Cylinder Head Removal and Installation

Note: For additional information on camshaft removal refer to camshaft, engine, service and repair: Service and Repair

- Tools Required
- KM-470-B Angular Torque Gauge
- J-28467-B Engine Assembly Lift Support


Removal Procedure





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 powertrain control module (PCM)/engine control module (ECM) ground terminal.
5. Drain the engine coolant. Refer to Cooling System; Coolant.
6. Disconnect the intake air temperature sensor connector.
7. Disconnect the breather tube from the valve cover.





8. Disconnect the air intake tube from the throttle body.
9. Disconnect the electronic ignition system (EI system) ignition coil connector.
10. Disconnect the pre-converter oxygen sensor connector.
11. Disconnect the idle air control valve connector.





12. Disconnect the throttle position sensor connector.
13. Disconnect the engine coolant temperature sensor connector.
14. Disconnect the coolant temperature sensor connector.
15. Disconnect the camshaft position sensor.
16. Remove the air filter housing bolts.
17. Remove the air filter housing.
18. Remove the right front wheel.
19. Remove the right front splash shield.
20. Install the engine assembly lift support J-28467-B.





21. Remove the right engine mount bracket and bolts.
22. Disconnect the upper radiator hose at the thermostat housing.
23. Remove the serpentine accessory drive belt. Refer to Steering; Power Steering Pump.





24. Remove the crankshaft pulley bolts.
25. Remove the crankshaft pulley.





26. Remove the front timing belt cover bolts.
27. Remove the front timing belt cover.
28. Remove the timing belt.
29. Disconnect the breather tube at the valve cover.
30. Remove the spark plug cover bolts.
31. Remove the spark plug cover.
32. Disconnect the ignition wires from the spark plugs.





33. Remove the valve cover nuts.
34. Remove the valve cover washers.
35. Remove the valve cover and the valve cover gasket.

Notice: Take extreme care to prevent any scratches, nicks or damage to the camshafts.





36. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
37. Remove the intake camshaft gear.
38. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
39. Remove the exhaust camshaft gear.





40. Remove the timing belt automatic tensioner bolts.
41. Remove the timing belt automatic tensioner.





42. Remove the timing belt idler pulley bolt and nut.
43. Remove the timing belt idler pulleys.
44. Remove the engine mount bolts.
45. Remove the engine mount.





46. Remove the rear timing belt cover bolts.
47. Remove the rear timing belt cover.





48. Remove the auxiliary catalytic converter nuts at the exhaust manifold.
49. Disconnect all of the necessary vacuum hoses.





50. Disconnect the fuel return line at the fuel pressure regulator.
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. Refer to Powertrain Management.





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 evaporative emission canister purge 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 cylinder head bolts.
64. Remove the cylinder head with the intake manifold and the exhaust manifold attached.

Notice: Prevent any engine oil or coolant from entering the cylinders when removing the cylinder head.

65. Remove the cylinder head gasket.

Cleaning Procedure
1. Clean the gasket surfaces of the cylinder head and the engine block.
2. Make sure the gasket surfaces of the cylinder head and the engine block are free of nicks and heavy scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to Cylinder Block Assembly; Service and Repair; Cylinder Head and Valve Train Components.

Installation Procedure
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 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. Connect the throttle cable at the throttle body and the intake manifold.





6. Install the generator-to- intake manifold support bracket.
7. Install the intake generator-to- manifold support bracket bolts.
Tighten the generator-to-intake manifold support bracket bolts to the intake manifold to 35 Nm (26 ft. lbs.).
8. Install the intake manifold support bracket bolt to the generator.
Tighten the intake manifold support bracket bolt at the generator to 20 Nm (115 ft. lbs.).
9. Connect the surge tank coolant hose at the throttle body.
10. Connect the coolant hose to the rear cylinder head and ignition coil EGR bracket.
11. Connect the fuel feed line at the fuel rail.





12. Connect the fuel return line at the fuel rail.
13. Connect all of the necessary vacuum hoses.
14. Install the fuel rail assembly. Refer to Powertrain Management.
15. Install the auxiliary catalytic converter nuts at the exhaust manifold flange.
Tighten the auxiliary catalytic converter-to-exhaust manifold nuts to 40 Nm (30 ft. lbs.).
16. Install the rear timing belt cover.





17. Install the rear timing belt cover bolts.
Tighten the rear timing belt cover bolts to 6 Nm (53 inch lbs.).
18. Install the engine mount and retaining bolts.
Tighten the engine mount retaining bolts to 60 Nm (44 ft. lbs.).
19. Install the timing belt automatic tensioner.





20. Install the timing belt automatic tensioner bolt.
Tighten the timing belt automatic tensioner bolts to 25 Nm (18 ft. lbs.).
21. Install the timing belt idler pulleys.
22. Install the timing belt idler pulley bolt and nut.
Tighten the timing belt idler pulley bolt to 25 Nm (118 ft. lbs.).
Tighten the timing belt idler pulley nut to 25 Nm (18 ft. lbs.).





23. Install the camshaft gears with the timing marks at the front.
24. Insert the guide pin of the intake camshaft into the "IN" bore.
25. Insert the guide pin of the exhaust camshaft into the "EX" bore.
26. Install the camshaft gears by counterholding on the hex of the camshaft with an open-ended wrench.
27. Install the camshaft gear with a new bolt to the camshaft.
Tighten the intake camshaft gear bolt to 50 Nm (37 ft. lbs.). Using the angular torque gauge KM-470-B, tighten the bolt another 60 degrees plus 15 degrees.





28. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.
Tighten the exhaust camshaft gear bolt to 50 Nm (37 ft. lbs.). Using the angular torque gauge KM-470-B, tighten the bolt another 60 degrees plus 15 degrees.





29. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear valve cover-to-cylinder head seal.
30. Install the valve cover and the valve cover gasket.
31. Install the valve cover washers.
32. Install the valve cover bolts.
Tighten the valve cover bolts to 8 Nm (71 inch lbs.).
33. Connect the, ignition wires to the spark plugs.
34. Install the spark plug cover.
35. Install the spark plug cover bolts.
Tighten the spark plug cover bolts to 3 Nm (27 inch lbs.).
36. Connect the breather tube to the valve cover.





37. Align the timing marks on the camshaft gears to the notches on the valve cover, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.





38. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.





39. Install the timing belt.
40. Check and adjust the timing belt tension. Refer to Timing Belt; Adjsutment.
41. Install the front timing belt cover.





42. Install the front timing belt cover bolts.
Tighten the upper and lower front timing belt cover bolts to 6 Nm (53 inch lbs.).
43. Install the crankshaft pulley.
44. Install the crankshaft pulley bolts.
Tighten the crankshaft pulley bolts to 20 Nm (15 ft. lbs.).





45. Install the right engine mount bracket and retaining bolts.
Tighten the right engine mount bracket retaining bolts to 60 Nm (44 ft. lbs.).
46. Remove the engine assembly lift support J-28467-B.
47. Install the serpentine accessory drive belt. Refer to Steering; Power Steering Pump.
48. Connect the upper radiator hose to the thermostat housing.
49. Install the right front splash shield.
50. Install the right front wheel.
51. Install the air filter housing.
52. Install the air filter housing bolts.
Tighten the air filter housing bolts to 8 Nm (71 inch lbs.).





53. Connect the air intake tube to the throttle body.
54. Connect the breather tube to the valve cover.
55. Connect the intake air temperature sensor connector.
56. Connect the camshaft position sensor.
57. Connect the coolant temperature sensor connector.
58. Connect the engine coolant temperature sensor connector.
59. Connect the idle air control valve connector.





60. Connect the throttle position sensor connector.
61. Install the evaporative emission canister purge solenoid bracket bolt.
Tighten the evaporative emission canister purge solenoid bracket bolt to 5 Nm (44 inch lbs.).
62. Connect the EI system ignition coil connector.
63. Connect the pre-converter oxygen sensor connector.
64. Connect the PCM/ECM ground terminal.





65. Install the fuel pump fuse.
66. Connect the negative battery ground cable.
67. Refill the engine cooling system. Refer to Cooling System; Coolant.