Removal and Replacement
Cylinder Head and Gasket Removal and InstallationTools Required:
KM-470-B Angular Torque Gauge
J-28467-B Engine Assembly Support Fixture
Removal
1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery cable.
4. Disconnect the Electronic Control Module (ECM) ground terminal.
5. Drain the engine coolant.
6. Disconnect the Manifold Air Temperature (MAT) sensor connector.
7. Disconnect the breather tube from the camshaft cover.
8. Disconnect the air cleaner outlet hose from the throttle body.
9. Disconnect the Direct Ignition System (DIS) coil connector.
10. Disconnect the oxygen (O2) sensor connector, if equipped.
11. Disconnect the Idle Air Control (IAC) valve connector.
12. Disconnect the Throttle Position Sensor (TPS) connector.
13. Disconnect the Engine Coolant Temperature (ECT) sensor connector.
14. Disconnect the Coolant Temperature Sensor (CTS) connector.
15. Remove the air cleaner housing bolts.
16. Remove the air cleaner housing.
17. Remove the right front wheel.
18. Remove the right front wheel well splash shield.
19. Install the engine assembly support fixture J-28467-B.
20. Remove the right engine mount bracket and bolts.
21. Disconnect the upper radiator hose at the thermostat housing.
22. Remove the serpentine accessory drive belt.
23. Remove the crankshaft pulley bolts.
24. Remove the crankshaft pulley.
25. Remove the front timing belt cover bolts.
26. Remove the front timing belt cover.
27. Remove the timing belt.
28. Disconnect the breather tube at the camshaft cover.
29. Remove the spark plug cover bolts.
30. Remove the spark plug cover.
31. Disconnect the ignition wires from the spark plugs.
32. Remove the camshaft cover bolts.
33. Remove the camshaft cover and the camshaft cover gasket.
34. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
35. Remove the intake camshaft gear.
36. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
37. Remove the exhaust camshaft gear.
38. Remove the timing belt automatic tensioner bolts.
39. Remove the timing belt automatic tensioner.
40. Remove the timing belt idler pulley bolt and nut.
41. Remove the timing belt idler pulleys.
42. Remove the engine mount bolts.
43. Remove the engine mount.
44. Remove the crankshaft gear.
45. Remove the CMP sensor.
46. Remove the water pump.
47. Remove the rear timing belt cover bolts.
48. Remove the rear timing belt cover.
49. Remove the exhaust flex pipe retaining nuts at the exhaust manifold studs.
50. Disconnect all of the necessary vacuum hoses.
51. Disconnect the fuel feed line at the fuel rail.
52. Remove the generator adjusting bracket retaining bolt and the bracket.
53. Disconnect the coolant hose at the rear cylinder head and ignition coil Exhaust Gas Recirculation (EGR) bracket.
54. Disconnect the surge tank coolant hose at the throttle body.
55. Remove the fuel rail assembly.
56. Remove the generator-to-intake manifold support bracket bolts at the cylinder head and the intake manifold.
57. Remove the generator support bracket.
58. Remove the intake manifold-to-generator strap bracket bolt and loosen the bolt on the generator.
59. Move the strap clear of the intake manifold.
60. Remove the Charcoal Canister Purge (CCP) and EGR solenoid bracket bolt and move the bracket clear.
61. Disconnect the throttle cable at the throttle body and the intake manifold.
62. Loosen all of the cylinder head bolts gradually and in the sequence shown.
63. Remove the camshaft.
64. Remove the cylinder head bolts.
65. Remove the cylinder head with the intake manifold and the exhaust manifold attached.
66. Remove the cylinder head gasket.
Installation
1. Install the cylinder head gasket.
2. Install the cylinder head with the intake manifold and the exhaust manifold attached.
3. Install the cylinder head bolts.
4. Tighten the cylinder head bolts gradually and in the sequence shown.
Tighten: Tighten the cylinder head bolts to 25 Nm (18 ft. lbs.) and turn the bolts another 3 turns of 90° using the angular torque gauge KM-470-B.
5. Install the camshaft.
6. Connect the throttle cable at the throttle body and the intake manifold.
7. Install the generator-to-intake manifold support bracket.
8. Install the intake generator-to-manifold support bracket bolts.
Tighten: Tighten the generator-to-intake manifold support bracket bolts to the intake manifold to 37 Nm (27 ft. lbs.).
9. Install the intake manifold support bracket bolt to the generator.
Tighten: Tighten the generator-to-intake manifold support bracket bolt at the generator to 22 Nm (16 ft. lbs.).
10. Connect the surge tank coolant hose at the throttle body.
11. Connect the coolant hose to the rear cylinder head and ignition coil EGR bracket.
12. Connect the fuel feed line at the fuel rail.
13. Connect the fuel return line at the fuel rail.
14. Connect all of the necessary vacuum hoses.
15. Install the fuel rail assembly.
16. Install the exhaust flex pipe retaining nuts at the exhaust manifold studs.
Tighten: Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts to 35 Nm (26 ft. lbs.).
17. Install the rear timing belt cover.
18. Install the rear timing belt cover bolts.
Tighten: Tighten the rear timing belt cover bolts to 7 Nm (62 inch lbs.).
19. Install the engine mount and the retaining bolts.
Tighten: Tighten the engine mount retaining bolts to 45 Nm (33 ft. lbs.).
20. Install the Camshaft Position (CMP) sensor.
21. Install the crankshaft gear.
22. Install the water pump.
23. Install the timing belt automatic tensioner.
24. Install the timing belt automatic tensioner bolt.
Tighten: Tighten the timing belt automatic tensioner bolts to 25 Nm (18 ft. lbs.).
25. Install the timing belt idler pulleys.
26. Install the timing belt idler pulley bolt and nut.
Tighten: Tighten the timing belt idler pulley bolt to 25 Nm (18 ft. lbs.).
27. Install the camshaft gears with the timing marks at the front.
28. Insert the guide pin of the intake camshaft into the "IN" bore.
29. Insert the guide pin of the exhaust camshaft into the "EX" bore.
30. Install the camshaft gears by counterholding on the hex of the camshaft with an open ended wrench.
31. Install the camshaft gear with a new bolt to the camshaft.
Tighten: Tighten the intake camshaft gear bolt to 50 Nm (37 ft. lbs.) turn the bolt another 60° and 15° using the angular torque gauge.
32. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.
Tighten: Tighten the exhaust camshaft gear bolt to 50 Nm (37 ft. lbs.) turn the bolt another 60° and 15° using the angular torque gauge.
33. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover-to-cylinder head seal.
34. Install the camshaft cover and the camshaft cover gasket.
35. Install the camshaft cover washers.
36. Install the camshaft cover bolts.
Tighten: Tighten the camshaft cover bolts to 8 Nm (71 inch lbs.).
37. Connect the ignition wires to the spark plugs.
38. Install the spark plug cover.
39. Install the spark plug cover bolts.
Tighten: Tighten the spark plug cover bolts to 8 Nm (71 inch lbs.).
40. Connect the breather tube to the camshaft cover.
41. Align the timing marks on the camshaft gears to the notches on the camshaft cover, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.
42. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
43. Install the timing belt.
44. Check and adjust the timing belt tension.
45. Install the front timing belt cover.
46. Install the front timing belt cover bolts.
Tighten: Tighten the front timing belt cover bolts to 6 Nm (53 inch lbs.).
47. Install the crankshaft pulley.
48. Install the crankshaft pulley bolts.
Tighten: Tighten the crankshaft pulley bolts to 12 Nm (106 inch lbs.).
49. Install the right engine mount bracket and retaining bolts.
Tighten: Tighten the engine mount bracket retaining bolts to 55 Nm (41 ft. lbs.).
50. Remove the engine assembly lift support J-28467-B.
51. Install the serpentine accessory drive belt.
52. Connect the upper radiator hose to the thermostat housing.
53. Install the right front wheel well splash shield.
54. Install the right front wheel.
55. Install the air cleaner housing.
56. Install the air cleaner housing bolts.
Tighten: Tighten the air cleaner housing bolts to 10 Nm (89 inch lbs.).
57. Connect the air cleaner outlet hose to the throttle body.
58. Connect the breather tube to the camshaft cover.
59. Connect the MAT sensor connector.
60. Connect the CTS connector.
61. Connect the engine CTS connector.
62. Connect the IAC valve connector.
63. Connect the TPS connector.
64. Install the CCP and the EGR solenoid bracket bolt.
Tighten: Tighten the charcoal canister purge and exhaust gas recirculation solenoid bracket bolt to 5 Nm (44 inch lbs.).
65. Connect the DIS coil connector.
66. Connect the O2 sensor connector, if equipped.
67. Connect the ECM ground terminal.
68. Install the fuel pump fuse.
69. Connect the negative battery ground cable.
70. Refill the engine cooling system.