Cylinder Head

Removal & Installation

Right Cylinder Head

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. With the vehicle in neutral, place it on a hoist.
3. Properly relieve the fuel system pressure.
4. Drain the cooling system.
5. Remove the intake manifold.
6. Remove the cooling fan shroud.
7. Remove the accessory drive belt.
8. Remove the left valve cover then the right valve cover.
9. Disconnect the generator.
10. Remove the accessory drive belt tensioner.
11. Remove the bolts and the generator mounting bracket and generator as an assembly.
12. Disconnect the engine wiring harness and detach the harness retainers.
13. Detach the engine wiring harness retainer.
14. Disconnect the crankshaft position (CKP) sensor.
15. Disconnect the wiring harness retainers.
16. Disconnect the coolant temperature indicator sender unit and the engine coolant temperature (ECT) sensor.

    NOTE: The coolant bypass hose will be removed with the thermostat housing.

17. Move the coolant bypass hose clamp off the coolant pump outlet.
18. Remove the bolts and the thermostat housing and coolant bypass hose.
19. Remove the bolt and the wiring harness retainer.
20. Remove the bolts and position the accessory bracket aside.
21. Disconnect the wiring harness casing from the left cylinder head.
22. Remove the bolt and the oil level indicator tube.
23. Using commercially-available spark plug boot pliers, disconnect the left-hand spark plug wires from the spark plugs.
24. Disconnect the fuel pulse damper vacuum hose.
25. Remove the fuel injection supply manifold. Keep the four bolts, the supply manifold, and the fuel injectors as an assembly.

    NOTE: Mark all of the roller followers to ensure they are installed in their original position during reassembly.

26. Use the valve spring compressor tool (303-581), or an equivalent, to remove the roller followers.

    Valve spring compressor tool

    NOTE: The crankshaft holding tool (303-573), or an equivalent, must be installed on the damper and should contact the engine block. This positions the engine at top dead center.

27. Using the crankshaft holding tool (303-573), set the No. 1 piston to top dead center.
28. Remove the right fender well splash shield.
29. Remove the right camshaft tensioner.
30. Remove the right exhaust manifold.
31. Remove the bolt and bracket.

    CAUTION
    The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

    NOTE: If necessary, use the camshaft gear torque adapter (303-565), or an equivalent, to remove camshaft sprocket bolt.

32. Remove the right camshaft sprocket bolt using the camshaft gear removal tool (303-575), or an equivalent.
33. Remove the chain guide bolt.

    CAUTION
    Remove the camshaft sprocket to prevent breaking the cassette and to gain clearance to remove the cylinder head.

    NOTE: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.

34. Remove the right-hand camshaft sprocket from the cassette.
35. Remove the eight 12 mm (0.47 in.) bolts and the two 8 mm (0.31 in.) bolts in the sequence shown, and remove the right cylinder head. Next, discard the head gasket and cylinder head bolts.

    The correct cylinder head bolt loosening sequence must be used to prevent warpage-4.0L engine

36. Clean the gasket mating services.

To Install:

1. Position the cylinder head gasket and the cylinder head.

   NOTE: Cylinder head bolts are torque-to-yield designed, so new bolts must be installed.

2. Install the 12 mm (0.47 in.) bolts and tighten in the following sequence:
   • Step 1: Tighten to 9 ft-lb (12 Nm).
   • Step 2: Tighten to 18 ft-lb (25 Nm).
3. Install the two 8 mm (0.31 in.) bolts.
   • Torque to 24 ft-lb (32 Nm).
4. Tighten the eight 12 mm (0.47 in.) bolts in the following sequence:
   • Step 1: Tighten the bolts 90 degrees.
   • Step 2: Tighten the bolts an additional 90 degrees.
5. Position the right camshaft sprocket in the chain and install it on the camshaft.

   CAUTION
   The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

6. Install the right camshaft sprocket bolt.
7. Install the chain guide bolt.
   • Torque to 89 in-lb (10 Nm).
8. Install the bracket and bolt.
   • Torque to 9 ft-lb (12 Nm).
9. Install the left exhaust manifold.

   CAUTION
   The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

   NOTE: Use the camshaft gear torque adapter (303-565), or an equivalent, to loosen the camshaft sprocket bolt. If necessary, loosen the right camshaft sprocket bolt with the camshaft gear removal tool (303-575), or an equivalent.

   NOTE: Notice that the camshaft timing slots are off-center.

10. Position the camshaft timing slots below the center line of the camshaft and install the camshaft holding tool adapter (303-576) and the camshaft holding tool (303-577), or equivalent tools, on the front of the right cylinder head.

11. Remove the right fender well splash shield.
12. Remove the right camshaft tensioner.

    NOTE: Leave the top two camshaft gear holding tool (303-564) clamp bolts loose.

13. Install the camshaft gear holding tool (303-564) and the camshaft gear holding tool adapter (303-578), or equivalent tools, on the rear of the right cylinder head.

14. Install the timing chain tensioner (303-571), or an equivalent tool.

    CAUTION
    The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

    NOTE: Use the camshaft gear torque adapter (303-565), or an equivalent, to tighten the camshaft sprocket bolt.

15. Next, tighten the camshaft gear holding tool (303-564) top two clamp bolts to 89 in. lb. (10 Nm).
    • Tighten the camshaft bolt to 45 ft. lb. (61 Nm).

16. Install the right camshaft tensioner.
    • Torque to 32 ft-lb (44 Nm).
17. Install the right fender well splash shield.
18. Remove the left camshaft tensioner.
19. If necessary, loosen the left camshaft sprocket bolt.

    NOTE: Leave the top two camshaft gear holding tool (303-564) clamp bolts loose.

20. Install the camshaft gear holding tool (303-564) and the camshaft gear holding tool adapter (303-578) special tools on the front of the left cylinder head.

    NOTE: The camshaft timing slots are off-center.

21. Position the camshaft timing slots below the center line of the camshaft and install the camshaft holding tool (303-577) and the camshaft holding tool adapter (303-576), or equivalent tools, on the rear of the left cylinder head.

22. Install the timing chain tensioner (303-571), or equivalent tool.
23. Next, tighten the camshaft gear holding tool (303-564) top two clamp bolts to 89 in-lb (10 Nm).
    • Tighten the camshaft bolt to 63 ft-lb (85 Nm).
24. Install the left-hand camshaft tensioner.
    • Torque to 32 ft-lb (44 Nm).

    NOTE: Install each roller follower in its original position.

25. Using the (303-581) valve spring compressor, or equivalent tool, install the camshaft roller followers.
26. Install the fuel injection supply manifold and fuel injectors as an assembly.
    • Torque to 17 ft-lb (23 Nm).
27. Install the fuel supply tube to the fuel manifold.
    • Torque to 53 in-lb (6 Nm).
28. Connect the fuel pulse damper vacuum hose.
29. Connect the left-hand spark plug wires to the spark plugs.
30. Install the oil level indicator tube and the bolt.
    • Torque to 89 in-lb (10 Nm).
31. Connect the wiring harness casing to the left cylinder head.
32. Install the accessory bracket and the bolts.
    • Torque to 31 ft-lb (42 Nm).
33. Position the wiring harness clip and install the bolt.
    • Torque to 15 ft-lb (20 Nm).
34. Install the thermostat housing and the bolts with the coolant bypass hose.
    • Torque to 8 ft-lb (11 Nm).
35. Connect the coolant bypass hose clamp.
36. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor.
37. Connect the electrical harness retainers.
38. Connect the crankshaft position (CKP) sensor.
39. Attach the engine wiring harness retainer.
40. Attach the wiring harness retainers and connect the electrical connector.
41. Position the generator mounting bracket and generator assembly and install the bolts.
    • Torque to 31 ft-lb (42 Nm).
42. Install the accessory drive belt tensioner.
    • Torque to 35 ft-lb (47 Nm).
43. Connect the generator.
    • Torque to 71 in-lb (8 Nm).
44. Install the right valve cover, then the left valve cover.
45. Install the accessory drive belt, then the cooling fan shroud.
46. Install the intake manifold.
47. Fill and bleed the cooling system.
48. Connect the negative battery cable.
49. Change the engine oil and filter.
50. Start the engine and check for leaks, repair if necessary.

Left Cylinder Head

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. With the vehicle in neutral, place it on a hoist.
3. Properly relieve the fuel system pressure.
4. Drain the cooling system.
5. Remove the intake manifold.
6. Remove the cooling fan shroud.
7. Remove the accessory drive belt.
8. Remove the left valve cover then the right valve cover.
9. Disconnect the generator electrical connections.
10. Remove the accessory drive belt tensioner.
11. Remove the bolts and the generator mounting bracket and generator as an assembly.
12. Disconnect the engine wiring harness and detach the harness retainers.
13. Detach the engine wiring harness retainer.
14. Disconnect the crankshaft position (CKP) sensor.
15. Disconnect the wiring harness retainers.
16. Disconnect the coolant temperature indicator sender unit and the engine coolant temperature (ECT) sensor.

    NOTE: The coolant bypass hose will be removed with the thermostat housing.

17. Move the coolant bypass hose clamp off the coolant pump outlet.
18. Remove the bolts and the thermostat housing and coolant bypass hose.
19. Remove the bolt and the wiring harness retainer.
20. Remove the bolts and position the accessory bracket aside.
21. Disconnect the wiring harness casing from the left cylinder head.
22. Remove the bolt and the oil level indicator tube.
23. Using commercially-available spark plug boot pliers, disconnect the left-hand spark plug wires from the spark plugs.
24. Disconnect the fuel pulse damper vacuum hose.
25. Remove the fuel injection supply manifold. Keep the four bolts, the supply manifold, and the fuel injectors as an assembly.

    NOTE: Mark all of the roller followers to ensure they are installed in their original position during reassembly.

26. Use the valve spring compressor tool (303-581), or an equivalent, to remove the roller followers.

    Valve spring compressor tool

    NOTE: The crankshaft holding tool (303-573), or an equivalent, must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).

27. Using the crankshaft holding tool (303-573), set the No. 1 piston to TDC.
28. Remove the left-hand exhaust manifold.
29. Remove the bolt and the ground strap.
30. Remove the engine wiring harness pin-type retainer.
31. Remove the left-hand hydraulic chain tensioner.
32. Remove the camshaft sprocket bolt.
33. Remove the chain guide bolt.

    CAUTION
    Remove the camshaft sprocket to prevent breaking the cassette and to gain clearance to remove the cylinder head.

    NOTE: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.

34. Remove the left camshaft sprocket from the chain cassette.
35. Remove the eight 12 mm (0.47 in.) bolts and the two 8 mm (0.31 in.) bolts in the sequence shown and remove the left cylinder head. Discard the head gaskets and cylinder head bolts.

    The correct cylinder head bolt loosening sequence must be used to prevent warpage-4.0L engine

36. Clean the gasket mating surfaces.

To Install:

1. Thoroughly clean all gasket mating surfaces. Remove all traces of old gasket material, oil, grease or dirt.
2. Ensure that the rubber band is holding the right-hand chain to the cassette.
3. Install a new head gasket and the cylinder head.

   NOTE: Cylinder head bolts are torque-to-yield designed, so new bolts must be installed.

4. Install the 12 mm (0.47 in.) bolts and tighten in the following sequence:
   • Step 1: Tighten to 9 ft-lb (12 Nm).
   • Step 2: Tighten to 18 ft-lb (25 Nm).
5. Install the two 8 mm (0.31 in.) bolts.
   • Torque to 24 ft-lb (32 Nm).
6. Tighten the eight 12 mm (0.47 in.) bolts in the following sequence:
   • Step 1: Tighten the bolts 90 degrees.
   • Step 2: Tighten the bolts an additional 90 degrees.
7. Install the left camshaft sprocket.

   The correct cylinder head bolt tightening sequence must be used

   CAUTION
   The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

8. Install the camshaft sprocket bolt.
9. Install the chain guide bolt.
   • Torque to 9 ft-lb (12 Nm).
10. Install the ground strap and bolt.
    • Torque to 18 ft-lb (25 Nm).
11. Install the engine wiring harness pin-type retainer.
12. Install the left exhaust manifold.

    CAUTION
    The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

    NOTE: Use the camshaft gear torque adapter (303-565), or an equivalent, to loosen the camshaft sprocket bolt. If necessary, loosen the right-hand camshaft sprocket bolt with the camshaft gear removal tool (303-575), or an equivalent.

    NOTE: Notice that the camshaft timing slots are off-center.

13. Position the camshaft timing slots below the center line of the camshaft and install the camshaft holding tool adapter (303-576) and the camshaft holding tool (303-577), or equivalent tools, on the front of the right-hand cylinder head.

14. Remove the right fender well splash shield.
15. Remove the right camshaft tensioner.

    NOTE: Leave the top two camshaft gear holding tool (303-564) clamp bolts loose.

16. Install the camshaft gear holding tool (303-564) and the camshaft gear holding tool adapter (303-578), or equivalent tools, on the rear of the right cylinder head.

17. Install the timing chain tensioner (303-571), or an equivalent tool.

    CAUTION
    The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

    NOTE: Use the camshaft gear torque adapter (303-565), or an equivalent, to tighten the camshaft sprocket bolt.

18. Next, tighten the camshaft gear holding tool (303-564) top two clamp bolts to 89 in. lb. (10 Nm).
    • Tighten the camshaft bolt to 45 ft. lb. (61 Nm).

19. Install the right-hand camshaft tensioner.
    • Torque to 32 ft-lb (44 Nm).
20. Install the right-hand fender well splash shield.
21. Remove the left camshaft tensioner.
22. If necessary, loosen the left camshaft sprocket bolt.

    NOTE: Leave the top two camshaft gear holding tool (303-564) clamp bolts loose.

23. Install the camshaft gear holding tool (303-564) and the camshaft gear holding tool adapter (303-578) special tools on the front of the left cylinder head.

    NOTE: The camshaft timing slots are off-center.

24. Position the camshaft timing slots below the center line of the camshaft and install the camshaft holding tool (303-577) and the camshaft holding tool adapter (303-576), or equivalent tools, on the rear of the left cylinder head.

25. Install the timing chain tensioner (303-571), or equivalent tool.
26. Next, tighten the camshaft gear holding tool (303-564) top two clamp bolts to 89 in-lb (10 Nm).
    • Tighten the camshaft bolt to 63 ft-lb (85 Nm).
27. Install the left camshaft tensioner.
    • Torque to 32 ft-lb (44 Nm).

    NOTE: Install each roller follower in its original position.

28. Using the (303-581) valve spring compressor, or equivalent tool, install the camshaft roller followers.
29. Install the fuel injection supply manifold and fuel injectors as an assembly.
    • Torque to 17 ft-lb (23 Nm).
30. Install the fuel supply tube to the fuel manifold.
    • Torque to 53 in-lb (6 Nm).
31. Connect the fuel pulse damper vacuum hose.
32. Connect the left spark plug wires to the spark plugs.
33. Install the oil level indicator tube and the bolt.
    • Torque to 89 in-lb (10 Nm).
34. Connect the wiring harness casing to the left cylinder head.
35. Install the accessory bracket and the bolts.
    • Torque to 31 ft-lb (42 Nm).
36. Position the wiring harness clip and install the bolt.
    • Torque to 15 ft-lb (20 Nm).
37. Install the thermostat housing and the bolts with the coolant bypass hose.
    • Torque to 8 ft-lb (11 Nm).
38. Connect the coolant bypass hose clamp.
39. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor.
40. Connect the electrical harness retainers.
41. Connect the crankshaft position (CKP) sensor.
42. Attach the engine wiring harness retainer.
43. Attach the wiring harness retainers and connect the electrical connector.
44. Position the generator mounting bracket and generator assembly and install the bolts.
    • Torque to 31 ft-lb (42 Nm).
45. Install the accessory drive belt tensioner.
    • Torque to 35 ft-lb (47 Nm).
46. Connect the generator electrical connections.
    • Torque to 71 in-lb (8 Nm).
47. Install the right valve cover, then the left valve cover.
48. Install the accessory drive belt, then the cooling fan shroud.
49. Install the intake manifold.
50. Fill and bleed the cooling system.
51. Connect the negative battery cable.
52. Change the engine oil and filter.
53. Start the engine and check for leaks, repair if necessary.