Cylinder Head Assembly: Service and Repair

Cylinder Head Replacement
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Special Tools

* EN-6333 - Timing Belt Tensioner Locking Pin

* EN-6340 - Camshaft Adjuster Locking Tool

* EN-6625 - Crankshaft Locking Device

* EN-6628-A - Camshaft Locking Tool

* EN-45059 - Angle Meter

For equivalent regional tools, refer to Special Tools Special Tools.

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.8L LWE) Air Cleaner Assembly Replacement (LWE)Air Cleaner Assembly Replacement (1.8L LUW) Air Cleaner Assembly Replacement (LUW).

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

4. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE-47716 Fill) Cooling System Draining and Filling (GE-47716 Fill).

5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

6. Remove the intake manifold. Refer to Intake Manifold Replacement Service and Repair.




7. Loosen the radiator inlet hose clamp (2).

8. Remove the radiator inlet hose (3) from the engine coolant thermostat (1).

9. Remove the heater outlet hose from the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement (1.8L LUW) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (1.4L LUV) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (1.8L LWE) Heater Outlet Hose Replacement.

10. Remove the heater inlet hose from the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement (1.8L LUW and LWE) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (1.4L LUV) Heater Inlet Hose Replacement.




11. Disconnect the thermostat wiring harness plug (1).

12. Remove the thermostat housing bracket nut (3).

13. Hang the thermostat housing bracket (2) with attached wiring harness aside.

14. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement Service and Repair.




15. Remove the 2 timing belt upper front cover bolts (2).

16. Remove the timing belt upper front cover (1).

17. Remove the camshaft cover. Refer to Camshaft Cover Replacement Service and Repair.

18. Remove the 2 camshaft position sensor. Refer to Camshaft Position Sensor Replacement Service and Repair.

19. Remove the 2 camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement.

20. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement Service and Repair.




21. Set the crankshaft balancer in direction of engine rotation until the markings (1) line up with the cylinder 1 at TDC.

22. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (Manual Transmission) Crankshaft Balancer Replacement (Manual Transmission)Crankshaft Balancer Replacement (Automatic Transmission) Crankshaft Balancer Replacement (Automatic Transmission).




23. Remove the 4 lower timing belt cover bolts (2).

24. Remove the lower timing belt cover (1).

25. Lower the vehicle.

26. Support the engine under the oil pan.




27. Remove the engine mount nut (3).

28. Remove the 5 engine mount bolts (1, 2).

29. Remove the engine mount (4).




30. Remove the 3 engine mount bracket bolts (1).

31. Remove the engine mount bracket (2).




32. Remove the center front timing belt cover from the rear timing belt cover at 2 locations.

33. Remove the center front timing belt cover (1).




34. Install the EN-6340 - locking tool into the camshaft adjusters.

Note: The spot type marking (4) on the intake camshaft adjuster does not correspond to the groove of EN-6340 - locking tool - left during this process but must be somewhat above as shown.

* Install the EN-6340 - locking tool - left (1) in the camshaft adjusters as shown.

Note: The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340 - locking tool - right.

* Install EN-6340 - locking tool - right (2) in the camshaft adjusters as shown.




35. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an allen key (1).

36. Install the EN-6333 - pin (3).





Note: Note the direction of the belt, if the timing belt will be reused.

37. Remove the timing belt (1).

38. Remove and DISCARD the timing belt tensioner bolt (3).

39. Remove the timing belt tensioner (2).

40. Raise the vehicle.




41. Remove the timing belt idler pulley bolt (1).

42. Remove the timing belt idler pulley (2).

43. Remove the EN-6625 - locking device.




44. Set the crankshaft in direction of engine rotation to 60 degrees (a) before TDC. Use the EN-45059 - meter and the crankshaft balancer bolt.





Note: Some engine oil will run out of the camshaft and the camshaft position actuator adjuster. That is the reason for the removal of the whole timing assembly.

45. Remove the crankshaft sprocket (1).

46. Lower the vehicle.

47. Remove the EN-6340 - locking tool.





Note: Note the arrows.

48. Turn the camshaft by the camshaft position actuator adjuster until the groove on the end of the camshafts is horizontal.




49. Install the EN-6628-A - locking tool (1).

50. Place a collecting basin underneath the vehicle.




51. Remove the camshaft position actuator adjuster closure bolt (1) of the intake camshaft position actuator adjuster and the exhaust camshaft position actuator adjuster (3).

Note: A second technician is required.

Note: Use an appropriate open-end wrench in order to counterhold the camshaft hexagon. A thin cross-section wrench is required for a better fit. The usage of EN-6628-A - locking tool is for the camshaft adjustment to prevent misalignment of the camshafts. The wrench is required to counterhold the camshafts during bolt torque procedure.

52. Remove and DISCARD the intake camshaft position actuator adjuster bolt and/or the exhaust camshaft position actuator adjuster bolt (2).

53. Remove the intake camshaft position actuator adjuster and the exhaust camshaft position actuator adjuster (3).

54. Remove the timing belt rear cover. Refer to Timing Belt Rear Cover Removal Timing Belt Rear Cover Removal.




55. Loosen the 10 cylinder head bolts in sequence as shown.

1. Loosen the 10 bolts 90 degrees.

2. Loosen the 10 bolts 180 degrees.




56. Remove and DISCARD the 10 cylinder head bolts (1).

57. Remove the cylinder head (2).

58. Remove and DISCARD the cylinder head gasket (3).

59. In case of re-use, then clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection Cylinder Head Cleaning and Inspection.

60. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Removal Engine Coolant Thermostat Housing Removal.

61. Remove the camshafts. Refer to Camshaft Removal Camshaft Removal.

62. Remove the valve lifter. Refer to Valve Lifter Removal Valve Lifter Removal.

63. Disassemble the cylinder head. Refer to Cylinder Head Disassemble Cylinder Head Disassemble.

Installation Procedure

1. Assemble the cylinder head. Refer to Cylinder Head Assemble Cylinder Head Assemble.

2. Install the valve lifter. Refer to Valve Lifter Installation Valve Lifter Installation.

3. Install the camshafts. Refer to Camshaft Installation Camshaft Installation.

4. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Installation Engine Coolant Thermostat Housing Installation.

5. Clean the sealing surfaces.

6. Inspect for plane surface.

* Cylinder block, cylinder head

* Straight-edge, feeler gauge




7. Install a NEW cylinder head gasket (3).

8. Install the cylinder head (2).





Caution: Refer to Fastener Caution Fastener Caution.

Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

9. Install 10 NEW cylinder head bolts (1).

10. Tighten the bolts as shown in sequence in 5 passes, using the EN-45059 - meter:

1. First pass to 25 Nm (18 lb ft)

2. Second pass to 90 degrees

3. Third pass to 90 degrees

4. Fourth pass to 90 degrees

5. Final pass to 45 degrees

11. Install the timing belt rear cover. Refer to Timing Belt Rear Cover Installation Timing Belt Rear Cover Installation.




12. Align the camshafts horizontally by the hexagon arrows, until the EN-6628-A - locking tool can be inserted in both camshafts.




13. Insert the EN-6628-A - locking tool (1) into the camshafts.





Note: If the cover is contaminated with oil, you have to clean it close.

Note: A second person is required. Counterhold against the hexagon of corresponding camshaft with an open-ended wrench.

14. Install intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator adjuster (3).

15. Install a NEW intake camshaft position actuator adjuster bolt and/or a NEW exhaust camshaft position actuator adjuster bolt (2).




16. Install the EN-6340 - locking tool into the camshaft position actuator adjusters.

Note: The spot type marking (4) on the intake camshaft position actuator adjuster does not correspond to the groove of EN-6340 - locking tool - left during this process but must be somewhat above as shown.

1. Install the EN-6340 - locking tool - left (1) in the camshaft position actuator adjusters as shown.

Note: The spot type marking (3) on the exhaust camshaft position actuator adjuster must correspond to the groove on EN-6340 - locking tool - right.

2. Install the EN-6340 - locking tool - right (2) in the camshaft position actuator adjusters as shown.

Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

Note: If the cover is contaminated with oil, you have to clean it close.

Note: A second technician is required.

Note: Use an appropriate open-end wrench in order to counterhold the camshaft hexagon. A thin cross-section wrench is required for a better fit. The Use of EN-6628-A - locking tool is for the camshaft adjustment to prevent misalignment of the camshafts. The wrench is required to counterhold the camshafts during bolt torque procedure.

17. Tighten the camshaft position actuator adjuster bolts (2) in three passes use the EN-45059 - meter:
Hold at the appropriate camshaft hexagon.

1. First pass tighten to 50 Nm (37 lb ft).

2. Second pass to 150 degrees.

3. Final pass to 15 degrees.

Note: Check the closure bolt seal ring.

18. Install the 2 camshaft position actuator adjuster closure plugs (1) and tighten to 30 Nm (22 lb ft).

19. Remove the EN-6628-A - locking tool.





Note: When installing the crankshaft sprocket, the cam and the groove must align (2).

20. Install the crankshaft sprocket (1).





Note: The crankshaft sprocket and oil pump housing must align.

21. Set the crankshaft in the direction of engine rotation to TDC. Use the crankshaft balancer bolt.





Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

22. Install the timing belt tensioner (2) and tighten the NEW timing belt tensioner bolt (1) in three passes use the EN-45059 - meter:

1. First pass tighten to 20 Nm (15 lb ft).

2. Second pass to 120 degrees.

3. Third pass to 15 degrees.





Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

23. Install the timing belt idler pulley (2) and tighten the NEW bolt (1) in three passes use the EN-45059 - meter:

1. First pass tighten to 20 Nm (15 lb ft).

2. Second pass to 120 degrees.

3. Third pass to 15 degrees.




24. Install the timing belt (1).

25. Guide the timing belt past the tensioner and place it on the crankshaft sprocket wheel.

26. Place the timing belt on the exhaust and intake camshaft position actuator adjusters.




27. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an allen key (1).

28. Remove the EN-6333 - pin (3).

Note: The timing belt tensioner moves automatically to the correct position.

29. Release tension on timing belt tensioner.

30. Lower the vehicle.




31. Install the engine mount bracket (2).

32. Install the 3 engine mount bracket bolts (1) tighten to 62 Nm (46 lb ft).




33. Install the engine mount (4).

34. Install the 2 engine mount bolts (1) and tighten to 62 Nm (46 lb ft).

Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

35. Install the 3 engine mount bolts (2) and tighten in three passes use the EN-45059 - meter.

1. First pass tighten to 50 Nm (37 lb ft).

2. Second pass to 60 degrees.

3. Third pass to 15 degrees.

36. Unsupport the engine.

37. Remove EN-6340 - locking tool.




38. Check the timing

Note: Note the marking at the camshaft sprockets.

* Turn the crankshaft 720 degrees in the direction of engine rotation by the bolt on the crankshaft balancer.

Note: The spot type marking (4) on the intake camshaft adjuster does not correspond to the groove of EN-6340 - locking tool - left during this process but must be somewhat above as shown.

* Install EN-6340 - locking tool - left (1) into the camshaft adjusters as shown.

Note: The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340 - locking tool - right.

* Install EN-6340 - locking tool - right (2) into the camshaft adjusters as shown.

* Raise the vehicle.





Note: The crankshaft sprocket and oil pump housing must align.

39. Check the crankshaft position.




40. Install the lower timing belt cover (1).

Caution: Refer to Fastener Caution Fastener Caution.

41. Install the 4 lower timing belt cover bolts (2) and tighten to 6 Nm (53 lb in).

42. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (Manual Transmission) Crankshaft Balancer Replacement (Manual Transmission)Crankshaft Balancer Replacement (Automatic Transmission) Crankshaft Balancer Replacement (Automatic Transmission).

43. Lower the vehicle.

44. Remove the EN-6340 - locking tool.

45. Install the camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement.

46. Install the 2 camshaft position sensors. Refer to Camshaft Position Sensor Replacement Service and Repair.

47. Install the camshaft cover. Refer to Camshaft Cover Replacement Service and Repair.




48. Install the timing belt upper front cover (1).

49. Install the 2 timing belt upper front cover bolts (2) and tighten to 6 Nm (53 lb in).

50. Install the exhaust manifold. Refer to Exhaust Manifold Replacement Service and Repair.




51. Install the radiator inlet hose (3) with the radiator inlet hose clamp (2) to the engine coolant thermostat (1).

52. Install the heater inlet hose to the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement (1.8L LUW and LWE) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (1.4L LUV) Heater Inlet Hose Replacement.

53. Install the heater outlet hose to the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement (1.8L LUW) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (1.4L LUV) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (1.8L LWE) Heater Outlet Hose Replacement.




54. Install the engine coolant thermostat housing bracket (2).

55. Install the engine coolant thermostat housing bracket nut (3) and tighten to 6 Nm (53 lb in).

56. Connect the thermostat wiring harness plug (1).

57. Install the intake manifold. Refer to Intake Manifold Replacement Service and Repair.

58. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.8L LWE) Air Cleaner Assembly Replacement (LWE)Air Cleaner Assembly Replacement (1.8L LUW) Air Cleaner Assembly Replacement (LUW).

59. Fill engine oil. Refer to Engine Mechanical Specifications Service Limits & General Specifications.

60. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

61. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE-47716 Fill) Cooling System Draining and Filling (GE-47716 Fill).