Cylinder Head Replacement - Right

Cylinder Head Replacement - Right

Tools Required
^ J41131 Engine Tilt Strap
^ J45059 Electronic Torque Angle Meter

Removal Procedure





1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield.
3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
4. Remove the HO2S from the right exhaust manifold.
5. Raise and support the vehicle. Refer to Vehicle Lifting.
6. Drain the cooling system.
7. Drain the engine oil.
8. Remove the catalytic converter from the right exhaust manifold.





9. Remove the right exhaust manifold heat shield bolts (2).
10. Remove the right exhaust manifold heat shield (1).





11. Remove the exhaust gas recirculation (EGR) valve adapter bolt (1) from the right exhaust manifold.
12. Lower the vehicle.
13. Remove the drive belt tensioner.





14. Remove the power steering pump bolts and reposition the power steering pump.
15. Rotate the engine to access the right cylinder head.
16. Remove the right spark plugs from the right cylinder head.
17. Remove the lower intake manifold.
18. Remove the EGR valve inlet adapter pipe from the right cylinder head.
19. Remove the right exhaust manifold.
20. Remove the right valve rocker arm cover.
21. Remove the right rocker arms and push rods.





22. Remove the right cylinder head bolts. Discard the cylinder head bolts.
23. Remove the right cylinder head.





24. Remove the cylinder head gasket.
25. Remove the caps, the springs, the valves and the seals from the cylinder head.
26. Clean the gasket mating surfaces on the cylinder head, the engine block and the intake manifold.
27. Clean the cylinder block bolt hole threads.
28. Inspect the engine block.
29. Inspect the cylinder head.

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





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).
1. Tighten the cylinder head bolts in the following sequence (1-8) to 50 Nm (37 ft. lbs.).
2. Use the J45059 to rotate the cylinder head bolts in the following sequence (1-8) an additional 120 degrees.

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.

Notice: 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.

Notice: 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 EGR valve inlet adapter pipe to the right cylinder head.
9. Install the lower intake manifold.
10. Install the right spark plugs to the right cylinder head.
11. Carefully release the J41131 and return the engine to the original position.





12. Install the power steering pump.
13. Install the power steering pump bolts.
Tighten the bolts to 34 Nm (25 ft. lbs.).
14. Install the drive belt tensioner.
15. Install the left and the right engine mount struts.
16. Raise the vehicle.





17. Install the exhaust gas recirculation (EGR) valve adapter bolt (1) to the right exhaust manifold.
Tighten the bolt to 29 Nm (21 ft. lbs.).





18. Install the right exhaust manifold heat shield (1).
19. Install the right exhaust manifold heat shield bolts (2).
Tighten the bolts to 10 Nm (89 inch lbs.).
20. Install the catalytic converter to the right exhaust manifold.
21. Lower the vehicle.





22. Install the HO2S to the right exhaust manifold.
Tighten the HO2S to 42 Nm (31 ft. lbs.).
23. Connect the HO2S electrical connector.
24. Install the fuel injector sight shield.
25. Fill the crankcase with engine oil.
26. Fill the cooling system.
27. Connect the negative battery cable.
28. Inspect for leaks.