Cylinder Head

Removal & Installation

2.4L Engine

To Remove:

1. Relieve the fuel system pressure.
2. Drain the coolant.
3. Remove the ECM or PCM.
4. Remove the battery and tray.
5. Remove the control wiring harness.
6. Remove the radiator hose.
7. Disconnect the EVAP purge hose.
8. Disconnect the brake booster vacuum hose.
9. Disconnect the pressure hose.
10. Remove the engine oil dipstick and tube.
11. Disconnect the knock sensor.
12. Remove the intake manifold stay.
13. Remove the exhaust manifold from the cylinder head.
14. Remove the upper timing belt cover.
15. Remove the engine front mounting bracket.
16. Turn the crankshaft clockwise and align the timing marks.
17. Secure the belt to the camshaft sprocket with plastic tie wraps.
18. Install special tool MD998738 through the timing belt under cover as shown to relieve the tension on the timing belt.

    Install special tool MD998738 through the timing belt under cover (2.4L)

    Use special tool MD998738 to relieve the tension on the belt (2.4L)

    Cylinder head bolt wrench (#MB991654)

19. Remove the camshaft sprocket.
20. Disconnect the upper radiator hose connection.
21. Disconnect the water cooler hose connection (A/T).
22. Disconnect the fuel line.
23. Remove the rocker arm cover.
24. Remove the cylinder head bolts in the sequence shown.
25. Loosen the cylinder head bolts using a cylinder head bolt wrench (special tool #MB991654). Loosen each of the bolts gradually and evenly in a few steps in the opposite of the tightening sequence.
26. Remove the cylinder head assembly.
27. Remove the cylinder head gasket.

To Install:

1. Clean the sealing surfaces thoroughly.
2. Install the cylinder head gasket. Make sure the mark "381" is facing up on the exhaust side.
3. Install the cylinder head assembly.
4. Before installing the cylinder head bolts, make sure the shank length of each bolt does not exceed 3.91 in (99.4 mm). Before installing each bolt, coat the threads and washers with clean engine oil.
5. Use a cylinder head bolt wrench (#MB991654) to tighten the bolts to 58 ft-lbs (78 Nm) in the sequence shown.

   Cylinder head bolt wrench (#MB991654)

6. Completely loosen all bolts in the reverse of the tightening order.
7. Retighten the bolts to 15 ft-lbs (20 Nm) in the sequence shown.
8. Make a straight line mark across each bolt head and cylinder head. Tighten the cylinder head bolts 90° in the specified order.

   CAUTION
   Make sure each bolt is tightened EXACTLY 90°. If a bolt is under-tightened, it might not be correctly fastened, and if it is over-tightened, loosen it fully and retighten it.

9. Tighten the bolts another 90° in the specified order. Make sure the alignment marks you made on the cylinder head bolts and the cylinder head line up correctly.
10. Install the rocker arm cover.
11. Connect the fuel line.
12. Connect the water cooler hose connection (A/T).
13. Connect the upper radiator hose connection.
14. Install the camshaft sprocket.
15. Remove the special tool to apply tension to the timing belt.
16. Remove the tie wraps and verify correct timing mark alignment.
17. Install the engine front mounting bracket.
18. Install the upper timing belt cover.
19. Install the exhaust manifold from the cylinder head.
20. Install the intake manifold stay.
21. Connect the knock sensor.
22. Install the engine oil dipstick and tube.
23. Connect the pressure hose.
24. Connect the brake booster vacuum hose.
25. Connect the EVAP purge hose.
26. Install the radiator hose.
27. Install the control wiring harness.
28. Install the battery and tray.
29. Install the ECM or PCM.
30. Refill the engine coolant.

3.8L Engine

Left Cylinder Head

To Remove:

1. Remove the intake manifold.
2. Remove the left exhaust manifold.
3. Remove the thermostat housing.
4. Remove the generator.
5. Remove the rocker arm cover.
6. Disconnect the CMP sensor, oil control valve and oil pressure switch connectors.
7. Remove the ground connection.
8. Remove the engine oil dipstick and tube.
9. Remove the camshaft sprocket.
10. Remove the timing belt rear center cover.
11. Remove the left cylinder head bolts using cylinder head bolt wrench (special tool #MD998051).
12. Remove the cylinder head assembly.
13. Remove the cylinder head gasket.

To Install:

1. Install the cylinder head gasket.
2. Install the cylinder head assembly. Make sure the beveled edge of the washers are facing upwards.
3. When installing the cylinder head bolts, use a cylinder head bolt wrench (special tool #MD998051) to tighten the bolts in the sequence shown in 2 or 3 steps. Torque bolts to 80 ft-lbs (108 Nm).

   Cylinder head bolt tightening sequence (3.8L)

4. Loosen the bolts completely and then tighten them again to 80 ft-lbs (108 Nm).
5. Install the timing belt rear center cover.
6. Install the camshaft sprocket.
7. Install the engine oil dipstick and tube.
8. Install the ground connection.
9. Connect the CMP sensor, oil control valve and oil pressure switch connectors.
10. Install the rocker arm cover.
11. Install the generator.
12. Install the thermostat housing.
13. Install the exhaust manifold.
14. Install the intake manifold.

Right Cylinder Head

To Remove:

1. Remove the intake manifold.
2. Remove the right exhaust manifold.
3. Remove the thermostat housing.
4. Remove the generator.
5. Remove the power steering pump and bracket.
6. Disconnect the oil control valve and oil pressure switch connectors.
7. Remove the rocker arm cover.
8. Remove the camshaft sprocket.
9. Remove the timing belt rear center cover.
10. Remove the left cylinder head bolts using cylinder head bolt wrench (special tool #MD998051).
11. Remove the cylinder head assembly.
12. Remove the cylinder head gasket.

To Install:

1. Install the cylinder head gasket.
2. Install the cylinder head assembly. Make sure the beveled edge of the washers are facing upwards.
3. When installing the cylinder head bolts, use a cylinder head bolt wrench (special tool #MD998051) to tighten the bolts in the sequence shown in 2 or 3 steps. Torque bolts to 80 ft-lbs (108 Nm).

   Cylinder head bolt tightening sequence (3.8L)

4. Loosen the bolts completely and then tighten them again to 80 ft-lbs (108 Nm).
5. Install the timing belt rear center cover.
6. Install the camshaft sprocket.
7. Connect the oil control valve and oil pressure switch connectors.
8. Install the rocker arm cover.
9. Install the power steering pump and bracket.
10. Install the generator.
11. Install the thermostat housing.
12. Install the exhaust manifold.
13. Install the intake manifold.