Cylinder Head Replacement - Right Side (L84)

Single Use Fasteners and Components Cylinder Head Bolt [10x] Cylinder Head Gasket Exhaust Manifold Bolt [5x] Exhaust Manifold Gasket Exhaust System Seal Fuel Feed Intermediate Pipe [2x] Fuel Injector Nozzle Housing Seal [8x] Fuel Injector Seal [4x] Intake Manifold Gasket [8x] Oil Filter Valve Rocker Arm Cover Gasket Special Tools Engine Controls and Fuel - 5.3L (L84) or 6.2L (L87) EN-49248 Injector Rail Assembly Remover EN-51092 Fuel Pump Installation Gauge EN-51955 Fuel Injector Seal Install/Sizer Equivalent regional tools: Special Tools Engine Mechanical - 5.3L (L84) or 6.2L (L87) EN-8089 Carbon Removal Brush EN-51767-2 Universal Stretchy Belt Installer Equivalent regional tools: Special Tools Removal Procedure

Warning

Refer to Diesel/Gasoline Vapors Warning

Warning

Refer to Safety Glasses Warning

Warning

In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning

Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.

1. Relieve the fuel system pressure. Fuel Pressure Relief
2. Drain the cooling system. Cooling System Draining and Filling
3. Engine Oil and Oil Filter » Remove and DISCARD — Engine Oil and Oil Filter Replacement
4. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
5. Front Wheelhouse Liner - Right Side » Remove Front Wheelhouse Liner Replacement
6. Wiring Harness » Position aside

Cylinder Head Replacement - Right Side (L84) — figure 1

7. Exhaust Manifold Heat Shield Bolt - Right Side (1) » Remove [3x]

Cylinder Head Replacement - Right Side (L84) — figure 2

8. Remove the right exhaust manifold heat shield (1) through the wheel opening.

Cylinder Head Replacement - Right Side (L84) — figure 3

9. Exhaust Heat Shield Bolt - Right Side (1) » Remove
10. Exhaust Front Pipe Heat Shield - Right Side (2) » Remove

Cylinder Head Replacement - Right Side (L84) — figure 4

11. Disconnect the heated oxygen sensor electrical connector.

Caution

Refer to Heated Oxygen and Oxygen Sensor Caution

Note

The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor. The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).

12. Remove the heated oxygen sensor (1) using a suitable tool.

Cylinder Head Replacement - Right Side (L84) — figure 5

13. Exhaust Front Pipe Nut - Right Side (1) » Remove [3x]

Cylinder Head Replacement - Right Side (L84) — figure 6

14. Spark Plug Wire - Right Side (1) @ Gas Engine Ignition Spark Plug » Remove and position aside [4x]

Cylinder Head Replacement - Right Side (L84) — figure 7

15. Exhaust Manifold Bolt - Right Side (1) » Remove and DISCARD [5x]

Cylinder Head Replacement - Right Side (L84) — figure 8

16. Remove the right side exhaust manifold (1) through the wheel opening.
17. Exhaust Manifold Gasket - Right Side (2) » Remove and DISCARD

Cylinder Head Replacement - Right Side (L84) — figure 9

18. Exhaust System Seal - Right Side (1) » Remove and DISCARD

Cylinder Head Replacement - Right Side (L84) — figure 10

19. Retainer Clip (1) @ Cylinder Head - Right Side (2) » Remove
20. Remove the support and lower the vehicle.

Cylinder Head Replacement - Right Side (L84) — figure 11

21. Plenum Front Panel Outer Reinforcement (1) » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation

Cylinder Head Replacement - Right Side (L84) — figure 12

22. Positive Crankcase Ventilation Fresh Air Tube (2) @ Air Cleaner Outlet Duct » Disconnect — Plastic Collar Quick Connect Fitting Service
23. Positive Crankcase Ventilation Fresh Air Tube (3) @ Positive Crankcase Ventilation Fitting » Disconnect — Plastic Collar Quick Connect Fitting Service
24. Positive Crankcase Ventilation Fresh Air Tube (1) » Remove

Cylinder Head Replacement - Right Side (L84) — figure 13

25. Air Cleaner Outlet Duct Bracket Bolt (1) » Remove
26. Remove engine wiring harness from air cleaner outlet duct bracket.

Cylinder Head Replacement - Right Side (L84) — figure 14

27. Air Cleaner Outlet Duct Clamp (2) » Loosen [2x]
28. Air Cleaner Outlet Duct (3) » Remove

Cylinder Head Replacement - Right Side (L84) — figure 15

29. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Disengage — Plastic Collar Quick Connect Fitting Service
30. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Remove and position aside

Cylinder Head Replacement - Right Side (L84) — figure 16

31. Engine Wiring Harness Connector (1) @ Throttle Body » Disconnect
32. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Remove [2x]
33. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Disconnect
34. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Disconnect

Cylinder Head Replacement - Right Side (L84) — figure 17

35. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [4x]

Cylinder Head Replacement - Right Side (L84) — figure 18

36. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [3x]

Cylinder Head Replacement - Right Side (L84) — figure 19

37. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Disconnect and reposition — Plastic Collar Quick Connect Fitting Service

Cylinder Head Replacement - Right Side (L84) — figure 20

Note

Some components not shown for graphic clarity.

38. Loosen the 10 intake manifold bolts (1) until the bolts are no longer threaded into the cylinder heads.
39. Move the intake manifold and intake manifold cover (2) forward enough to gain access to the rear engine wiring harness retainers.

Cylinder Head Replacement - Right Side (L84) — figure 21

40. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [3x]

Cylinder Head Replacement - Right Side (L84) — figure 22

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

41. Remove the intake manifold and intake manifold cover (1) as an assembly.
42. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.

Cylinder Head Replacement - Right Side (L84) — figure 23

43. Intake Manifold Gasket (1) » Remove and DISCARD [8x]

Cylinder Head Replacement - Right Side (L84) — figure 24

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

Warning

Refer to Safety Glasses Warning

44. Fuel Pump Insulator (1) » Remove

Cylinder Head Replacement - Right Side (L84) — figure 25

Caution

Fuel feed intermediate pipes will be delivered with shipping caps that are meant to protect the mating joint threads. Do NOT remove shipping caps until the pipe is to be installed and joints are to be secured. Failure to do so could result in damage to the mating threads.

Note

Do NOT reuse the fuel feed intermediate pipe (2). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

45. Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) » Loosen until disengaged [2x]
46. Fuel Feed Intermediate Pipe (2) » Remove and DISCARD

Cylinder Head Replacement - Right Side (L84) — figure 26

Note

Do NOT reuse the fuel feed intermediate pipe (3). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

47. Fuel Feed Intermediate Pipe Nut (1) » Loosen until disengaged [2x]
48. Fuel Feed Pipe Bolt (2) » Remove
49. Fuel Feed Intermediate Pipe (3) » Remove and DISCARD
50. Disconnect fuel injection fuel rail connectors as needed.

Cylinder Head Replacement - Right Side (L84) — figure 27

51. Grasp the valve rocker arm cover insulator (3) and lift up disengaging the 3 upper intake manifold sight shield grommets (1) from the 3 valve rocker arm cover insulator retainers (2).
52. Valve Rocker Arm Cover Insulator (3) » Remove
53. Inspect the 3 upper intake manifold sight shield grommets (1) on the valve rocker arm cover insulator (3) and replace as necessary.

Cylinder Head Replacement - Right Side (L84) — figure 28

54. Heater Hose Clip Bracket Bolt (1) » Remove
55. Heater Inlet and Outlet Hose Bracket (2) » Reposition
56. Engine Wiring Harness Connector @ Ignition Coil » Disconnect [4x]

Cylinder Head Replacement - Right Side (L84) — figure 29

57. Oil Level Indicator Tube Bolt (1) » Remove
58. Oil Level Indicator Tube @ Cylinder Head - Right Side » Remove

Cylinder Head Replacement - Right Side (L84) — figure 30

59. Valve Rocker Arm Cover Bolt (1) » Loosen until disengaged [10x]
60. Valve Rocker Arm Cover - Right Side (2) » Remove

Cylinder Head Replacement - Right Side (L84) — figure 31

61. Valve Rocker Arm Cover Gasket (2) @ Valve Rocker Arm Cover (1) » Remove and DISCARD

Cylinder Head Replacement - Right Side (L84) — figure 32

Note

Only replace the valve rocker arms and valve push rods as required. The rocker arm pivot support bolts are not serviced separately. Place the valve rocker arms and valve push rods in a rack so they can be installed in the same location from which they were removed.

62. Valve Rocker Arm Pivot Support Bolt (1) » Loosen until disengaged [8x]
63. Valve Rocker Arm (2) » Remove [8x]

Cylinder Head Replacement - Right Side (L84) — figure 33

64. Valve Push Rod (1) » Remove [8x]

Cylinder Head Replacement - Right Side (L84) — figure 34

Note

Some components not shown for graphic clarity.

65. Engine Wiring Harness Ground Bolt (1) » Remove
66. Engine Wiring Harness (2) @ Cylinder Head » Disconnect

Cylinder Head Replacement - Right Side (L84) — figure 35

67. Generator Bolt (1) » Loosen until disengaged

Cylinder Head Replacement - Right Side (L84) — figure 36

Caution

This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

68. Cylinder Head Bolt (1) » Remove and DISCARD [10x]

Cylinder Head Replacement - Right Side (L84) — figure 37

Caution

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

69. Cylinder Head (1) » Remove
70. Cylinder Head Gasket (2) » Remove and DISCARD

Cylinder Head Replacement - Right Side (L84) — figure 38

71. Remove the 4 gas engine ignition spark plugs (1) and place each gas engine ignition spark plugs (1) in a tray marked with the corresponding cylinder numbers.

Cylinder Head Replacement - Right Side (L84) — figure 39

72. Clean the cylinder head around the fuel injectors on bank 2 of any dirt or buildup.

Note

The 4 bank 2 fuel injection fuel rail bolts (1) are retained in the bank 2 fuel injection fuel rail (2) and may be difficult to remove.

73. Remove the 4 bank 2 fuel injection fuel rail bolts (1).

Cylinder Head Replacement - Right Side (L84) — figure 40

Note

In some cases, the fuel injectors may be difficult to remove because of heavy carbon build-up or other factors. If the fuel injectors are difficult to remove, apply solvent to the base of the fuel injector bores, and allow adequate soaking time, to loosen the fuel injectors. The bank 2 fuel injection fuel rail and fuel injectors (2) are removed as an assembly.

74. Install 2 sets of EN-49248 Injector Rail Assembly Remover (1) on bank 2.
75. Install one EN-49248 Injector Rail Assembly Remover (1) in each of the bank 2 fuel injection fuel rail bolt bores.
76. Turn each EN-49248 Injector Rail Assembly Remover (1) an even amount to pull the fuel injection fuel rail bank 2 and fuel injectors (2) out evenly.

Caution

Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

77. Simultaneously lift both ends of the bank 2 fuel injection fuel rail (2) and remove from the right side cylinder head.

Cylinder Head Replacement - Right Side (L84) — figure 41

78. Fuel Injector Nozzle Housing Seal (1) » Remove and DISCARD [8x]

Cylinder Head Replacement - Right Side (L84) — figure 42

79. Fuel Injector Seal (1) » Remove and DISCARD [4x] Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Cylinder Head Replacement - Right Side (L84) — figure 43

Note

When cleaning a cylinder head in a thermal type oven, do not exceed 204°C (400°F). Be careful not to scuff the chamber.

1. Clean the following components: 1.1. Use the J-8089 Carbon Removal Brush (1) in order to remove the carbon from the combustion chambers. 1.2. Gasket surfaces 1.3. Valve stems and heads on a buffing wheel 1.4. Bolt hole threads 1.5. Remove all dirt, debris, or threadlocking material from the bolt holes.

Cylinder Head Replacement - Right Side (L84) — figure 44

2. Inspect the fuel rail injector bores and clean with EN-47909 Injector Bore and Sleeve Cleaning Kit (1), if required.
3. Inspect the cylinder head for the following conditions: 3.1. Cracks in the exhaust ports and combustion chambers 3.2. External cracks in the water chambers 3.3. Gasket surfaces for excessive scratches or gouging 3.4. Bolt hole threads for debris or damaged threads Thread Repair Thread Repair Specifications

Cylinder Head Replacement - Right Side (L84) — figure 45

4. Inspect the cylinder head for warpage. Engine Mechanical Specifications

Cylinder Head Replacement - Right Side (L84) — figure 46

5. Using the J-9666 Valve Spring Tester (1), measure the valve spring tension. Engine Mechanical Specifications.

Cylinder Head Replacement - Right Side (L84) — figure 47

6. Clean all sealing surfaces.
7. Dry the intake manifold with compressed air.
8. Inspect the intake manifold cylinder head deck for warpage.
9. Place a straight edge (1) across the intake manifold cylinder head deck surface.
10. Inspect the intake manifold for the following conditions: 10.1. Inspect for loose threaded inserts or studs. 10.2. Inspect for damaged or broken vacuum fitting. 10.3. Inspect the intake manifold assembly for cracks or other damage. 10.4. Inspect for damaged intake manifold gasket sealing surfaces.
11. Position the straight edge (1) across a minimum of two runner port openings and check for warpage using a feeler gage. Engine Mechanical Specifications
12. Inspect the ventilation system passages for restrictions.

Cylinder Head Replacement - Right Side (L84) — figure 48

13. Clean the exhaust manifold (1) and heat shield (2) in solvent.
14. Dry the exhaust manifold (1) with compressed air.
15. Inspect the exhaust manifold (1) to the cylinder head exhaust manifold gasket surface for excessive scratches or gouging.
16. Inspect for a loose, damaged, or cracked heat shield (2).
17. Inspect the heat shield bolts (3) for damaged threads.

Cylinder Head Replacement - Right Side (L84) — figure 49

18. Use a straight edge (1) and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold cylinder head deck with warpage in excess of 0.25 mm (0.01 in) within the 2 front or 2 rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak. Exhaust manifolds not within specifications MUST be replaced.

Cylinder Head Replacement - Right Side (L84) — figure 50

19. Remove the 8 ignition coil bolts (1) and 4 ignition coils (2) before cleaning the valve rocker arm cover (3) in solvent. Do NOT submerge the 4 ignition coils (2) in solvent.
20. Inspect the valve rocker arm cover (3) for the following conditions: 20.1. Scoring or damage to the gasket surfaces 20.2. Ventilation system passages for restrictions 20.3. Threaded bolt holes for damage or debris
21. Install the 4 ignition coils (2).

Caution

Refer to Fastener Caution.

22. Install and tighten the 8 ignition coil bolts (1). Fastener Specifications

Cylinder Head Replacement - Right Side (L84) — figure 51

Note

Components that are to be used again must be marked, sorted or organized for assembly.

23. Clean the components in cleaning solvent.

Warning

Refer to Safety Glasses and Compressed Air Warning.

24. Dry the components with compressed air.
25. Inspect the valve lifters for the following conditions: 25.1. Broken or collapsed spring (1) 25.2. Worn pushrod socket (2) 25.3. Plugged lubrication hole (3) 25.4. Plugged lifter oil switching hole (4) 25.5. Flat spots on the roller (5) 25.6. Worn or damaged roller bearing (6) The roller should rotate freely with no binding or roughness. 25.7. Scuffed or worn sides (7)

Cylinder Head Replacement - Right Side (L84) — figure 52

26. Inspect the valve lifter guides for the following conditions:
27. Cracks or damage (1)
28. Excessive wear in the lifter mounting bores (2)

Cylinder Head Replacement - Right Side (L84) — figure 53

Note

Parts that are to be used again must be marked, sorted or organized for assembly.

29. Mark, sort, or organize the components for assembly.
30. Clean the components with cleaning solvent.

Warning

Refer to Safety Glasses and Compressed Air Warning.

31. Dry the components with compressed air.
32. Inspect the valve rocker arms bearings (2) for binding or roughness.
33. Inspect the valve rocker arm pushrod sockets (3) and valve stem mating surfaces (1). These surfaces should be smooth with no scoring or exceptional wear.
34. Inspect the pushrods for worn or scored ends. These surfaces should be smooth with no scoring or exceptional wear.
35. Inspect the pushrods for bends. Roll the pushrod on a flat surface to determine if the pushrod is bent.
36. Inspect the pushrod oil passages for restrictions.
37. Inspect the rocker arm pivot supports for cracks, wear, or other damage.

Note

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation.

38. Inspection the spark plug wire for the following conditions: 38.1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 38.2. Inspect for any signs of cracks or splits in the wires.
39. Inspect each boot for the following conditions: 39.1. Tearing 39.2. Piercing 39.3. Arcing 39.4. Carbon tracking 39.5. Corroded terminals
40. If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Installation Procedure

Note

The 4 bank 2 fuel injector seals (1) should be clean and free of debris prior to installation.

Note

Do NOT use any type of lubricant when installing the NEW 4 bank 2 fuel injector seals (1) on the fuel injector.

1. Fuel Injector Seal (1) » Install NEW [4x]

Cylinder Head Replacement - Right Side (L84) — figure 54

Note

Do NOT use any type of lubricant when installing NEW seals (2) on the injector.

2. Install EN-51955-1 Long Protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN- 51955-1 Long Protector. 2.1. Using EN-51955-4 Pusher (1), install the seal onto the first recessed area (4) of the fuel injector and remove EN-51955-4 Pusher.

Note

The EN-51955-5 Sizer is two sided, and either direction will size the seal correctly. 2.2. Compress the seal with your fingers, then resize the seal using the EN-51955-5 Sizer (5).

Cylinder Head Replacement - Right Side (L84) — figure 55

Note

Do NOT use any type of lubricant when installing NEW seals (2) on the injector.

3. Install EN-51955-2 Short Protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN- 51955-2 Short Protector. 3.1. Using EN-51955-4 Pusher (1), install the seal onto the second recessed area (4) of the fuel injector.

Note

The EN-51955-5 Sizer is two sided, and either direction will size the seal correctly. 3.2. Compress the seal with your fingers, then resize the seal using the EN-51955-5 Sizer (5). 3.3.  Inspect the NEW fuel injector nozzle housing seals on ALL injectors, ensuring the seals are seated correctly. All seals must be fixed tight, and accurately to the fuel injector nozzle, with no overlap, buckling, or corrugation present. Replace any seal that is incorrectly seated on the fuel injector nozzle with a NEW seal.

Cylinder Head Replacement - Right Side (L84) — figure 56

Note

The 4 bank 2 fuel injection fuel rail bolts (1) are retained into the fuel injection fuel rail (2). Care should be taken to ensure that the thread locking is installed after the 4 bank 2 fuel injection fuel rail bolts (1) are installed to the bank 2 fuel injection fuel rail (2).

4. Install the 4 fuel injection fuel rail bolts (1) to the bank 2 fuel injection fuel rail (2).
5. Prepare the 4 bank 2 fuel injection fuel rail bolts (1) for installation as follows: 5.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 5.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 5.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 5.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
6. Install the bank 2 fuel injection fuel rail (2) to the right side cylinder head.
7. Fuel Injection Fuel Rail Bolt (1) » Hand tighten [4x]

Caution

Refer to Fastener Caution

8. Fuel Injection Fuel Rail Bolt (1) » Tighten [4x] — Fastener Specifications

Caution

Refer to Component Fastener Tightening Caution

9. Gas Engine Ignition Spark Plug (1) » Install and tighten [4x] — Fastener Specifications

Note

Ensure the proper orientation of the gasket using the marks provided on the gasket. Gaskets are stamped with orientation marks. Make sure “FRONT” is visible on the top of the gasket and toward the front of the engine.

10. Cylinder Head Gasket (2) » Install NEW
11. Cylinder Head (1) » Install

Caution

This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

12. Cylinder Head Bolt (1) » Install NEW and hand tighten [10x]
13. Cylinder Head Bolt (1) » Tighten in sequence [10x] — Fastener Specifications
14. Connect the electrical wiring harness connectors to the bank 2 fuel injection fuel rail.

Note

Some components not shown for graphic clarity.

15. Generator Bolt (1) » Install and tighten — Fastener Specifications

16. Engine Wiring Harness (2) @ Cylinder Head » Connect

17. Engine Wiring Harness Ground Bolt (1) » Install and tighten — Ground Repair

18. Lubricate the flange of the 8 valve rocker arm bolts with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers

19. Lubricate the 8 valve rocker arms and push rods with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers

Note

When using the valve train components again, always install the components to the original location and position. Valve lash is net build. No valve adjustment is required. Ensure the push rods seat properly to the valve lifter sockets. The rocker arm bolts are not serviced separately. DO NOT tighten the rocker arm bolts at this time.

20. Valve Push Rod (1) » Install [8x]

21. Valve Rocker Arm (2) » Install [8x]

22. Valve Rocker Arm Pivot Support Bolt (1) » Hand tighten [8x]

23. Valve Rocker Arm Pivot Support Bolt (1) » Tighten [8x] — Fastener Specifications

24. Valve Rocker Arm Cover Gasket (2) @ Valve Rocker Arm Cover (1) » Install NEW

Note

Some components not shown for graphic clarity.

25. Valve Rocker Arm Cover - Right Side (2) » Install

26. Valve Rocker Arm Cover Bolt (1) » Hand tighten [10x]

27. Valve Rocker Arm Cover Bolt (1) » Tighten in sequence [10x] — Fastener Specifications

28. Engine Wiring Harness Connector @ Ignition Coil » Connect [4x]

29. Heater Inlet and Outlet Hose Bracket (2) » Reposition

30. Heater Hose Clip Bracket Bolt (1) » Install and tighten — Fastener Specifications

31. Oil Level Indicator Tube @ Cylinder Head - Right Side » Install

32. Oil Level Indicator Tube Bolt (1) » Install and tighten — Fastener Specifications

Cylinder Head Replacement - Right Side (L84) — figure 57

33. Valve Rocker Arm Cover Insulator (3) » Install
34. Install the 3 upper intake manifold sight shield grommets (2) to the 3 valve rocker arm cover insulator retainers (1).

Cylinder Head Replacement - Right Side (L84) — figure 58

Note

Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (3) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

35. Fuel Feed Intermediate Pipe (1) » Install NEW 35.1. Slide the 2 fuel feed intermediate pipe nuts (3) back along fuel feed intermediate pipe  (1) to reveal the 2 formed ends (2) of the fuel feed intermediate pipe (1). 35.2. Carefully install the 2 formed ends (2) of the fuel feed intermediate pipe (1) into the sockets of the left and right fuel injection fuel rail. Take care not to hit the 2 formed ends  (2) of the fuel feed intermediate pipe (1) on the threaded sockets on the fuel injection fuel rails. 35.3. Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (3).
36. Fuel Feed Pipe Bolt (4) » Tighten — Fastener Specifications
37. Fuel Feed Intermediate Pipe Nut (3) » Tighten [2x] — Fastener Specifications

Cylinder Head Replacement - Right Side (L84) — figure 59

Note

Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (2) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.

38. Fuel Feed Intermediate Pipe (1) » Install NEW 38.1. Slide the 2 fuel feed intermediate pipe nuts (2) back along fuel feed intermediate pipe  (1) to reveal the 2 formed ends (3) of the fuel feed intermediate pipe (1). 38.2. Carefully install the 2 formed ends (3) of the fuel feed intermediate pipe (1) into the sockets of the fuel pump (4) and the fuel feed intermediate pipe (5). Take care not to hit the 2 formed ends (3) of the fuel feed intermediate pipe (1) on the threaded sockets of the fuel pump (4) and fuel feed intermediate pipe (5). 38.3. Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (2).
39. Fuel Feed Intermediate Pipe Nut (2) » Tighten [2x] — Fastener Specifications
40. Connect fuel injection fuel rail connectors as needed.

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 41. Fuel Pump Insulator (1) » Install 42. Prepare the 10 intake manifold bolts for installation as follows: 42.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 42.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 42.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 42.4. Ensure there are no gaps in the thread locking adhesive once applied to the component. 43. Remove the covers from the cylinder head passages.

44. Intake Manifold Gasket (1) » Install NEW [8x]

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

45. Position the intake manifold and Intake manifold cover (1) to install harness retainers.

46. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [3x]

47. Move the intake manifold and intake manifold cover (2) into place.

Note

Some components not shown for graphic clarity.

48. Intake Manifold Bolt (1) » Hand tighten [10x]

49. Intake Manifold Bolt (1) » Tighten in sequence [10x] — Fastener Specifications

50. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Install — Plastic Collar Quick Connect Fitting Service

51. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [3x]

52. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [4x]

53. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Connect

54. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Connect

55. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Install [2x]

56. Engine Wiring Harness Connector (1) @ Throttle Body » Connect

57. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Install

58. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Engage — Plastic Collar Quick Connect Fitting Service

59. Air Cleaner Outlet Duct (3) » Install

60. Air Cleaner Outlet Duct Clamp (2) » Tighten [2x] — Fastener Specifications

61. Air Cleaner Outlet Duct Bracket Bolt (1) » Install and tighten — Fastener Specifications

62. Install engine wiring harness to air cleaner outlet duct bracket.

63. Positive Crankcase Ventilation Fresh Air Tube (1) » Install

64. Positive Crankcase Ventilation Fresh Air Tube (3) @ Positive Crankcase Ventilation Fitting » Connect — Plastic Collar Quick Connect Fitting Service

65. Positive Crankcase Ventilation Fresh Air Tube (2) @ Air Cleaner Outlet Duct » Connect — Plastic Collar Quick Connect Fitting Service

66. Plenum Front Panel Outer Reinforcement (1) » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

67. Raise and support the vehicle. Lifting and Jacking the Vehicle

68. Retainer Clip (1) @ Cylinder Head - Right Side (2) » Install

69. Exhaust System Seal - Right Side (1) » Install NEW

70. Exhaust Manifold Gasket - Right Side (2) » Install NEW

71. Install the right side exhaust manifold (1) through the wheel opening.

72. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 72.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 72.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 72.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 72.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

73. Exhaust Manifold Bolt - Right Side (1) » Install NEW and hand tighten [5x]

74. Exhaust Manifold Bolt - Right Side (1) » Tighten in sequence [5x] — Fastener Specifications

75. Inspect the inside of the spark plug rubber boots for a thin, even coat of grease. If there is no grease present or additional grease is necessary, apply a thin coating of dielectric grease evenly to the inside of the spark plug rubber boots up to a depth of 15 mm from the end of the boots. Adhesives, Fluids, Lubricants, and Sealers

76. Push the 4 boots of the spark plug wires (1) onto the 4 gas engine ignition spark plugs (2) until 2 audible clicks are heard.

77. Exhaust Front Pipe Nut - Right Side (1) » Install and hand tighten [3x]

78. Exhaust Front Pipe Nut - Right Side (1) » Tighten [3x] — Fastener Specifications

Note

A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers

Caution

Refer to Component Fastener Tightening Caution

79. Install and tighten the heated oxygen sensor  (1) using a suitable tool. Fastener Specifications

80. Connect the heated oxygen sensor electrical connector.

81. Exhaust Front Pipe Heat Shield - Right Side (2) » Install

82. Exhaust Heat Shield Bolt - Right Side (1) » Install and tighten — Fastener Specifications

83. Install the right exhaust manifold heat shield (1) through the wheel opening.

84. Exhaust Manifold Heat Shield Bolt - Right Side (1) » Install and hand tighten [3x]

85. Exhaust Manifold Heat Shield Bolt - Right Side (1) » Tighten [3x] — Fastener Specifications

86. Wiring Harness » Position the wiring harness.

87. Front Wheelhouse Liner - Right Side » Install Front Wheelhouse Liner Replacement

88. Engine Oil and Oil Filter » Install NEW — Engine Oil and Oil Filter Replacement

89. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

90. Fill the cooling system to the proper level. Cooling System Draining and Filling

91. Start the engine and check for coolant leaks.

92. Check for oil leaks.

93. Inspect for fuel leaks.

94. Inspect the exhaust system for leaks.

95. Run the windshield wipers for two complete cycles then turn off the windshield wipers.

96. Ensure the windshield wipers are in the full park position.

97. Perform the throttle body idle air flow compensation reset. Throttle Body Idle Air Flow Compensation Reset