Cylinder Head, Removal and Installation

Cylinder head, removing and installing

Removing (engine installed)

Note: The following procedure refers to the left cylinder head.

- Remove ribbed belt, refer to Ribbed Belt/Service and Repair Drive Belt
- Remove toothed camshaft drive belt, Refer to Timing Components/Toothed Belt/Service and Repair Service and Repair Vibration damper remains installed.






- Disconnect exhaust pipe from exhaust manifold.






- Drain engine coolant at drain plug (arrow) using special tool 3247, and at drain plug in bottom of radiator.
- Remove intake air duct between Mass Air Flow (MAF) sensor and intake manifold.
- Disconnect all spark plug wire connectors.
- Disconnect all harness connectors from fuel injectors.
- Disconnect crankcase vents on left and right cylinder head covers.






- Disconnect fuel supply line -1 and return line -2-.
- Unclip cover for intake air silencer.
- Remove both screws under cover.
- Push back and lift intake air silencer upward and disconnect vacuum hose on left side.
- Remove intake air silencer.
- Remove left-side cover for fuel injector lines.






- Remove accelerator pedal cable retaining clip. Disconnect accelerator pedal cable and move to one side.
- Disconnect vacuum hoses from vacuum pump and intake manifold.
- Disconnect line between EVAP canister purge solenoid valve and throttle valve at throttle body.
- Disconnect Idle Air Control (IAC) valve harness connector.
- Disconnect Throttle Position (TP) sensor harness connector at throttle body.






- Disconnect vacuum hose on cruise control vacuum control actuator.
- Disconnect harness connector for Camshaft Position (CMP) sensor.
- Disconnect vacuum hose from Intake Manifold Tuning (IMT) valve (blue).
- Disconnect harness connectors for Heated Oxygen Sensors (H02S) at engine compartment bulkhead, and move to one side.
- Disconnect vacuum line from EVAP canister purge regulator valve at throttle housing.






- Disconnect hydraulic line (arrow).






- Remove bolts (arrows) and remove intake manifold.
- Seal off openings using clean cloth rags.
- Disconnect coolant hose at rear of cylinder head.






- Remove CO tap tube.
- Disconnect Heated Oxygen Sensor (H02S).
- Remove exhaust manifold heat shield.
- Remove cylinder head cover.
- Remove rear camshaft drive belt guard.
- Disconnect hose between hydraulic fluid reservoir to hydraulic pump.
- Remove cylinder head bolts, and remove cylinder head.

Checking cylinder head distortion






- Measure at several points with precision straight edge. Max. permissible distortion: 0.05 mm (0.002 in)

Installing

- Clean sealing surfaces.
- Install cylinder head gasket.

Lettering on gasket must face toward cylinder head.

- Install cylinder head, and check position on centering pins in cylinder block.
- Install cylinder head bolts hand tight only.

Tightening sequence:






- Tighten cylinder head bolts in two stages:
Stage 1: 60 Nm (44 ft lb)
Stage 2: additional 1/2-turn (180°)

Notes: For final 1/2-turn, two 1/4-turns (90°) are also permissible.
It is not necessary to re-tighten the bolts, or to check bolt tightening torque during the next maintenance service.