Cylinder Head - LH

Cylinder Head - LH

Material(s)






Removal

NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

1. Remove the LH (Left Hand) camshafts. REFER to Camshaft Removal and Replacement.

2. If equipped, remove the heat shield and disconnect the block heater electrical connector.

- Remove the block heater wiring harness from the engine.





3. Disconnect the 6 fuel injector electrical connectors (3 shown).





4. Disconnect the 2 LH (Left Hand) CMP (Camshaft Position) sensor electrical connectors.





5. Remove the 2 bolts and the 2 CMP (Camshaft Position) sensors.





6. Disconnect the LH (Left Hand) HO2S (Heated Oxygen Sensor) electrical connector.





7. Disconnect the LH (Left Hand) CMS (Catalyst Monitor Sensor) electrical connector.

1. Remove the wiring harness retainer from the rear of the LH (Left Hand) cylinder head.





8. Disconnect the A/C compressor electrical connector.





9. Remove the nut and disconnect the generator B+ cable.





10. Disconnect the generator electrical connector.





11. Detach the wiring harness retainer from the generator.





12. Disconnect the CHT (Cylinder Head Temperature) sensor electrical connector.





13. Disconnect the EOP (Engine Oil Pressure) switch electrical connector and the wiring harness pin-type retainer.





14. Remove the nut, 2 bolts and the A/C (Air Conditioning) compressor.





15. Remove the nut, bolt and the generator.





16. NOTE: If necessary, lubricate the HO2S (Heated Oxygen Sensor) with penetrating and lock lubricant to assist in removal.

Remove the LH (Left Hand) HO2S (Heated Oxygen Sensor).





17. Remove the 3 bolts and the LH (Left Hand) exhaust heat shield.





18. Remove the 6 nuts and the LH (Left Hand) catalytic converter.

1. Discard the nuts and the gasket.





19. Clean and inspect the catalytic converter flange. REFER to Exhaust Manifold Cleaning and Inspection Exhaust Manifold Cleaning and Inspection.

20. Remove and discard the 6 LH (Left Hand) exhaust manifold studs.





21. Remove the LH (Left Hand) cylinder block drain plug.

1. Allow coolant to drain from the cylinder block.





22. Remove the 4 nuts and the RH catalytic converter.

- Discard the nuts and the gasket.





23. Remove the RH (Right Hand) cylinder block drain plug or, if equipped, the block heater.

1. Allow coolant to drain from the cylinder block.





24. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. REFER to Spring Lock Couplings Spring Lock Couplings.





25. Remove the 2 thermostat housing-to-lower intake manifold bolts.





26. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Remove the 10 bolts and the lower intake manifold.

1. Remove and discard the intake manifold and thermostat housing gaskets.

2. Clean and inspect all sealing surfaces.





27. NOTICE: Do not use power tools to remove the bolt or damage to the LH (Left Hand) primary timing chain guide may occur.

Remove the bolt and the LH (Left Hand) primary timing chain guide.





28. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

Remove the valve tappets from the cylinder head.





29. Inspect the valve tappets. REFER to Valve Tappet Inspection Valve Tappet Inspection.

30. Remove and discard the M6 bolt.





31. NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.

Remove and discard the 8 bolts from the cylinder head.

1. Remove the cylinder head.

2. Discard the cylinder head gasket.





32. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence.

1. Remove any large deposits of silicone or gasket material with a plastic scraper.

2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.

3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

33. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. REFER to Cylinder Head Distortion Cylinder Head Distortion and REFER to Cylinder Block Distortion Cylinder Block Distortion.

Installation

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

NOTE: The valve tappets must be installed in their original positions. Coat the valve tappets with clean engine oil prior to installation.

1. Install a new gasket, the LH (Left Hand) cylinder head and 8 new bolts. Tighten the bolts in the sequence shown below in 5 stages:

- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 35 Nm (26 lb-ft).

- Stage 3: Tighten 90 degrees.

- Stage 4: Tighten 90 degrees.

- Stage 5: Tighten 45 degrees.





2. Install the M6 bolt.

- Tighten to 10 Nm (89 lb-in).





3. NOTE: The valve tappets must be installed in their original positions.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

Install the valve tappets.





4. Install the LH upper primary timing chain guide and the bolt.

- Tighten to 10 Nm (89 lb-in).





5. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





6. Install the 2 thermostat housing-to-lower intake manifold bolts.

- Tighten to 10 Nm (89 lb-in).





7. Connect the fuel supply tube-to-fuel rail quick connect coupling.





8. If equipped, install the block heater wiring harness onto the engine.

- Stage 1: Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 10 Nm (89 lb-in).

- Stage 2: Tighten the block heater to 40 Nm (30 lb-ft).





9. Using a new gasket, install the RH (Right Hand) catalytic converter and 4 new nuts.

- Tighten to 40 Nm (30 lb-ft).





10. Install the LH (Left Hand) cylinder block drain plug.

- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.





11. Install 6 new LH (Left Hand) exhaust manifold studs.

- Tighten to 12 Nm (106 lb-in).





12. Using a new gasket, install the LH (Left Hand) catalytic converter and 3 new lower LH (Left Hand) catalytic converter manifold-to-cylinder head nuts. Tighten in 2 stages in the sequence shown:

- Stage 1: Tighten the 3 lower LH (Left Hand) catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).

- Stage 2: Install the 3 new upper LH (Left Hand) catalytic converter manifold-to-cylinder head nuts and tighten to 25 Nm (18 lb-ft).





13. Install the LH (Left Hand) exhaust heat shield and the 3 bolts.

- Tighten to 12 Nm (106 lb-in).





14. NOTE: Apply anti-seize to the threads of the HO2S (Heated Oxygen Sensor) prior to installing.

Install the LH (Left Hand) HO2S (Heated Oxygen Sensor).

- Tighten to 48 Nm (35 lb-ft).





15. Install the generator, the bolt and the nut.

- Tighten to 48 Nm (35 lb-ft).





16. Install the A/C (Air Conditioning) compressor the nut and 2 bolts.

- Tighten to 25 Nm (18 lb-ft).





17. Connect the EOP (Engine Oil Pressure) switch electrical connector and the wiring harness pin-type retainer.





18. Attach the wiring harness retainer to the generator.





19. Connect the generator electrical connector.





20. Connect the generator B+ cable and install the nut.

- Tighten to 7 Nm (62 lb-in).





21. Connect the A/C compressor electrical connector.





22. Connect the LH (Left Hand) CMS (Catalyst Monitor Sensor) electrical connector.

1. Install the wiring harness retainer to the rear of the LH (Left Hand) cylinder head.





23. Connect the LH (Left Hand) HO2S (Heated Oxygen Sensor) electrical connector.





24. NOTE: Lubricate the CMP (Camshaft Position) sensor O-ring seal with clean engine oil before installing the CMP (Camshaft Position) sensor.

Install the 2 CMP (Camshaft Position) sensors and the 2 bolts.

- Tighten to 10 Nm (89 lb-in).





25. Connect the 2 LH (Left Hand) CMP (Camshaft Position) sensor electrical connectors.





26. Connect the 6 fuel injector electrical connectors (3 shown).





27. If equipped, position the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.





28. Install the LH (Left Hand) camshafts. REFER to Installation Removal and Replacement.