Cylinder Head Assembly: Service and Repair

Cylinder Head Replacement

Special Tools

EN-45059 - Angle Meter

For equivalent regional tools, refer to Special Tools (LDK, LHU) Tools and Equipment.

Removal Procedure

1. Remove the engine coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement Engine Coolant Air Bleed Hose Replacement.

2. Remove the turbocharger. Refer to Turbocharger Replacement Turbocharger Replacement.

3. Remove the exhaust camshaft. Refer to Exhaust Camshaft Replacement Exhaust Camshaft Replacement.

4. Remove the intake camshaft. Refer to Intake Camshaft Replacement Intake Camshaft Replacement.




5. Loosen the cylinder head bolts in sequence as shown.




6. Remove and DISCARD the 14 cylinder head bolts (1) and (2).

7. Remove the cylinder head (3).

8. Remove and DISCARD the cylinder head gasket (4).

9. Remove the intake manifold. Refer to Intake Manifold Replacement Intake Manifold Replacement.

10. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement (2.4L LEA) Service and RepairExhaust Manifold Replacement (2.0L LHU) Service and Repair.

11. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair.

12. Remove the hydraulic valve lash adjuster. Refer to Hydraulic Valve Lash Adjuster Replacement Service and Repair.

Installation Procedure

1. Install the hydraulic valve lash adjuster. Refer to Hydraulic Valve Lash Adjuster Replacement Service and Repair.

2. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair.

3. Install the intake manifold. Refer to Intake Manifold Replacement Intake Manifold Replacement.

4. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (2.4L LEA) Service and RepairExhaust Manifold Replacement (2.0L LHU) Service and Repair.

5. Clean the sealing surfaces of cylinder head and engine block.




6. Install a NEW cylinder head gasket (4).

7. Install the cylinder head (3).

8. Install the 14 cylinder head bolts (1) and (2).




9. Fasten the cylinder head bolts hand tighten in sequence as shown.

Caution: Refer to Fastener Caution Fastener Caution.

Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

10. Tighten the NEW cylinder head bolts a first pass in the sequence as shown to 30 Nm (22 lb ft).

11. Tighten the cylinder head bolts a final pass in the sequence shown and additional 155 degrees, using the EN-45059 - meter.

12. Tighten the 4 cylinder head front bolts to 35 Nm (26 lb ft).

13. Install the intake camshaft. Refer to Intake Camshaft Replacement Intake Camshaft Replacement.

14. Install the exhaust camshaft. Refer to Exhaust Camshaft Replacement Exhaust Camshaft Replacement.

15. Install the engine coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement Engine Coolant Air Bleed Hose Replacement.

16. Install the turbocharger. Refer to Turbocharger Replacement Turbocharger Replacement.

17. Replace the engine oil filter and the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.