Cylinder Head Replacement (Drivers Side)

REMOVAL PROCEDURE

- TOOL REQUIRED
- J 36660 Torque/Angle Meter

1. Disconnect the negative battery cable.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Remove the intake plenum.
3. Remove the intake air resonator.
4. Remove the intake manifold.





5. Remove the intake manifold spacer bolts (1).
6. Remove the intake manifold spacer (2).
7. Remove the coolant bridge.
8. Remove the LH valve cover.
9. Remove the front timing belt cover.
10. Remove the timing belt.
11. Remove the timing belt tensioner bracket.
12. Remove all four of the camshaft gears.
13. Remove the water pump.
14. Remove the rear timing belt cover.
15. Remove the camshaft sensor electrical connection.
16. Remove the exhaust camshaft.





17. Remove the coolant pipe/engine lift bracket bolt (2) from the cylinder head.
18. Grasp the oil level indicator tube (4) firmly.
19. Pull the oil indicator tube upwards to remove the oil indicator tube.
20. Remove the upper radiator hose clamp.
21. Remove the upper radiator hose from the coolant pipe.





22. Twist the coolant intake pipe to remove the coolant intake pipe.
23. Pull away the left exhaust manifold from the cylinder head. The left exhaust manifold will not be completely removed. The manifold must be separated from the cylinder head to allow for the cylinder head removal.
24. Remove the ignition coil electrical connection.





25. Use the reverse of the tightening sequence (8, 7, 6, 5, etc.) to loosen the cylinder head bolts in stages.
26. Remove the cylinder head bolts.
27. Remove the cylinder head.
28. Remove the cylinder head gasket.





29. Remove the ignition coil from the ignition coil bracket to expose the bracket screws.
30. Remove the ignition coil bracket.
31. Clean and inspect the cylinder head and the sealing surfaces.

INSTALLATION PROCEDURE
1. Install the ignition coil bracket to the cylinder head.
2. Install the ignition coil to the ignition coil bracket.





3. Install the new cylinder head gasket with OBEN/TOP imprint toward the front of the engine.
4. Install the cylinder head to the engine block ensuring adequate clearance from all wires, components, etc.





5. Install the new cylinder head bolts.
- Use the J 36660 and the proper tightening sequence (1, 2, 3, etc.) to tighten the cylinder head bolts, in stages, to 25 Nm (18 ft lbs) * 90 degrees + 90 degrees + 90 degrees * 15 degrees.

Important: Use new cylinder head bolts. The required tightening method stretches the bolts, therefore the cylinder head bolts are not reusable.

6. Install the ignition coil electrical connection.
7. Install the left exhaust manifold to the cylinder head.





8. Replace the two sealing rings on the coolant pipe.
9. Lubricate the two sealing rings with coolant.
10. Install the coolant pipe.
11. Install the upper radiator hose to the coolant pipe.
12. Install the upper radiator hose clamp.





13. Install the oil level indicator tube (4).
14. Install the coolant pipe/engine lift bracket bolt (2) to the cylinder head. Ensure the bolt passes through all attached components.
- Tighten the coolant pipe/engine lift bracket bolt to the cylinder head to 20 Nm (15 ft lbs).

15. Install the exhaust camshaft.
16. Install the exhaust camshaft sensor electrical connection.
17. Install the rear timing belt cover.
18. Install the water pump.
19. Install all four of the camshaft gears.
20. Install the timing belt tensioner bracket.
21. Install the timing belt.
22. Install the front timing belt cover.
23. Install the LH valve cover.
24. Install the coolant bridge.





25. Install the intake manifold spacer (2).
26. Install the intake manifold spacer bolts (1).
- Tighten the intake manifold spacer bolts in a spiral direction, starting from the inside and working outward, to 20 Nm (115 ft lbs).

27. Install the intake manifold.
28. Install the intake air resonator.
29. Install the intake plenum.
30. Reconnect the negative battery cable and reprogram the applicable accessories.