Cylinder head — removal and installation

Special tool

	Universal Flange Holding Wrench 205-072 (15-030A)
	Socket wrench for cylinder head bolts 303-392 (21-167)
	Hose Clamp Remover/Installer 303-397 (24-003)

General equipment: Rolling jack.

Removal

WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.

1. Remove the intake manifold. For more information, refer to the Intake Manifold chapter in this section.

2. Remove the cylinder head cover. For more information, refer to the Cylinder Head Cover chapter in this section.

3. Drain the coolant from the cooling system. Refer to Section 303-03 for additional information.

4.

CAUTION: The crankshaft must be turned in the normal direction of rotation.

NOTE: The camshaft sprocket timing mark must be at the 12 o'clock position.

NOTE: Mark the position of the timing chain.

Turn the engine over until piston No.1 reaches the top dead center (TDC) position.




5. Remove the exhaust manifold heat shield (engine shown removed for clarity).



6. Remove the hydraulic timing chain tensioner.



7. Disconnect the oil level indicator dipstick tube from the cylinder head.



8. Raise and support the vehicle. Refer to Section 100-02 for additional information.


9. Remove the exhaust manifold (the engine is shown removed for clarity).

• Loosen the nuts in the order shown.
• Discard the gasket as it is no longer needed.

10. Lower the vehicle.

11. Using the special tool, disconnect the coolant hoses from the coolant circulation control unit.



12. Using the special tool, disconnect the coolant hose from the coolant line.



13. Using the special tool, disconnect the coolant hose from the expansion tank of the cooling system.




14. Disconnect the coolant hose from the panel with the opening for the radiator grille.



15. Remove the expansion tank.



16. Disconnect the power steering fluid reservoir and place it aside.



17. Disconnect the coolant line from the front engine mount.




18. Using a trolley jack, support the engine assembly with the gearbox in the block with the drive axle.

19. Remove the front engine mount.



20. Remove the front engine mount bracket mounting bolt.



21.

NOTE: Using a suitable piece of wire, tie the timing chain to prevent it from falling into the cylinder block.

Using a special tool, remove the camshaft sprocket.



22.

NOTE: Loosen the cylinder head bolts in the sequence shown.

Using a special tool, remove the cylinder head.

• Route the timing chain through the cylinder head and tie it to the cylinder block.
• Discard the gasket as it is no longer needed.
• Discard the cylinder head mounting bolts as they are no longer needed.

Installation

1.

NOTE: Install new cylinder head bolts.

NOTE: Install a new cylinder head gasket.

NOTE: Route the timing chain through the cylinder head and tie it to the cylinder head.

Using a special tool, install the cylinder head.

• Tighten the cylinder head bolts in the sequence shown in four stages.
• Stage 1: Tighten bolts 1 through 10 to 40 Nm.
• Step 2: Tighten the front two bolts (M8) to 15 Nm.
• Step 3: Tighten the front two bolts (M8) 45 degrees.
• Step 4: Turn bolts 1 through 10 120 degrees.

2.

NOTE: The camshaft sprocket timing mark must be at the 12 o'clock position.

NOTE: The camshaft sprocket timing mark and the marked timing chain links must be aligned with each other.

Install the camshaft sprocket and timing chain.



3. Using the special tool, tighten the camshaft sprocket mounting bolt.



4. Install the front engine mount bracket mounting bolt.



5. Install the front engine mount.



6. Remove the trolley jack.

7. Connect the coolant line to the front engine mount.



8. Secure the power steering fluid reservoir to the wheel arch.



9. Install the expansion tank of the cooling system.



10. Connect the coolant hose to the panel with the opening for the radiator grille.



11. Using the special tool, connect the coolant hose to the expansion tank of the cooling system.



12. Using the special tool, connect the coolant hose to the coolant line.



13. Using the special tool, connect the coolant hoses to the coolant circulation control unit.



14. Raise and support the vehicle. Refer to Section 100-02 for additional information.

15.

NOTE: Install a new exhaust manifold gasket.

Install the exhaust manifold (engine shown removed for clarity).

• Tighten the nuts in the sequence shown in two stages.
• Stage 1: 15 Nm
• Stage 2: 20 Nm

16. Lower the vehicle.

17. Connect the oil level indicator tube to the cylinder head.



18. Install the hydraulic timing chain tensioner.



19. Install the exhaust manifold heat shield (engine shown removed for clarity).



20. Install the cylinder head cover. For more information, refer to the Cylinder Head Cover chapter in this section.

21. Install the intake manifold. For more information, refer to the Intake Manifold chapter in this section.

22. Fill the cooling system with coolant and bleed the system. Refer to Section 303-03 for additional information.