Cylinder Head Replacement

Cylinder Head Replacement

Tools Required

J 45059 Angle Meter

Removal Procedure




1. Remove the hood.
2. Remove the fuel rail.
3. Remove the exhaust manifold.
4. Remove the turbocharger coolant feed pipe.
5. Remove the timing chain.
6. Drain the cooling system.
7. Remove the fuel pump acoustic cover.




8. Remove the negative battery cable ground terminal bolt (5).
9. Remove the negative battery cable ground terminal (6) from the engine lift bracket.




10. Disconnect the engine wiring harness electrical connector (2) from the intake camshaft position (CMP) sensor.
11. Remove the evaporative emission (EVAP) canister purge solenoid valve.




12. Disconnect the engine wiring harness electrical connector (4) from the exhaust CMP sensor.
13. Disconnect the engine wiring harness electrical connector (3) from the engine coolant temperature (ECT) sensor.




14. Reposition the radiator inlet hose clamp at the engine.
15. Remove the radiator inlet hose from the cylinder head.




16. Remove the cylinder head bolts in the sequence shown. Discard the bolts.




17. Remove the cylinder head and place on a clean work surface.
18. Remove the cylinder head gasket.
19. Clean all of the gasket surfaces.
20. Use the following steps when cleaning the cylinder head and cylinder block surfaces:
^ Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge either surface.

Important: DO NOT use any other method or technique to clean these gasket surfaces.

^ Use a NEW razor blade on the cylinder head and a NEW blade on the cylinder block.

Important: Be careful not to gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the NEW gasket.

^ Hold the razor blade as parallel to the gasket surface as possible.

21. Clean the old sealer/lube and any dirt from around the bolt holes.

Important: DO NOT use a tap to clean the cylinder head bolt holes.

22. Clean the bolts holes with a nylon bristle brush.
23. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.

Disassembly Procedure




1. Remove the exhaust (1) and intake (2) camshaft position actuator solenoid valve bolts and valves.
2. Remove the fuel pump bolts (5), pump (4), and gasket (3).
3. Remove the intake camshaft position sensor (CMP) bolt (6) and sensor (7).
4. Remove the front engine lift bracket bolt (9) and bracket (8).




5. Remove the exhaust CMP sensor bolt (1) and sensor (2).
6. Remove the rear engine lift bracket bolt (3) and bracket (4).
7. Remove the intake camshaft, follower, and adjuster.
8. Remove the exhaust camshaft, follower, and adjuster.
9. Disassemble the cylinder head.

Assembly Procedure




1. Assemble the cylinder head.
2. Install the exhaust camshaft, follower, and adjuster.
3. Install the intake camshaft, follower, and adjuster.

Notice: Refer to Fastener Notice.

4. Position the rear engine lift bracket (4) and install the bolt (3).

Tighten the bolt to 25 N.m (18 lb ft).

5. Inspect the exhaust CMP sensor O-ring seal and replace if necessary.
6. Install the exhaust CMP sensor (2) and bolt (1).

Tighten the bolt to 10 N.m (89 lb in).




7. Position the front engine lift bracket (8) and install the bolt (9).

Tighten the bolt to 25 N.m (18 lb ft).

8. Inspect the intake CMP sensor O-ring seal and replace if necessary.
9. Install the intake CMP (7) and bolt (6).

Tighten the bolt to 10 N.m (89 lb in).

10. Position the fuel pump gasket (3), and install the fuel pump (4) and bolts (5).

Tighten the bolts to 15 N.m (11 lb ft).

11. Install the exhaust (1) and intake (2) camshaft position actuator solenoid valves and bolts.

Tighten the bolts to 10 N.m (89 lb in).

Installation Procedure





Important: DO NOT use any sealing material.

1. Install the cylinder head gasket.
2. Install the cylinder head.
3. Lightly apply clean engine oil to the threads and the bottom side flange of the head bolts and allow the oil to drain before installing.
4. Install NEW cylinder head bolts.




5. Install and tighten the cylinder head bolts in the sequence shown.

Tighten the bolts to 30 N.m (22 lb ft) plus an additional 155 degrees using the J 45059.




6. Install the NEW front cylinder head bolts.

Tighten the bolts to 35 N.m (26 lb ft).




7. Install the radiator inlet hose to the cylinder head.
8. Position the radiator inlet hose clamp at the engine.




9. Connect the engine wiring harness electrical connector (4) to the exhaust CMP sensor.
10. Connect the engine wiring harness electrical connector (3) to the ECT sensor.
11. Install the EVAP canister purge solenoid valve.




12. Connect the engine wiring harness electrical connector (2) to the intake CMP sensor.




13. Position the negative battery cable ground terminal (6) to the engine lift bracket.
14. Install the negative battery cable ground terminal bolt (5).

Tighten the bolt to 10 N.m (89 lb in).




15. Install the fuel pump acoustic cover.
16. Fill the cooling system.
17. Install the timing chain.
18. Install the turbocharger coolant feed pipe.
19. Install the exhaust manifold.
20. Install the fuel rail.
21. Install the hood.