Cylinder Head, Removal and Installation
Cylinder head, removing and installing
WARNING!
^ DO NOT re-use fasteners that are worn or deformed in normal use.
^ Some fasteners are designed to be used only once, and are unreliable and may fail the second time. This includes, but is not limited to nuts, bolts, washers, circlips and coffer pins. Always follow the recommendations, replace these fasteners with new parts where indicated and any other time when deemed necessary by inspection.
^ To prevent contact corrosion, use only approved nuts, bolts and washers, etc. These fasteners have a special coating and are identified by green coloring.
CAUTION! After installing hydraulic lifters, do not start the engine for about 30 minutes, otherwise the valves will strike pistons. Turn the crankshaft two complete revolutions by hand before starting engine.
Note: Cylinder heads with cracks between valve seats or between valve seat inserts and spark plug threads can continue to be used without reduced service life, if cracks are not wider than 0.3 mm (0.012 inch) or when no more than 4 turns of the spark plug threads are cracked.
Cylinder head cover, left
Removing
^ Remove engine cover panel -arrows-.
^ Remove cover -2-.
^ Remove coolant expansion tank-arrows-.
^ Disconnect connector for coolant level sensor and set expansion tank aside.
^ Remove hose -1-.
^ Remove hose -2-.
^ Remove bracket -3-.
^ Disconnect connectors -4- from ignition coils.
^ Remove ignition coils -5-.
^ Remove cylinder head cover.
Installing
Install cylinder head cover in reverse order of removal but note the following:
Note:
^ Replace cylinder head cover gaskets if damaged.
^ Apply a small amount of sealant D545300A2 to sealing points -arrows on upper surface of cylinder head.
CAUTION! Part numbers are listed here for reference only. Always check with your Parts department for the latest information.
^ Tighten bolts for cylinder head cover crosswise and in sequence shown.
Cylinder Head Cover To Cylinder Head 10 Nm (7 ft. lbs.)
Ignition Coil To Cylinder Head Cover 10 Nm (7 ft. lbs.)
Right cylinder head cover
Removing
^ Remove engine cover panel -arrows-.
^ Remove cover -1-.
^ Remove intake air duct for air cleaner.
^ Disconnect fuel supply and fuel return lines-1-.
^ Disconnect hose -2-.
^ Disconnect connectors -1- from ignition coils.
^ Remove bracket -2-.
^ Remove ignition coils -3-.
^ Disconnect crankcase breather hose.
^ Remove cylinder head cover.
Installing
Install cylinder head in reverse order of removal but note the following:
Note: Replace cylinder head cover gaskets if damaged.
^ Apply a small amount of sealant D 545 300 A2 to sealing points -arrows- on sealing surface of cylinder head.
^ Tighten cylinder cover according to number sequence in illustration.
Cylinder Head Cover To Cylinder Head 10 Nm (7 ft. lbs.)
Ignition Coil To Cylinder Head Cover 10 Nm (7 ft. lbs.)
Cylinder head, left,
Removing
CAUTION!
^ DO NOT re-use fasteners that are worn or deformed in normal use.
^ Some fasteners are designed to be used only once and are unreliable and may fail the second time. This includes, but is not limited to nuts, bolts, washers, circlips and coffer pins. Always follow the recommendations - replace these fasteners with new parts where indicated and any other time when deemed necessary by inspection.
^ To prevent contact corrosion, use only approved nuts, bolts and washers, etc. These fasteners have a special coating and are identified by green coloring.
Note:
^ Secure all hose connections with original equipment hose clamps.
^ Always replace opened or cut ties wraps in the same position when installing.
^ Replace cylinder Headbeats.
^ Replace seals, gaskets, self-locking nuts and bolts which have specified tightening instructions
^ When installing a new cylinder head or cylinder head gasket, drain all old coolant and re-fill with new coolant, Refer to Cooling System.
^ Unbolt guide tube for oil dipstick from cylinder head.
^ Remove engine cover -arrows-.
^ Remove cylinder head covers -1- and -2-.
^ Remove intake air duct for air cleaner.
WARNING!
^ Fire hazard! Do not have anything in the area that can ignite fuel or fumes.
^ Clean fuel connections and cover with rag to catch fuel spray.
^ Disconnect fuel supply and return lines -1-.
^ Disconnect hose -2-.
^ Remove upper bolt between exhaust manifold and exhaust pipe.
^ Disconnect connector for left oxygen sensor-arrow- and move wiring aside.
^ Disconnect connector -2- for oxygen sensor and free wiring to oxygen sensor.
^ From below remove bolts -arrows- between exhaust manifold and exhaust pipe.
^ Remove exhaust pipe from retainer -arrow-.
^ Loosen double clamp -1- and move it forward.
^ Carefully remove exhaust pipe.
CAUTION! DO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.
^ Remove toothed belt guard.
^ Disconnect connector -2-.
^ Disconnect connector -3-.
^ Remove toothed belt from camshafts.
^ Remove camshaft sprocket for cylinder bank 5-8.
^ Loosen bolts -1-.
^ Remove bolts -2- and remove toothed belt cover.
^ Disconnect hose -1-.
^ Remove bolts -2-.
^ Disconnect connector -3-.
^ move bolt -4- and remove oil pipe.
^ Remove bolts -5- and take out combination valve.
^ Remove coolant line -arrows-.
^ Disconnect hose -1-.
^ Disconnect hose -2-.
^ Remove bracket -3-.
^ Disconnect connectors -4- from ignition coils.
^ Remove ignition coils -5-.
^ Disconnect connector -6-.
^ Remove cylinder head cover.
^ Disconnect connector -1- for knock sensor, cylinder bank 5-8.
^ Disconnect connectors -arrows- from injectors, cylinder bank 5-8, and move wiring harness clear.
^ Disconnect connector for knock sensor, cylinder bank 1-4.
^ Disconnect connectors from injectors, cylinder bank 1-4.
^ Disconnect connector -1-.
^ Disconnect hose -2-.
^ Remove bolts -8-.
^ Disconnect connector -9-.
^ Remove coolant pipe.
^ Remove intake manifold.
^ Loosen cylinder head bolts in sequence shown.
^ Remove cylinder head and place on suitable soft surface.
Cylinder head, right, removing
Note:
^ Secure all hose connections with correct hose clips (same as original equipment) Parts catalog
^ Replace all cable ties, which are opened or cut during removing in the same position when installing.
^ Replace cylinder headbeats.
^ Always replace seals, gaskets, self locking nuts and bolts with specified tightening instructions.
^ When installing a new cylinder head or cylinder head gasket, drain all old coolant and re-fill with new coolant.
CAUTION! Always dispose of old coolant properly.
^ Drain coolant.
^ Remove engine cover -arrows-.
^ Remove cylinder head covers -1- and -2-.
^ Remove intake air duct between air cleaner and throttle body.
WARNING!
^ Fire hazard! Do not have anything in the area that can ignite fuel or fumes
^ Clean fuel connections and cover with rag to catch fuel spray.
^ Disconnect fuel supply and return lines -1-.
^ Disconnect hose -2-.
^ Remove engine cover-arrows-
^ Remove cylinder head covers -1- and -2-.
^ Remove intake air duct to air cleaner.
WARNING! Fire hazard! Keep away anything that could ignite fuel or fumes. Clean connections before disconnecting. Cover with rag while disconnecting to prevent fuel spray.
^ Disconnect fuel supply and return lines -1-.
^ Disconnect hose -2
^ Remove upper bolt between exhaust pipe and exhaust manifold.
^ Disconnect connector for oxygen sensor at left -arrow- and free wiring.
^ Disconnect connector -2- for oxygen sensor after Three Way Catalytic (TWC) converter and free wiring down to oxygen sensor.
^ Remove toothed belt guard.
^ Disconnect connector -1- from Camshaft Position (CMP) sensor.
^ Disconnect connector -2-.
^ Disconnect connector -3-.
^ Remove toothed belt from camshafts.
^ Remove idler wheel -1-.
^ Remove toothed belt cover -arrows-.
^ Disconnect connectors -1- from ignition coils.
^ Remove bracket -2-.
^ Remove ignition coils -3-.
^ Disconnect crankcase breather hose.
^ Remove cylinder head cover.
^ Disconnect connector -1- for oxygen sensor for cylinder bank 5-8.
^ Disconnect connectors -arrow- from fuel injectors of cylinder bank 5-8 and move wiring aside.
^ Disconnect connector for knock sensor for cylinder bank 1-4.
^ Disconnect connectors from fuel injectors of cylinder bank 1-4.
^ Remove coolant line -arrows-.
^ Remove hose-2-.
^ Disconnect connector -1-.
^ Remove bracket -3-.
^ Disconnect connector -4-.
^ Disconnect ground cable -5- from cylinder head.
^ Remove bolts -6-.
^ Disconnect hose -7- from combination valve.
^ Remove bolts -8-.
^ Disconnect connector -9-.
^ Remove coolant line.
^ Remove intake manifold.
^ Loosen cylinder head bolt in numerical sequence.
^ Remove cylinder head and place on soft surface.
Cylinder head, installing
CAUTION!
^ DO NOT re-use fasteners that are worn or deformed in normal use.
^ Some fasteners are designed to be used only once and are unreliable and may fail the second time. This includes, but is not limited to nuts, bolts, washers, circlips and coffer pins. Always follow the recommendations in this manual - replace these fasteners with new parts where indicated and any other time when deemed necessary by inspection.
^ To prevent contact corrosion, use only approved nuts, bolts and washers) etc. These fasteners have a special coating and are identified by green coloring.
Note:
^ Replace cylinder head bolts.
^ Remove old sealer carefully to avoid long scratches.
^ Remove all grinding compound.
^ Remove all oil or coolant from cylinder head bolt holes in crankcase.
^ Handle gaskets carefully. Damage to silicone can cause leaks.
^ Place cylinder head gasket on spacer sleeves. Marking on gasket "Oben" (top) or part number must face cylinder head.
^ After repairs do not start engine before turning crankshaft carefully for two full turns to avoid valves from contacting pistons.
Install cylinder head in reverse order of removal but note the following:
Identification markings on cylinder head gasket. "Oben" (top) or part number must face cylinder head.
^ Install cylinder head.
^ Insert cylinder head bolts and tighten by hand.
^ Tighten cylinder head bolts in four stages in sequence shown as follows:
- Tighten with torque wrench:
1st stage: 35 Nm (26 ft. lbs.)
2nd stage: 60 Nm (44 ft. lbs.)
- Tighten with normal fixed wrench:
3rd stage: 1/4 turn (90°) further
4th stage: 1/4 turn (90°) further
Note: It is not necessary to re-tighten cylinder head bolts after repairs have been performed.
^ To replace gaskets for intake manifold, remove bolts -1-.
Tightening torque 0.6 Nm (5 inch lbs.).
Locating stud for intake manifold -2-; tightening torque 7 Nm (62 inch lbs.).
Note: Replace cylinder head cover gaskets if damaged.
^ Apply a small amount of sealant D545300A2 to sealing points -arrows on upper surface of cylinder head.
^ Tighten bolts for cylinder head cover crosswise and in stages.
^ Install toothed belt on camshafts.
^ Relieving tension in exhaust system.
CAUTION! Part numbers are listed here for reference only. Always check with your Parts department for the latest information.
^ Tighten cylinder head bolts in sequence shown.
Tightening torques
Dipstick Guide Tube To Cylinder Head 10 Nm (7 ft. lbs.)
Toothed Belt Guard To Cylinder Head 10 Nm (7 ft. lbs.)
Front Coolant Pipe To Cylinder Head 10 Nm (7 ft. lbs.)
Cylinder Head Cover To Cylinder Head 10 Nm (7 ft. lbs.)
Intake Manifold To Cylinder Head 10 Nm (7 ft. lbs.)
Ignition Coil To Cylinder Head 10 Nm (7 ft. lbs.)
Combination Valve To Cylinder Head 8 Nm (71 inch lbs.)
Locating Stud For Intake Manifold 7 Nm (62 inch lbs.)
Locating Bolt For Intake Manifold Gasket 0.6 Nm (5 inch lbs.)
Exhaust Pipe With Catalytic Converter To Exhaust Retainer 25 Nm (18 ft. lbs.)
Exhaust Pipe With Catalytic Converter To Exhaust Manifold 25 Nm (18 ft. lbs.)
Double Clamp For Exhaust Pipe 40 Nm (29 ft. lbs.)