Cylinder Head Replacement - Front
Cylinder Head Replacement (Front)^ Tools Required
- SA9140E Torque Angle Gage
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the intake air cleaner.
3. Remove the intake plenum.
4. Remove the intake manifold.
5. Remove the intake manifold spacer bolts.
6. Remove the intake manifold spacer.
7. Remove the coolant bridge.
8. Drain the coolant.
9. Remove the upper radiator hose from the coolant extension housing.
Important: The powertrain must be lifted up in order to remove the coolant extension housing.
10. Support the powertrain using a floor jack under the oil pan.
11. Remove the front transaxle mount through the bolt.
12. Raise the powertrain with a floor jack in order to provide clearance to pull out the extension housing over the coolant module.
13. Remove the oil level indicator tube and coolant extension tube bolt.
14. Remove the oil level indicator tube by pulling upwards.
15. Twist the coolant extension housing to remove.
16. Remove the front camshaft cover.
17. Remove the grounds from the front lift bracket.
18. Disconnect the oxygen sensor electrical connection.
19. Remove the down pipe to the exhaust manifold nuts.
20. Remove the front timing belt cover.
21. Remove the timing belt.
22. Remove the timing belt tensioner bracket.
23. Remove the rear timing belt cover.
24. Remove the camshaft sensor electrical connection.
Important: The intake camshaft is marked with the letter A and the exhaust camshaft is marked with the letter E.
Important: It is not necessary to remove the intake camshaft for head bolt access.
25. Remove the exhaust camshaft.
26. Loosen the cylinder head bolts in the stages in the sequence shown.
27. Remove the cylinder head bolts.
28. Remove the cylinder head.
29. Remove the cylinder head gasket.
30. Clean and inspect the cylinder head and sealing surfaces.
31. Remove the exhaust manifold.
Installation Procedure
Notice: Refer to Fastener Notice in Service Precautions.
1. Install the exhaust manifold and the new gasket.
^ Tighten the exhaust manifold nut to 20 Nm (15 ft. lbs.).
2. Install the new cylinder head gasket with the part number imprint toward the top of the engine.
3. Install the cylinder head to the engine block ensuring the adequate clearance from all the wires, components, etc.
Important: Use the new cylinder head bolts. The required tightening method stretches the bolts to their yield point. Therefore, the cylinder head bolts are not reusable.
Important: Use the SA9140E and the proper tightening sequence to tighten the cylinder head bolts in stages.
4. Install the new cylinder head bolts.
^ Tighten the cylinder head bolts to 25 Nm (18 ft. lbs.) plus 90° plus 90° plus 90° plus 15°.
5. Replace the 2 sealing rings on the coolant pipe.
6. Lubricate the 2 sealing rings with coolant.
7. Install the coolant pipe and the engine lift bracket bolt to the cylinder head. Ensure that the bolt passes through all of the attached components.
^ Tighten the coolant pipe engine lift bracket bolt to 20 Nm (15 ft. lbs.).
8. Install the upper radiator hose to the coolant pipe.
9. Install the upper radiator hose clamp.
10. Lower the powertrain and align the front transaxle mount and the mounting bracket using a floor jack.
11. Install the front transaxle mount through bolt.
12. Remove the floor jack.
13. Install the 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 the exhaust camshaft.
Important: It is not necessary to remove the intake camshaft for head bolt access.
15. Install the exhaust camshaft sensor electrical connection.
16. Install the rear timing belt cover.
17. Coat the threaded pin with Threadlocker LOCTITE 242 compound or equivalent.
18. Install the rear timing belt cover bolts.
^ Tighten the rear timing belt cover bolt to 8 Nm (71 inch lbs.).
19. Install the rear timing belt threaded pin.
^ Tighten the rear timing belt cover threaded pin to 10 Nm (89 inch lbs.).
20. Install all 4 camshaft gears.
21. Install the timing belt tensioner bracket.
22. Install the timing belt.
23. Install the front timing belt cover.
24. Install the front camshaft cover.
25. Install the coolant bridge and new coolant bridge seals.
26. Apply sealing compound LOCTITE 518, or equivalent, to the sealing surface.
^ Tighten the coolant bridge bolts to 30 Nm (22 ft. lbs.).
27. Install the intake manifold spacer.
28. Install the intake manifold spacer bolts. Tighten the intake manifold spacer bolts in a spiral direction, starting from the inside and working outward.
^ Tighten the intake manifold spacer bolt 20 Nm (15 ft. lbs.).
29. Install the intake manifold.
30. Install the intake plenum.
31. Install the intake air cleaner.
32. Refill the coolant.
33. Connect the negative battery cable.
^ Tighten the battery terminal bolts to 17 Nm (13 ft. lbs.).