Cylinder Head Replacement - Rear
Cylinder Head Replacement (Rear)^ Tools Required
- SA9140E Torque Angle Gage
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the intake plenum.
3. Remove the intake air resonator.
4. Remove the intake manifold.
5. Remove the intake manifold spacer bolts.
6. Remove the intake manifold spacer.
7. Remove the coolant bridge.
8. Remove the engine ventilation chamber.
9. Remove the rear camshaft cover.
10. Remove the front timing belt cover.
11. Remove the timing belt.
12. Remove the timing belt tensioner bracket.
13. Remove all 4 camshaft gears.
14. Remove the rear timing belt cover.
15. Remove the exhaust manifold pipe heat shield.
Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.
16. Raise the vehicle on a hoist.
Notice: Avoid excessive movement of the pipe.
17. Remove the front exhaust manifold pipe to rear exhaust manifold pipe fasteners.
18. Remove the rear exhaust manifold pipe to exhaust manifold pipe nuts.
19. Pull down the rear exhaust manifold pipe just enough to remove the gasket.
20. Remove the old gasket and discard.
21. Drain the coolant.
22. Lower the vehicle.
23. Remove the EGR to exhaust manifold pipe.
Important: The intake camshaft is marked with the letter A and the exhaust camshaft is marked with the letter E.
24. Remove the exhaust camshaft.
Important: Use the loosening sequence to remove the cylinder head.
25. Remove the cylinder head bolts.
26. Remove the cylinder head.
27. Remove the cylinder head gasket.
28. Remove the exhaust manifold.
Important: It is not necessary to remove the intake camshaft for head bolt access.
29. Clean and inspect the cylinder head and sealing surfaces.
Installation Procedure
Notice: Refer to Fastener Notice in Service precautions.
1. Install the rear exhaust manifold to the cylinder head.
^ Tighten the exhaust manifold nut to 20 Nm (15 ft. lbs.).
2. Install the new cylinder head gasket with the part number imprint toward the top of the engine.
3. Install the cylinder head to engine block ensuring the adequate clearance from all wires, components, etc.
Important: Use the new cylinder head bolts. The required tightening method stretches the bolts to their yield point. Therefore the cylinder head bolts are not reusable.
Important: Use the SA9140E and the proper tightening sequence to tighten the cylinder head bolts in stages.
4. Install the new cylinder head bolts.
^ Tighten the cylinder head bolt to 25 Nm (18 ft. lbs.) plus 90° plus 90° plus 90° plus 15°.
5. Install the exhaust camshaft.
6. Install the rear timing belt cover.
7. Install all 4 camshaft gears.
8. Install the timing belt tensioner bracket.
9. Install the timing belt.
10. Install the front timing belt cover.
11. Install the rear camshaft cover.
12. Install the coolant bridge and new coolant bridge seals.
13. Apply sealing compound LOCTITE 518, or equivalent, to the sealing surface.
^ Tighten the coolant bridge bolts to 30 Nm (22 ft. lbs.).
14. Install the engine ventilation chamber.
^ Tighten the engine ventilation chamber bolts to 8 Nm (71 inch lbs.).
15. Install the intake manifold spacer.
16. Install the intake manifold spacer bolts, and apply LOCTITE 242 to the bolts.
17. Tighten the intake manifold spacer bolts in a spiral direction, starting from the inside and working outward.
^ Tighten the intake manifold spacer bolt to 20 Nm (15 ft. lbs.).
18. Install the intake manifold.
19. Install the intake plenum.
20. Install the intake air cleaner.
21. Refill the coolant.
22. Connect the negative battery cable.
^ Tighten the battery terminal bolts to 17 Nm (13 ft. lbs.).
23. Install the EGR to exhaust manifold pipe.
^ Tighten the EGR pipe bolts to 25 Nm (18 ft. lbs.).
24. Raise the vehicle.
25. Install the exhaust manifold pipe gasket and assembly.
26. Install the exhaust manifold pipe nuts.
^ Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 Nm (25 ft. lbs.).
27. Lower the vehicle.
28. Start the vehicle and inspect for exhaust leaks.