Cylinder Head Replacement Left

Special Tools

J 36660-A Electronic Torque Angle Meter

1. Disconnect the negative battery ground cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

Notice: Modifications made to the engine or its individual components can effect the vehicle's emission controls and may cause the Malfunction Indicator Lamp (MIL), Check Engine, or Service Engine Soon lamp to illuminate. Modifications may also cause the vehicle to fail a required Emission Inspection/Maintenance test.

4. Carefully remove the throttle body air inlet duct.
5. Remove the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
6. Remove the left engine mount strut bracket.
7. Remove the upper intake manifold. Refer to Intake Manifold Replacement or Supercharger Replacement .
8. Remove the lower intake manifold. Refer to Intake Manifold Replacement .
9. Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement .
10. Remove the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
11. Remove the left rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement .



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



14. Remove the cylinder head gasket.
15. Install the springs, the caps, the seals, and the valves to 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: Modifications made to the engine or its individual components can effect the vehicle's emission controls and may cause the Malfunction Indicator Lamp (MIL), Check Engine, or Service Engine Soon lamp to illuminate. Modifications may also cause the vehicle to fail a required Emission Inspection/Maintenance test.

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 push rods and rocker arms. Refer to Valve Rocker Arm and Push Rod Replacement .
6. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
7. Install the left 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 or Supercharger Replacement .
10. Install the left engine mount strut bracket.
11. Install the right 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. Fill the cooling system. Refer to Cooling System Draining and Filling .
15. Connect the negative battery ground cable. Refer to Battery Negative Cable Disconnection and Connection .
16. Inspect for proper fluid levels.
17. Inspect for leaks.

Cylinder Head Replacement Right

Special Tools

1. Disconnect the negative battery ground cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

Notice: Modifications made to the engine or its individual components can effect the vehicle's emission controls and may cause the Malfunction Indicator Lamp (MIL), Check Engine, or Service Engine Soon lamp to illuminate. Modifications may also cause the vehicle to fail a required Emission Inspection/Maintenance test.

3. Remove the drive belt. Refer to Drive Belt Replacement .
4. Drain 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 pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement .
7. Rotate the engine forward for access:

7.1.	Remove the engine mount struts. Refer to Engine Mount Strut Replacement .

7.2.	Carefully disconnect the throttle body air inlet duct.

7.3.	Apply the parking brake.

7.4.	Place the transaxle in Neutral.

7.5.	Install the J 41131 .

7.6.	Rotate the engine toward the front of the vehicle for component access.

8. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
9. Remove the power steering pump. Refer to Power Steering Pump Replacement .
10. Remove the heater hoses from the engine. Refer to Heater Hoses Replacement .
11. Remove the right spark plug wires. Refer to Spark Plug Wire Harness Replacement .
12. Remove the right spark plugs. Refer to Spark Plug Replacement .
13. Disconnect the oxygen sensor electrical connector.
14. Disconnect the throttle and cruise control cables. Refer to Accelerator Control Cable Bracket Replacement for the 3.8L engine.
15. Disconnect the electrical connector from the throttle vacuum line.
16. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement for the 3.8L engine.



17. Remove the exhaust gas recirculation (EGR) valve wiring harness heat shield bolt and nut.
18. Remove the EGR valve wiring harness heat shield.



19. Remove the EGR valve nuts.
20. Remove the EGR valve.



21. Remove the EGR valve outlet pipe bolt and nut.
22. Remove the EGR valve outlet pipe.



23. Remove the EGR valve adapter bolt from the right exhaust manifold.



24. Remove the EGR valve adapter bolts from the right cylinder head.
25. Remove the EGR valve adapter from the right cylinder head.
26. Remove the upper intake manifold. Refer to Intake Manifold Replacement or Supercharger Replacement .
27. Remove the lower intake manifold. Refer to Intake Manifold Replacement .
28. Remove the engine lift hook.
29. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Replacement .
30. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement .
31. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
32. Remove the right rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement .



33. Remove the cylinder head bolts. Discard the bolts.
34. Remove the cylinder head.



35. Remove the cylinder head gasket.
36. Remove the springs, the caps, the seals, and the valves from the cylinder head. Refer to Cylinder Head Disassemble .
37. Clean the mating surfaces on the cylinder head, cylinder block and the intake manifold.
38. Clean the cylinder block bolt hole threads.
39. Inspect the engine block. Refer to Engine Block Cleaning and Inspection .
40. Inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection .

Notice: Modifications made to the engine or its individual components can effect the vehicle's emission controls and may cause the Malfunction Indicator Lamp (MIL), Check Engine, or Service Engine Soon lamp to illuminate. Modifications may also cause the vehicle to fail a required Emission Inspection/Maintenance test.

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 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 .
7. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement .
8. Install the exhaust crossover pipe.
9. Install the engine lift hook.
10. Install the lower intake manifold. Refer to Intake Manifold Replacement .
11. Install the upper intake manifold. Refer to Intake Manifold Replacement or Supercharger Replacement .



12. Install the EGR valve adapter to the right cylinder head.
13. Install the EGR valve adapter bolts to the right cylinder head.

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




14. Install the EGR valve pipe bolt to the right exhaust manifold.

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




15. Install the EGR valve outlet pipe.
16. 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).




17. Install the EGR valve.
18. Install the EGR valve nuts.

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




19. Install the EGR valve wiring harness heat shield and the heat shield bolt and nut.

Tighten
Tighten the EGR valve wiring harness heat shield 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. Refer to Accelerator Control Cable Bracket Replacement for the 3.8L engine.
23. Connect the oxygen sensor electrical connector.
24. Install the right spark plugs. Refer to Spark Plug Replacement .
25. Install the right spark plug wires. Refer to Spark Plug Wire Harness Replacement .
26. Install the heater hoses to the engine. Refer to Heater Hoses Replacement .
27. Install the power steering pump. Refer to Power Steering Pump Replacement .
28. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
29. Return the engine to the proper position:

29.1.

Carefully release the J 41131 . Carefully return the engine to the proper position.

29.2.

Place the transaxle in Park.

29.3.

Release the parking brake.

29.4.

Carefully install the throttle body air inlet duct.

29.5.

Install the engine mount struts. Refer to Engine Mount Strut Replacement .

30. Connect the three-way catalytic converter pipe to the right exhaust manifold. Refer to Catalytic Converter Replacement .
31. Install the generator. Refer to Generator Replacement .
32. Fill the cooling system. Refer to Cooling System Draining and Filling .
33. Install the drive belt. Refer to Drive Belt Replacement .
34. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
35. Fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement .
36. Connect the negative battery ground cable. Refer to Battery Negative Cable Disconnection and Connection .
37. Inspect for proper fluid levels.
38. Inspect for leaks.