Cylinder Head Assembly: Service and Repair

2L & 2L-T ENGINES

1. Disconnect battery ground cable.
2. Drain cooling system, then remove radiator from vehicle.
3. Mark then disconnect all emission control hoses from cylinder head and remove air cleaner assembly as needed.
4. On 2L exc. California models, remove hose from air cleaner assembly.
5. On 2L-T engines, disconnect expansion tank hose from water outlet, then remove turbocharger.
6. Disconnect and plug heater hoses.
7. Disconnect accelerator cable from bracket.
8. Disconnect A/C vacuum hose from VSV, if equipped.
9. Remove A/C compressor from mounting bracket and position aside. Do not disconnect refrigerant lines from compressor.
10. Disconnect and plug fuel lines.
11. Disconnect glow plug current sender, water temperature sensor, glow plug resistor and water temperature sender gauge electrical connectors.

Fig. 6 Cylinder head & timing belt exploded view:

12. Mark then remove fuel injection lines, nozzles and fuel inlet line, Fig. 6.
13. Disconnect PCV valve hose from PCV valve, if equipped.
14. Remove cylinder head cover attaching bolts, then the cylinder head cover.
15. Remove timing belt. Refer to ``Timing Belt, Replace'' for procedure.
16. Remove camshaft timing sprocket.
17. Disconnect accelerator connecting rod from accelerator link.
18. On California models, remove EVR valve EGR valve and EGR valve adapter.
19. Remove intake manifold attaching bolts, then the intake manifold and left side engine bracket.
20. Remove water outlet attaching bolts, then the water outlet assembly.
21. Remove right side engine bracket, if equipped.
22. Remove A/C bracket, if equipped.
23. On turbocharged models, remove turbocharger oil pipe retaining clip and union bolt, then disconnect pipe from hose and plug hose.
24. On turbocharged models, remove heat insulator, then on all models, remove exhaust manifold retaining bolts and the manifold.
25. Remove camshaft oil seal retainer attaching bolts, then the retainer.

Fig. 9 Rocker shaft bolt removal sequence:

26. Gradually loosen then remove rocker shaft assembly retaining bolts in three steps in sequence shown in Fig. 9. Remove rocker shaft assembly, camshaft and bearings.

Fig. 7 Cylinder head bolt removal sequence:

27. Gradually loosen then remove cylinder head bolts in three steps in sequence shown in Fig. 7.

Fig. 10 Rocker shaft bolt tightening sequence:

Fig. 8 Cylinder head bolt tightening sequence:

28. Reverse procedure to install. Torque rocker shaft assembly retaining bolts in three steps in sequence shown in Fig. 10, to 14 ft. lbs. Torque cylinder head bolts in three steps in sequence shown in Fig. 8, to 87 ft. lbs.