Right Side (Rear)

REMOVAL PROCEDURE





1. Disconnect the battery ground (negative) cable.

Notice: Refer to Engine Emissions Notice in Service Precautions.

2. Remove the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair
3. Drain the engine coolant from the cooling system.
4. Remove the drive belt from the generator.
5. Remove the generator.
6. Disconnect the three-way catalytic converter pipe from the right manifold.
7. Remove the engine mount struts.
8. Rotate the engine forward for access.
9. Remove the drive belt tensioner.
10. Remove the power steering pump.
11. Remove the heater hoses from the engine.
12. Remove the right spark plug wires.
13. Remove the right spark plugs.
14. Disconnect the oxygen sensor electrical connector.
15. Carefully remove the throttle body air inlet duct.
16. Disconnect the throttle and cruise control cables.
17. Disconnect the electrical connector from the throttle vacuum line.
18. Remove the fuel rail.
19. Remove the Exhaust Gas Recirculation (EGR) valve shield bracket bolt and nut.
20. Remove the EGR valve shield bracket.
21. Remove the EGR valve nuts.





22. Remove the EGR valve.





23. Remove the EGR valve outlet pipe bolt and nut.
24. Remove the EGR valve outlet pipe.





25. Remove the EGR valve adapter bolt from the right exhaust manifold.





26. Remove the EGR valve adapter bolts from the right cylinder head.
27. Remove the EGR valve adapter from the right cylinder head.
28. Remove the upper intake manifold.
29. Remove the engine lift hook.
30. Remove the exhaust crossover pipe.
31. Remove the right exhaust manifold.
32. Remove the right valve rocker arm cover.
33. Remove the right rocker arms and push rods.





34. Remove the cylinder head bolts. Discard the cylinder head bolts.
35. Remove the cylinder head.





36. Remove the cylinder head gasket.
37. Remove the springs, the caps, the seals, and the valves from the cylinder head.
38. Clean the mating surfaces on the cylinder head, the cylinder block, and the intake manifold.
39. Clean the cylinder block bolt hole threads.
40. Inspect the engine block.
41. Inspect the cylinder head.

INSTALLATION PROCEDURE

^ Tools Required
- J 36660 Electronic Torque Angle Meter





1. Install the springs, the caps, the seals, and the valves to the cylinder head.

Notice: Refer to Engine Emissions Notice in Service Precautions.

2. Position the head gasket with the arrow pointing to the front of the engine.

Notice: Head gaskets are not interchangeable. The head gasket must be installed with the arrow pointing to the front of the engine. Installing the head gasket in any other direction will cause gasket failure and possible engine failure.





3. Install the cylinder head.





4. Install the new cylinder head bolts (1-8).
4.1. Tighten the cylinder head bolts (1-8) in sequence to 50 Nm (37 ft. lbs.).
4.2. Rotate each cylinder head bolt (1-8) 120 degrees in sequence. Use the J 36660.

Notice:
^ This bolt is designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system or the components may be damaged.
^ This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage.
^ Refer to Fastener Notice in Service Precautions.

5. Install the right push rods and rocker arms.
6. Install the right valve rocker arm cover.
7. Install the right exhaust manifold.
8. Install the exhaust crossover pipe.
9. Install the engine lift hook.
10. Connect the three-way catalytic converter pipe to the right (rear) manifold.
11. Install the upper intake manifold.





12. Install the EGR valve adapter to the right cylinder head.
13. Install the EGR valve adapter bolts to the right cylinder head.
^ Tighten the EGR valve adapter bolts to 50 Nm (37 ft. lbs.).





14. Install the EGR valve adapter bolt to the right exhaust manifold.
^ Tighten the EGR valve adapter bolt to 29 Nm (21 ft. lbs.).





15. Install the EGR valve outlet pipe.
16. Install the EGR valve outlet pipe bolt and nut.
^ Tighten the EGR valve outlet pipe bolt and nut to 29 Nm (21 ft. lbs.).





17. Install the EGR valve.
18. Install the EGR valve nuts.
^ Tighten the EGR valve nuts to 29 Nm (21 ft. lbs.).





19. Install the EGR valve shield bracket.
20. Install the EGR valve shield bracket bolt and nut.
^ Tighten the EGR valve shield bracket bolt and nut to 10 Nm (89 inch lbs.).
21. Install the fuel rail.
22. Connect the electrical connector to the throttle vacuum line.
23. Install the throttle and cruise control cables.
24. Carefully install the throttle body air inlet duct.
25. Connect the oxygen sensor electrical connector.
26. Install the right spark plugs.
27. Install the right spark plug wires.
28. Install the heater hoses to the engine.
29. Install the power steering pump.
30. Install the drive belt tensioner.
31. Return the engine to the proper position.
32. Install the engine mount struts.
33. Connect the three-way catalytic converter pipe to the right (rear) exhaust manifold.
34. Install the generator.
35. Fill the cooling system.
36. Install the drive belt.
37. Install the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair
38. Connect the battery ground (negative) cable.
39. Inspect for proper fluid levels.
40. Inspect for leaks.