Cylinder Head Replacement Left

Special Tools

J 36660-A Electronic Torque Angle Meter

Notice: Refer to Engine Emission Notice in the Preface section.

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Drain the cooling system of engine coolant. Refer to Cooling System Draining and Filling .
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
4. Carefully disconnect the throttle body air inlet duct.
5. Remove the left engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
6. Remove the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
7. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
8. Remove the lower intake manifold. Refer to Intake Manifold Replacement .
9. Remove the left (front) exhaust manifold. Refer to Exhaust Manifold Replacement .
10. Remove the left (front) valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
11. Remove the left (front) rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement .



12. Remove the cylinder head bolts. Discard the cylinder head bolts.
13. Remove the cylinder head.



14. Remove the cylinder head gasket.
15. Remove the springs, the caps, the seals, and the valves from the cylinder head. Refer to Cylinder Head Disassemble .
16. Clean the mating surfaces on the cylinder head, cylinder block and the intake manifold.
17. Clean the cylinder block bolt hole threads.
18. Inspect the engine block. Refer to Engine Block Cleaning and Inspection .
19. Inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection .

Notice: Refer to Engine Emission Notice in the Preface section.

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: Refer to Fastener Notice in the Preface section.

Notice: 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.

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.




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

Tighten

•	Tighten the cylinder head bolts (1-8) in sequence to 50 N·m (37 lb ft).

•	Rotate each cylinder head bolt (1-8) 120 degrees in sequence. Use the J 36660-A .

5. Install the left (front) push rods and rocker arms. Refer to Valve Rocker Arm and Push Rod Replacement .
6. Install the left (front) valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
7. Install the left (front) exhaust manifold. Refer to Exhaust Manifold Replacement .
8. Install the lower intake manifold. Refer to Intake Manifold Replacement .
9. Install the upper intake manifold. Refer to Intake Manifold Replacement .
10. Install the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
11. Install the left engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
12. Carefully install the throttle body air inlet duct.
13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
14. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection .
15. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling .
16. Inspect for proper fluid levels.
17. Inspect for leaks.

Cylinder Head Replacement Right

Special Tools

J 36660-A Electronic Torque Angle Meter

Notice: Refer to Engine Emission Notice in the Preface section.

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
3. Remove the drive belt. Refer to Drive Belt Replacement .
4. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling .
5. Remove the generator. Refer to Generator Replacement .
6. Disconnect the three-way catalytic converter from the right (rear) manifold. Refer to Catalytic Converter Replacement .
7. Remove the engine mount struts. Refer to Engine Mount Strut Replacement .
8. Rotate the engine forward for access.
9. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
10. Remove the power steering pump. Refer to Power Steering Pump Replacement .
11. Remove the heater hoses from the engine. Refer to Heater Hoses Replacement (3.8L) .
12. Remove the rear spark plug wires. Refer to Spark Plug Wire Harness Replacement .
13. Remove the rear spark plugs. Refer to Spark Plug Replacement .
14. Disconnect the HO2S (oxygen sensor) electrical connector.
15. Carefully disconnect 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 Injection Fuel Rail Assembly Replacement for the 3.8L engine.



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.



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 (rear) exhaust manifold.



26. Remove the EGR valve adapter bolts from the right (rear) cylinder head.
27. Remove the EGR valve adapter from the right (rear) cylinder head.
28. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
29. Remove the engine lift hook.
30. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Replacement .
31. Remove the right (rear) exhaust manifold. Refer to Exhaust Manifold Replacement .
32. Remove the right (rear) valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
33. Remove the right (rear) 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, cylinder block and the intake manifold.
39. Clean the cylinder block bolt hole threads.
40. Inspect the engine block. Refer to Engine Block Cleaning and Inspection .
41. Inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection .

Notice: Refer to Engine Emission Notice in the Preface section.

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: Refer to Fastener Notice in the Preface section.

Notice: 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.

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.




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

Tighten

1. Tighten the cylinder head bolts (1-8) in sequence to 50 N·m (37 lb ft).
2. Rotate each cylinder head bolt (1-8) 120 degrees in sequence. Use the J 36660-A .
5. Install the right (rear) push rods and rocker arms. Refer to Valve Rocker Arm and Push Rod Replacement .
6. Install the right (rear) valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
7. Install the right (rear) exhaust manifold. Refer to Exhaust Manifold Replacement .
8. Install the exhaust crossover pipe. Refer to Exhaust Crossover Replacement .
9. Install the engine lift hook.
10. Install the upper intake manifold. Refer to Intake Manifold Replacement .



11. Install the EGR valve adapter to the right (rear) cylinder head.
12. Install the EGR valve adapter bolts to the right (rear) cylinder head.

Tighten
Tighten the EGR valve adapter bolts to 50 N·m (37 lb ft).




13. Install the EGR valve adapter bolt to the right (rear) exhaust manifold.

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




14. Install the EGR valve outlet pipe.
15. Install the EGR valve outlet pipe bolt and nut.

Tighten
Tighten the EGR valve outlet pipe bolt and nut to 29 N·m (21 lb ft).




16. Install the EGR valve.
17. Install the EGR valve nuts.

Tighten
Tighten the EGR valve nuts to 29 N·m (21 lb ft).




18. Install the EGR valve shield bracket.
19. Install the EGR valve shield bracket bolt and nut.

Tighten
Tighten the EGR valve shield bracket bolt and nut to 10 N·m (89 lb in).

20. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement for the 3.8L engine.
21. Connect the electrical connector to the throttle vacuum line.
22. Connect the throttle and cruise control cables.
23. Carefully install the throttle body air inlet duct.
24. Connect the oxygen sensor (HO2S) electrical connector.
25. Install the rear spark plugs. Refer to Spark Plug Replacement .
26. Install the rear spark plug wires. Refer to Spark Plug Wire Harness Replacement .
27. Install the heater hoses to the engine. Refer to Heater Hoses Replacement (3.8L) .
28. Install the power steering pump. Refer to Power Steering Pump Replacement .
29. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
30. Return the engine to the proper position.
31. Install the engine mount struts. Refer to Engine Mount Strut Replacement .
32. Connect the three-way catalytic converter pipe to the right (rear) manifold. Refer to Catalytic Converter Replacement .
33. Install the generator. Refer to Generator Replacement .
34. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling .
35. Install the drive belt. Refer to Drive Belt Replacement .
36. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
37. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection .
38. Inspect for proper fluid levels.
39. Inspect for leaks.