Cylinder Head Replacement - Left Side

REMOVAL PROCEDURE





1. Disconnect the battery negative cable.
2. Drain the cooling system.
3. Remove the air cleaner assembly from the vehicle.
4. Remove the drive belts from the pulleys.
5. Remove the fan clutch from the water pump.
6. Remove the engine cover from the vehicle
7. Remove the upper intake manifold from the lower intake manifold.
8. Remove the lower intake manifold from the cylinder head.
9. Remove the turbocharger from the engine block.
10. Remove the valve rocker arm covers from the cylinder head.
11. Remove the valve rocker arm assemblies and the push rods.
12. Remove the radiator hoses from the vehicle.
13. Remove the thermostat housing from the cylinder heads.
14. Remove the exhaust manifolds from the cylinder heads.
15. Remove the air conditioning compressor.
16. Remove the A/C mounting bracket and secure to the side.
17. Remove the oil level indicator and tube.
18. Remove the generator mounting bracket from the cylinder head and secure to the side.
19. Remove the wire harness and electrical connectors; move aside.
20. Remove the cylinder head bolts (in sequence from the cylinder head).





21. Remove the cylinder heads from the engine block.
22. Disassemble the cylinder head assembly. Refer to Cylinder Head Disassemble under Engine Unit Repair.

INSTALLATION PROCEDURE





1. Assemble the cylinder head assembly. Refer to Cylinder Head Assemble under Engine Unit Repair.

IMPORTANT: Do not use a sealer on the head gasket. The head gasket is manufactured with the proper amount of sealant "printed" on its surface. Additional sealer may cause leakage or malfunction. In addition, some sealers may attack the sealant already on the head gasket.

2. Install the head gasket to the block over the dowel pins.





3. Install the cylinder head to the engine block.





4. Install the cylinder head bolts in the cylinder heads.





5. Install the cylinder head bolts to the cylinder head (in sequence) and tighten in 4 passes.
5.1. Bolts to 25 Nm (20 ft. lbs.).
5.2. Retighten bolts to 75 Nm (55 ft. lbs.).
5.3. In sequence, tighten all bolts an additional 90-100 degrees (1/4 + turn).

NOTICE: Refer to Fastener Notice in Service Precautions.

6. Install the push rods and the valve rocker arm to the cylinder head.
7. Install the valve rocker arm cover to the cylinder head.
8. Install the generator mounting bracket to the cylinder head.
9. Install the A/C mounting bracket to the front of the engine assembly.
10. Install the exhaust manifold to the cylinder head. Refer to Exhaust Manifold Installation under Engine Unit Repair.
11. Install the oil level indicator and tube.
12. Install the turbocharger assembly to the engine block.
13. Install the thermostat housing assembly to the cylinder head.
14. Install the radiator hoses in the vehicle.
15. Install the lower intake manifold to the cylinder head.
16. Install the upper intake manifold to the lower intake manifold.
17. Install the wiring harness, electrical connectors and brackets.
18. Install the air conditioning compressor mounting bracket.
19. Install the fan clutch to the water pump assembly.
20. Install the drive belt on the pulleys.
21. Install the air cleaner assembly in the vehicle.
22. Install the engine cover to the vehicle.
23. Fill the cooling system with the proper quantity and grade of coolant.
24. Connect the battery negative cables to the batteries.