Cylinder Head, Removal and Installation

Cylinder head, removing and installing (Engine installed)

Removal procedures refer to the left cylinder head

Removing

- Remove ribbed belt, refer to Drive Belts, Mounts, Brackets and Accessories/Ribbed Belt/Service and Repair Drive Belt
- Remove toothed belt, refer to Timing Components/Toothed Belt/Service and Repair Service and Repair (Vibration damper remains installed)
- Disconnect exhaust pipe from manifold.






- Disconnect exhaust hose to Exhaust Gas Recirculation (EGR) valve at manifold.






- Drain engine coolant at drain plug (arrow) using special tool 3247, and at drain plug in bottom of radiator.
- Remove air hose between Mass Air Flow (MAF) sensor and intake manifold.
- Disconnect all spark plug connectors.
- Disconnect all harness connectors on fuel injectors.
- Disconnect positive crankcase ventilation connections on left and right cylinder head covers.
- Disconnect fuel supply and return lines.
- Unclip cover on intake air housing.
- Remove both screws under cover.
- Push back and lift intake air housing upwards.
- Pull vacuum hose off left side and remove housing.
- Remove left hand cover for fuel injector lines.






- Unclip, disconnect and uncover accelerator pedal cable.
- Disconnect vacuum hose from vacuum pump (if applicable) and intake manifold.
- Disconnect hose from EVAP canister purge regulator valve to throttle body.
- Disconnect harness connectors for Idle Air Control (IAC) valve and Throttle Position (TP) sensor.






- Disconnect vacuum hose on cruise control vacuum control actuator.
- Disconnect harness connectors for oil pressure sensor, oil pressure switch and camshaft position sensor.
- Disconnect vacuum hose on intake manifold changeover valve (blue) as well as from the EGR valve (brown).
- Disconnect harness connectors for Heated Oxygen Sensors (HO2S) at fire wall and move to one side.
- Remove EGR valve from intake manifold.






- Remove hydraulic hose bracket and Ground (GND) wires on intake manifold (arrow).






- Remove bolts (arrows) and remove intake manifold.
- Seal off openings using clean cloth rags.
- Disconnect coolant hose at rear of cylinder head.

Note: After loosening the intake manifold mounting bolts, all cylinder head bolts must be tightened 1/4-turn (90°).






- Remove CO tap tube.
- Remove oxygen sensor.
- Remove exhaust manifold heat shield.
- Remove cylinder head cover.
- Remove rear toothed belt guard.
- Disconnect hose from hydraulic reservoir to pump.
- Remove cylinder head.

Installing

- Clean sealing surfaces.
- Install cylinder head gasket.
Lettering on gasket must face toward cylinder head

- Install cylinder head.
- Check centering pins in cylinder block.
- Install cylinder head bolts and tighten by hand.

Tightening sequence:






- Tighten cylinder head bolts in two stages:
Stage 1 60 Nm (44 ft lb)
Stage 2 additional 1/2-turn (180°)

Note: For final 1/2-turn, two 1/4-turns (90°) are also permissible.
It is not necessary to retighten the cylinder head bolts after repairs or as part of the maintenance service.