Removal And Installation

REMOVAL 

1. Disconnect and isolate the negative battery cable.
2. Remove the engine cover and air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION  .
3. Remove the crankcase breather hose. Refer to TUBE, CRANKCASE BREATHER, REMOVAL AND INSTALLATION .
4. Disconnect the oil vapor pipe quick coupling from the cylinder head cover.
5. Remove the ignition coils. Refer to COIL, IGNITION, REMOVAL AND INSTALLATION .

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6. Unlock and disconnect the four Variable Valve Actuation Assembly (VVAA) wire harness connectors (1).
7. Disengage the wire harness from the retainer (2).

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8. Remove the oil filler cap and dipstick (1).
9. Unlock and disconnect the turbocharger air pressure sensor wire harness connector (2).
10. Unlock and disconnect the turbocharger air temperature sensor wire harness connector (3).
11. Unlock and disconnect the inlet air temperature (IAT) sensor wire harness connector (4).
12. Unlock and disconnect the turbocharger wastegate actuator wire harness connector (5).
13. Unlock and disconnect the turbocharger by-pass solenoid valve wire harness connector (6).
14. Remove the bolts (7a), disengage the wiring harness retainers (7b) and reposition the wire harness (7c).

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15. Remove the bolt (1) securing the turbocharger air outlet pipe to the cylinder head cover.

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16. Release the quick coupling and disconnect the brake servo vacuum hose (1).
17. Disengage the Oxygen sensor wire harness connector (2) from the wire harness support bracket.
18. Disengage the wire harness from the retainer (3).
19. Remove the bolts (4a) and reposition the wire harness support bracket (4b).

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20. Loosen the capture bolts (1a) and remove the cylinder head cover (1b).
21. Remove any residual sealant from the cylinder head and cylinder head cover sealing surfaces.

INSTALLATION 

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1. Install NEW  gaskets (1a) and (1b) on the cylinder head cover.

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2. Apply sealant in the designated areas (1) on the cylinder head.
   Fig 1: Cylinder Head Cover Tightening Sequence

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3. Install the cylinder head cover onto the cylinder head.
4. Using the sequence shown, tighten the cylinder head cover bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
5. Install the wire harness support bracket and securely tighten the bolts.
6. Engage the wire harness to the retainer.
7. Engage the Oxygen sensor wire harness connector to the wire harness support bracket.
8. Connect the brake servo vacuum hose quick coupling.
9. Install and securely tighten the bolt securing the turbocharger air outlet pipe to the cylinder head cover.
10. Install the oil filler cap and dipstick.
11. Position the wire harness, engage the wiring harness retainers and securely tighten the bolts.
12. Connect and lock the four Variable Valve Actuation Assembly (VVAA) wire harness connectors.
13. Connect and lock the turbocharger air pressure sensor wire harness connector.
14. Connect and lock the inlet air temperature (IAT) sensor wire harness connector.
15. Connect and lock the turbocharger air temperature sensor wire harness connector.
16. Connect and lock the turbocharger wastegate actuator wire harness connector.
17. Connect and lock the turbocharger by-pass solenoid valve wire harness connector.
18. Install the ignition coils. Refer to COIL, IGNITION, REMOVAL AND INSTALLATION .
19. Connect the oil vapor pipe quick coupling to the cylinder head cover.
20. Install the crankcase breather hose. Refer to TUBE, CRANKCASE BREATHER, REMOVAL AND INSTALLATION .
21. Install the air cleaner body and engine cover. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION  .
22. Connect the negative battery cable.