Cylinder Head Replacement
Removal Procedures1. Disconnect the negative battery cables.
^ For the front battery, refer to Battery Cable Replacement (Battery Cable Negative) in Starting and Charging.
^ For the auxiliary battery, refer to Battery Cable Replacement (Battery Cable Aux. Negative) in Starting and Charging.
2. Drain the cooling system.
3. Remove the engine cover from the vehicle.
4. Remove the air cleaner from the vehicle.
5. Remove the air intake duct from the turbocharger.
6. Remove the transmission oil level indicator and tube from the upper intake manifold.
7. Remove the fan shroud from the radiator.
8. Remove the drive belt from the pulleys.
9. Remove the engine cooling fan from the water pump pulley.
10. Remove the left accessory bracket from the engine block.
11. Remove the vacuum pump from the right accessory bracket.
12. Remove the right accessory bracket from the engine block.
13. Remove the heater hoses from the thermostat housing.
14. Remove the oil level indicator tube from the engine assembly.
15. Remove the thermostat housing crossover from the cylinder heads.
16. Remove the upper intake manifold from the lower intake manifold.
17. Remove the turbocharger from the engine block.
18. Remove the lower intake manifold from the cylinder heads.
19. Remove the front lower cylinder head bolt (5) and drain the coolant from the engine block.
19.1. Insert a cooper tube (3/8 inch x 12 to 18 inch long) and a hose into bolt hole (5)
19.2. Siphon coolant from the engine block
20. Remove the valve rocker arm covers from the cylinder heads.
21. Remove the valve rocker arms, shafts, and push rods from the cylinder heads.
22. Remove the exhaust manifolds from the cylinder heads.
23. Remove the copper tube used as a siphon from the cylinder head.
24. Remove the remaining cylinder head bolts from the cylinder heads in sequence.
25. Remove the cylinder heads from the engine block.
26. Remove the cylinder head gasket from the engine block.
27. Disassemble the cylinder heads.
Installation Procedures
1. Assemble the cylinder heads.
2. Install the cylinder head gasket to the engine block.
3. Install the cylinder heads to the engine block.
Notice: Refer to Fastener Notice in Service Precautions.
4. Install the cylinder head bolts and tighten in sequence in four passes.
4.1. Tighten the bolts to 25 Nm (20 ft. lbs.).
4.2. Tighten the bolts to 75 Nm (55 ft. lbs.).
4.3. Retighten the bolts to 75 Nm (55 ft. lbs.).
4.4. In sequence, tighten all bolts an additional 90 to 100 degrees (1/4+ turn).
5. Install the exhaust manifolds to the cylinder heads.
6. Install the valve rocker arms, shafts, and push rods to the cylinder heads.
7. Install the valve rocker arm covers to the cylinder heads.
8. Install the lower intake manifold to the cylinder heads.
9. Install the turbocharger to the engine block.
10. Install the upper intake manifold to the lower intake manifold.
11. Install the thermostat housing coolant crossover to the cylinder heads.
12. Install the transmission indicator and tube to the engine block.
13. Install the oil level indicator tube to the engine block.
14. Install the heater hoses to the thermostat housing.
15. Install the right accessory bracket to the engine block.
16. Install the vacuum pump to the right accessory bracket.
17. Install the left accessory bracket to the engine block.
18. Install the engine cooling fan on the water pump pulley.
19. Install the drive belt on the pulleys.
20. Install the fan shroud on the radiator.
21. Install the air intake duct to the turbocharger.
22. Install the air cleaner assembly in the vehicle.
23. Refill the cooling system.
24. Connect the battery negative cables to the batteries.
25. Install the engine cover in the vehicle.