Cylinder Head Replacement

Cylinder Head Replacement

^ Tools Required
- J 45059 Angle Meter

Removal Procedure





1. Remove the intake manifold.
2. Remove the exhaust manifold.
3. Remove the timing chain.
4. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill).
5. Remove the negative battery cable ground terminal bolt.





6. Disconnect the intake camshaft position (CMP) sensor electrical connector.
7. Remove the evaporative emission (EVAP) canister purge solenoid valve.





8. Disconnect the exhaust CMP sensor electrical connector (1).
9. Remove the engine harness ground terminal bolt (2) and terminal (3).
10. Disconnect the engine coolant temperature (ECT) sensor electrical connector (4).





11. Remove the cylinder head bolts in the sequence shown. Discard the bolts.





12. Remove the cylinder head.
13. Remove the cylinder head gasket.
14. Clean all of the gasket surfaces.
15. Use the following steps when cleaning the cylinder head and cylinder block surfaces:
^ Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge either surface.

^ Important: DO NOT use any other method or technique to clean these gasket surfaces.

Use a NEW razor blade on the cylinder head and a NEW blade on the cylinder block.

^ Important: Be careful not to gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the NEW gasket.

Hold the razor blade as parallel to the gasket surface as possible.
16. Clean the old sealer/lube and any dirt from around the bolt holes.

17. Important: DO NOT use a tap to clean the cylinder head bolt holes.

Clean the bolts holes with a nylon bristle brush.
18. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.

Installation Procedure





1. Important: DO NOT use any sealing material.

Install the cylinder head gasket.
2. Install the cylinder head.
3. Lightly apply clean engine oil to the threads and the bottom side flange of the head bolts and allow the oil to drain before installing.
4. Install NEW cylinder head bolts.





5. Notice: Refer to Fastener Notice.

Install and tighten the cylinder head bolts in the sequence shown.
Tighten the bolts to 30 Nm (22 ft. lbs.) plus an additional 155 degrees using the J 45059.





6. Install the NEW front cylinder head bolts.
Tighten the bolts to 35 Nm (26 ft. lbs.).





7. Connect the ECT sensor electrical connector (4).
8. Install the engine harness ground terminal (3) and bolt (2).
Tighten the bolt to 10 Nm (89 inch lbs.).
9. Connect the exhaust CMP sensor electrical connector (1).





10. Important: Ensure that the intake CMP sensor wire is routed behind the EVAP purge solenoid valve bracket.

Install the EVAP canister purge solenoid valve.
11. Connect the intake CMP sensor electrical connector.





12. Install the negative battery cable ground terminal bolt.
Tighten the bolt to 10 Nm (89 inch lbs.).
13. Install the timing chain.
14. Install the exhaust manifold.
15. Install the intake manifold.
16. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill).