Cylinder Head Assembly: Service and Repair

Cylinder Head Replacement

Special Tools

* EN-470-B - Angular Torque Wrench

* EN-953-A - Fixing Tool

* EN-955-10 - Fixing Pin from EN-955 - Kit

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Open the hood.

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

3. Remove the engine sight shield.

4. Remove the air cleaner assembly along with the air cleaner outlet duct. Refer to Air Cleaner Assembly Replacement Air Cleaner Assembly Replacement and Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

5. Remove the positive crankcase ventilation pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Service and Repair.

6. Remove the intake manifold. Refer to Intake Manifold Replacement Service and Repair.

7. Remove the turbocharger. Refer to Turbocharger Replacement Service and Repair.




8. Remove the engine control module wiring harness (1) from camshaft cover:

* Disconnect the intake camshaft position sensor wiring harness plug (7).

* Disconnect the intake camshaft position actuator solenoid valve wiring harness plug (6).

* Disconnect the exhaust camshaft position sensor wiring harness plug (4).

* Disconnect the exhaust camshaft position actuator solenoid valve wiring harness plug (5).

* Disconnect the engine coolant temperature sensor wiring harness plug (3).




9. Place a drain pan underneath the vehicle.

10. Remove the oil cooler inlet hose clamp and the oil cooler inlet hose (1).

11. Remove the radiator inlet hose clamp and the radiator inlet hose (4).

12. Remove the engine coolant air bleed hose (2).

13. Disconnect the engine coolant temperature sensor wiring harness plug (3).

14. Remove the heater inlet hose from the water outlet. Refer to Heater Inlet Hose Replacement (1.8L LUW and LWE) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (1.4L LUV) Heater Inlet Hose Replacement.




15. Remove the ground cable bolt (2) and the ground cable (1).




16. Unclip the radiator outlet hose quick connector clamp (2).

17. Remove the radiator outlet hose (3) from the engine coolant thermostat housing (1).

18. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side Engine Mount Bracket Replacement - Right Side.

19. Remove the drive belt. Refer to Drive Belt Replacement Service and Repair.

20. Remove the water pump pulley. Refer to Water Pump Pulley Removal Water Pump Pulley Removal.




21. Remove 5 engine front cover bolts (1, 2).

22. Remove 3 water pump bolts (3).

23. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side Engine Mount Bracket Replacement - Right Side.

24. Install the engine mount. Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.

25. Remove the ignition coil. Refer to Ignition Coil Replacement Service and Repair.

26. Remove the camshaft cover. Refer to Camshaft Cover Replacement Service and Repair.

27. Set engine to TDC. Refer to Camshaft Timing Chain Adjustment Camshaft Timing Chain Adjustment.

28. Remove the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Removal Camshaft Position Actuator Solenoid Valve Removal.




29. Remove the timing chain tensioner plug (1) from the engine front cover.





Note: Remove and reinstall the EN-953-A - fixing tool for this step.

30. Install a wrench (1) to the hexagon of the intake camshaft and rotate it in direction of the arrow to apply tension to the timing chain and hold.




31. Install EN-955-10 - pin (2) to the timing chain tensioner bore (1) to secure it in place.

32. Remove the wrench from the intake camshaft.




33. Remove 2 upper timing chain guide bolts (1).

34. Remove upper timing chain guide (2).




35. Loosen the intake camshaft sprocket bolt (2) while holding the hexagon of intake camshaft sprocket with a wrench (1).

36. Loosen the exhaust camshaft sprocket bolt while holding with a wrench.




37. Remove the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1).




38. Remove the 2 camshaft sprockets (2) along with the timing chain (1) and place it in the engine front cover.




39. Loosen the 12 cylinder head bolts in the sequence as shown. Use the following procedure:

1. Loosen the cylinder head bolts 90°.

2. Loosen the cylinder head bolts 180°.

40. Remove and DISCARD the 12 cylinder head bolts.

41. Move the cylinder head assembly slightly in direction of the transmission.

Note: Mind the timing chain tensioner and the timing chain guide pin.

Note: A second technician is required.

42. Remove the cylinder head assembly.

43. Remove the cylinder head gasket.

44. Remove the assembly parts from cylinder head:

* Remove the EN-953-A - fixing tool.

* Remove the engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing Removal Engine Coolant Thermostat Housing Removal.

* Remove the water outlet. Refer to Water Outlet Removal Water Outlet Removal.

* Remove the intake camshaft. Refer to Intake Camshaft Removal Intake Camshaft Removal.

* Remove exhaust camshaft. Refer to Exhaust Camshaft Removal Exhaust Camshaft Removal.

* Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Removal Hydraulic Valve Lash Adjuster Arm Removal.

* Remove the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Removal Hydraulic Valve Lash Adjuster Removal.

* Remove the 3 engine lift brackets.

Installation Procedure

1. Install the cylinder head assembly parts:

* Install the 3 engine lift brackets.

Caution: Refer to Fastener Caution Fastener Caution.

* Install the 3 engine lift bracket bolts and tighten to 22 Nm (16 lb ft).

* Install the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Installation Hydraulic Valve Lash Adjuster Installation.

* Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Installation Hydraulic Valve Lash Adjuster Arm Installation.

* Install the exhaust camshaft. Refer to Exhaust Camshaft Installation Exhaust Camshaft Installation.

* Install the intake camshaft. Refer to Intake Camshaft Installation Intake Camshaft Installation.

* Install the water outlet. Refer to Water Outlet Installation Water Outlet Installation.

* Install the engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing Installation Engine Coolant Thermostat Housing Installation.

Note: Adjust the camshafts using the hexagon and a wrench.

* Install the EN-953-A - fixing tool.




2. Cut the 2 elastomer sealing lips (1) from engine front cover gasket.

3. Bend down the engine front cover gasket at the predetermined breaking points (arrows).

4. Clean sealing surfaces of engine front cover and engine block from grease and old gasket material.

5. Inspect cylinder block and cylinder head for flatness. Refer to Cylinder Head Cleaning and Inspection Cylinder Head Cleaning and Inspection and Engine Block Cleaning and Inspection Engine Block Cleaning and Inspection.





Note: The thickness of the sealing bead should be 2 mm (0.0787 in).

6. Apply sealing compound to the shown areas (1). Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers.

Note: Mind the marking on the cylinder head gasket for top side.

7. Install the cylinder head gasket to engine block.




8. Install 2 engine front cover bolts (1) in order to guide the NEW upper engine front cover gasket.

9. Install the NEW upper engine front cover gasket.

10. Apply sealing compound to the shown areas (2). The thickness of the sealing bead should be 2 mm (0.0787 in).





Note: A second technician is required. Guide the timing chain guide pin (2) to the timing chain guide and the timing chain tensioner (1) with the installed fixing pin through the timing chain tensioner plug bore in engine front cover.

11. Install the cylinder head (3).

12. Loosely install 12 NEW cylinder head bolts.




13. Adjust the cylinder head to the engine front cover. Use a rubber mallet.

14. Locate the engine front cover to cylinder head by installing 3 bolts (1).

15. Tighten the 3 bolts (1) to 8 Nm (71 lb in).





Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

16. Tighten the cylinder head bolts in the sequence as shown and in the following order:

1. Tighten the cylinder head bolts to 35 Nm (26 lb ft).

2. Tighten the cylinder head bolts an additional 180°. Use EN-470-B - wrench.

17. Loosen the 3 bolts from engine front cover.




18. Install the 5 remaining bolts to engine front cover and water pump.

19. Tighten the 5 engine front cover bolts (1, 2) to 8 Nm (71 lb in).

20. Tighten the 3 water pump bolts (3) to 8 Nm (71 lb in).

21. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side Engine Mount Bracket Replacement - Right Side.

22. Install the water pump pulley. Refer to Water Pump Pulley Installation Water Pump Pulley Installation.

23. Install the drive belt. Refer to Drive Belt Replacement Service and Repair.

24. Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side Engine Mount Bracket Replacement - Right Side.

25. Install the engine mount. Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.




26. Install the 2 camshaft sprockets (2) along with the timing chain (1).





Note: Camshaft position exciter wheels should stay rotatable.

27. Install the 2 camshaft position exciter wheels (1) and the 2 camshaft sprocket bolts (2).

28. Adjust engine to TDC and tighten the camshaft sprockets and install upper timing chain tensioner guide. Refer to Camshaft Timing Chain Adjustment Camshaft Timing Chain Adjustment.

29. Rotate the crankshaft for 720° and check the engine timing again. Repeat the adjustment procedure if necessary.

30. Remove all special tools for timing chain adjustment and install and tighten the timing chain tensioner plug. Refer to Camshaft Timing Chain Adjustment Camshaft Timing Chain Adjustment.

31. Install the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Installation Camshaft Position Actuator Solenoid Valve Installation.

32. Install the camshaft cover. Refer to Camshaft Cover Replacement Service and Repair.

33. Install the ignition coil and connect the ignition coil wiring harness plug. Refer to Ignition Coil Replacement Service and Repair.




34. Connect radiator outlet hose (3) to engine coolant thermostat housing (1). Clip quick connector (2).




35. Install the ground cable (1) and the ground cable bolt (2) and tighten to 20 Nm (15 lb ft).




36. Install the radiator inlet hose (4) and the radiator inlet hose clamp to the water outlet.

37. Install the oil cooler inlet hose (1) and the oil cooler inlet hose clamp to the water outlet.

38. Connect the engine coolant air bleed hose (2) to the water outlet.

39. Connect the engine coolant temperature sensor wiring harness plug (3).

40. Install the heater inlet hose to the water outlet. Refer to Heater Inlet Hose Replacement (1.8L LUW and LWE) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (1.4L LUV) Heater Inlet Hose Replacement.




41. Install the engine control module wiring harness to the camshaft cover:

* Connect the engine coolant temperature sensor wiring harness plug (3).

* Connect the exhaust camshaft position actuator solenoid valve wiring harness plug (5).

* Connect the exhaust camshaft position sensor wiring harness plug (4).

* Connect the intake camshaft position actuator solenoid valve wiring harness plug (6).

* Connect the intake camshaft position sensor wiring harness plug (7).

42. Install the turbocharger. Refer to Turbocharger Replacement Service and Repair.

43. Install the intake manifold. Refer to Intake Manifold Replacement Service and Repair.

44. Install the air cleaner assembly in compound with the air cleaner outlet duct. Refer to Air Cleaner Assembly Replacement Air Cleaner Assembly Replacement and Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

45. Install the engine sight shield.

46. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

47. Fill coolant fluid. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE-47716 Fill) Cooling System Draining and Filling (GE-47716 Fill).

48. Check and correct engine oil.

49. Close the hood.