Cylinder Head Assembly: Service and Repair

Cylinder Head Replacement

Special Tools

* EN-470-B - Angular Torque Wrench

* EN-955 - Fixing Pin

* EN-953-A - Fixing Tool

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Remove the exhaust manifold and turbocharger as an assembly. Refer to Turbocharger Replacement Service and Repair.

3. Remove the intake manifold. Refer to Intake Manifold Replacement Service and Repair.

4. Remove the water outlet. Refer to Water Outlet Replacement (LUV) Service and Repair.

5. Remove the camshaft position actuator solenoid valve intake and exhaust. Refer to Camshaft Position Actuator Solenoid Valve Replacement Service and Repair.

6. Adjust the engine to TDC. Refer to Camshaft Timing Chain Inspection Service and Repair.




7. Remove the timing chain tensioner plug (1) from the engine front cover.





Note: Remove and reinstall the EN-953-A fixing tool for this step.

8. Install a wrench (1) on the cast hexagonal portion of the intake camshaft, rotate the camshaft toward the exhaust camshaft in order to apply tension.




9. Install EN-955 - pin(2) to the timing chain tensioner bore (1) to secure it in place.

10. Remove the wrench from intake camshaft.




11. Remove the upper timing chain guide bolts (1).

12. Remove the upper timing chain guide (2).




13. Loosen the intake camshaft sprocket bolt (2) while holding up the hexagon of the intake camshaft with a wrench (1).

14. Loosen the exhaust camshaft sprocket bolt while holding up the hexagon of the exhaust camshaft with a wrench.




15. Remove and DISCARD the camshaft sprocket bolts (2) and the camshaft position exciter wheels (1).

16. Remove the both camshaft position sensors. Refer to Camshaft Position Sensor Replacement Service and Repair.




17. Remove the camshaft sprockets (2) and timing chain (1) as one unit.

18. Allow the camshaft sprockets (2) and timing chain (1) rest on the front cover. Do NOT remove sprockets or chain.

19. Install the engine support fixture. Refer to Engine Support Fixture Service and Repair.

20. Remove the engine mount bracket. Refer Engine Mount Bracket Replacement - Right Side Engine Mount Bracket Replacement - Right Side.

21. Remove the drive belt. Refer to Drive Belt Replacement Service and Repair.

22. Remove the water pump pulley. Refer to Water Pump Pulley Replacement (LUV) Service and RepairWater Pump Pulley Replacement (LUW) Service and Repair.




23. Remove 5 engine front cover bolts (1, 2).

24. Remove 3 water pump bolts (3).

25. Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side Engine Mount Bracket Replacement - Right Side.

26. Install engine mount. Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.

27. Remove engine support fixture. Refer Engine Support Fixture Service and Repair.




28. Loosen the 12 cylinder head bolts in the sequence as shown above. Use the following procedure:

* First pass: Loosen the cylinder head bolts 90 degrees.

* Final pass: Loosen the cylinder head bolts 180 degrees.





Note: Do not damage the guide sleeves (4, 5).

29. Remove and DISCARD the 12 cylinder head bolts (1).

30. With the aid of an assistant, lift the timing chain side of the cylinder head assembly slightly in direction of the transmission.

31. Remove the cylinder head (2).

32. Remove the cylinder head gasket (3) and discard the gasket.




33. With the cylinder head out of vehicle, bend the top third of the engine front cover gasket (1) back and forth until snaps off at the breaking point.

34. Remove the assembly parts from cylinder head:

* Remove the EN-953-A fixing tool

* Remove the intake camshaft. Refer to Intake Camshaft Removal Service and Repair.

* Remove the exhaust camshaft. Refer to Exhaust Camshaft Removal Service and Repair.

* Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Removal Service and Repair.

* Remove the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Removal Service and Repair.

* Remove the spark plug. Refer to Spark Plug Replacement Service and Repair.

* Remove the engine oil pressure indicator switch.

* Remove the timing chain tensioner. Refer to Timing Chain Tensioner Removal Service and Repair.

* Remove the 3 engine lift brackets.

35. For disassembly of the cylinder head. Refer to Cylinder Head Disassemble Service and Repair.

36. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection Service and Repair.

37. Transfer parts as necessary.

Installation Procedure

1. For assembly of the cylinder head. Refer to Cylinder Head Assemble Service and Repair.

Caution: Refer to Fastener Caution Fastener Caution.

2. Install the cylinder head assembly parts:

* Install the 3 engine lift bracket bolts and tighten to 22 Nm (16 lb ft).

* Install the timing chain tensioner. Refer to Timing Chain Tensioner Installation Service and Repair.

* Install the engine oil pressure indicator switch and tighten to 20 Nm (15 lb ft)

* Install the spark plug. Refer to Spark Plug Replacement Service and Repair.

* Install the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Installation Service and Repair.

* Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Installation Service and Repair.

* Install the exhaust camshaft. Refer to Exhaust Camshaft Installation Service and Repair.

* Install the intake camshaft. Refer to Intake Camshaft Installation Service and Repair.

* Install the EN-953-A - fixing tool.

Note: Adjust the camshafts by means of the hexagon and a spanner.

3. Clean sealing surfaces of engine front cover and engine block from grease and old gasket material.





Note: The engine front cover gasket comes as a complete unit.

4. Before installation the of the new front cover gasket, bend the top third of the engine front cover gasket (1) back and forth until snaps off at the breaking point.




5. Apply a 2 mm (0.0787 in) bead of RTV sealant to the areas shown (1).

6. Install a NEW cylinder head gasket. The marking "Top" should point to the cylinder head.




7. Install engine front cover bolts (1) in order to guide the NEW upper engine front cover gasket.

8. Apply a 2 mm (0.0787 in) bead of RTV sealant to the areas shown (2).





Note: A second mechanic is required.

9. Guide the timing chain guide pin (2) to the timing chain guide and the timing chain tensioner (1) with the installed fixing pin through the timing chain tensioner plug bore in engine front cover.




10. Install the cylinder head (2).

11. Loosely install 12 NEW cylinder head bolts (1).




12. Adjust the cylinder head to the engine front cover. Use a rubber mallet.

13. Position the engine front cover to cylinder head by installing 3 bolts (1).

14. Tighten the 3 bolts (1) to 8 Nm (71 lb in).




15. Tighten the cylinder head bolts in the sequence as shown and in the following order.

* Tighten the cylinder head bolts to 35 Nm (26 lb ft).

* Tighten the cylinder head bolts an additional 180°. Use EN-470-B - wrench.




16. Loosen the bolts from engine front cover (1).




17. Install the remaining bolts to engine front cover and water pump.

18. Tighten the engine front cover bolts (1, 2) to 8 Nm (71 lb in).

19. Tighten the water pump bolts (3) to 8 Nm (71 lb in).

20. Install the engine support fixture. Refer to Engine Support Fixture Service and Repair.

21. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side Engine Mount Bracket Replacement - Right Side.

22. Install the water pump pulley. Refer to Water Pump Pulley Replacement (LUV) Service and RepairWater Pump Pulley Replacement (LUW) Service and Repair.

23. Install the drive belt. Refer to Drive Belt Replacement Service and Repair.

24. Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side Engine Mount Bracket Replacement - Right Side.

25. Install the engine mount. Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.

26. Remove the engine support fixture. Refer to Engine Support Fixture Service and Repair.




27. Install the camshaft sprockets (2) and timing chain (1) as one unit.




28. Install the camshaft position exciter wheels (1).

29. Install the NEW camshaft sprocket bolts (2) and tighten to 50 Nm (37 lb ft) plus 60 degrees.

30. Install the both camshaft position sensors. Refer to Camshaft Position Sensor Replacement Service and Repair.

31. Remove the EN-955 - pin to apply tension to the timing chain.

32. Adjust the camshaft timing chain. Refer to Camshaft Timing Chain Inspection Service and Repair.




33. Install the upper timing chain guide (2).

34. Install the upper timing chain guide bolts (1) and tighten to 8 Nm (71 lb in).





Caution: Refer to Component Fastener Tightening Caution Component Fastener Tightening Caution.

35. Install the timing chain tensioner plug and tighten to 50 Nm (37 lb ft).

36. Install the camshaft position actuator solenoid valve intake and exhaust. Refer to Camshaft Position Actuator Solenoid Valve Replacement Service and Repair.

37. Install the exhaust manifold and turbocharger as an assembly. Refer to Turbocharger Replacement Service and Repair.

38. Install the Intake manifold. Refer to Intake Manifold Replacement Service and Repair.

39. Fill coolant fluid. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

40. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

41. Check and correct the engine oil.

42. Test the vehicle using the following procedure:

1. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.

2. Start the engine and listen for unusual noises.

3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.

4. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.

5. Listen for sticking lifter and other unusual noises.

6. Inspect for fuel, oil and/or coolant leaks while the engine is running.

43. Inspect for coolant, oil, gas or exhaust leaks.