Cylinder Head Assembly: Service and Repair
Cylinder Head
Removal
1. General remarks.
^ The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine.
^ If necessary, use Special Tool 412-108 to remove coolant and ventilation hoses.
^ Owing to special model variants, some steps do not apply to all vehicles. These are clearly marked in the text.
2. Release the fuel pressure.
3. CAUTION: Disconnect the battery negative cable.
If necessary, separate cable ties and install on installation.
4. WARNING: To prevent the risk of scalding, place a thick cloth over the filler cap before opening the cooling circuit. Failure to do so may result in personal injury.
Open the coolant reservoir.
5. Raise the vehicle.
6. WARNING: Danger of scalding if the engine is warm.
Drain the coolant from the radiator.
^ Install the radiator drain plug after draining the coolant.
7. Detach the brake booster pipe from the intake manifold.
^ Release the quick release coupling and pull out the brake booster pipe.
8. Disconnect the oil pressure switch connector.
9. Lower the vehicle.
10. Remove the air cleaner housing.
1. Pull out the plug of the mass air flow (MAP) sensor.
2. Detach the PCV hose.
3. Detach the intake hose.
^ Remove the air cleaner housing from the rubber bushings
11. Detach the accelerator cable and the speed control cable (if equipped).
1. Unhook the cable.
2. Pull off the plastic clip and lay the accelerator cable to one side.
12. Detach the EGR valve and EGR pipe bracket.
13. Pull off the vacuum hoses.
14. Disconnect the fuel injector wiring.
15. Disconnect the camshaft position (CMP) sensor.
16. WARNING: Escaping fuel. Observe the safety regulations for working with fuel.
Detach the fuel lines.
^ Detach the ground cable.
17. Detach the heat shield.
18. Detach the thermostat housing.
19. Detach the catalytic converter from the exhaust manifold.
20. Detach the power steering pipe bracket and the oil level indicator tube.
21. Detach the bracket from the power steering pump.
1. Remove the lower studs.
2. Remove the upper bolts
22. Detach the generator.
1. Loosen the bolt.
2. Remove the bolt.
23. Unscrew the upper bolt from the generator bracket.
24. Remove the timing belt.
25. NOTE: Loosening sequence.
Unscrew the bolts of the camshaft bearing caps evenly in several stages two turns at a time.
^ Remove the oil seals.
^ Remove the camshafts.
^ Remove the tappets and keep them in order.
26. CAUTION: Mark the bolts to be reused with one or two punch marks. Bolts can be reused twice. Discard bolts as necessary.
CAUTION: The cylinder head must be cooled to ambient temperature.
NOTE: Loosening sequence
Remove the cylinder head bolts.
27. Remove the cylinder head.
Installation
1. General remarks.
^ If necessary, use Special Tool 412-108 to install coolant and ventilation hoses.
2. Preparatory operations
CAUTION: Do not damage the cylinder liner surfaces. Remove carbon deposits from the top edge of the cylinder.
^ Remove gasket residue with seal remover and a spatula.
^ Thoroughly clean the threaded holes of the cylinder head bolts.
3. Check the cylinder head deformation.
4. Make up two locating studs as shown.
5. Install a new cylinder head cover gasket on the cylinder block.
1. Position a new cylinder head gasket.
2. Insert the fabricated locating studs.
3. Check that the locating studs are seated correctly.
6. Install the cylinder head. Position the cylinder head on the cylinder block.
7. CAUTION: Do not retighten the cylinder head bolts.
Cylinder Head Torque Sequence:
Tighten the cylinder head bolts in three stages in the sequence indicated.
^ Stage 1: 20 Nm
^ Stage 2: 40 Nm
^ Stage 3: 90 degrees.
^ Apply engine oil to the tappets and insert them.
8. Apply sealant to camshaft bearing cap numbers 0 and 5 in the areas shown.
9. Turn the crankshaft to approximately 60 degrees before TDC on cylinder number 1.
10. NOTE: Identification numbers are provided on the outer face of the camshaft bearing caps.
Lay the camshaft in place so that none of the cams is at full lift.
^ Lubricate the camshaft and camshaft bearing caps with engine oil.
11. NOTE: Screw in the camshaft bearing cap bolts evenly in several stages, in the sequence shown, a half turn at a time and tighten them in two stages.
Tighten the bolts of the camshaft bearing caps.
^ Stage 1: 10 Nm
^ Stage 2:.19 Nm
12. Install the camshaft oil seals.
^ Lubricate the camshaft and oil seal lip with engine oil.
^ Using the special tool install a new oil seal.
NOTE: Do not tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts.
^ Attach the timing belt pulleys.
13. Install the timing belt.
14. Lower the vehicle.
15. Attach the power steering pump bracket.
1. Screw in the upper bolts.
2. Insert the lower studs.
^ Tighten the bolts and nuts.
16. Install the upper bolt to the generator bracket.
17. Attach the generator.
18. Attach the oil level indicator tube and the power steering pipe bracket.
19. Attach the catalytic converter to the exhaust manifold.
20. Attach the thermostat housing with new gasket.
21. Attach the heat shield.
22. Attach the fuel lines.
23. Connect the camshaft position (CMP) sensor.
24. Connect the fuel injector wiring.
25. Attach the EGR valve with a new gasket and EGR pipe bracket.
26. Attach the accelerator cable and the speed control cable (if equipped).
27. Push on the vacuum hoses.
28. Attach the air filter housing. Press the air filter housing into the rubber bushings.
1. Push on the mass air flow (MAP) sensor multiplug.
2. Attach the PCV hose.
3. Attach the intake hare
29. Raise and support the vehicle.
30. Push on the oil pressure switch electrical connector
31. Attach the brake booster pipe and the PCV hose to the intake manifold.
32. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Standard finishing operations
^ Connect the battery negative cable.
^ Top up the coolant.
^ Close the coolant expansion tank.
^ Check fluid levels and correct if necessary.
^ Check the routing of vacuum hoses and cables and secure them with cable ties.
^ Check fluid levels again and correct if necessary.
NOTE: The engine oil temperature must be at least 80°C.
^ Change the engine oil and the oil filter.