Cylinder Head Replacement
Removal Procedure1. Remove the fuel tank filler cap in order to release the fuel vapor pressure in the fuel tank. After releasing the pressure, reinstall the filler cap.
2. Release the fuel pressure. Refer to Fuel Pressure Release.
Caution: Refer to Battery Disconnect Caution in Service Precautions.
3. Disconnect the negative battery cable.
4. Drain the cooling system. Refer to Draining and Filling Cooling System.
5. Disconnect the Intake Air Temperature (IAT) sensor.
6. Disconnect the Mass Air Flow (MAF) sensor.
7. Depress the electrical harness clamps and remove the harness from the air cleaner assembly.
8. Remove the air intake hose (7) from the throttle body.
9. Remove the accelerator cable (2) from the accelerator cable bracket (1).
10. Remove the accelerator cable from the throttle body bellcrank (3).
11. Disconnect the following electrical connectors:
^ Throttle Position (TP) sensor (4)
^ Idle Air Control (IAC) valve (3)
^ Engine Coolant Temperature (ECT) sensor (2)
^ Evaporative emission canister purge valve
12. Remove the EVAP canister purge valve vacuum hose.
13. Remove the EVAP canister purge valve bracket bolt.
14. Remove the EVAP canister purge valve bracket and valve assembly.
15. Remove the coolant hose from the throttle body (1).
16. Disconnect the following electrical connectors:
^ Exhaust Gas Recirculation (EGR) connector (4)
^ Manifold Absolute Pressure (MAP) sensor connector (1)
^ Engine ground wire (2) from intake manifold
17. Remove the brake booster supply hose (3) from the intake manifold.
Important: Use a shop rag to catch any fuel that may leak during the disconnection of the fuel lines.
18. Disconnect the inlet fuel line (4).
19. Disconnect the return fuel line (3).
20. Remove the upper radiator hose from the thermostat housing (1).
21. Remove the upper generator mounting bracket (2).
22. Remove the lower intake manifold support bracket (2) from the intake manifold (1).
23. Remove the crankcase vent hose (1).
24. Remove the PCV hose from the PCV valve (3).
25. Disconnect the fuel injector 6-way connector at the rear of the intake manifold.
26. Remove the EGR valve.
27. Disconnect the Heated Oxygen Sensor (HO2S1) electrical connector.
28. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
29. Remove the following from the exhaust manifold and engine block:
^ 2 bolts
^ 1 nut
^ The exhaust manifold reinforcement bracket (1)
30. Remove the following from the exhaust manifold (1):
^ 2 bolts
^ The front pipe/Three Way Catalytic Converter (TWC) assembly (3)
31. Lower the vehicle.
32. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement.
33. Remove the timing belt. Refer to Timing Belt Replacement.
34. Remove the camshaft. Refer to Camshaft Replacement.
Important: Loosen the cylinder head bolts gradually in the specified sequence to prevent the cylinder head distortion.
35. Remove the cylinder head bolts from the cylinder block.
36. Remove the cylinder head, intake manifold, and exhaust manifold as an assembly.
37. Clean the mating surfaces of the following:
^ The cylinder head
^ The cylinder block
38. Clean all the bolt threads and bolts.
39. Inspect the cylinder head. Refer to Cylinder Head Clean and Inspect.
Notice: Refer to Fastener Notice in Service Precautions.
40. Inspect the oil jet (2) in the cylinder head for any obstructions and ensure that the oil jet is tightened to its torque specification.
^ Tighten the oil jet to 5 Nm (44 inch lbs.).
Installation Procedure
1. Apply clean engine oil to the threaded portion of all of the cylinder bolts.
2. Install the new cylinder head gasket to the cylinder block.
3. Install the cylinder head, intake manifold, and exhaust manifold as an assembly onto the cylinder block.
4. Secure the cylinder head with ten bolts.
Notice: Refer to Fastener Notice in Service Precautions.
5. Tighten the cylinder head bolts (1) in 3 separate steps, following the illustrated sequence.
5.1. Tighten the 10 cylinder head bolts on the first pass to 35 Nm (26 ft. lbs.).
5.2. Tighten the 10 cylinder head bolts on the second pass to 55 Nm (41 ft. lbs.).
5.3. Tighten the 10 cylinder head bolts on the final (third) pass to 70 Nm (52 ft. lbs.).
6. After attaining the proper cylinder head torque, the cylinder head bolts will need to be loosened in the reverse order that they were tightened. After loosening the cylinder head bolts, retorque the cylinder head to specifications.
7. Tighten the cylinder head bolts (1) in three separate steps, following the illustrated sequence.
8. Tighten
8.1. Tighten the ten cylinder head bolts on the first pass to 35 Nm (26 ft. lbs.).
8.2. Tighten the ten cylinder head bolts on the second pass to 55 Nm (41 ft. lbs.).
8.3. Tighten the ten cylinder head bolts on the final (third) pass to 70 Nm (52 ft. lbs.).
9. Install the camshaft. Refer to Camshaft Replacement.
10. Install the timing belt. Refer to Timing Belt Replacement.
11. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement.
12. Raise and support the vehicle. Refer to Vehicle Lifting.
13. Install the front pipe/TWC assembly (3) with a new gasket (2) to the exhaust manifold (1). Secure the assembly with 2 bolts.
^ Tighten the exhaust manifold-to-front pipe/TWC assembly bolts to 50 Nm (37 ft. lbs.).
14. Install the exhaust manifold brackets (1) to the exhaust manifold and the engine block. Secure the brackets with 1 nut and 2 bolts.
^ Tighten the engine mount-to-exhaust bracket bolts to 54 Nm (40 ft. lbs.).
^ Install the exhaust bracket-to-exhaust manifold nut to 50 Nm (37 ft. lbs.).
15. Lower the vehicle.
16. Connect the (HO2S1) electrical connector.
17. Install the crankcase vent hose (1).
18. Install the PCV hose (3) to the PCV valve.
19. Connect the fuel injector 6-way connector at the rear of the intake manifold.
20. Install the lower intake manifold support bracket (2) to the intake manifold (1). Secure the bracket with 2 bolts.
^ Tighten the lower intake manifold support bracket bolts to 50 Nm (37 ft. lbs.).
21. Install the upper generator mounting bracket (2). Secure the bracket with 2 bolts.
^ Tighten the upper generator mounting bracket bolts to 50 Nm (37 ft. lbs.).
22. Adjust the generator drive belt tension. Refer to Drive Belt Replacement.
23. Reinstall the EVAP canister.
24. Install the upper radiator hose to the thermostat housing (1).
25. Install the fuel inlet hose (1) to the fuel line union.
26. Install the fuel return hose (2) to the fuel line union.
27. Connect the following electrical connectors:
^ Exhaust gas recirculation (EGR) connector (4)
^ Manifold absolute pressure (MAP) sensor connector (1)
^ Engine ground wire (2) from intake manifold
28. Install the Brake booster supply hose (3) to the intake manifold.
29. Connect the following electrical connectors:
^ Throttle position (TP) sensor (4) Idle air control (IAC) valve (3)
^ Engine coolant temperature (ECT) sensor (2)
^ Evaporative emission canister purge valve
30. Install the EVAP canister purge valve vacuum hose.
31. Install the coolant hose to the throttle body (1).
32. Install the accelerator cable (2) to the accelerator cable bracket (1).
33. Install the accelerator cable to the throttle body bellcrank (3). Adjust the accelerator cable as necessary. Refer to Accelerator Controls Cable Replacement.
34. Connect the intake air temperature (IAT) sensor.
35. Connect the mass air flow (MAP) sensor.
36. Install the electrical harness clamps to the air cleaner assembly.
37. Install the air intake hose (7) to the throttle body.
38. Refill the cooling system as necessary. Refer to Draining and Filling Cooling System.
39. Install the negative battery cable.
^ Tighten the battery cable bolt to 15 Nm (11 ft. lbs.).