Cylinder Head LH - VIN Range: G00442->G45703 (12.29.02)

Cylinder Head LH - VIN Range: G00442->G45703 (12.29.02)





Removal

All vehicles

CAUTION: If a replacement cylinder head is to be installed to a vehicle with variable camshaft timing (VCT) the cylinder head must have the oil gallery blind rivet removed before installation.

1. Remove the air deflector.
2. Disconnect the crankshaft position sensor electrical connector.





3. Remove the crankshaft position sensor.





4. Install the special tool.





Vehicles without supercharger
5. Remove the intake manifold.

Vehicles with supercharger
6. Remove the charge air cooler.

7. NOTE: Left-hand shown, right-hand similar.

Remove the lower intake manifold.





All vehicles
8. Remove the engine front cover.

Vehicles without supercharger
9. Remove the right-hand variable camshaft timing oil control unit housing.
^ Remove and discard the O-ring seals.





10. Remove the left-hand variable camshaft timing oil control unit housing.
^ Remove and discard the O-ring seals.





All vehicles
11. Install the special tool to the left-hand cylinder head.





12. Install the special tool to the right-hand cylinder head.





13. Remove the primary timing chain tensioner assembly.





14. Remove the primary timing chain tensioner guide.





15. Remove the primary timing chain.





16. CAUTION: Make sure the secondary timing chain and camshaft sprockets are free to rotate.

Loosen the camshaft sprockets.





17. Remove the primary timing chain guide.





18. Remove the primary timing chain tensioner assembly.





19. Remove the primary timing chain tensioner guide.





20. Remove the primary timing chain.





21. Remove the primary timing chain tensioner guide.





22. Remove the secondary timing chain tensioner retaining bolts.





23. Remove the camshaft sprockets.
^ Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.





24. Remove the camshaft setting tool.





25. Remove the camshaft bearing caps.
^ Remove the camshaft bearing cap retaining bolts evenly and in stages.
^ Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).





26. Remove the left-hand exhaust camshaft.





27. Remove the camshaft bearing caps.
^ Remove the camshaft bearing cap retaining bolts evenly and in stages.
^ Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).





28. Remove the left-hand inlet camshaft.





29. Remove the left-hand cylinder head.
^ Remove the bolts in the indicated sequence.





30. CAUTION: Only use a plastic scrapper to clean off old gasket.

Remove the cylinder head gasket.

^ Clean the gasket mating faces.





31. CAUTION: Only use a plastic scrapper to clean off old gasket.

Clean the cylinder head locating dowels.





32. Clean and inspect the cylinder head and cylinder block.

Installation

All vehicles

1. CAUTION: If a replacement cylinder head is to be installed to a vehicle with VCT the cylinder head must have the oil gallery blind rivet removed before installation.

CAUTION: Make sure that all debris is removed from the cylinder head and cylinder head oil gallery.

Vehicles fitted with VCT: Remove the blind rivet from the VCT oil gallery.

^ Identify the VCT oil supply gallery and the 8 mm (0.31 inch) blind rivet.
^ Using a suitable 3 mm (0.12 inch) punch release the center of the blind rivet until it is released from the outer part of the blind rivet.
^ Using a suitable extraction tool, remove the remaining part of the blind rivet.





2. Clean the component mating faces.
3. Check cylinder head face for distortion, across the center and from corner to corner.





4. For cylinder head face distortion data, refer to specifications.

5. NOTE: For cylinder head with distortion above the maximum allowance, the cylinder head material must be measured.

Measure the cylinder head material.

^ Check measurement from the center of the exhaust dowel to the cylinder head face as shown.
^ If the measurement is less than 51.88 mm the cylinder head requires replacement.





6. CAUTION: The head gasket must be installed over the cylinder block dowels.

Install a new cylinder head gasket.





7. NOTE: Tighten the bolts 1 to 10 in the sequence shown.

Install the left-hand cylinder head.

1) Tighten bolts 1 to 10 to 20 Nm.
2) Tighten bolts 1 to 10 to 35 Nm.
3) Tighten bolts 1 to 10 to 90°.
4) Tighten bolts 1 to 10 to 90°.
5) Tighten bolts 11 to 12 to 25 Nm.





8. NOTE: Make sure all components are clean.

Apply oil (EP-90) to the camshaft and bearing surfaces, as follows:

^ To the upper face of each bearing surface in the cylinder head.
^ To the upper face of each bearing surface in each bearing cap.
^ On the cam lobes ONLY, not on the base circle area.





9. Install the left-hand inlet camshaft.





10. CAUTION: Alternate bolt tightening to correctly seat the camshaft bearing caps.

Install the camshaft bearing cap bolts evenly.

^ Tighten to 10 Nm.





11. Install the left-hand exhaust camshaft.





12. CAUTION: Alternate bolt tightening to correctly seat the camshaft bearing caps.

Install the camshaft bearing cap bolts evenly.

^ Tighten to 10 Nm.





13. Install the camshaft setting tool.





14. CAUTION: Do not tighten the camshaft sprocket retaining bolts.

CAUTION: Make sure the secondary timing chain and camshaft sprockets are free to rotate.

Install the camshaft sprockets.

^ Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.





15. Using a suitable tool, retain the left-hand timing chain tensioner piston.





16. Install the secondary timing chain tensioner retaining bolts.
^ Tighten to 12 Nm.





17. Release the tension in the left-hand timing chain tensioner.
^ Remove the retaining tool.
18. Install the timing chain tensioning tool 303-532 to the exhaust camshaft sprocket.
^ Reposition the camshaft sprockets for the most advantageous position for use of the tool.





19. Install the primary timing chain tensioner guide.
^ Tighten to 12 Nm.





20. CAUTION: Make sure the timing chain slack is on the tensioned side of the timing chain.

Install the primary timing chain.

^ Install the primary chain over the crankshaft sprocket and the intake sprocket.





21. Install the primary timing chain tensioner guide.
^ Tighten to 12 Nm.





22. CAUTION: During timing chain tensioner compression, do not release the ratchet stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.

Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.





23. NOTE: The timing chain tensioner piston should retract with minimal force. If binding occurs, reposition the timing chain tensioner to eliminate side loading.

Slowly compress the left-hand timing chain tensioner.

24. NOTE: The retaining tool must remain in the timing chain tensioner until the timing chain tensioner is installed to the engine with the piston bottomed in the bore.

Using a suitable tool, retain the left-hand timing chain tensioner piston.





25. Install the primary timing chain tensioner assembly.
^ Tighten to 12 Nm.





26. Release the tension in the left-hand timing chain tensioner.
^ Remove the retaining tool.

27. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.

Using the special tool apply force to the tool in an anti-clockwise direction to tension the primary timing chain on its drive side.

^ Tighten to 120 Nm.





28. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.

Using the special tool apply force to the tool in an anti-clockwise direction.

^ Tighten to 120 Nm.





29. Install the primary timing chain guide.
^ Tighten to 12 Nm.





30. CAUTION: Make sure the timing chain slack is on the tensioned side of the timing chain.

Install the primary timing chain.

^ Install the primary chain over the crankshaft sprocket and the intake sprocket.





31. Install the primary timing chain tensioner guide.
^ Tighten to 12 Nm.





32. CAUTION: During timing chain tensioner compression, do not release the ratchet stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.

Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.





33. NOTE: The timing chain tensioner piston should retract with minimal force. If binding occurs, reposition the timing chain tensioner to eliminate side loading.

Slowly compress the right-hand timing chain tensioner.

34. NOTE: The retaining tool must remain in the timing chain tensioner until the timing chain tensioner is installed to the engine with the piston bottomed in the bore.

Using a suitable tool, retain the right-hand timing chain tensioner piston.





35. Install the primary timing chain tensioner assembly.
^ Tighten to 12 Nm.





36. Release the tension in the right-hand timing chain tensioner.
^ Remove the retaining tool.

37. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.

Using the special tool apply force to the tool in an anti-clockwise direction to tension the primary timing chain on its drive side.

^ Tighten to 120 Nm.





38. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.

Using the special tool apply force to the tool in an anti-clockwise direction.

^ Tighten to 120 Nm.





39. Remove the special tool from the right-hand cylinder head.





40. Remove the special tool from the left-hand cylinder head.





Vehicles without supercharger
41. Install the left-hand variable camshaft timing oil control unit housing.
^ Install new O-ring seals.
^ Tighten to 22 Nm.





42. Install the right-hand variable camshaft timing oil control unit housing.
^ Install new O-ring seals.
^ Tighten to 22 Nm.





All vehicles
43. Remove the special tool.





44. Install the crankshaft position sensor.
^ Tighten to 10 Nm.





45. Connect the crankshaft position sensor electrical connector.





46. Install the air deflector.

Vehicles without supercharger
47. Install the intake manifold.

Vehicles with supercharger
48. Install the lower intake manifold.
^ Tighten to 22 Nm.





49. Install the charge air cooler.

All vehicles
50. Install the engine front cover.
51. Carry out the valve clearance check. Testing and Inspection