Cylinder Head Assembly: Service and Repair
Cylinder head/gasket, replacing
Note! The illustrations in this service information are used for different model years andlor models. Some variation may occur. However, the essential information in the illustrations is always correct.
Note! There are a number of versions of the variable valve timing unit. Therefore it is extremely important to always read the information referring to the engine variant/model year to be remedied.
Removal
Preparation
Remove
- the radiator breather tube from the expansion tank. Install lock grip pliers
- the cap from the expansion tank
- the battery negative lead.
- the right front wheel
- the plastic nuts on the cover at the right fender liner.
Draining the coolant
Raise the car. Remove the splash guard from under the engine.
Open the engine nipple.
Drain the coolant into a container.
Close the nipple.
Remove the screw that holds the inlet pipe for the coolant pump to the cylinder block.
Separating the exhaust system
Release the heated oxygen sensor (HO2S) wiring from the rear engine mounting.
Remove the nuts where the manifold and the front exhaust pipe divide.
Disconnect the brake pipe from the holder on the SIPS member.
Remove the screws holding the SIPS member to the bodywork.
Press the exhaust system backward.
Removing components
Remove
- the cross stay between the suspension turrets
- the hose and connector from the air assisted control valve
- the intake hose between the mass air flow (MAF) sensor and the electronic throttle module (ETM)
- the crankcase ventilation hose from the connection at the inlet hose
- the cover over the ignition coils
- the upper timing cover.
Remove
- the ground strip from the cylinder head
- the air preheater hose between the air cleaner and the heat deflector plate above the manifold
- the torque rod bracket
- the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head
- the camshaft position sensor (CMP) housing and trigger wheel
- the cover at the rear edge of the exhaust camshaft
- the mounting screws for the ignition coil and the screws for the two ground terminals
- the connector from the variable valve timing solenoid. Lift up and put the ignition coils and wiring to one side.
Note! Mark up the ignition coils before removal.
Remove the crankcase ventilation hose from the top of the camshaft cover.
Draining the fuel line
Drain the fuel line. See Draining the fuels system
Removing the fuel rail
Remove
- the injector covers
- the connectors from the injectors. Place the wiring to one side.
Separate the fuel line quick-release connector. Use tool 951 2666.
Remove the screws holding the fuel pipe and air distribution pipe to the intake manifold.
Carefully pull off the fuel pipe and the air distribution pipe as one.
Removing the intake manifold
Remove
- all 5 vacuum hoses from the intake manifold. (see the illustration)
- the screw holding the dip stick pipe to the intake manifold
- the screw at the support bracket (under the intake manifold)
- the starter motor. Place it to one side.
Disconnect the connector for the electronic throttle module.
Remove
- the upper coolant hose from the thermostat housing.
Fold the hose out of the way
- the upper screws securing the intake manifold to the cylinder head. Lift up and twist the intake manifold. This is so that the fuel pressure pipe releases from the intake manifold.
Note! Handle the fuel pressure pipe carefully so that it is not damaged.
- the hose for the water-heated crankcase ventilation from the thermostat housing.
Disconnect the connector for the coolant temperature sensor.
Setting up the engine
Separate the connectors for the ABS sensor and level sensor in the expansion tank.
Lift up the expansion tank and the brake fluid reservoir. Place them on top of engine.
Warning! Ensure that no servo oil leaks out. It is extremely flammable!
Remove the auxiliaries belt.
Remove the front timing cover.
Position the upper timing cover.
Turn the crankshaft clockwise until the markings at the crankshaft and camshafts are aligned with the markings on the oil pump and the upper timing cover.
Remove the upper timing cover.
Removing the timing belt
Slacken off the center screw for the belt tensioner slightly.
Hold the center screw secure. Turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock.
Remove
- the timing belt from the timing gear pulleys for the camshafts
- the screw that holds the inner timing cover to the cylinder head.
Install tool 999 5452 at the rear of the camshafts.
Removing the timing gear pulley
Remove
- the plug at the front of the variable valve timing unit (TX55)
- the center screw in the variable valve timing unit (TX55).
Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.
Timing gear pulleys without variable valve timing units:
Remove the screws. Remove the timing gear pulley.
Remove tool 999 5452.
Reinstall the expansion tank and the brake fluid reservoir at the right wheel arch.
Releasing the inlet pipe for the coolant pump
Remove the two screws at the coolant pipe connection to the bypass channel.
Carefully turn the pipe to remove it from the cylinder block.
Removing the camshaft cover and cylinder head
Remove
- Variable valve timing solenoid
- spark plugs for cylinders 1 and 5.
Install 2 tools 999 5454. Leave a 2-3 mm gap to the camshaft cover.
Ensure that the screw in the spark plug well is fully tightened.
The screws holding the camshaft cover to the cylinder head.
Use pliers 999 5670 to lift the cover from the cylinder head.
Install the pliers at the stop lugs.
Start with cylinder 1 and work alternately backward.
Slacken off the wing nuts approximately 2 turns. Repeat the procedure.
Carefully press out the front and rear camshaft seals.
Note! Take care not to damage the sealing surfaces on the camshafts.
Remove
- tools 999 5454
- the camshaft cover
- the camshafts.
Lift out the valve lifters. Use a magnet or a suction cup.
Note! Mark up and position the lifters so that their original positions can be established.
Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center.
Get help to lift off the cylinder head.
Note! Do not damage the mating surfaces.
When replacing or working on the cylinder head
Remove
- the thermostat housing
- the heat deflector plate above the manifold
- the manifold and gaskets.
Note! Do not damage the mating surfaces.
Cleaning
Clean the gasket faces for:
- the manifold. Check that the studs are tightened
- the coolant bypass channel
- the thermostat housing
- the intake manifold
- the cylinder block
- camshaft cover.
Blow the oil ducts clean.
Note! Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.
Warning! Use a fume hood or extractor when using gasket solvent!
Installing the cylinder head
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling
Tightening torques
Note! For tightening torques not in the text, see Tightening torque
Aligning the crankshaft
Remove the blind cover plug.
Turn the crankshaft clockwise slightly.
Install the crankshaft stop 999 5451. Ensure that it bottoms out against the cylinder block.
Turn the crankshaft counter-clockwise until it stops against the crankshaft stop.
Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
When replacing or working on the cylinder head
Install
- thermostat housing. Use a new gasket
- the manifold. Use new gaskets. Lubricate the studs using paste 116 1408
- the heat deflector plate above the manifold.
Note! Handle the cylinder head carefully so that the gasket faces are not damaged.
Installing the cylinder head
Install a new cylinder head gasket.
Install the cylinder head.
Ensure that no wiring or hoses are trapped between the cylinder head and cylinder block.
Use new screws. Lubricate and install all the screws. Tighten the screws as illustrated.
Tighten the screws in the following order:
1. 20 Nm
2. 60 Nm
3. Angle-tighten 130°. Use protractor 951 2050.
Installing valve lifters and camshafts
Note! When installing a new cylinder head, the valve clearance must be set. See Valve clearance setting/adjusting.
Lubricate the valve guide wells.
Install all the valve lifters.
Note! Make sure that the lifters are in the same position as before.
Lubricate the camshaft bearing seats.
Install the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line.
Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line.
Applying liquid gasket
Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.
Install new 0-rings around the spark plug wells at the cylinder head.
Apply liquid gasket 116 1059 on the camshaft cover. Use roller 951 2767.
The surface must be completely covered without any excess.
Caution! Ensure that no liquid gasket gets into the oil ducts.
Installing the camshaft covers
Lubricate the camshaft lobes the camshaft bearing surfaces and the top of the valve lifters.
Install the camshaft cover.
Install press tool 999 5454 (2x).
Tighten the camshaft cover screws alternately keeping it parallel to the cylinder head using the press tools. Install all the screws. Tighten the screws from the middle and outwards.
Remove the press tools.
Install
- the variable valve timing (VVT) solenoid. Use a new gasket
- the spark plugs. Tighten to 30 Nm
- the hose for the water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.
Connect the connector to the coolant temperature sensor.
Installing the intake pipe for the coolant pump
Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.
Note! Apply thread sealant, P/N 116 056, to the screw threads.
Installing the rear camshaft seal
To clean the shaft journal and mating surface use emery cloth P/N 951 1024.
Note! When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.
Use drift 999 5450.
Lubricate the surface of the seal that the camshaft rotates against.
Press in the seal until the drift bottoms out.
Note! If there are wear grooves on the camshaft, the seal can be pressed in a further 2 mm by reversing the sleeve.
Install camshaft adjustment tool 999 5452 at the rear of the camshafts.
Check that the screws securing the adjustment tool to the camshafts and the screws holding the tool together are well tightened.
Installing the front camshaft seal
Lift up the brake fluid reservoir and the expansion tank. Place them on top of engine.
Use drift 999 5718 on camshafts with variable valve timing units. Use drift 999 5719 on camshafts without variable valve timing.
Lubricate the surface of the seal that the camshaft rotates against.
Use the variable valve timing unit/timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.
Remove the drift
Install the screw holding the inner timing cover to the cylinder head.
Installing the timing gear pulley for the camshafts
Note! The purpose of the section, "Installing the VVT unit/timing gear pulley", described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.
Timing gear pulleys with variable valve timing units
Slacken off but do not remove the screws which secure the timing gear pulley to the variable valve timing unit. Press the variable valve timing unit I timing gear on to the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
Turn the variable valve timing unit counter-clockwise as far as it will go.
Remove the center screw. Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.
Continue turning clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover.
Caution! Do not turn counter-clockwise during this procedure!
Check that the timing gear pulley is still in its limit position at the oval holes.
Tighten the center screw for the variable valve timing (VVT) unit. Tighten to 120 Nm.
Check that the variable valve timing unit does not rotate when tightening.
Install the center plug. Tighten to 35 Nm.
Timing gear pulleys without variable valve timing units
Install the timing gear pulley and the screws. Install two screws without tightening. Allow the third screw to protrude.
Adjust the timing gear pulleys so that the markings on the timing gear pulleys/upper timing cover correspond.
Installing the timing belt
Tighten the center screw on the belt tensioner. Tighten to 5 Nm.
Turn the variable valve timing unit clockwise to the stop. Hold it secure in the limit position (see the illustration). Install the belt in the following order:
1. Crankshaft
2. Idler pulley
3. Intake camshaft
4. Exhaust camshaft
5. Water pump
6. Belt tensioner
Note! Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.
Check that the markings correspond.
Tensioning the timing belt
This adjustment is always carried out on a cold engine. A suitable temperature is approximately 20°C.
At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Hold the center screw secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
Tighten the three screws at the timing gear pulley for the intake camshaft. Tighten to 10 Nm.
Tighten the three screws at the timing gear pulley for the exhaust camshaft. Tighten to 20 Nm.
Note! The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.
Turn the eccentric back so that the indicator reaches the marked position in the center of the window.
Remember to hold the center screw secure at the same time.
Secure the eccentric and tighten the center screw. Tighten to 20 Nm.
Check that the indicator is in the correct position.
Remove camshaft adjustment tool 999 5451. Remove crankshaft stop 999 5452.
Install the plug with a new sealing washer. Tighten to 40 Nm.
Checking the markings and belt tension
Press the timing belt to check that the indicator on the tensioner moves easily.
Position the upper timing cover
Turn the crankshaft two turns. Check that the markings on the crankshaft timing gear pulley and the camshaft timing gear pulley match up with the markings on the oil pump and upper timing cover respectively.
Check that the indicator on the belt tensioner is within the marked position.
Remove the upper timing cover.
Installing components
Install
- front timing cover
- the auxiliaries belt
- the expansion tank
- the servo oil reservoir
- the bleed hose for the expansion tank. Tighten the clamp.
Check that the hoses are correctly positioned.
Connect the connectors for:
- The ABS sensor by the right suspension turret
- the coolant level sensor in the expansion tank.
Install
- the starter motor
- the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm
- the trigger wheel. Ensure that the trigger wheel is correctly positioned against the camshaft
- the camshaft position (CMP) sensor housing
- a new cover at the rear edge of the exhaust camshaft
- the upper torque rod bracket.
Installing the intake manifold and gasket
Note! Ensure that the gasket faces are clean.
Install
- a new gasket. The gasket is held in position by the lower screws for the intake manifold
- the intake manifold. Lower and turn the pipe so that the fuel pressure pipe enters the cavity in the intake pipe at cylinders 1 and 2.
Note! Handle the fuel pressure pipe carefully so that it is not damaged.
- the remaining screws holding the intake manifold to the cylinder head. Tighten to 20 Nm.
Route the crankcase ventilation hose through the cavity in the intake manifold at cylinders 2 and 3.
- all the vacuum hoses (see the illustration)
- the screw at the support bracket under the intake manifold
- the screw holding the dip stick pipe to the intake manifold.
Connect the throttle body (TB) connector to the engine wiring.
Installing the fuel and air distribution pipe
Lubricate the 0-rings on the air distribution pipe. Use lubricant 1161 380.
Install the fuel/air distribution pipe. Use new screws.
Route the crankcase ventilation hose. Connect it to the top of the camshaft cover. Use a new clamp.
Press the quick-release connector for the fuel pressure line until it clicks. Pull the connection to check that it is secure.
Install
- the connectors for the injectors
- the cover plate over the connectors
- the upper coolant hose. Tighten the clamp.
Installing components
Install
- the ignition coils according to the earlier markings. Check that the connectors for the ignition coils are secure
- the screws for both the ground terminals between the ignition coils
- the screws holding both the ground strips from the firewall to the cylinder head
- the cover over the ignition coils
- the upper timing cover
- the air preheater hose between the air cleaner and the heat deflector plate above the manifold
- the inlet hose between the mass air flow (MAF) sensor and the electronic throttle module
- the crankcase ventilation hose to the nipple on the inlet hose
- the hose and connector for the air assisted control valve. Tighten the clamp
- the engine stabilizer brace between the suspension turrets. Secure the servo hose to the right mounting on the support brace.
Assembling the exhaust system
Install new gasket at the manifold. Lubricate the studs. Use paste 116 1408.
Lift up and align the front exhaust system against the manifold.
Install the screws holding the SIPS member to the bodywork. Tighten the screws.
Press the brake pipe into place in the holders on the SIPS member.
Secure the wiring for the front heated oxygen sensor (H02S) in the clip at the rear engine mounting.
Note! Check that the wiring for the heated oxygen sensor (HO2S) is not too close to the exhaust system.
Install new nuts where the front exhaust system and the manifold divide. Tighten.
Finishing
Install
- the screw that holds the inlet pipe for the coolant pump to the cylinder block
- the splash guard under the engine
- the nuts for the cover in the right fender liner
- the right front wheel. See inst~allin wheels
- the battery negative lead.
Check
Replace the oil and oil filter.
Check:
- the engine oil level
- the servo oil level
- the coolant level.
Warm up the engine until the thermostat opens.
Check the engine for leaks
Top up the coolant if necessary.