Cylinder Head Replacement - Rear
CYLINDER HEAD REPLACEMENT REARTOOLS REQUIRED
- SA9140E Torque Angle Gauge
REMOVAL
1. Disconnect negative battery cable.
2. Remove intake manifold and spacer.
3. Drain coolant.
4. Remove coolant bridge.
5. Remove coolant bridge seals.
6. Remove rear camshaft cover.
7. Disconnect rear 02 sensor connector.
8. Remove timing belt.
9. Remove rear timing belt cover.
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.
10. Raise vehicle.
11. Disconnect 02 sensors.
NOTICE: Excessive movement of the pipe can damage the flex pipe.
12. Remove front exhaust manifold pipe to rear exhaust manifold pipe fasteners.
IMPORTANT: Rear exhaust manifold will stay on cylinder head during cylinder head removal.
13. Remove rear exhaust manifold pipe to exhaust manifold nuts.
14. Pull down rear exhaust manifold pipe nuts enough to remove gasket.
15. Remove old gasket and discard.
16. Lower vehicle.
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.
IMPORTANT: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E".
17. Remove exhaust camshaft.
NOTICE: It is not necessary to remove intake camshaft to access head bolts.
NOTICE: Use loosening sequence to remove cylinder head.
18. Remove cylinder head bolts.
19. Remove cylinder head.
20. Support engine with Loot jack and block of wood under oil pan.
21. Remove Three Bar Engine Support Fixture.
22. Remove cylinder gasket.
23. Remove exhaust manifold.
INSTALLATION
1. Transfer all components to new cylinder head if cylinder head was serviced.
2. Install new cylinder head gasket with part number imprint toward the top of the 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. Use Torque Angle Gauge SA9140E (or equivalent) to properly tighten cylinder head bolts. Cylinder head bolts must be torqued in sequence.
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. Install Three Bar Engine Support Fixture to 6 Cylinder (L81) B.
6. Install exhaust camshaft.
7. Install rear timing belt cover.
8. Install front timing belt cover.
9. Remove Three Bar Engine Support Fixture.
10. Install rear camshaft cover.
11. Connect rear 02 sensor connector.
12. Properly position coolant bridge seals on block.
13. Install coolant bridge into position.
14. Install coolant bridge bolts.
Torque:
Coolant Bridge Bolts: 30 N.m (22 ft. lbs.)
15. Install intake manifold spacer and tighten bolts in sequence.
Torque:
Intake Manifold Spacer Bolts: 20 N.m (25 ft. lbs.)
16. Install intake manifold.
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. Install exhaust manifold pipe gasket and assembly
19. Install exhaust manifold pipe nuts
Torque:
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 N.m (25 ft. lbs.)
20. Lower vehicle
21. Refill coolant
22. Connect negative battery cable
Torque:
Battery Terminal Bolt: 17 N.m (13 ft. lbs.)