Cylinder Head Replacement

Cylinder Head Replacement

Tools Required

J 45059 Angle Meter

Removal Procedure




1. Remove the hood.
2. Remove the intake manifold.
3. Remove the exhaust manifold.
4. Remove the timing chain.
5. Drain the cooling system.
6. Remove the negative battery cable ground terminal bolt.
7. Remove the negative battery cable ground terminal and engine harness ground terminal from the cylinder head.




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




10. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
11. Remove the engine harness ground terminal bolt (1) and reposition the engine harness ground terminal (2).
12. Disconnect the engine wiring harness electrical connector (6) from the engine coolant temperature (ECT) sensor.




13. Reposition the radiator inlet hose clamp at the engine.
14. Remove the radiator inlet hose from the cylinder head.




15. Remove the intake manifold cover bracket bolts and bracket.




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




17. Remove the cylinder head.
18. Remove the cylinder head gasket.
19. Clean all of the gasket surfaces.
20. 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.
21. Clean the old sealer/lube and any dirt from around the bolt holes.

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

22. Clean the bolts holes with a nylon bristle brush.
23. 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





Important: DO NOT use any sealing material.

1. 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.

Notice: Refer to Fastener Notice.




5. Install and tighten the cylinder head bolts in the sequence shown.

Tighten the bolts to 30 N.m (22 lb ft) plus an additional 155 degrees using the J 45059.




6. Install the NEW front cylinder head bolts.

Tighten the bolts to 35 N.m (26 lb ft).




7. Install the radiator inlet hose to the cylinder head.
8. Position the radiator inlet hose clamp at the engine.




9. Install the intake manifold cover bracket and bolts.

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




10. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
11. Position the engine wiring harness ground terminal (2) and install the bolt (1).

Tighten the bolt to 10 N.m (89 lb in).

12. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.





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

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




15. Position the engine harness ground terminal behind the negative battery cable terminal and position against the cylinder head.
16. Install the negative battery cable ground terminal bolt.

Tighten the bolt to 10 N.m (89 lb in).

17. Install the timing chain.
18. Install the exhaust manifold.
19. Install the intake manifold.
20. Fill the cooling system.
21. Install the hood.