Cylinder Head Removal and Installation

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

CYLINDER HEAD AND GASKET

- Tools Required
- J-42492 Timing Belt Adjuster
- KM-470-B Angular Torque Gauge

Removal Procedure





1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative batted cable.
4. Disconnect the Powertrain Control Module/Engine Control Module (PCM/ECM) ground terminal from the intake manifold.
5. Drain the engine coolant.
6. Disconnect the intake air temperature (IAT) 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 (EI) system ignition coil connector.
10. Disconnect the pre-converter oxygen sensor connector.
11. Disconnect the fuel injector harness connectors.





12. Disconnect the idle air control (IAC) valve connector.
13. Disconnect the throttle position sensor (TPS) connector.
14. Remove the alternator adjusting bolt and the alternator drive belt.
15. Disconnect the engine coolant temperature (ECT) sensor connector.
16. Disconnect the coolant temperature sensor (CTS) connector.





17. Remove the air filter housing bolts.
18. Remove the air filter housing.
19. Remove the right front wheel.
20. Remove the right front splash shield.
21. Disconnect the upper radiator hose at the thermostat housing.





22. Remove the A/C compressor drive belt, if equipped.
23. Remove the power steering pump pulley bolts, if equipped.

Important: Push the engine assembly toward the battery to remove the power steering pump pulley.

24. Remove the power steering pump pulley, if equipped.
25. Remove the crankshaft pulley bolt.
26. Remove the crankshaft pulley.
27. Remove the upper front timing belt cover bolts.
28. Remove the upper front timing belt cover.
29. Remove the lower front timing belt cover bolts.
30. Remove the lower front timing belt cover.
31. Remove the power steering pump, if equipped.
32. Install the engine mount-to-engine mount bracket retaining bolts and tighten the bolts to secure the engine if the power steering was removed.
- Tighten the engine mount-to-engine mount bracket retaining bolts to 60 Nm (44 ft. lbs.).





33. Align the camshaft gear timing marks.
34. Slightly loosen the coolant pump retaining bolts.





35. Rotate the coolant pump counterclockwise using the timing belt adjuster J-42492 to relieve the timing belt tension.
36. Remove the timing belt.
37. Disconnect the crankcase ventilation tube at the valve cover.
38. Remove the spark plug cover bolts.
39. Remove the spark plug cover.
40. Disconnect the camshaft position (CMP) sensor.
41. Disconnect the ignition wires from the spark plugs.





42. Remove the valve cover nuts.
43. Remove the valve cover washers.
44. Remove the valve cover and the valve cover gasket.

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





45. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
46. Remove the intake camshaft gear.
47. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
48. Remove the exhaust camshaft gear.





49. Remove the rear timing belt cover bolts.
50. Remove the exhaust manifold heat shield bolts.
51. Remove the exhaust manifold heat shield.





52. Remove the auxiliary catalytic converter retaining nuts at the exhaust manifold.
53. Disconnect all of the necessary vacuum hoses.
54. Disconnect the fuel return line at the fuel pressure regulator.





55. Disconnect the fuel feed line at the fuel rail.
56. Disconnect the heater inlet hose at the cylinder head.
57. Disconnect the surge tank coolant hose at the throttle body.





58. Remove the upper intake manifold support bracket bolts.
59. Disconnect the throttle cable at the throttle body and the intake manifold.





60. Loosen all of the cylinder head bolts gradually and in the sequence shown.
61. Remove the cylinder head bolts.
62. 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 heads.

63. 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.

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.). Adjust the bolts to 70 degrees plus 70 degrees plus 30 degrees using the angular torque gauge KM-470-B.
5. Connect the throttle cable at the throttle body and the intake manifold.





6. Install the intake manifold support bracket upper bolts to the intake manifold.
- Tighten the intake manifold support bracket upper bolts to the intake manifold to 25 Nm (18 ft. lbs.).
7. Connect the surge tank coolant hose at the throttle body.
8. Connect the heater inlet hose to the cylinder head.





9. Connect the fuel feed line at the fuel rail.
10. Connect the fuel return line at the fuel rail.
11. Connect all of the necessary vacuum hoses.
12. Install the exhaust manifold heat shield.
13. Install the exhaust manifold heat shield bolts.
- Tighten the exhaust manifold heat shield bolts to 15 Nm (11 ft. lbs.).
14. Install the auxiliary catalytic converter retaining nuts at the exhaust manifold flange.
- Tighten the auxiliary catalytic converter-to-exhaust manifold nuts to 40 Nm (30 ft. lbs.).





15. Install the rear timing belt cover bolts.
- Tighten the rear timing belt cover bolts to 10 Nm (89 inch lbs.)

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

16. Install the intake camshaft gear.





17. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.
- Tighten the intake camshaft gear bolt to 67.5 Nm (49 ft. lbs.).
18. Install the exhaust camshaft gear.





19. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.
- Tighten the exhaust camshaft gear bolt to 67.5 Nm (49 ft. lbs.)
20. Apply a small amount of gasket sealant to the corners of the front camshaft caps, and the top of the rear valve cover to cylinder head seal.





21. Install the valve cover and the valve cover gasket.
22. Install the valve cover washers.
23. Install the valve cover nuts.
- Tighten the valve cover nuts to 9 Nm (80 inch lbs.).
24. Connect the ignition wires to the spark plugs.
25. Install the spark plug cover.
26. Install the spark plug cover bolts.
- Tighten the spark plug cover bolts to 3 Nm (27 inch lbs.).
27. Connect the camshaft position (CMP) sensor connector.
28. Connect the crankcase ventilation tube to the valve cover.





29. Align the timing marks on the camshaft gears.





30. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover.
31. Install the timing belt.





32. Rotate the coolant pump clockwise using the timing belt adjuster J-42492 to apply tension to the timing belt.
- Tighten the coolant pump retaining bolts to 10 Nm (89 inch lbs.)
33. Check and adjust the timing belt tension.
34. Install the power steering pump, if equipped.
35. Install the engine mount-to-engine mount bracket retaining bolts if the power steering pump was installed.
- Tighten the engine mount-to-engine mount bracket retaining bolts to 60 Nm (44 ft. lbs.).





36. Install the upper and lower front timing belt cover.
37. Install the upper and lower front timing belt cover bolts.
- Tighten the upper and lower front timing belt cover bobs to 10 Nm (89 inch lbs.).
38. Install the crankshaft pulley.
39. Install the crankshaft pulley bolt.
- Tighten the crankshaft pulley bolt to 95 Nm (70 ft. lbs.) using a torque wrench. Using the angular torque gauge KM-470-B tighten the crankshaft pulley bolt to 30 degrees plus 15 degrees.
40. Install the power steering pump pulley, if equipped.
41. Install the power steering pump pulley bobs, if equipped.
- Tighten the power steering pump pulley bolts to 25 Nm (18 ft. lbs.).
42. Connect the CTS connector.
43. Connect the ECT sensor connector.
44. Install the alternator drive belt.
45. Install the alternator adjusting bolt.
- Tighten the alternator adjusting bolt to 20 Nm (15 ft. lbs.).





46. Install the A/C compressor drive belt, if equipped.
47. Connect the upper radiator hose to the thermostat housing.
48. Install the right front splash shield.
49. Install the right front wheel.
50. Install the air filter housing.
51. Install the air filter housing bolts.
- Tighten the air filter housing bolts to 8 Nm (71 inch lbs.).





52. Connect the air intake tube to the throttle body.
53. Connect the breather tube to the valve cover.
54. Connect the IAT sensor connector.





55. Connect the IAC valve connector.
56. Connect the TPS connector.
57. Connect the EI system ignition coil connector.
58. Connect the fuel injector harness connectors.
59. Connect the pre-converter oxygen sensor connector.
60. Connect the PCM/ECM ground terminal at the intake manifold.





61. Install the fuel pump fuse.
62. Connect the negative battery ground cable.
63. Refill the engine cooling system.