Cylinder Head Replacement Front

Tools Required

SA9140E Torque Angle Gauge

1. Disconnect the negative battery cable.
2. Remove the intake air cleaner. Air Cleaner Assembly Replacement
3. Remove the intake plenum. Intake Plenum Replacement
4. Remove the intake manifold. Intake Manifold Replacement
5. Remove the intake manifold spacer bolts.



6. Remove the intake manifold spacer.



7. Remove the coolant bridge. Refer to Engine Coolant Bridge Replacement.



8. Drain the coolant.



9. Remove the upper radiator hose from the coolant extension housing.

Important: The powertrain must be lifted up in order to remove the coolant extension housing.

10. Support the powertrain using a floor jack under the oil pan.



11. Remove the front transaxle mount through the bolt.



12. Raise the powertrain with a floor jack in order to provide clearance to pull out the extension housing over the coolant module.
13. Remove the oil level indicator tube and coolant extension tube bolt.
14. Remove the oil level indicator tube by pulling upwards.



15. Twist the coolant extension housing to remove.



16. Remove the front camshaft cover. Camshaft Cover Replacement .
17. Remove the grounds from the front lift bracket.
18. Disconnect the oxygen sensor electrical connection.



19. Remove the down pipe to the exhaust manifold nuts.



20. Remove the front timing belt cover. Timing Belt Front Cover Replacement
21. Remove the timing belt. Timing Belt Replacement
22. Remove the timing belt tensioner bracket. Timing Belt Replacement



23. Remove the rear timing belt cover. Timing Belt Front Cover Replacement
24. Remove the camshaft sensor electrical connection.

Important: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E".

Important: It is not necessary to remove the intake camshaft for head bolt access.

25. Remove the exhaust camshaft. Camshaft Replacement



26. Loosen the cylinder head bolts in the stages in the sequence shown.
27. Remove the cylinder head bolts.
28. Remove the cylinder head.
29. Remove the cylinder head gasket.
30. Clean and inspect the cylinder head and sealing surfaces.
31. Remove the exhaust manifold.

1. Install the exhaust manifold and the new gasket.

Tighten
Tighten the exhaust manifold nut to 20 N·m (15 lb ft).

2. Install the new cylinder head gasket with the part number imprint toward the top of the engine.
3. Install the cylinder head to the engine block ensuring the adequate clearance from all the wires, components, etc.




Important: Use the new cylinder head bolts. The required tightening method stretches the bolts to their yield point. Therefore, the cylinder head bolts are not reusable.

Important: Use the SA9140E and the proper tightening sequence to tighten the cylinder head bolts in stages.

4. Install the new cylinder head bolts.

Tighten
Tighten the cylinder head bolts to 25 N·m (18 lb ft) + 90° + 90° + 90° + 15 °.




5. Replace the 2 sealing rings on the coolant pipe.
6. Lubricate the 2 sealing rings with coolant.



7. Install the coolant pipe and the engine lift bracket bolt to the cylinder head. Ensure that the bolt passes through all of the attached components.

Tighten
Tighten the coolant pipe/engine lift bracket bolt to 20 N·m (15 lb ft).

8. Install the upper radiator hose to the coolant pipe.
9. Install the upper radiator hose clamp.



10. Lower the powertrain and align the front transaxle mount and the mounting bracket using a floor jack.
11. Install the front transaxle mount through bolt.
12. Remove the floor jack.



13. Install the upper radiator hose.




Important: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E".

14. Install the exhaust camshaft. Camshaft Replacement

Important: It is not necessary to remove the intake camshaft for head bolt access.

15. Install the exhaust camshaft sensor electrical connection.



16. Install the rear timing belt cover.
17. Coat the threaded pin with Threadlocker LOCTITE® 242 compound or equivalent.
18. Install the rear timing belt cover bolts.

Tighten
Tighten the rear timing belt cover bolt to 8 N·m (71 lb in).

19. Install the rear timing belt threaded pin.

Tighten
Tighten the rear timing belt cover threaded pin to 10 N·m (89 lb in).




20. Install all 4 camshaft gears. Camshaft Drive Sprocket Replacement
21. Install the timing belt tensioner bracket. Timing Belt Tensioner Pulley Replacement
22. Install the timing belt. Timing Belt Replacement
23. Install the front timing belt cover. Timing Belt Front Cover Replacement



24. Install the front camshaft cover. Camshaft Cover Replacement .



25. Install the coolant bridge. Refer to Engine Coolant Bridge Replacement.



26. Install the intake manifold spacer.
27. Install the intake manifold spacer bolts. Tighten the intake manifold spacer bolts in a spiral direction, starting from the inside and working outward.

Tighten
Tighten the intake manifold spacer bolt 20 N·m (15 lb ft).




28. Install the intake manifold. Intake Manifold Replacement
29. Install the intake plenum. Intake Plenum Replacement
30. Install the intake air cleaner. Air Cleaner Assembly Replacement



31. Refill the coolant.
32. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

Cylinder Head Replacement Rear

Tools Required

SA9140E Torque Angle Gage

1. Disconnect the negative battery cable.
2. Remove the intake plenum. Intake Plenum Replacement
3. Remove the intake air resonator. Resonator Replacement
4. Remove the intake manifold.



5. Remove the intake manifold spacer bolts.
6. Remove the intake manifold spacer.



7. Remove the coolant bridge. Water Crossover Removal



8. Remove the engine ventilation chamber.



9. Remove the rear camshaft cover.



10. Remove the front timing belt cover. Timing Belt Front Cover Replacement .
11. Remove the timing belt. Timing Belt Replacement
12. Remove the timing belt tensioner bracket. Timing Belt Tensioner Pulley Replacement .
13. Remove all 4 camshaft gears. Camshaft Drive Sprocket Replacement
14. Remove the rear timing belt cover. Timing Belt Rear Cover Replacement .



15. Remove the exhaust manifold pipe heat shield.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

16. Raise the vehicle on a hoist.




Notice: Avoid excessive movement of the pipe.

17. Remove the front exhaust manifold pipe to rear exhaust manifold pipe fasteners.



18. Remove the rear exhaust manifold pipe to exhaust manifold pipe nuts.
19. Pull down the rear exhaust manifold pipe just enough to remove the gasket.
20. Remove the old gasket and discard.



21. Drain the coolant.
22. Lower the vehicle.



23. Remove the EGR to exhaust manifold pipe.




Important: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E."

24. Remove the exhaust camshaft. Camshaft Replacement




Important: Use the loosening sequence to remove the cylinder head.

25. Remove the cylinder head bolts.
26. Remove the cylinder head.
27. Remove the cylinder head gasket.
28. Remove the exhaust manifold.

Important: It is not necessary to remove the intake camshaft for head bolt access.

29. Clean and inspect the cylinder head and sealing surfaces. Cylinder Head Cleaning and Inspection

1. Install the rear exhaust manifold to the cylinder head. Exhaust Manifold Installation

Tighten
Tighten the exhaust manifold nut to 20 N·m (15 lb ft).

2. Install the new cylinder head gasket with the part number imprint toward the top of the engine.
3. Install the cylinder head to engine block ensuring the adequate clearance from all wires, components, etc.




Important: Use the new cylinder head bolts. The required tightening method stretches the bolts to their yield point. Therefore the cylinder head bolts are not reusable.

Important: Use the SA9140E and the proper tightening sequence to tighten the cylinder head bolts in stages.

4. Install the new cylinder head bolts.

Tighten
Tighten the cylinder head bolt to 25 N·m (18 lb ft) + 90° + 90° + 90° + 15°.

5. Install the exhaust camshaft. Camshaft Replacement



6. Install the rear timing belt cover. Timing Belt Rear Cover Replacement



7. Install all 4 camshaft gears. Camshaft Drive Sprocket Replacement
8. Install the timing belt tensioner bracket. Timing Belt Tensioner Pulley Replacement .
9. Install the timing belt. Timing Belt Replacement
10. Install the front timing belt cover. Timing Belt Front Cover Replacement



11. Install the rear camshaft cover. Camshaft Cover Replacement



12. Install the coolant bridge. Water Crossover Removal
13. Apply sealing compound LOCTITE® 518, or equivalent, to the sealing surface.



14. Install the engine ventilation chamber.

Tighten
Tighten the engine ventilation chamber bolts to 8 N·m (71 lb in).




15. Install the intake manifold spacer.
16. Install the intake manifold spacer bolts, and apply LOCTITE® 242 to the bolts.
17. Tighten the intake manifold spacer bolts in a spiral direction, starting from the inside and working outward.

Tighten
Tighten the intake manifold spacer bolt to 20 N·m (15 lb ft).




18. Install the intake manifold. Intake Manifold Replacement
19. Install the intake plenum. Intake Plenum Replacement
20. Install the intake air cleaner. Air Cleaner Assembly Replacement
21. Refill the coolant.
22. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

23. Install the EGR to exhaust manifold pipe.

Tighten
Tighten the EGR pipe bolts to 25 N·m (18 lb ft).




24. Raise the vehicle.
25. Install the exhaust manifold pipe gasket and assembly.
26. Install the exhaust manifold pipe nuts.

Tighten
Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N·m (25 lb ft).

27. Lower the vehicle.
28. Start the vehicle and inspect for exhaust leaks.