Cylinder Head Replacement - Front
CYLINDER HEAD REPLACEMENT FRONTTOOLS REQUIRED
- SA9105E Three Bar Engine Support Tool
- SA9140E Torque Angle Gauge
REMOVAL
1. Disconnect negative battery cable.
2. Remove intake manifold and spacer.
3. Drain coolant.
4. Remove coolant bridge bolts.
5. Remove coolant bridge seals.
6. Remove upper radiator hose from coolant pipe.
7. Remove oil level indicator tube and coolant pipe tube bolt.
8. Remove oil level indicator tube by pulling upwards.
9. Twist coolant pipe to remove front thermostat housing.
10. Remove engine lift bracket.
11. Remove front camshaft cover.
12. Remove ECM from ECU bracket.
13. Remove electrical grounds from cylinder head
14. Disconnect oxygen sensor electrical connection.
15. Disconnect oxygen sensor harness from bracket.
16. Remove rear engine lift bracket.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
17. Raise vehicle.
18. Remove front exhaust manifold down pipe.
19. Lower vehicle
20. Remove timing belt.
21. Remove rear timing belt cover.
IMPORTANT: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E".
NOTICE: It is not necessary to remove intake camshaft for head bolt access.
22. Remove exhaust camshaft.
23. Install floor jack with a block of wood under oil pan and support engine.
24. Remove Three Bar Engine Support Tool SA9105F.
25. Loosen cylinder head bolts in sequence shown.
26. Remove cylinder head bolts.
27. Remove cylinder head.
28. Clean and inspect cylinder head and sealing surfaces.
29. Disassemble cylinder head and service necessary.
INSTALLATION
1. With cylinder head assembled (except exhaust camshaft) install exhaust manifold and new gasket.
Torque:
Exhaust Manifold Nut: 20 N.m (15 ft. lbs.)
2. Install new cylinder head gasket with part number imprint toward the top of engine.
3. Install cylinder head to engine block ensuring adequate clearance from all wires, components, etc.
IMPORTANT: Use new cylinder head bolts. The required tightening method stretches the bolts to their yield point, Therefore, the cylinder head bolts are not reusable.
NOTICE: Use Torque Angle Gauge SA9140E (or equivalent) and the proper tightening sequence to tighten cylinder head bolts in stages.
4. Install new cylinder head bolts.
Torque:
Cylinder Head Bolt: 25 N.m (18 ft. lbs.) + 90 degrees + 90 degrees + 90 degrees + 15 degrees
5. Replace the two sealing rings on coolant pipe if pipe was remove earlier.
6. Lubricate the two sealing rings with coolant.
7. Properly position engine lift bracket.
8. Install coolant pipe into position and fully seat pipe into housing if removed earlier.
9. Install oil level indicator tube.
10. Install coolant pipe and engine lift bracket bolt to cylinder head. Ensure that bolt passes through all attached components.
Torque:
Coolant Pipe/Engine Lift Bracket Bolt: 20 N.m (15 ft. lbs.)
11. Install Three Bar Engine Support Fixture to 6 Cylinder (1,81) B.
12. Remove floor jack with block of wood.
13. Install upper radiator hose to coolant pipe.
14. Install upper radiator hose clamp.
IMPORTANT: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E"
15. Install exhaust camshaft.
16. Install rear timing belt cover.
17. Install front timing belt cover.
18. Remove Three Bar Engine Support Fixture.
19. Install front camshaft cover.
20. Properly position coolant bridge seals on block.
21. Install coolant bridge into position.
22. Install coolant bridge bolts.
Torque:
Coolant Bridge Bolt: 30 N.m (22 ft. lbs.)
23. Install intake manifold spacer and tighten bolts in sequence.
Torque:
Intake Manifold Spacer-to-Cylinder Head Bolt: 16 N.m (11 ft. lbs.)
24. Install intake manifold.
25. Refill coolant.
26. Connect negative battery cable.
Torque:
Battery Terminal Bolt: 17 N.m (13 ft. lbs.)