Cylinder Head Replacement - Right or Rear

Removal Procedure

Notice: Refer to Engine Emission Notice in Service Precautions.





1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Service Precautions.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
3. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the drive belt from the generator. Refer to Drive Belt Replacement.
5. Remove the generator. Refer to Generator Replacement in Starting and Charging.
6. Disconnect the three-way catalytic converter pipe from the right manifold.
7. Remove the engine mount struts. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right).
8. Rotate the engine forward for access.
9. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
10. Disconnect the power steering pump. Refer to Power Steering Pump Replacement in Steering.
11. Remove the heater hoses from the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
12. Remove the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
13. Remove the right spark plugs. Refer to Spark Plug Replacement in Powertrain Management.
14. Disconnect the oxygen sensor electrical connector.
15. Carefully remove the throttle body air inlet duct.
16. Disconnect the throttle and cruise control cables.
17. Disconnect the electrical connector from the throttle vacuum line.
18. Remove the fuel rail. Refer to Fuel Rail Assembly Replacement (VIN K) in Powertrain Management.
19. Remove the Exhaust Gas Recirculation (EGR) valve shield bracket bolt and nut.
20. Remove the EGR valve shield bracket.





21. Remove the EGR valve nuts.
22. Remove the EGR valve. Refer to EGR Valve Replacement in Powertrain Management.





23. Remove the EGR valve outlet pipe bolt and nut.
24. Remove the EGR valve outlet pipe.





25. Remove the EGR valve adapter bolt from the right exhaust manifold.





26. Remove the EGR valve adapter bolts from the right cylinder head.
27. Remove the EGR valve adapter from the right cylinder head.
28. Remove the upper intake manifold or Supercharger.
29. Remove the engine lift hook.
30. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Replacement.
31. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement (Right).
32. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Right Rear).
33. Remove the right rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement.





34. Remove the cylinder head bolts. Discard the cylinder head bolts.
35. Remove the cylinder head.





36. Remove the cylinder head gasket.
37. Remove the springs, the caps, the seals, and the valves from the cylinder head. Refer to Cylinder Head Disassemble.
38. Clean the mating surfaces on the cylinder head, the cylinder block, and the intake manifold.
39. Clean the cylinder block bolt hole threads.
40. Inspect the engine block. Refer to Engine Block Clean and Inspect.
41. Inspect the cylinder head. Refer to Cylinder Head Clean and Inspect.

Installation Procedure

^ Tools Required
- J 36660 Electronic Torque Angle Meter

Notice: Refer to Engine Emission Notice in Service Precautions.





1. Install the springs, the caps, the seals, and the valves to the cylinder head. Refer to Cylinder Head Assemble.

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 sequence to 50 Nm (37 ft. lbs.).
4.2. Rotate each cylinder head bolt (1-8) 120 degrees in sequence. Use the J 36660.
5. Install the right push rods and rocker arms. Refer to Valve Rocker Arm and Push Rod Replacement.
6. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement (Right Rear).
7. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement (Right).
8. Install the exhaust crossover pipe. Refer to Exhaust Crossover Replacement.
9. Install the engine lift hook.
10. Connect the three-way catalytic converter pipe to the right (rear) manifold.
11. Install the upper intake manifold or supercharger.





12. Install the EGR valve adapter to the right cylinder head.
13. Install the EGR valve adapter bolts to the right cylinder head.
Tighten the EGR valve adapter bolts to 50 Nm (37 ft. lbs.).





14. Install the EGR valve adapter bolt to the right exhaust manifold.
Tighten the EGR valve adapter bolt to 29 Nm (21 ft. lbs.).





15. Install the EGR valve outlet pipe.
16. Install the EGR valve outlet pipe bolt and nut.
Tighten the EGR valve outlet pipe bolt and nut to 29 Nm (21 ft. lbs.).





17. Install the EGR valve.
18. Install the EGR valve nuts.
Tighten the EGR valve nuts to 29 Nm (21 ft. lbs.).




19. Install the EGR valve shield bracket.
20. Install the EGR valve shield bracket bolt and nut.
Tighten the EGR valve shield bracket bolt and nut to 10 Nm (89 inch lbs.).
21. Install the fuel rail. Refer to Fuel Rail Assembly Replacement in Powertrain Management.
22. Connect the electrical connector to the throttle vacuum line.
23. Install the throttle and cruise control cables.
24. Carefully install the throttle body air inlet duct.
25. Connect the oxygen sensor electrical connector.
26. Install the right spark plugs. Refer to Spark Plug Replacement in Powertrain Management.
27. Install the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
28. Install the heater hoses to the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
29. Install the power steering pump. Refer to Power Steering Pump Replacement in Steering.
30. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
31. Return the engine to the proper position.
32. Install the engine mount struts. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right).
33. Connect the three-way catalytic converter pipe to the right (rear) exhaust manifold.
34. Install the generator. Refer to Generator Replacement in Starting and Charging.
35. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
36. Install the drive belt. Refer to Drive Belt Replacement.
37. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
38. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Service Precautions.
39. Inspect for proper fluid levels.
40. Inspect for leaks.