For 1990-2009 cars

#### Tools Required

• | J 45059 Angle Meter

• | J 42385-100 Head/Main Bolt Thread Repair Kit

### Removal Procedure

1. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
2. Remove the engine cover. Refer to Engine Cover Replacement .
3. Depressurize the fuel system. Refer to Fuel Pressure Relief.

Caution: Refer to Battery Disconnect Caution in the Preface section.

4. Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.
5. Drain the cooling system. Refer to Cooling System Draining and Filling.
6. Remove the intake manifold assembly. Refer to Intake Manifold Replacement.
7. Remove the engine coolant air bleed pipe and cover. Refer to Engine Coolant Air Bleed Hose Replacement.
8. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
9. Remove the left side ignition coils. Refer to Ignition Coil Replacement .
10. Remove the spark plugs. Refer to Spark Plug Replacement.
11. Remove the left side exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side.

Important: The locking tang on the power steering reservoir bracket (1) must be released before removing the power steering reservoir (2).

12. Remove the power steering reservoir (2) from the power steering pump power steering reservoir bracket (1) and position the power steering reservoir (2) aside.
13. Remove the power steering pump (2) to power steering pump bracket retaining bolts (3) and position the power steering pump (2) away from the power steering pump bracket (1).
14. Remove the power steering pump bracket to engine retaining bolts (1).
15. Remove the power steering pump bracket (2).
16. Detach the powertrain wiring harness strap (3) from the rear cylinder head bracket (1).
17. Remove the powertrain wiring harness ground cable to cylinder head retaining bolt (2).
18. Disconnect the coolant temperature sensor electrical connector (1).
19. Remove the left side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side.
20. Remove the left side valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement.

Important: The cylinder head bolts are torque to yield bolts and are single use only fasteners.

21. Remove and discard the cylinder head bolts (1) 10 places, (2) 5 places.

Discard the bolts.

Notice: After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.

22. Remove the cylinder head (3).

Important: Cylinder head gaskets must be discarded whenever the cylinder head has been removed from the cylinder block.

23. Remove the cylinder head gasket (1).

Discard the gasket.

24. Clean and inspect the cylinder head and the cylinder block sealing surfaces. Refer to Cylinder Head Cleaning and Inspection and Engine Block Cleaning and Inspection.
25. If necessary, perform the following steps:

Disassemble the cylinder head. Refer to Cylinder Head Disassemble.

### Installation Procedure

1. If necessary, perform the following steps:

Assemble the cylinder head. Refer to Cylinder Head Assemble.

Important: Make sure the locating sleeves (2) are correctly installed to the maximum height (A) of 8.3 mm (0.33 in).

2. Install the locating sleeves (2) into the cylinder block (1).

Important: The cylinder head gasket (3) will fit on either side of the engine. Make sure the tab on the cylinder head gasket (1) is located towards the front half point and the stamping FRONT on the cylinder head gasket (2) is facing the front of the engine.

Important: Do not use any type of sealant on the cylinder head gasket (3), unless specified.

3. Install the NEW cylinder head gasket (3) correctly over the locating sleeves.
4. Install the cylinder head with the exhaust manifold to the engine. Refer to Cylinder Head Installation - Left Side.
5. Install the left side valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement.
6. Install the left side valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side.
7. Connect the coolant temperature sensor electrical connector (1).

Notice: Refer to Fastener Notice in the Preface section.

8. Install the engine wiring harness ground connector to cylinder head retaining bolt (2).

Tighten
Tighten the bolt to 10 N·m (89 lb in).

9. Attach the powertrain wiring harness strap (3) to the rear cylinder head bracket (1).
10. Install the power steering pump bracket (2).
11. Install the power steering pump bracket to engine retaining bolts (1).

Tighten
Tighten the bolts to 58 N·m (43 lb ft).

12. Position the power steering pump (2) on the power steering pump bracket (1).
13. Install the power steering pump to power steering pump bracket retaining bolts (3).

Tighten
Tighten the bolts to 30 N·m (22 lb ft).

Important: Make sure the power steering reservoir (2) and the locking tang on the power steering reservoir bracket (1) are engaged to avoid an induced rattle condition.

14. Install the power steering reservoir (2) to the power steering pump power steering reservoir bracket (1).
15. Install the left side exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side.
16. Install the spark plugs. Refer to Spark Plug Replacement.
17. Install the left side ignition coils. Refer to Ignition Coil Replacement .
18. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
19. Install the engine coolant air bleed pipe and cover. Refer to Engine Coolant Air Bleed Hose Replacement.
20. Install the intake manifold assembly. Refer to Intake Manifold Replacement.
21. Refill the cooling system. Refer to Cooling System Draining and Filling.
22. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.
23. Install the engine cover. Refer to Engine Cover Replacement .
24. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.