Cylinder Head Replacement

Cylinder Head Replacement

Removal Procedure




1. Remove the 2 engine cover fasteners.
2. Remove the 2 engine cover plastic retainers.
3. Remove the engine cover (1) from the engine.
4. Relieve the fuel pressure.

Caution: Refer to Battery Disconnect Caution.

5. Disconnect the negative battery cable.
6. Remove the right side engine splash shield.
7. Remove the left side engine splash shield.
8. Drain the cooling system.
9. Drain the engine oil.
10. Lower the vehicle.




11. Remove the serpentine drive belt.
12. Remove the generator.




13. Remove the accelerator cable from the throttle body (1).
14. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
15. Disconnect the EVAP canister purge valve vacuum hoses.
16. Disconnect the air cleaner housing vacuum hose.




17. Disconnect the intake air temperature (IAT) sensor.
18. Remove the air cleaner hose and cap assembly (1).
Disconnect the throttle position (TP) sensor connector.
19. Disconnect the idle air control (IAC) Valve connector.
20. Disconnect the manifold absolute pressure (MAP) sensor connector.
21. Remove the two coolant bypass hose clamps from the throttle body.
22. Remove the coolant bypass hoses.




23. Disconnect the four fuel injector connectors (1).
24. Remove the radiator inlet hose.
25. Remove the following items from the intake manifold:
^ The 2 bolts (3, 4)
^ The fuel injector harness
26. Position the fuel injector harness above the intake manifold.
27. Remove the intake manifold support bracket bolts and bracket.
28. Remove the fuel injector harness brackets.
29. Disconnect the oxygen sensor connector.
30. Remove the oxygen sensor.
31. Raise and support the vehicle.




32. Remove the following items from the exhaust pipe at the manifold.
^ The 2 bolts (1, 2)
^ The springs
33. Remove the exhaust pipe to manifold seal.




34. On AWD, remove the 1 bolt (1) from the exhaust manifold to the support bracket.




35. On 2WD, remove the exhaust manifold support bracket bolt.
36. On all vehicles, lower the vehicle.
37. Disconnect the two ignition coil connectors.
38. Remove the ignition coil harness retaining bolts, then position harness aside.
39. Disconnect the fuel line at the fuel rail.
40. Remove the injector fuel rail hold down clamp.




41. Remove the ignition coils (1, 2, 3, 4).
42. Remove the following items from the cylinder head:
^ The 3 bolts
^ The fuel rail
^ The 2 ground wire bolts
^ The ground wires
43. Remove the heater hose at the cylinder head.
44. Remove the following items from the cylinder head:
^ The one bolt
^ The water bypass pipe
45. Disconnect the cam sensor electrical connector.
46. Remove the following items:
^ The 1 bolt
^ The camshaft sensor
47. Disconnect the engine coolant temperature sensor electrical connector.
48. Disconnect the camshaft position actuator solenoid valve electrical connector.
49. Remove the bolt and camshaft position actuator solenoid valve and O-ring.
50. Remove the camshaft position actuator oil filter plug, filter and O-ring.
51. Remove the two PCV hoses from the cylinder head cover.
52. Remove the cylinder head cover from the cylinder head.
53. Disconnect the power steering oil pressure switch connector.
54. Raise and support the vehicle.




55. Remove the 2 power steering pump through bolts and nuts (1).
56. Remove the power steering pump.
57. Position the power steering pump aside.
58. Remove the crankshaft pulley.




59. Disconnect the crankshaft sensor electrical connector, then remove the following items:
^ The crankshaft position sensor bolt (5)
^ The crankshaft position sensor
60. Lower the vehicle.
61. Set the number 1 piston to top dead center.
62. Align the camshaft timing sprockets.
63. Support the engine with a floor jack. Be sure to place a block of wood between the floor jack and the engine.
64. Remove the drive belt tensioner nut.
65. Raise the engine, then remove the following items:
^ The drive belt tensioner bolt
^ The drive belt tensioner
66. Remove the following items:
^ The 6 right side engine mount bolts
^ The engine mount




67. Remove the timing chain tensioner bolts (1, 2).
68. Remove the timing chain tensioner.
69. Remove the engine mount bracket as follows:
^ Remove the 3 bolts
^ Remove the bracket




70. Remove the timing chain cover bolts and nuts (1-15).
71. Remove the timing chain cover.
72. Remove the crank sensor reluctor.
73. Remove the following items:
^ The timing chain slipper bolt
^ The slipper




74. Remove the following items:
^ The crankshaft sprocket
^ The timing chain




75. Remove the camshaft sprocket bolts.
76. Remove the camshaft sprockets.




77. Remove the following items in sequence:
^ The camshaft bearing cap bolts
^ The camshaft bearing caps
78. Remove the camshafts.
79. Remove the valve lifters. Keep the lifters in order so that the lifters can be reinstalled in the original location.

Important: Use a wooden block in order to protect the oil pan when lifting the engine.

80. Use a floor jack in order to raise the engine.
81. Remove the intake manifold.
82. Remove the exhaust manifold.




83. Remove the following items in sequence:
^ The cylinder head bolts
^ The cylinder head washers




84. Remove the cylinder head.




85. Remove the cylinder head gasket (1).




86. Clean the cylinder block mating surfaces.




87. Clean the cylinder head mating surface.
88. Clean the timing chain cover mating surface.

Installation Procedure

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.

1. Clean the threads in the cylinder block.
2. Install the new cylinder head gasket on the cylinder block.
3. Install the cylinder head on the cylinder block.

Notice: This bolt is designed to permanently stretch when tightened, and therefore MUST be replaced anytime it is removed. 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.

4. Install the cylinder head bolts and washers into the cylinder head.





Notice: Refer to Fastener Notice.

5. Progressively torque the cylinder head bolts using 3 steps in the sequence shown.

Tighten the cylinder head bolts to 25 N.m (18 lb ft).

Tighten the cylinder head bolts to 49 N.m (36 lb ft).

After reaching the torque of 49 N.m (36 lb ft). Use a J 36660-A and tighten the cylinder head bolts an additional 90 degrees.

6. Install the intake manifold.
7. Install the exhaust manifold.
8. Install the intake camshaft.
9. Install the exhaust camshaft.
10. Install the timing chain.
11. Install the timing chain housing.
12. Install the crankshaft pulley.
13. Install the cylinder head cover.
14. Install the engine mount bracket as follows:
^ Position the engine mount bracket
^ Install the 3 bolts

Tighten the bolts to 47 N.m (35 lb ft).

15. Install the drive belt tensioner.
16. Install the right side engine mount.
17. Install the crankshaft position sensor.
18. Install the power steering pump.

Tighten the power steering pump bolts to 37 N.m (27 lb ft).

19. Connect the power steering oil pressure switch electrical connector.
20. Install the engine coolant temperature (ECT) sensor.
21. Install the camshaft sensor.
22. Use the 1 bolt in order to secure the camshaft sensor.

Tighten the camshaft sensor bolt to 15 N.m (11 lb ft).

23. Install the camshaft position actuator O-ring, filter and oil filter.
24. Install a new O-ring and the camshaft position actuator solenoid.

Tighten the camshaft position actuator solenoid valve bolt to 15 N.m (11 lb ft).

25. Connect the camshaft position actuator solenoid valve electrical connector.
26. Connect the engine coolant temperature sensor electrical connector.




27. Install the water bypass pipe (1) to the cylinder head.
28. Use the 1 bolt in order to secure the coolant bypass pipe to the cylinder head.

Tighten the coolant bypass pipe to 15 N.m (11 lb ft).

29. Install the heater hose to the cylinder head.
30. Install the engine ground wires to the cylinder head.
31. Use the 2 bolts in order to secure the engine ground wires.

Tighten the ground wire bolts to 15 N.m (11 lb ft).

32. Install the fuel rail to the cylinder head.
33. Use the 3 bolts in order to secure the fuel rail.

Tighten the fuel rail bolts to 14 N.m (10 lb ft).

34. Connect the fuel line to the fuel rail.
35. Install the heater hose to the cylinder head.




36. Install the 4 ignition coils (1, 2, 3, 4).
37. Connect the ignition coil connectors.
38. Remove the engine support fixture.
39. Raise and support the vehicle.




40. On AWD, install the one bolt (1) from the manifold to the support bracket.

Tighten the exhaust support bracket bolt to 35 N.m (26 lb ft).




41. On 2WD, install the exhaust manifold support bracket bolt.

Tighten the exhaust support bracket bolt to 50 N.m (37 lb ft).




42. Use a new seal in order to install the exhaust pipe to the exhaust manifold.
43. Use the 2 bolts and two springs (1, 2) in order to secure the exhaust pipe.

Tighten the exhaust pipe flange bolts to 62 N.m (46 lb ft).

44. Install the left side engine splash shield.
45. Install the right side engine splash shield.
46. Lower the vehicle.
47. Install the oxygen sensor.
48. Install the injector harness brackets.
49. Connect all of the necessary vacuum hoses.
50. Install the intake manifold support bracket.
51. Use the support bracket bolts in order to secure the intake manifold support bracket.

Tighten the intake support bracket bolts to 50 N.m (37 lb ft).

52. Install the fuel injector harness to the intake manifold.
53. Use the three bolts in order to secure the fuel injector harness.

Tighten the fuel injector harness bolts to 12 N.m (106 lb in).

54. Install the radiator inlet hose.
55. Connect the 4 fuel injector connectors.
56. Connect the temperature sensor connector.
57. Install the 2 coolant bypass hoses to the throttle body.
58. Use the 2 hose clamps in order to secure the two coolant bypass hoses.
59. Connect the MAP sensor connector.
60. Connect the IAC valve connector.
61. Connect the TP sensor connector.
62. Install the air cleaner hose and cap assembly.
63. Connect the IAT sensor connector.
64. Install the accelerator cable to the throttle body.
65. Install the generator (1).




66. Install the serpentine drive belt.
67. Refill the engine oil.
68. Refill the engine coolant.