion of the intake camshaft, rotate the camshaft toward the exhaust camshaft in order to apply tension.

Fig. 74: Timing Chain Tensioner Bore And Pin

9. Install EN-955 pin (2) to the timing chain tensioner bore (1) to secure it in place.
10. Remove the wrench from intake camshaft.

Fig. 75: Upper Timing Chain Guide And Bolts

11. Remove the upper timing chain guide bolts (1).
12. Remove the upper timing chain guide (2).

Fig. 76: Intake Camshaft Sprocket Bolt And Hexagonal Wrench

13. Loosen the intake camshaft sprocket bolt (2) while holding up the hexagon of the intake camshaft with a wrench (1).
14. Loosen the exhaust camshaft sprocket bolt while holding up the hexagon of the exhaust camshaft with a wrench.

Fig. 77: Camshaft Position Exciter Wheels And Camshaft Sprocket Bolts

15. Remove and DISCARD the camshaft sprocket bolts (2) and the camshaft position exciter wheels (1).
16. Remove the both camshaft position sensors. Refer to Camshaft Position Sensor Replacement .

Fig. 78: Timing Chain And Camshaft Sprockets

17. Remove the camshaft sprockets (2) and timing chain (1) as one unit.
18.  Allow the camshaft sprockets (2) and timing chain (1) rest on the front cover. Do NOT remove sprockets or chain.
19. Install the engine support fixture. Refer to Engine Support Fixture.
20. Remove the engine mount bracket. Refer Engine Mount Bracket Replacement - Right Side.
21. Remove the drive belt. Refer to Drive Belt Replacement.
22. Remove the water pump pulley. Refer to Water Pump Pulley Replacement (LUJ, LUV) .

Fig. 79: Engine Front Cover Bolts And Water Pump Bolts

23. Remove 5 engine front cover bolts (1, 2).
24. Remove 3 water pump bolts (3).
25. Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
26. Install engine mount. Refer to Engine Mount Replacement - Right Side.
27. Remove engine support fixture. Refer Engine Support Fixture.

Fig. 80: Cylinder Head Bolts Loosening Sequence

28. Loosen the 12 cylinder head bolts in the sequence as shown above. Use the following procedure:

• First pass: Loosen the cylinder head bolts 90 degrees.
• Final pass: Loosen the cylinder head bolts 180 degrees.

Fig. 81: Cylinder Head, Gasket, Bolts And Guide Sleeves

NOTE: Do not damage the guide sleeves (4, 5).

29. Remove and DISCARD the 12 cylinder head bolts (1).
30.  With the aid of an assistant, lift the timing chain side of the cylinder head assembly slightly in direction of the transmission.
31. Remove the cylinder head (2).
32. Remove the cylinder head gasket (3) and discard the gasket.

Fig. 82: Top Third Of Engine Front Cover Gasket

33. With the cylinder head out of vehicle, bend the top third of the engine front cover gasket (1) back and forth until snaps off at the breaking point.
34. Remove the assembly parts from cylinder head

• Remove the EN-953-A fixing tool
• Remove the intake camshaft. Refer to Intake Camshaft Removal.
• Remove the exhaust camshaft. Refer to Exhaust Camshaft Removal.
• Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Removal.
• Remove the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Removal.
• Remove the spark plug. Refer to Spark Plug Replacement .
• Remove the engine oil pressure indicator switch.
• Remove the timing chain tensioner. Refer to Timing Chain Tensioner Removal.
• Remove the 3 engine lift brackets.

35. For disassembly of the cylinder head. Refer to Cylinder Head Disassemble.
36. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection.
37. Transfer parts as necessary

Cylinder head replacement - Installation Procedure

1. For assembly of the cylinder head. Refer to Cylinder Head Assemble.

CAUTION: Refer to Fastener Caution .

2. Install the cylinder head assembly parts:

• Install the 3 engine lift bracket bolts and tighten to 22 (16 lb ft).
• Install the timing chain tensioner. Refer to Timing Chain Tensioner Installation.
• Install the engine oil pressure indicator switch and tighten to 20 (15 lb ft)
• Install the spark plug. Refer to Spark Plug Replacement .
• Install the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Installation.
• Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Installation.
• Install the exhaust camshaft. Refer to Exhaust Camshaft Installation.
• Install the intake camshaft. Refer to Intake Camshaft Installation.
• Install the EN-953-A fixing tool.

NOTE: Adjust the camshafts by means of the hexagon and a spanner.

3. Clean sealing surfaces of engine front cover and engine block from grease and old gasket material.

Fig. 83: engine front cover gasket

NOTE: The engine front cover gasket comes as a complete unit.

4. Before installation the of the new front cover gasket, bend the top third of the engine front cover gasket (1) back and forth until snaps off at the breaking point.

Fig. 84: Sealing Compound Application Area

5. Apply a 2 mm (0.0787 in) bead of RTV sealant to the areas shown (1).
6. Install a NEW cylinder head gasket. The marking "Top" should point to the cylinder head.

Fig. 85: Engine Front Cover Bolts And Sealing Compound Application Areas

7. Install engine front cover bolts (1) in order to guide the NEW upper engine front cover gasket.
8.  Apply a 2 mm (0.0787 in) bead of RTV sealant to the areas shown (2).

Fig. 86: Timing Chain Tensioner, Guide Pin And Cylinder Head

NOTE: A second mechanic is required.

9. Guide the timing chain guide pin (2) to the timing chain guide and the timing chain tensioner (1) with the installed fixing pin through the timing chain tensioner plug bore in engine front cover.

Fig. 87: Cylinder Head, Gasket, Bolts And Guide Sleeves

10. Install the cylinder head (2).
11. Loosely install 12 NEW cylinder head bolts (1).

Fig. 88: Engine Front Cover Bolts

12. Adjust the cylinder head to the engine front cover. Use a rubber mallet.
13. Position the engine front cover to cylinder head by installing 3 bolts (1).

CAUTION: Refer to Fastener Caution .

14. Tighten the 3 bolts (1) to 8 N.m (71 lb in).

Fig. 89: Cylinder Head Bolts Tightening Sequence

15. Tighten the cylinder head bolts in the sequence as shown and in the following order.

• Tighten the cylinder head bolts to 35 (26 lb ft).
• Tighten the cylinder head bolts an additional 180º. Use EN-470-B wrench.

Fig. 90: Engine Front Cover Bolts

16. Loosen the bolts from engine front cover (1).

Fig. 91: Engine Front Cover Bolts And Water Pump Bolts

17. Install the remaining bolts to engine front cover and water pump.
18. Tighten the engine front cover bolts (1, 2) to 8 N.m (71 lb in).
19. Tighten the water pump bolts (3) to 8 N.m (71 lb in).
20. Install the engine support fixture. Refer to Engine Support Fixture.
21. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
22. Install the water pump pulley. Refer to Water Pump Pulley Replacement (LUJ, LUV) .
23. Install the drive belt. Refer to Drive Belt Replacement.
24.  Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
25. Install the engine mount. Refer to Engine Mount Replacement - Right Side.
26. Remove the engine support fixture. Refer to Engine Support Fixture.

Fig. 92: Timing Chain And Camshaft Sprockets

27. Install the camshaft sprockets (2) and timing chain (1) as one unit.

Fig. 93: Camshaft Position Exciter Wheels And Camshaft Sprocket Bolts

28. Install the camshaft position exciter wheels (1).
29. Install the NEW camshaft sprocket bolts (2), hand tight only.
30. Install the both camshaft position sensors. Refer to Camshaft Position Sensor Replacement .
31. Remove the EN-955 pin to apply tension to the timing chain.
32. Adjust the camshaft timing chain. Refer to Camshaft Timing Chain Adjustment

Fig. 94: Upper Timing Chain Guide And Bolts

33. Install the upper timing chain guide (2).
34. Install the upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).

Fig. 95: Timing Chain Tensioner Plug

35. Install the timing chain tensioner plug and tighten to 50 N.m (37 lb ft).
36.  Install the camshaft position actuator solenoid valve intake and exhaust. Refer to Camshaft Position Actuator Solenoid Valve Replacement .
37. Install the turbocharger. Refer to Turbocharger Replacement.
38. Install the Intake manifold. Refer to Intake Manifold Replacement.
39. Fill coolant fluid. Refer to Cooling System Draining and Filling .
40. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
41. Check and correct the engine oil.
42. Test the vehicle using the following procedure:

1. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
2. Start the engine and listen for unusual noises.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
4. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
5. Listen for sticking lifter and other unusual noises.
6. Inspect for fuel, oil and/or coolant leaks while the engine is running.

43. Inspect for coolant, oil, gas or exhaust leaks.

READ NEXT: