Cylinder Head Replacement - Front
CYLINDER HEAD REPLACEMENT-FRONT(IN-VEHICLE)
- TOOLS REQUIRED
- SA9140E Torque Angle Gauge
REMOVAL
1. Disconnect negative battery cable.
2. Remove intake air cleaner.
3. Remove intake plenum.
4. Remove intake manifold.
5. Remove intake manifold spacer bolts.
6. Remove intake manifold spacer.
7. Remove coolant bridge.
8. Drain coolant.
9. Remove upper radiator hose from coolant extension housing.
IMPORTANT: The powertrain must be lifted up in order to remove the coolant extension housing.
10. Support powertrain using a floor jack under oil pan.
11. Remove front transaxle mount through bolt.
12. Raise powertrain with floor jack in order to provide clearance to pull out extension housing over coolant module.
13. Remove oil level indicator tube and coolant extension tube bolt.
14. Remove oil level indicator tube by pulling upwards.
15. Twist coolant extension housing to remove.
16. Remove front camshaft cover.
17. Remove grounds from front lift bracket.
18. Disconnect oxygen sensor electrical connection.
19. Remove down pipe to exhaust manifold nuts.
20. Remove front timing belt cover.
21. Remove timing belt.
22. Remove timing belt tensioner bracket.
23. Remove rear timing belt cover.
24. Remove camshaft sensor electrical connection.
IMPORTANT: The intake camshaft is marked with the letter "A,' and the exhaust camshaft is marked with the letter "E."
25. Remove exhaust camshaft.
Note: It is not necessary to remove intake camshaft for head bolt access.
26. Loosen cylinder head bolts in stages in sequence shown.
27. Remove cylinder head bolts.
28. Remove cylinder head.
29. Remove cylinder head gasket.
30. Clean and inspect cylinder head and sealing surfaces.
31. Remove exhaust manifold.
INSTALLATION
1. Install exhaust manifold and new gasket.
Torque:
Exhaust Manifold Nut: 20 Nm (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.
Note: Use Torque Angle Gauge SA9140E and the proper tightening sequence to tighten cylinder head bolts in stages.
4. Install new cylinder head bolts.
Torque:
Cylinder Head Bolt: 25 Nm (18 ft. lbs.) + 90° + 90° + 90° + 15°
5. Replace the two sealing rings on coolant pipe.
6. Lubricate the two sealing rings with coolant.
7. 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 Nm (15 ft. lbs.)
8. Install upper radiator hose to coolant pipe.
9. Install upper radiator hose clamp.
10. Lower powertrain and align front transaxle mount and mounting bracket using floor jack.
11. Install front transaxle mount through bolt.
12. Remove floor jack.
13. Install upper radiator hose.
IMPORTANT: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E."
14. Install exhaust camshaft.
Note: It is not necessary to remove intake camshaft for head bolt access.
15. Install exhaust camshaft sensor electrical connection.
16. Install rear timing belt cover.
17. Coat threaded pin with Threadlocker Loctite 242 compound or equivalent.
18. Install rear timing belt cover bolts.
Torque:
Rear Timing Belt Cover Bolt: 8 Nm (71 inch lbs.)
19. Install rear timing belt threaded pin.
Torque:
Rear Timing Belt Cover Threaded Pin: 10 Nm (89 inch lbs.)
20. Install all four camshaft gears.
21. Install timing belt tensioner bracket.
22. Install timing belt.
23. Install front timing belt cover.
24. Install front camshaft cover.
25. Install coolant bridge.
26. Install intake manifold spacer.
27. Install intake manifold spacer bolts. Tighten intake manifold spacer bolts in a spiral direction starting from inside and working outward.
Torque:
Intake Manifold Spacer Bolt: 20 Nm (15 ft. lbs.)
28. Install intake manifold.
29. Install intake plenum.
30. Install intake air cleaner.
31. Refill coolant.
32. Connect negative battery cable.