Cylinder Head, Installing

Cylinder head, installing

Note:
- Always replace cylinder head bolts.
- Note inner 12-point or Polydrive versions of cylinder head bolts, Cylinder Head Bolts, Convert From Inner 12-Point to Polydrive
- Always replace self-locking nuts, bolts, gaskets and O-rings.
- Carefully remove any sealant residue from cylinder head or engine block repairs. Avoid any scratches or scoring.
- Thoroughly remove all sanding and grinding residue.
- Do not remove new cylinder head gasket from package until immediately before installing.
- Handle gasket with extra care. Silicon layer and grooved areas can be damaged leading to leakage.
- Pocket holes in engine block for cylinder head bolts must be free of oil and coolant.




- Before installing cylinder head, set crankshaft and camshaft to TDC Cyl. 1 marking (arrows).




- Loosen bolts -1- and -2- at turbocharger bracket two turns to reduce likelihood of any tension while installing cylinder head.




- Install cylinder head gasket.

Note:
- Pay close attention to pilot pins (arrows) in engine block.
- Pay attention to installation position marking for cylinder head gasket: Part number must be visible from intake side.

- Install cylinder head.
- Insert cylinder head bolts and hand tighten.




- Tighten cylinder head bolts in sequential order, in two stages:
Step 1 = 60 Nm (44 ft. lbs.)
Step 2 = additional 1/2 turn using rigid wrench (180° is equivalent to two 90° turns)

Note: It is not necessary to re-tighten the bolts.

- Using new gasket, bolt turbocharger to exhaust manifold and bolt bracket to engine block.
- Install cylinder head cover. Service and Repair
- Install toothed belt (adjust valve timing), Service and Repair

Note: Follow all procedures for removing and installing toothed belt.

- Install ribbed belt and ribbed belt tensioner. Service and Repair

Note: When installing ribbed belt, make sure it is seated correctly on the pulleys.

- Adjust Accelerator Pedal (AP) cable.
- Replace coolant. Service and Repair

CAUTION! Be sure the ignition is Switched OFF. Failure to do so may damage the Engine Control Module (ECM).

- Switch ignition off and reconnect battery Ground (GND) strap.
- After connecting battery, enter anti-theft code for radio.
Refer to Radio operating manual
- Using power window switch, raise windows to stop.
- Operate all power window switches again for at least one second in "close" direction to activate "one touch" opening/closing function.
- Set clock to correct time.
- Perform throttle valve control module adaptation to Engine Control Module (ECM).







Tightening torques