Cylinder Head Replacement - Right
Cylinder Head Replacement- Right^ Tools Required
- J 41131 Engine Tilt Strap
- J 36660-A Electronic Torque Angle Meter
Removal Procedure
Notice: Refer to Engine Emission Notice in Service Precautions.
1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Drain the cooling system.
5. Drain the engine oil.
6. Remove the three-way catalytic converter pipe from the right exhaust manifold.
7. Remove the exhaust gas recirculation (EGR) valve adapter bolt from the right exhaust manifold.
8. Lower the vehicle.
9. Remove the drive belt tensioner.
10. Remove the power steering pump and reposition.
11. Install the J41131.
12. Rotate the engine to access the right cylinder head.
13. Remove the right spark plugs from the right cylinder head.
14. Disconnect the oxygen sensor electrical connector (4).
15. Remove the lower intake manifold.
16. Remove the EGR valve nuts.
17. Remove the EGR valve.
18. Remove the EGR valve adapter bolts from the right cylinder head.
19. Remove the EGR valve adapter from the right cylinder head.
20. Remove the engine lift bracket.
21. Remove the exhaust crossover pipe.
22. Remove the right exhaust manifold.
23. Remove the right valve rocker arm cover.
24. Remove the right rocker arms and push rods.
25. Remove the right cylinder head bolts. Discard the bolts.
26. Remove the right cylinder head.
27. Remove the cylinder head gasket.
28. Remove the caps, the springs, the valves and the seals from the cylinder head.
29. Clean the gasket mating surfaces on the cylinder head, the cylinder block and the intake manifold.
30. Clean the cylinder block bolt hole threads.
31. Inspect the engine block.
32. Inspect the cylinder head.
Installation Procedure
Notice: Refer to Fastener Notice in Service Precautions.
1. Install the valves, the seals, the springs and the caps to the cylinder head.
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.
2. Position the head gasket with the arrow pointing to the front of the engine.
3. Install the cylinder head.
Notice: This bolt is designed to permanently stretch when tightened. 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 in Service Precautions.
4. Install the new cylinder head bolts (1-8).
4.1. Tighten the cylinder head bolts (1-8) in the following sequence to 50 Nm (37 ft. lbs.).
4.2. Use the d 36660-A to rotate the cylinder head bolts an additional (1-8) 120 degrees.
5. Install the right push rods and rocker arms.
6. Install the right valve rocker arm cover.
7. Install the right exhaust manifold.
8. Install the exhaust crossover pipe.
9. Install the engine lift hook.
10. Install the right lift bracket bolt and nut.
^ Tighten the engine lift bracket bolt and nut to 30 Nm (22 ft. lbs.).
11. Install the EGR valve adapter to the right cylinder head.
12. Install the EGR valve adapter bolts to the right cylinder head.
^ Tighten the EGR valve adapter bolts to 50 Nm (37 ft. lbs.).
13. Install the EGR valve.
14. Install the EGR valve nuts.
^ Tighten the EGR valve nuts to 29 Nm (21 ft. lbs.).
15. Install the lower intake manifold.
16. Connect the oxygen sensor electrical connector (4).
17. Install the right spark plugs to the right cylinder head.
18. Carefully release the J41131. Return the engine to the proper position.
19. Install the power steering pump.
20. Install the power steering pump bolts.
^ Tighten the power steering pump bolts to 34 Nm (25 ft. lbs.).
21. Install the drive belt tensioner.
22. Install the left and the right engine mount struts.
23. Raise the vehicle.
24. Install the EGR valve pipe bolt to the right exhaust manifold.
^ Tighten the EGR valve pipe bolt to 29 Nm (21 ft. lbs.).
25. Install the three-way catalytic converter pipe to the right exhaust manifold.
26. Lower the vehicle.
27. Install the fuel injector sight shield.
28. Fill the crankcase with engine oil.
29. Fill the cooling system.
30. Connect the negative battery cable.
31. Inspect for leaks.