Removal and Installation

REMOVAL

WARNING:
- DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
- FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING.

1. Disconnect the battery ground cable.
2. Remove the intake manifold.
3. Remove the timing chain/belts.





4. Compress and slide the hose clamp back and remove the heater water hose.





5. Install the Lifting Handles.





6. Remove the bolts and the cylinder head (6049).
- Discard the head gasket and clean the engine block surface.
- The LH is shown. The RH is similar.

CAUTION: These bolts must be replaced with new bolts. They are tighten-to-yield designed and cannot be reused.

7. Clean and inspect the mating surface of the cylinder head.

CAUTION: Do not use metal scrapers wire brushes, power abrasive discs or other abrasive means to clean the aluminum retain plate. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

INSTALLATION





1. Rotate the crankshaft to position the keyway at 12 o'clock.





2. Install the head gasket over the dowel pins.

NOTE: Do not turn the crankshaft until otherwise instructed.





3. Install the cylinder head on the head gasket and loosely install the bolts.
- The LH is shown; the RH is similar.





4. Tighten the LH bolts in the sequence shown.
- Stage 1: Tighten to 37-43 Nm (27-32 ft. lbs.)
- Stage 2: Tighten an additional 85 degrees to 95 degrees
- Stage 3: Tighten an additional 85 degrees to 95 degrees

NOTE: Be sure to tighten the bolts in three stages.

5. Install the timing chain/belts.
6. Install the intake manifold.
7. Connect the battery ground cable.