Cylinder Head

Cylinder Head

Special Tools:

Material:

Removal

Both sides
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair
2. Drain the engine cooling system.
3. Remove the roller followers.
4. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt.





RH side
5. Remove the bolts and position the heater hose tube bracket aside.





6. Disconnect the battery ground cable. For additional information, refer to Battery.
7. Disconnect the generator electrical connections and disconnect the pushpin.





8. Remove the bolt and the accessory drive belt tensioner.





9. Remove the generator mounting bracket assembly.





10. Remove the heater hose from the thermostat housing.





11. Disconnect the engine coolant temperature (ECT) sensor electrical connector.





12. Disconnect the upper radiator hose.





13. Position the coolant bypass hose clamp aside.





14. Remove the bolts and the thermostat housing.





15. Remove the bolt and position the engine wiring harness aside.





16. Remove the engine ground strap.





17. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid damage to the spark plug wire.

NOTE: Spark plug wires must be connected to the correct spark plug. Mark the spark plug wires for installation reference.

With a twisting motion, use the special tool to pull the spark plug wires from the RH spark plugs.





18. Remove the catalytic converter-to-RH exhaust manifold nuts.





19. Remove the nuts, the RH exhaust manifold and the gasket.
^ Discard the nuts and the gasket.





20. Remove and discard the 6 RH exhaust manifold studs.
21. Remove the RH side hydraulic chain tensioner.





22. Install the special tools.
^ Tighten to 10 Nm (89 inch lbs.).





23. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, remove the RH camshaft bolt.





24. Remove the RH side cassette bolt.





25. CAUTION: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head. Leaving the sprocket in place can damage the cassette and prevent the cylinder head from being removed.

NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.

Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.





LH side
26. Disconnect the radio ignition interference capacitor electrical connector.





27. Remove the bolts.





28. Remove the bolts and position the A/C compressor and power steering pump bracket aside.





29. Remove the bolts and the coil bracket.





30. Remove the oil level indicator tube.





31. Remove the catalytic converter-to-LH exhaust manifold nuts.





32. Remove the nuts, the LH exhaust manifold and the gasket.
^ Discard the nuts and the gasket.





33. Remove and discard the 6 LH exhaust manifold studs.
34. Remove the LH side hydraulic chain tensioner.





35. Install the special tools.
^ Tighten the top clamp bolts to 10 Nm (89 inch lbs.).





36. Remove the LH side camshaft sprocket bolt.





37. Remove the LH side cassette bolt.





38. CAUTION: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head. Leaving the sprocket in place can damage the cassette and prevent the cylinder head from being removed.

NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.

Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.





Both sides

39. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help lift the cylinder head from the vehicle.

CAUTION: On the RH side, when lifting the cylinder head, be careful to avoid contacting the A/C tube or the A/C tube can be damaged.

NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Remove the cylinder heads.
^ Remove the cylinder head bolts in the sequence shown. Discard all bolts.
^ Remove and discard the head gasket.





40. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

Clean and inspect the mating surfaces.
41. Inspect the cylinder head and the cylinder block for flatness.

Installation

Both sides
1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
2. Position the cylinder head gasket on the block.





RH side

3. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.

CAUTION: On the RH side, when lifting the cylinder head, be careful to avoid contacting the A/C tube or the A/C tube can be damaged.

NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).





4. Install 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).





5. Tighten the eight 12-mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.





6. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Tightening the bolt can result in incorrect engine timing.

Remove the rubber band. Install the camshaft sprocket and bolt.





7. Install the RH side cassette bolt.
^ Tighten to 10 Nm (89 inch lbs.).





8. Inspect the RH exhaust manifold gasket mating surfaces for flatness.
9. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).

10. Position a new gasket, the RH exhaust manifold and the new nuts.
^ Tighten to 22 Nm (16 ft. lbs.).





11. Install the catalytic converter-to-RH exhaust manifold nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





12. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots.

Connect the spark plug wires to the RH spark plugs.
13. Install the engine ground strap and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





14. Position the engine wiring harness and install the bolt.
^ Tighten to 47 Nm (35 ft. lbs.).





15. NOTE: Inspect the O-ring seal. Install a new O-ring seal if necessary.

Install the thermostat housing and the bolts.
^ Tighten to 11 Nm (8 ft. lbs.).





16. Position the coolant bypass hose clamp.





17. Install the upper radiator hose.





18. Connect the engine coolant temperature (ECT) sensor electrical connector.





19. Install the heater hose to the thermostat housing.





LH side

20. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.

NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).





21. Install 2 new 8-mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).





22. Tighten the eight 12-mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten 90 degrees.
^ Stage 2: Tighten an additional 90 degrees.





23. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Tightening the bolt can result in incorrect engine timing.

Remove the rubber band. Install the camshaft sprocket and bolt.





24. Install the LH side cassette bolt.
^ Tighten to 12 Nm (9 ft. lbs.).





25. Inspect the LH exhaust manifold gasket mating surfaces for flatness.
26. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).

27. Position a new gasket, the LH exhaust manifold and install the new nuts.
^ Tighten to 22 Nm (16 ft. lbs.).





28. Install the catalytic converter-to-LH exhaust manifold nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





29. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots.

Connect the spark plug wires to the LH spark plugs.
30. Install the oil level indicator tube and bolt.
^ Tighten to 10 Nm (89 inch lbs.).





Both sides
31. Time the camshafts.

RH side
32. Install the generator mounting bracket assembly and the bolts.
^ Tighten to 42 Nm (31 ft. lbs.).





33. Position the accessory drive belt tensioner and install the bolt.
^ Tighten to 47 Nm (35 ft. lbs.).





34. Connect the generator electrical connections and install the pushpin.
^ Tighten to 8 Nm (71 inch lbs.).





35. Connect the battery ground cable. For additional information, refer to Battery.
36. Position the heater hose tube bracket and install the bolts.
^ Tighten the rear bolt to 23 Nm (17 ft. lbs.).
^ Tighten the front bolt to 34 Nm (25 ft. lbs.).





LH side
37. Install the ignition coil bracket and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





38. Install the A/C compressor and power steering pump bracket and the bolts.
^ Tighten to 42 Nm (31 ft. lbs.).





39. Install the ignition coil bracket-to-accessory drive bracket bolts.
^ Tighten to 10 Nm (89 inch lbs.).





40. Connect the radio ignition interference capacitor electrical connector.





Both sides
41. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.





42. Fill and bleed the engine cooling system.