Cylinder Head/Gasket, Replacing

Cylinder head/gasket, replacing

Note! Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Note! There are a number of versions of the VVT-unit. Therefore, it is very important to always read the information referring to the engine variant/model year to be worked on.

Removal

Preparation

Remove:
- the radiator breather tube from the expansion tank. Install lock grip pliers
- the cap from the expansion tank
- the battery negative lead. First read Battery, disconnecting Battery Disconnecting
- the right front wheel
- the plastic nuts on the cover at the right fender liner.

Removing the three-way catalytic converter (TWC)

Remove:
- the cross stay between the suspension turrets
- the preheating hose between the heat deflector plate and the air cleaner (ACL)
- the front heated oxygen sensor (HO2S) wiring from the clips and clamps. Disconnect the wiring
- the upper heat deflector plate
- the nuts for the exhaust manifold.

Hint: Use rust solvent or similar on the studs.

Raise the car.

Remove:
- the front SIPS member
- unhook the exhaust system from the rubber mounting
- the screw in the support bracket for the exhaust manifold. Unhook the exhaust manifold from the cylinder head.

Draining the coolant

Raise the car. Remove the splash guard from under the engine.
Open the engine nipple.
Drain the coolant into a clean container.
Close the nipple.

Removing components

Remove:
- the intake hose between the mass air flow (MAF) sensor and the electronic throttle module (ETM)
- the cover over the ignition coils
- the upper timing cover.

Note! Mark up the ignition coils before removal.

Remove:
- the ground strip between the cylinder head and the firewall
- the upper and lower engine stabilizer brace
- the camshaft position sensor (CMP) housing and trigger wheel
- the mounting screws for the ignition coil and the screws for the two ground terminals
- disconnect the connector for the variable valve timing solenoid. Lift up and put the ignition coils and wiring to one side.

Draining the fuel line

Drain the fuel line. See Fuel system pressure release Service and Repair.

Removing the intake manifold

Remove:
- the crankcase ventilation hose from the top of the cam cover
- the protective cover over the injector connectors.

Disconnect the connectors from:
- the injectors
- the manifold absolute pressure (MAP) sensor in the fuel line
- the temperature sensor in the thermostat housing. Place the wiring to one side.

- Remove the mounting screws from the fuel rail
- Spray universal oil or similar around the injector nozzle at the terminal on the intake manifold
- Gently work the fuel rail and injector nozzles loose
- Separate the quick-release fuel line connector by pressing the blue clips on both sides. See Fuel line, lock Service and Repair.

Remove
- all 4 vacuum hoses from the intake pipe. (see the illustration). Disconnect the connector on the Positive temperature coefficient (PTC) nipple for crankcase ventilation (5).

Remove:
- the screw holding the dip stick pipe to the intake manifold
- the clip for the servo pressure pipe
- the screw at the support bracket (under the intake manifold). Disconnect the connector for the electronic throttle module (ETM)
- unscrew the four upper screws completely. Slacken off the lower screws a few turns
- the intake manifold. Lift the intake manifold approximately 20 mm. Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap
- the hose on the Positive temperature coefficient (PTC) nipple for crankcase ventilation. Lift out the intake manifold
- the upper coolant hose.

Removing components

- Separate the connectors for the ABS sensor and level sensor in the expansion tank
- Lift up the expansion tank and the brake fluid reservoir. Place them on top of engine.

Warning! Make sure that no power steering fluid leaks out. It is very flammable.

- Remove the auxiliaries belt.

Setting up the engine

- Remove the front timing cover
- Position the upper timing cover
- Turn the crankshaft clockwise until the markings at the crankshaft and camshafts are aligned with the markings on the oil pump and the upper timing cover
- Remove the upper timing cover.

Removing the timing belt

Slacken off the center screw for the belt tensioner slightly.
Hold the center screw still. Turn the tensioner eccentric clockwise to 10 o'clock using a 6 mm Allen key.

Remove
- the timing belt from the timing gear pulleys for the camshafts
- the screw that holds the inner timing cover to the cylinder head.
Install tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool at the rear of the camshafts.

Removing the timing gear pulley

- Remove the cable duct from its mountings on the right-hand suspension turret.

Note! Do not damage the paintwork.

- Remove the plug at the front of the variable valve timing unit (TX55).

Note! Oil will leak out. Collect any oil using paper or similar.

- Remove the center screw from the variable valve timing unit (TX55).
Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.
Remove tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.
Reinstall the expansion tank and the brake fluid reservoir at the right wheel arch.

Releasing the inlet pipe for the coolant pump

Remove the two screws at the coolant pipe connection to the bypass channel.
Carefully turn the pipe to remove it from the cylinder block.

Removing the camshaft cover and cylinder head

Remove:
- Variable valve timing solenoid
- spark plugs for cylinders 1 and 5.
Install 2 tools 999 5454 PRESS TOOL 999 5454 Press Tool. Leave a 2-3 mm gap to the camshaft cover.
Ensure that the screw in the spark plug well is fully tightened.
Remove all the screws securing the camshaft cover to the cylinder head.

Use pliers 999 5670 Pliers 999 5670 Pliers to lift the cover from the cylinder head.
Install the pliers at the stop lugs.
Start with cylinder 1 and work alternately backward.
Slacken off the wing nuts approximately 2 turns. Repeat the procedure.

Carefully press out the front and rear camshaft seals.

Note! Be very careful so that the sealing faces on the camshafts are not damaged.

Remove:
- tools 999 5454
- the camshaft cover
- the camshafts.
Lift out the valve lifters. Use a magnet or a suction cup.

Note! Mark up and position the lifters so that their original positions can be established.

Remove the screws holding the cylinder head on the cylinder block.
Start at the sides and work alternately towards the center.
Get help to lift off the cylinder head.

Note! Work very carefully to avoid damaging the contact faces.

When replacing or working on the cylinder head

Remove:
- thermostat housing.

Note! Work very carefully to avoid damaging the contact faces.

Cleaning

Cleaning the gasket faces

Clean the gasket faces for:
- the manifold. Check that the studs are tightened and not damaged
- the coolant bypass channel
- the thermostat housing
- the intake manifold
- the cylinder block
- camshaft cover.
Blow the oil ducts clean.

Note! Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Warning! When using gasket solvent, work shall be done in a fume hood or by an air extractor!

Installing the cylinder head

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.

Tightening torques

Note! For tightening torques, see: Tightening torque Tightening Torque.

Aligning the crankshaft

Remove:
- the starter motor
- the blind cover plug.
Turn the crankshaft clockwise slightly.
Install the crankshaft stop999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool. Ensure that it bottoms out against the engine block.
Turn the crankshaft counter-clockwise until it stops against the crankshaft stop.
Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Installing the cylinder head

Install a new cylinder head gasket.
Installing the cylinder head requires help from another person.
Install the cylinder head.
Ensure that no wiring or hoses are trapped between the cylinder head and cylinder block.
Use new screws. Lubricate and install all the screws.
Tighten the screws as illustrated.
Tighten, see: Tightening torque Tightening Torque.

Installing valve lifters and camshafts

Note! When installing a new cylinder head, the valve clearance must be set. See Valve clearance Adjustments.

Lubricate the valve lifter wells.
Install all the valve lifters.

Note! Make sure that the lifters end up in the same position as before.

Lubricate the camshaft bearing positions.
Install the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line.
Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line.

Applying liquid gasket

Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.
Install new O-rings around the spark plug wells at the cylinder head.
Apply liquid gasket 116 1059 on the camshaft cover.
Use roller 951 2767 Roller 951 2767 Roller.
The surface must be completely covered without any excess.

Caution! Make sure that no liquid gasket gets into the oil channels.

Installing the camshaft covers

Lubricate the camshaft lobes, the camshaft bearing surfaces and the top of the valve lifters.
Install the camshaft cover.
Install press tool 999 5454 PRESS TOOL 999 5454 Press Tool (2x).
Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.
Install all the screws. Tighten the screws from the middle and outwards.
Remove the press tools.

Install
- the variable valve timing (VVT) solenoid. Use a new gasket
- the spark plugs. Tighten. See Tightening torque Tightening Torque.

Installing the intake pipe for the coolant pump

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note! Apply thread sealant, P/N 116 056, to the screw threads.

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note! Cleaning shall be done in the direction around the shaft journal, not in and out. It is very important that any residue from the emery cloth or any other contaminants are completely removed before the new seal ring is installed.

Installing the rear camshaft seal

Use drift 999 5450 PUNCH 999 5450 Punch.
Lubricate the surface of the seal that the camshaft rotates against.
Press in the seal until the drift bottoms out.

Note! If there are wear grooves on the camshaft the seal can be pressed in another 2 mm, by turning around the tool's sleeve.

Install camshaft adjustment tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool at the rear of the camshafts.
Check that the screws securing the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Installing the front camshaft seal

Note! The purpose of the section, "Installing the VVT-unit/timing belt pulley", described here is to make sure that the VVT-unit is positioned correctly and to reset the camshaft timing belt pulley to the correct position using the markings made at the factory. This is to make sure that the conditions are correct for any later troubleshooting.

Lift up the brake fluid reservoir and the expansion tank. Place them on top of engine.
Use drift 999 5718 Drift 999 5718 Drift
Lubricate the surface of the seal that the camshaft rotates against.
Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.
Remove the drift.
Install the screw holding the inner timing cover to the cylinder head.

Checking and adjusting
Check and adjust the variable valve timing unit.

Installing components

Install:
- front timing cover
- the auxiliaries belt
- the expansion tank
- the servo oil reservoir
- the bleed hose for the expansion tank. Tighten the clamp.
Check that the hoses are positioned correctly.

Connect the connectors for:
- The ABS sensor by the right suspension turret
- the coolant level sensor in the expansion tank.

Install
- the starter motor
- the trigger wheel. Ensure that the trigger wheel is correctly positioned against the camshaft
- the camshaft position (CMP) sensor housing
- the upper torque rod bracket.

Installing the intake manifold and gasket

Note! Make sure that the gasket faces are thoroughly clean.

Install:
- a new gasket held in position by the lower intake manifold screws
- the intake manifold
- the crankcase ventilation. The crankcase ventilation must be installed through the gap between the second and third channels
- the hose for the Positive temperature coefficient (PTC) nipple
- the lower screws. Tighten all the screws
- the screw at the support bracket (under the intake manifold).

Install:
- all 4 vacuum hoses on the intake manifold. (See the illustration)
- connect the connector on the Positive temperature coefficient (PTC) nipple for crankcase ventilation (5).

Installing the fuel and air distribution pipe

- Install the fuel rail and injector nozzle
- Press the quick-release connector together until a clicking sound is heard. See Fuel line, lock Service and Repair. Use new screws and tighten.

Install:
- the connectors on the injectors and manifold absolute pressure (MAP) sensor in the fuel line and Positive temperature coefficient (PTC) nipple
- the connector to the throttle body (TB).

Install:
- the cover plate over the injectors
- the crankcase ventilation hose on the top of the camshaft cover. Use a new clamp
- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the cover over the ignition coils
- the dip stick in the intake manifold
- the clip for the power steering delivery line
- the ignition coils according to the earlier markings. Check that the connectors for the ignition coils are secure
- the screws for both the ground terminals between the ignition coils.

Installing the exhaust manifold
Install new gaskets.
Hook the manifold into position. Loosely install 2 nuts.
Install the rubber mounting on the exhaust system.
Install the front SIPS bracket.

Install:
- the remaining nuts for the exhaust manifold. Tighten
- the upper heat deflector plate
- the front wiring for the heated oxygen sensor (HO2S) using clips and clamps. Connect the wiring
- the preheating hose between the heat deflector plate and the air cleaner (ACL)
- the ground strip between the cylinder head and the firewall
- the engine stabilizer brace between the suspension turrets.

Finishing

Install:
- the splash guard under the engine
- the nuts for the cover in the right-hand fender liner
- the right front wheel Installing wheels Service and Repair
- the battery negative lead. Also read Battery, disconnecting Battery Disconnecting.

Check
Replace the oil and oil filter.

Check:
- the engine oil level
- the servo oil level
- the coolant level.
Warm up the engine until the thermostat opens.
Check the engine for leaks.
Top up the coolant if necessary.