Cylinder Head - RH

Cylinder Head - RH

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 RH (Right Hand) camshafts. REFER to Camshaft .

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 2 RH (Right Hand) CMP (Camshaft Position) sensor electrical connectors.





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





5. Remove the bolt and the ground cable from the RH (Right Hand) cylinder head.





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

- Allow coolant to drain from the cylinder block.






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

- Allow coolant to drain from the cylinder block.






8. NOTE: Heat shield removed from graphic for clarity.
Remove the 6 nuts and the RH (Right Hand) exhaust manifold. Discard the nuts and exhaust manifold gaskets.






9. Clean and inspect the RH (Right Hand) exhaust manifold. REFER to Exhaust Manifold Cleaning and Inspection .

10. Remove and discard the 6 RH (Right Hand) exhaust manifold studs.





11. NOTICE: Do not use power tools to remove the bolt or damage to the RH (Right Hand) primary timing chain guide may occur.

Remove the bolt and the RH (Right Hand) primary timing chain guide.





12. Remove the 2 bolts and the engine lifting eye.





13. NOTE: Index-mark the location of the bracket on the cylinder head for installation.
Remove the bolt and the upper intake manifold bracket.





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





15. 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.






16. Disconnect the CHT (Cylinder Head Temperature) sensor jumper harness.





17. 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.





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

19. Remove and discard the M6 bolt.





20. 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.






21. 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.

22. 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 and REFER to 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 RH (Right 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 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. Connect the CHT (Cylinder Head Temperature) sensor jumper harness.





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. NOTE: Align the bracket with the index mark made during removal.
Install the upper intake manifold bracket and the bolt.
- Tighten to 10 Nm (89 lb-in).





8. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).





9. Install the RH (Right Hand) primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).





10. Install 6 new RH (Right Hand) exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).





11. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

NOTE: Heat shield removed from graphic for clarity.
Using a new gasket, install the RH (Right Hand) exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).





12. If equipped, install the block heater wiring harness onto the engine.
- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
- Tighten the block heater to 40 Nm (30 lb-ft).





13. Install the LH (Left Hand) cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.





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





15. Install the ground cable and bolt to the RH (Right Hand) cylinder head.
- Tighten to 10 Nm (89 lb-in).





16. Install the 2 CMP (Camshaft Position) sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





17. Connect the 2 RH (Right Hand) CMP (Camshaft Position) sensor electrical connectors.





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





19. Install the RH (Right Hand) camshafts. REFER to Camshaft .