Cylinder Head Removal and Installation

Cylinder Head Removal and Installation SPECIAL TOOLS

• Counterhold tool No. 999 5199, or equivalent • Drift tool No. 999 5449, or equivalent • Drift tool No. 999 5450, or equivalent • Crankshaft Locking tool No. 999 5451, or equivalent • Camshaft locking tool No. 999 5452, or equivalent • Holder tool No. 999 5453, or equivalent • Press tool No. 999 5454, or equivalent

PROCEDURE

1. Disconnect battery ground lead and drain coolant

• Disconnect battery ground lead. • Remove expansion vessel cap. • Connect tube to drain cock on right-hand side of engine. • Open cock and collect coolant. • Close drain cock.

2. Remove components from right-hand side of cylinder head

• Remove exhaust manifold as described in steps 1 through 3 of Exhaust Manifold. See: Exhaust System\Exhaust Manifold\Service and Repair

• Remove coolant pipe bolts (two).

3. Remove timing belt/tensioner

• Remove Timing Belt as described in Replacement steps 1 through 6. See: Timing Belt\Service and Repair

• Remove transmission mounting plate bolt

4. Remove intake manifold and components from left-hand side of cylinder head

• Carry out step 1 through 4 and step 7 of replacement. See: Intake Manifold\Service and Repair

• Remove coolant temperature sensor. • Disconnect coolant hose from thermostat housing

5. Remove:

• ignition coils (mark positions) • camshaft pulleys, using counterhold tool No. 999 5199, or

equivalent. Mark pulleys (intake and exhaust side).

6. Remove components at engine rear:

• camshaft position sensor • switch mounting bracket • ground terminals 1 and 2 • temperature sensor connector • coolant hoses at rear

7. Remove top half of cylinder head

• Undo bolts (46). • Tap top half of cylinder head carefully upwards with copper mallet.

Tap joint lugs and camshaft front ends. • Remove camshafts

8. Remove cylinder head

• Undo cylinder head bolts starting at outside edge and working inwards.

• Remove head. • Remove head gasket.

9. Clean:

• mating faces between exhaust manifold and cylinder head • cylinder block joint • coolant pipe joint • joint faces between top and bottom halves of cylinder head

NOTE: Use soft putty knife and if necessary gasket solvent part No. 1161 340-3, or equivalent, for this purpose. Do not use a metal blade. A fume hood or extractor must be used if using gasket solvent.

10. Align timing mark on crankshaft Remove starter motor.

• Remove protective plug. • Mount crankshaft locking tool No. 999 5451, or equivalent. • Turn crankshaft counterclockwise until stopped by tool.

11. Install bottom half of cylinder head

• Use new cylinder head gasket. • Oil bolts. • Tighten bolts in three stages as follows: Stage 1:20 Nm (15 ft. lbs.)

Stage 2:60 Nm (44 ft. lbs.) Stage 3: Tighten an additional130°

• Cylinder head gasket, replacement • Install new O-rings in spark plug wells. • Oil camshaft bearing seats.

12. Apply liquid sealing compound

• Apply liquid sealing compound, part No. 1161 059-9, or equivalent to upper section of cylinder head. Use roller.

NOTE: Ensure that compound does not penetrate coolant or oil passages.

• Oil camshaft bearing seats. • Install camshafts. Locate at front end using holder tool No. 999 5453, or

equivalent, and at rear end with camshaft locking tool No. 999 5452, or equivalent.

13. Install upper section of cylinder head

• Place component in position. • Tighten against lower section using two press tools 999 5454. • Tighten bolts to 17 Nm (13 ft. lbs.) starting from inside and working

outwards. • Remove holder tool No. 999 5453 and press tool No. 999 5454.

14. Install camshaft front seals

• Use drift tool No. 999 5449, or equivalent. • Grease seals. • Tap in seals.

15. Mount camshaft pulleys

• Place upper transmission cover in position. • Mount camshaft pulleys. • Align timing marks Tighten each pulley with two bolts. • Remove upper transmission cover. • Insert transmission mounting plate bolt.

16. Install timing belt

• Place belt around crankshaft and right-hand idler. • Place belt over camshaft pulleys, press over tensioner pulley.

17. Install belt tensioner

• Tighten tensioner bolts to 25 Nm (18 ft. lbs.). • Slacken camshaft pulley bolts. • Withdraw tensioner locking pin.

18. Tighten camshaft pulleys

• Insert third bolt and tighten bolts alternately to (20 Nm ft. lbs.). • Use counterhold tool No. 999 5199, or equivalent.

19. Remove locking tools (999 5451, 999 5452)

• Remove crankshaft locking tool refit protective plug and install starter motor.

• Remove camshaft locking tool. • Install upper transmission cover.

20. Check timing marks

• Check that timing marks on crankshaft and camshaft pulleys are correctly aligned.

21. Install new seal

• Use drift tool No. 999 5450, or equivalent. • Grease seal. • Press in seal.

NOTE: Seal is normally located in same plane as edge of inside shoulder. If shaft end is worn. seal may be located a further 2 mm (0.08 in).

22. Install/reconnect:

• temperature sensor connector • ground terminals 1 and 2 • cover • switch mounting bracket • shutter (note position) • camshaft position sensor • coolant hoses

23. Install:

• ignition coils • spark plug cover • front transmission cover • auxiliaries drive belt • vibration damper guard • splash guard under engine

24. Assemble components on left side of cylinder head Install intake manifold as per steps 11, 12 and 14 of replacement. See: Intake Manifold\Service and Repair Reconnect coolant hose to thermostat housing.

• Reconnect coolant temperature sensor.

25. Assemble components on right side of cylinder head Install:

• coolant pipe with new gasket • exhaust manifold with new gaskets • heat shield • front exhaust pipe

NOTE: Undo bolted joint after catalytic converter and retighten, to 25 Nm (18 ft. lbs.). This is necessary to prevent stresses in the system.

26. Fill system with coolant/change oil and oil filter Reconnect battery ground lead.

• Fill engine with oil. • Oil capacity. incl. filter: 5.75 L (6 US qts)

excl. filter: 5.25 L (5.5 US qts)

• Fill cooling system.

Run engine until thermostat opens and top up coolant as required.

• Inspect for leaks.