Cylinder Head Removal and Installation
Cylinder Head Removal1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant.
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant.
9. Remove the engine assembly.
10. Remove the timing chain.
11. Remove the intake manifold support bracket.
12. Remove the power steering pump.
13. Remove the EGR valve.
14. Remove the EGR pipes.
15. Remove the EGR adapter.
16. Remove the heater pipe.
17. Remove the exhaust manifold.
18. Remove the exhaust manifold gasket.
19. Remove the Camshaft Position (CMP) sensor.
20. Remove the Engine Coolant Temperature Sensor (ECTS).
21. Remove the coolant outlet port.
22. Remove the cylinder head bolts in the sequence shown and the cylinder head.
23. Remove the cylinder head gasket.
24. Remove the liquid gasket.
Cylinder Head Installation
1. Installation should follow the removal procedure in the reverse order.
2. Clean the contact surfaces between the cylinder head and the cylinder block.
3. Install the dowel pin.
4. Apply the liquid gasket (Loctite (R) 5900-118585) on the surface of the cylinder block as described in the illustration.
5. Install the cylinder head gasket.
6. Apply the liquid gasket (Loctite (R) 5900-118585) on the upper surface of the cylinder head gasket as described in the illustration
7. Install the cylinder head. Tighten the cylinder head bolts from center to outer as is described in the illustration.
Tighten the cylinder head bolts to 20 Nm (15 ft. lbs.). After finishing the initial tightening, tighten all the cylinder head bolts to 25 Nm (18 ft. lbs.) and turn the bolts another two (2) turns of 70°.
8. Install the coolant outlet port.
Tighten the coolant outlet port retaining bolts to 8 - 12 Nm (71 - 106 inch lbs.).
9. Install the Engine Coolant Temperature Sensor (ECTS).
10. Install the Camshaft Position (CMP) sensor.
11. Discard used exhaust manifold gasket and replace with a new one.
12. Install the exhaust manifold.
13. Install the heater pipe.
14. Install the EGR adapter.
Tighten the EGR adapter retaining bolts to 18 - 22 Nm (13 - 16 ft. lbs.).
15. Install the EGR pipes.
16. Install the EGR valve.
17. Install the power steering pump.
Tighten the power steering pump retaining bolts to 20 - 30 Nm (15 - 22 ft. lbs.).
18. Install the intake manifold support bracket.
Tighten the intake manifold support bracket bolt to 20 - 30 Nm (15 - 22 ft. lbs.).
19. Install the timing chain and the timing chain cover.
20. Install the cylinder head cover.
21. Install the oil pan.
22. Install the engine assembly.