Cylinder Head Replacement - Right

Cylinder Head Replacement - Right
Tools Required
^ J45059 Angle Meter

Removal Procedure





1. Remove the lower intake manifold.
2. Remove the power steering pump bolts and reposition the power steering pump.
3. Remove the right exhaust manifold.
4. Remove the right rocker arms and push rods.





5. Remove the exhaust gas recirculation (EGR) valve nuts.
6. Remove the EGR valve.





7. Remove the EGR valve adapter bolts.
8. Remove the EGR valve adapter.





9. Remove and discard the cylinder head bolts.
10. Remove the right cylinder head.





11. Remove the cylinder head gasket.
12. Remove the caps, springs, valves, and seals from the cylinder head.
13. Inspect the engine block.
14. Inspect the cylinder head.
15. Clean the gasket mating surfaces on the cylinder head, the engine block and the intake manifold.
16. Clean the cylinder block bolt hole threads.

Installation Procedure

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.





1. Install the valves, seals, springs, and caps to the cylinder head.
2. Position the head gasket with the arrow pointing to the front of the engine.





3. Install the cylinder head.





4. Notice: This bolt is designed to permanently stretch when tightened, and therefore MUST be replaced anytime it is removed. 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.

Install NEW cylinder head bolts (1-8).
Tighten the bolts in the sequence shown to 50 Nm (37 ft. lbs.) plus an additional 120 degrees using J45059.





5. Install the EGR valve adapter to the right cylinder head.
6. Install the EGR valve adapter bolts to the right cylinder head.
Tighten the bolts to 50 Nm (37 ft. lbs.).





7. Install the EGR valve.
8. Install the EGR valve nuts.
Tighten the nuts to 29 Nm (21 ft. lbs.).





9. Install the right rocker arms and push rods.
10. Install the right exhaust manifold.
11. Position and install the power steering pump and bolts.
Tighten the bolts to 34 Nm (25 ft. lbs.).
12. Install the lower intake manifold.