Cylinder Head Replacement - Right

CYLINDER HEAD REPLACEMENT - REAR (IN-VEHICLE)

TOOLS REQUIRED
- SA9140E Torque Angle Gauge

REMOVAL





1. Disconnect negative battery cable.
2. Remove intake plenum.
3. Remove intake air resonator.
4. Remove intake manifold.





5. Remove intake manifold spacer bolts.
6. Remove intake manifold spacer.





7. Remove coolant bridge.





8. Remove engine ventilation chamber.





9. Remove rear camshaft cover.





10. Remove front timing belt cover.
11. Remove timing belt.
12. Remove timing belt tensioner bracket.
13. Remove all four camshaft gears.
14. Remove rear timing belt cover.





15. Remove exhaust manifold pipe heat shield.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST.

16. Raise vehicle on hoist.





17. Remove front exhaust manifold pipe to rear exhaust manifold pipe fasteners.

NOTICE: Excessive movement of the pipe can damage the flex pipe.





18. Remove rear exhaust manifold pipe to exhaust manifold pipe nuts.
19. Pull down rear exhaust manifold pipe just enough to remove gasket.
20. Remove old gasket and discard.





21. Drain coolant.
22. Lower vehicle.





23. Remove EGR to exhaust manifold pipe.





IMPORTANT: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E."

24. Remove exhaust camshaft.





NOTICE: Use loosening sequence to remove cylinder head.

25. Remove cylinder head bolts.
26. Remove cylinder head.
27. Remove cylinder head gasket.
28. Remove exhaust manifold.

NOTICE: It is not necessary to remove intake camshaft for head bolt access.

29. Clean and inspect cylinder head and sealing surfaces.

INSTALLATION





1. Install rear exhaust manifold to the cylinder head.
Torque:
Exhaust Manifold Nut: 20 Nm (15 ft. lbs.)
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.

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 degrees + 90 degrees + 90 degrees + 15 degrees
5. Install exhaust camshaft.
6. Install rear timing belt cover.





7. Install all four camshaft gears.
8. Install timing belt tensioner bracket.
9. Install timing belt.
10. Install front timing belt cover.





11. Install rear camshaft cover.





12. Install coolant bridge.
13. Apply sealing compound Loctite- 518 (or equivalent) to sealing surface.





14. Install engine ventilation chamber.
Torque:
Engine Ventilation Chamber Bolts: 8 Nm (71 inch lbs.)





15. Install intake manifold spacer.
16. Install intake manifold spacer bolts, and apply Loctite- 242 to bolts. Tighten intake manifold spacer bolts in a spiral direction, starting from the inside and working outward.
Torque:
Intake Manifold Spacer Bolt: 20 Nm (15 ft. lbs.)





17. Install intake manifold.
18. Install intake plenum.
19. Install intake air cleaner.
20. Refill coolant.
21. Connect negative battery cable.
Torque:
Battery Terminal Bolts: 17 Nm (13 ft. lbs.)





22. Install EGR to exhaust manifold pipe.
Torque:
EGR Pipe Bolts: 25 Nm (19 ft. lbs.)





23. Raise vehicle.
24. Install exhaust manifold pipe gasket and assembly.
25. Install exhaust manifold pipe nuts
Torque:
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 Nm (25 ft. lbs.)
26. Lower vehicle.
27. Start vehicle and inspect for exhaust leaks.