Cylinder Head Assembly: Service and Repair

REMOVAL
1. Drain cooling system, remove radiator fan module, and radiator.
2. Remove refrigerant from air conditioning system using a refrigerant recovery machine. Remove air conditioning condenser.
3. Remove accessory drive belts.
4. Remove hood side panels.
5. Remove right headlamp module for easier access to compressor bolts.
6. Remove air conditioning compressor mounting bolts and set compressor aside.
7. Remove compressor bracket from engine.
8. Remove crankshaft damper.
9. Remove timing belt covers.
10. Remove timing belt and camshaft sprockets.
11. Remove exhaust manifold upper heat shields and manifold attaching bolts.
12. Remove upper and lower intake manifolds.
13. Remove cylinder head cover(s).





14. Remove rear timing belt cover to cylinder head fasteners (Fig. 10). Remove the rear covers.





15. The right side timing belt cover has O-rings located behind it for water pump passages (Fig. 11).





16. Remove cylinder head bolts in reverse order of tightening sequence (Fig. 12).
17. Remove cylinder head(s).

CLEANING
1. Use a gasket removal compound to soften the old gasket material.

CAUTION: When cleaning the cylinder head and block mating surfaces, do not use a metal scraper because the sealing surfaces could be cut or ground. Instead, use a wooden or plastic scraper.

2. Make sure the gasket and/or foreign material does not enter the oil feed hole or the oil return holes.

INSPECTION
1. Before cleaning, check for leaks, damage and cracks.
2. Clean cylinder head and oil passages.





3. Check cylinder head for flatness (Fig. 13).
4. Cylinder head must be flat within:
- Standard dimension = less than 0.05 mm (0.002 inch)
- Service Limit = 0.2 mm (0.008 inch))
- Grinding Limit = Maximum of 0.2 mm (0.008 inch)) is permitted.

CAUTION: 0.20 mm (0.008 inch) MAX is a combined total dimension of the stock removal limit from cylinder head and block top surface (Deck) together.

INSTALLATION





NOTE: The cylinder head bolts are tightened using a torque-to-yield procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced (Fig. 14).

Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced.

1. Before installing cylinder head bolts the threads should be oiled with engine oil.





2. Install head gasket over locating dowels. Ensure the gasket is installed on the correct side (Fig. 15).
3. Install cylinder head over dowels.
4. Tighten the cylinder head bolts in the sequence shown in (Fig. 12). Using the 4 step torque-turn method, tighten according to the following values:
- First All to 61 Nm (45 ft. lbs.)
- Second All to 88 Nm (65 ft. lbs.)
- Third All (again) to 88 Nm (65 ft. lbs.)
- Fourth + 1/4 Turn Do not use a torque wrench for tints step.
5. Bolt torque after 1/4 turn should be over 90 ft. lbs. in the tightening direction. If not, replace the bolt.
6. Install rear timing belt covers. Use new O-rings on the water pump passages on the right side cover. Tighten bolts to specified torque:
- M10 - 54 Nm (40 ft. lbs.)
- M8 - 28 Nm (20 ft. lbs.)
- M6 - 12 Nm (105 in. lbs.)
7. Install cylinder head cover(s).
8. Install lower and upper intake manifolds.
9. Install exhaust manifold(s) and heat shields.
10. Install camshaft sprockets and timing belt.
11. Install timing belt covers.
12. Install crankshaft damper.
13. Install AC compressor bracket to engine.
14. Install AC compressor to bracket.
15. Install right headlamp module and hood side panels.
16. Install accessory drive belts.
17. Install air conditioning condenser and evacuate and recharge air conditioning system.
18. Install radiator and radiator fan module.
19. Fill cooling system.