Special Tools

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
3. Disconnect the heated oxygen sensor (HO2S) electrical connector (1).
4. Remove the HO2S (2) from the right exhaust manifold.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Drain the cooling system. Refer to Cooling System Draining and Filling.
7. Drain the engine oil.
8. Remove the catalytic converter from the right exhaust manifold. Refer to Catalytic Converter Replacement.



9. Remove the right exhaust manifold heat shield bolts (2).
10. Remove the right exhaust manifold heat shield (1).



11. Remove the exhaust gas recirculation (EGR) valve adapter bolt from the right exhaust manifold.
12. Lower the vehicle.
13. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.



14. Remove the power steering pump bolts and reposition the power steering pump.
15. Rotate the engine to access the right cylinder head. Refer to Rotating the Engine for Service Access.
16. Remove the right spark plugs from the right cylinder head. Refer to Spark Plug Replacement.
17. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement.
18. Remove the EGR valve inlet adapter pipe from the right cylinder head. Refer to Exhaust Gas Recirculation Inlet Pipe Replacement.
19. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side.
20. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right Side.
21. Remove the right rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement.



22. Remove the right cylinder head bolts. Discard the cylinder head bolts.
23. Remove the right cylinder head.



24. Remove the cylinder head gasket.
25. Remove the caps, the springs, the valves and the seals from the cylinder head. Refer to Cylinder Head Disassemble.
26. Clean the gasket mating surfaces on the cylinder head, the engine block and the intake manifold.
27. Clean the cylinder block bolt hole threads.
28. Inspect the engine block. Refer to Engine Block Cleaning and Inspection.
29. Inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection.

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




Caution: 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.

Caution: Refer to Fastener Caution in the Preface section.





Caution: This bolt is designed to permanently stretch when tightened, and therefore MUST be replaced anytime it is removed. 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.

Caution: 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.

4. Install the new cylinder head bolts (1-8).

Tighten

1. Tighten the cylinder head bolts in the following sequence (1-8) to 50 N·m (37 lb ft).
2. Use the J 45059 to rotate the cylinder head bolts in the following sequence (1-8) an additional 120 degrees.
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 Side.
7. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side.
8. Install the EGR valve inlet adapter pipe to the right cylinder head. Refer to Exhaust Gas Recirculation Inlet Pipe Replacement.
9. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement.
10. Install the right spark plugs to the right cylinder head. Refer to Spark Plug Replacement.
11. Carefully release the J 41131 and return the engine to the original position.



12. Install the power steering pump.
13. Install the power steering pump bolts.

Tighten
Tighten the bolts to 34 N·m (25 lb ft).

14. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
15. Install the left and the right engine mount struts. Refer to Engine Mount Strut Replacement - Right Side and Engine Mount Strut Replacement - Left Side.
16. Raise the vehicle.



17. Install the exhaust gas recirculation (EGR) valve adapter bolt to the right exhaust manifold.

Tighten
Tighten the bolt to 29 N·m (21 lb ft).




18. Install the right exhaust manifold heat shield (1).
19. Install the right exhaust manifold heat shield bolts (2).

Tighten
Tighten the bolts to 10 N·m (89 lb in).

20. Install the catalytic converter to the right exhaust manifold. Refer to Catalytic Converter Replacement.
21. Lower the vehicle.



22. Install the HO2S (2) to the right exhaust manifold.

Tighten
Tighten the HO2S to 42 N·m (31 lb ft).

23. Connect the HO2S electrical connector (1).
24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
25. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement.
26. Fill the cooling system. Refer to Cooling System Draining and Filling.
27. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
28. Inspect for leaks.