Cylinder Head Assembly: Service and Repair

Cylinder Head Replacement

Special Tools

* BO-38185 - Hose Clamp Pliers

* EN-45059 - Angle Meter

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

Removal Procedure

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

2. Relieve fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.

3. Disconnect the fuel feed pipe. Refer to Fuel Feed Pipe Replacement Service and Repair.

4. Disconnect EVAP purge solenoid pipes from solenoid. Refer to Evaporative Emission System Hose/Pipe Replacement Service and Repair.

5. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

6. Remove the coolant surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.




7. Loosen the radiator inlet hose clamp (1) at the engine using BO-38185 - pliers.

8. Remove the radiator inlet hose (2) from the engine.




9. Remove the inlet and outlet heater hose clamp (1) at the engine using BO-38185 - pliers.

10. Remove the inlet hose (2) and outlet (3) from the engine.




11. Disconnect the throttle body heater inlet pipe (1).




12. Remove the ignition coil (2). Refer to Ignition Coil Replacement Service and Repair.

13. Disconnect PCV hose. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Service and Repair.




14. Remove the camshaft cover (1). Refer to Camshaft Cover Replacement Service and Repair.

15. Install engine support fixture. Refer to Engine Support Fixture Service and Repair.

16. Remove the engine mount. Refer to Engine Mount Replacement Engine Mount Replacement.




17. Remove the drive belt (1). Refer to Drive Belt Replacement Service and Repair.




18. Remove the engine mount bracket (1). Refer to Engine Mount Bracket Replacement Engine Mount Bracket Replacement.




19. Remove the upper timing cover (1). Refer to Timing Belt Upper Front Cover Replacement Timing Belt Upper Front Cover Replacement.

20. Remove the timing belt center front cover. Refer to Timing Belt Center Front Cover Replacement Timing Belt Center Front Cover Replacement.

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




22. Remove the crankshaft balancer (2). Refer to Crankshaft Balancer Replacement Service and Repair.




23. Remove the timing belt lower front cover (1). Refer to Timing Belt Lower Front Cover Replacement Timing Belt Lower Front Cover Replacement.




24. Remove the timing belt tensioner bolt (1) and the timing belt tensioner (2). Refer to Timing Belt Tensioner Replacement Service and Repair.




25. Remove the timing belt (1). Refer to Timing Belt Replacement Service and Repair.




26. Remove the camshaft sprocket intake (1) and exhaust (2). Refer to Camshaft Sprocket Replacement Service and Repair.




27. Remove the timing belt rear cover (1). Refer to Timing Belt Rear Cover Replacement Timing Belt Rear Cover Replacement.

28. Remove the exhaust manifold. Refer to Exhaust Manifold with Catalytic Converter Replacement (LUW) Service and Repair.

29. Place a floor jack with block of wood under the oil pan.

30. Remove the engine support fixture. Refer to Engine Support Fixture Service and Repair.





Note: Disconnect electrical and reposition harness and hose as necessary.

31. Remove the ten cylinder head bolts in sequence as shown.

* Loosen the 10 bolts 90°.

* Loosen the 10 bolts 180°.

32. Remove the cylinder head and place on a suitable base.

33. Remove the cylinder head gasket.




34. Remove the intake manifold bolts (1) intake manifold (2).

35. Remove engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LUW) Service and Repair.

36. Remove the 2 camshaft position actuator solenoid valve. Refer Camshaft Position Actuator Solenoid Valve Replacement Service and Repair.

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

38. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection Service and Repair.

39. For disassembly of the cylinder head, refer to Cylinder Head Disassemble Service and Repair.

Installation Procedure

1. For assembly of the cylinder head, refer to Cylinder Head Assemble Service and Repair.

2. Clean sealing surfaces of engine front cover and engine block from grease and old gasket material.

3. Install the 2 camshaft position sensor. Refer to Camshaft Position Sensor Replacement Service and Repair.

4. Install the 2 camshaft position actuator solenoid valve. Refer Camshaft Position Actuator Solenoid Valve Replacement Service and Repair.

5. Install engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LUW) Service and Repair.





Caution: Refer to Fastener Caution Fastener Caution.

6. Install the intake manifold (2) and the intake manifold bolts (1) and tighten to 20 Nm (15 lb ft).




7. Install the cylinder head (2) with the NEW gasket and hand start the NEW bolts.





Note: Note the correct tightening sequence.

8. Tighten the bolts (1) in 5 passes. Use the EN-45059 sensor kit :

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

* Second pass to 90°.

* Third pass to 90°.

* Fourth pass to 90°.

* Final pass to 45°.

9. Install engine support fixture. Refer to Engine Support Fixture Service and Repair.

10. Remove the floor jack from the vehicle.

11. Install the exhaust manifold. Refer to Exhaust Manifold with Catalytic Converter Replacement (LUW) Service and Repair.




12. Install the timing belt rear cover (1) and tighten to 6 Nm (53.1 lb in).




13. Install the camshaft sprocket intake (1) and exhaust (2). Refer to Camshaft Sprocket Replacement Service and Repair.




14. Install the timing belt (1). Refer to Timing Belt Replacement Service and Repair.




15. Install the timing belt tensioner bolt (1) and the timing belt tensioner (2). Refer to Timing Belt Tensioner Replacement Service and Repair.




16. Install the timing belt lower front cover (1). Refer to Timing Belt Lower Front Cover Replacement Timing Belt Lower Front Cover Replacement.




17. Install the crankshaft balancer (2). Refer to Crankshaft Balancer Replacement Service and Repair.

18. Install the timing belt center front cover. Refer to Timing Belt Center Front Cover Replacement Timing Belt Center Front Cover Replacement.




19. Install the upper timing cover (1). Refer to Timing Belt Upper Front Cover Replacement Timing Belt Upper Front Cover Replacement.




20. Install the engine mount bracket (1). Refer to Engine Mount Bracket Replacement Engine Mount Bracket Replacement.




21. Install the drive belt (1). Refer to Drive Belt Replacement Service and Repair.

22. Install the engine mount. Refer to Engine Mount Replacement Engine Mount Replacement.

23. Remove engine support fixture. Refer to Engine Support Fixture Service and Repair.




24. Install the camshaft cover (1). Refer to Camshaft Cover Replacement Service and Repair.

25. Connect PCV hose. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Service and Repair.




26. Install the ignition coil (2). Refer to Ignition Coil Replacement Service and Repair.




27. Connect the throttle body heater inlet pipe (1).




28. Install the inlet hose (2) and outlet (3) to the engine.

29. Install the inlet and outlet heater hose clamp (1) at the engine using BO-38185 - pliers.




30. Install the radiator inlet hose (2) to the engine.

31. Install the radiator inlet hose clamp (1) at the engine using BO-38185 - pliers.

32. Install the coolant surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.

33. Connect the fuel feed pipe. Refer to Fuel Feed Pipe Replacement Service and Repair.

34. Connect EVAP purge solenoid pipes from solenoid. Refer to Evaporative Emission System Hose/Pipe Replacement Service and Repair.

35. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

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

37. Check and correct the engine oil.