Cylinder Head Assembly: Service and Repair

1. Relieve fuel pressure as follows:
a. With engine running, disconnect fuel pump connector.
b. Allow engine to deplete fuel supply, then turn ignition Off. Failure to release pressure prior to disconnecting fuel lines may cause fire or personal injury.
2. Disconnect battery ground cable, drain cooling system, then disconnect upper radiator hose.
3. Disconnect engine cooling fan motor electrical connector, then remove radiator.
4. Disconnect accelerator cable from throttle body.
5. Disconnect breather hose and purge hose from air intake hose.
6. On turbocharged models, remove two turbocharger air hoses.
7. On all models, disconnect air bypass hose from air intake hose, then remove air intake hose.
8. Disconnect air flow sensor electrical connector, then remove air cleaner assembly.
9. Mark and disconnect necessary electrical connectors and vacuum hoses, release harness from clips and secure aside.
10. Disconnect fuel hoses, heater hoses and the brake booster hose.
11. Remove engine center cover, then disconnect connections for fuel injectors, spark plug wires and control wiring harness.
12. Remove timing belt as follows:
a. Remove undercover.
b. Using a wood block and a jack, place wood block on engine oil pan and raise engine only enough to relieve tension on top engine mount, then remove mount and bracket.
c. Remove engine drive belts. Prior to removing water pump drive belt, loosen water pump pulley bolts.
d. Remove crankshaft pulley.
e. Remove upper and lower timing covers.
f. Remove tensioner pulley and bracket.
g. Disconnect PCV hose, then remove rocker cover.

Fig. 8 Aligning Timing Marks:

Fig. 9 Cylinder Head Bolt Loosening Sequence:

Fig. 10 Cylinder Head Bolt Tightening Sequence:

h. Rotate crankshaft clockwise to bring No. 1 cylinder to top dead center compression stroke. Rotate crankshaft only in clockwise direction. The No. 1 cylinder is at top dead center compression stroke when the timing marks on camshaft sprockets are aligned with upper surface of cylinder head and dowel pins on camshaft sprockets are facing up as shown, Fig. 8.
i. Remove auto tensioner.
j. Mark timing belt indicating direction of rotation, then remove timing belt.
13. Remove heat shield, then disconnect water pipe from cylinder head.
14. Disconnect and plug oil return line from turbocharger.
15. Remove tension rod from between cylinder head and intake housing.
16. Disconnect exhaust pipe from turbocharger.
17. Remove bolts attaching intake manifold to support.
18. Using wrench tool No. MD998051 or equivalent, remove cylinder head attaching bolts in sequence as shown, Fig. 9. Loosen head bolts evenly, in two or three steps to prevent cylinder head warpage. When removing cylinder head use care not to disturb the camshaft sprockets. After removing cylinder head, clean gasket surfaces on head and block.
19. Remove intake and exhaust manifolds.
20. Reverse procedure to install, noting the following:
a. Tighten exhaust manifold nuts to specifications.
b. Tighten intake manifold bolts to specifications.
c. Ensure new cylinder head gasket has proper identification mark for engine. Position gasket with identification mark facing up and towards front of engine.
d. Tighten cylinder head bolts in sequence as shown, Fig. 10. Tighten cylinder head bolts to specifications. Ensure head bolt washers are correctly installed.
e. Ensure camshaft and crankshaft timing marks are correctly aligned.
f. Tighten auto tensioner bolt to specifications.
g. Tighten timing cover bolts to specifications.
h. Tighten tensioner pulley bracket bolts to specifications.
i. Tighten crankshaft pulley bolts to specifications.
j. Tighten water pump pulley bolts to specifications.
k. Tighten top engine mount bolts to specifications.
l. Tighten top engine mount bracket bolts to specifications.
m. Tighten intake manifold support bolts to specifications.
n. Tighten oil return pipe bolts to specifications.
o. Tighten water pipe bolt to specifications.
p. Tighten tension rod bolt to specifications.
q. Tighten engine center cover and rocker cover bolts to specifications.
r. When installing rocker cover, apply 3M sealant No. 8660 or equivalent to semi-circular packing.
s. Tighten fuel return hose fitting bolts to specifications.