Previous Next

Cylinder Head

Removal & Installation

2.0L Engine

To Remove:

  1. Relieve the fuel system pressure.
  2. Drain the coolant.
  3. Remove the under cover.
  4. Remove the air cleaner.
  5. Remove the water hose and pipe.
  6. Disconnect the accelerator cable.
  7. Disconnect the following connectors;
  8. Disconnect the brake booster vacuum hose.
  9. Disconnect the high pressure fuel line.
  10. Remove the upper front timing belt cover.
  11. Turn the crankshaft clockwise to align the timing mark so that No.1 cylinder is at TDC on the compression stroke.
  12. Secure the timing belt to the camshaft sprocket with clips or tie wraps.
  13. Remove the camshaft sprocket using special tool to prevent it from turning.

    14. Removing and installing cam sprocket bolt

  14. Remove the intake manifold stay connecting bolts.
  15. Loosen the cylinder head bolts using a cylinder head bolt wrench (special tool #MB991653). Loosen each of the bolts gradually and evenly in a few steps in the opposite of the tightening sequence.
  16. Remove the cylinder head assembly.
  17. Remove the cylinder head gasket.

To Install:

Cylinder head bolt tightening sequence (2.0L)

  1. Clean the sealing surfaces thoroughly.
  2. Install the cylinder head gasket making sure to match the holes carefully.
  3. Install the cylinder head assembly.
  4. Before installing the cylinder head bolts, make sure the shank length of each bolt does not exceed 3.91 in (99.4 mm). Before installing each bolt, coat the threads and washers with clean engine oil.

    5. Cylinder head bolt length (2.0L)

  5. Use a cylinder head bolt wrench to tighten the bolts to 55 ft-lbs (74 Nm) in the sequence shown.

    6. Cylinder head bolt wrench

  6. Completely loosen all bolts in the reverse of the tightening order.
  7. Retighten the bolts to 15 ft-lbs (20 Nm) in the sequence shown.
  8. Make a straight line mark across each bolt head and cylinder head. Tighten the cylinder head bolts 90° in the specified order.

    9. CAUTION
    Make sure each bolt is tightened EXACTLY 90°. If a bolt is under-tightened, it might not be correctly fastened, and if it is over-tightened, loosen it fully and retighten it.

  9. Tighten the bolts another 90° in the specified order. Make sure the alignment marks you made on the cylinder head bolts and the cylinder head line up correctly.
  10. Install the intake manifold stay connecting bolts.
  11. Install the camshaft sprocket using special tool to prevent it from turning.
  12. Install the upper front timing belt cover.
  13. Connect the high pressure fuel line.
  14. Connect the brake booster vacuum hose.
  15. Connect the following connectors;
  16. Connect the accelerator cable.
  17. Install the water hose and pipe.
  18. Install the air cleaner.
  19. Install the under cover.
  20. Refill the cooling system.
2.0L Turbo Engine

To Remove:

Cylinder head removal/installation (2.0L Turbo)

  1. Relieve the fuel system pressure.
  2. Remove the under cover and side cover.
  3. Drain the coolant and engine oil.
  4. Remove the strut tower bar.
  5. Remove the air cleaner and air duct.
  6. Remove the battery.
  7. Disconnect the accelerator cable.
  8. Remove the center cover from the rocker cover.
  9. Remove the radiator.
  10. Remove the front axle crossmember bar.
  11. Remove the front exhaust pipe.
  12. Remove the starter.
  13. Remove the timing belt.
  14. Remove the engine control and transaxle wiring harness.
  15. Remove the ground cable.
  16. Remove the EGR vacuum regulator valve and bracket.
  17. Disconnect the brake booster vacuum hose.
  18. Remove the engine oil dipstick and tube.
  19. Disconnect the EVAP purge hose.
  20. Remove the generator bracket bolt.
  21. Remove the battery wiring harness.
  22. Remove the intake manifold stay.
  23. Remove the oil return tube.
  24. Remove the turbo bracket.
  25. Disconnect the coolant hose.
  26. Disconnect the fuel lines.

    27. Cylinder head bolt wrench (#MB991654)

  27. Loosen the cylinder head bolts using a cylinder head bolt wrench (special tool #MB991654). Loosen each of the bolts gradually and evenly in a few steps in the opposite of the tightening sequence.
  28. Remove the cylinder head assembly.
  29. Remove the cylinder head gasket.

To Install:

  1. Clean the sealing surfaces thoroughly.
  2. Install the cylinder head gasket. Make sure the mark "63" is facing up on the exhaust side.

    3. Cylinder head gasket id mark location

  3. Install the cylinder head assembly.
  4. Before installing the cylinder head bolts, make sure the shank length of each bolt does not exceed 3.91 in (99.4 mm). Before installing each bolt, coat the threads and washers with clean engine oil.

    5. Cylinder head bolt length

  5. Use a cylinder head bolt wrench (#MB991654) to tighten the bolts to 58 ft-lbs (78 Nm) in the sequence shown.

    6. Cylinder head bolt wrench (#MB991654)

    Cylinder head bolt tightening sequence (2.4L)

  6. Completely loosen all bolts in the reverse of the tightening order.
  7. Retighten the bolts to 15 ft-lbs (20 Nm) in the sequence shown.
  8. Make a straight line mark across each bolt head and cylinder head. Tighten the cylinder head bolts 90° in the specified order.

    9. CAUTION
    Make sure each bolt is tightened EXACTLY 90°. If a bolt is under-tightened, it might not be correctly fastened, and if it is over-tightened, loosen it fully and retighten it.

  9. Tighten the bolts another 90° in the specified order. Make sure the alignment marks you made on the cylinder head bolts and the cylinder head line up correctly.
  10. Install the oil return tube.
  11. Connect the fuel lines.
  12. Connect the coolant hose.
  13. Install the turbo bracket.
  14. Install the intake manifold stay.
  15. Install the battery wiring harness.
  16. Install the generator bracket bolt.
  17. Connect the EVAP purge hose.
  18. Install the engine oil dipstick and tube.
  19. Connect the brake booster vacuum hose.
  20. Install the EGR vacuum regulator valve and bracket.
  21. Install the ground cable.
  22. Install the engine control and transaxle wiring harness.
  23. Install the timing belt.
  24. Install the starter.
  25. Install the front exhaust pipe.
  26. Install the front axle crossmember bar.
  27. Install the radiator.
  28. Install the center cover from the rocker cover.
  29. Connect the accelerator cable.
  30. Install the battery.
  31. Install the air cleaner and air duct.
  32. Install the strut tower bar.
  33. Install the under cover and side cover.
  34. Add the correct amount of new oil to the engine.
  35. Refill the cooling system.
2.4L Engine

To Remove:

Cylinder head removal/installation 1 of 2 (2.4L)

Cylinder head removal/installation 2 of 2 (2.4L)

  1. Relieve the fuel system pressure.
  2. Drain the coolant.
  3. Remove the strut tower bar.
  4. Remove the engine cover.
  5. Remove the air cleaner.
  6. Disconnect the accelerator cable.
  7. Remove the control wiring harness.
  8. Remove the battery wiring harness.
  9. Remove the lower radiator hose routing bracket.
  10. Disconnect the EVAP hose.
  11. Disconnect the brake booster vacuum hose.
  12. Remove the engine oil dipstick and tube.
  13. Disconnect the knock sensor.
  14. Remove the battery harness.
  15. Remove the intake manifold stay.
  16. Remove the exhaust manifold from the cylinder head.
  17. Remove the upper timing belt cover.
  18. Turn the crankshaft clockwise and align the timing marks.
  19. Secure the belt to the camshaft sprocket with plastic tie wraps.
  20. Install special tool MD998738 through the timing belt under cover as shown to relieve the tension on the timing belt.

    21. Install special tool MD998738 through the timing belt under cover (2.4L)

    Use special tool MD998738 to relieve the tension on the belt (2.4L)

    Cylinder head bolt wrench (#MB991654)

  21. Remove the camshaft sprocket with timing belt attached.
  22. Disconnect the upper radiator hose connection.
  23. Disconnect the coolant hose connection.
  24. Disconnect the fuel line.
  25. Remove the rocker arm cover.
  26. Loosen the cylinder head bolts using a cylinder head bolt wrench (special tool #MB991654). Loosen each of the bolts gradually and evenly in a few steps in the opposite of the tightening sequence.
  27. Remove the cylinder head assembly.
  28. Remove the cylinder head gasket.

To Install:

Cylinder head bolt tightening sequence (2.4L)

  1. Clean the sealing surfaces thoroughly.
  2. Install the cylinder head gasket. Make sure the mark "381" is facing up on the exhaust side.
  3. Install the cylinder head assembly.
  4. Before installing the cylinder head bolts, make sure the shank length of each bolt does not exceed 3.91 in (99.4 mm). Before installing each bolt, coat the threads and washers with clean engine oil.
  5. Use a cylinder head bolt wrench (#MB991654) to tighten the bolts to 58 ft-lbs (78 Nm) in the sequence shown.

    6. Cylinder head bolt wrench (#MB991654)

  6. Completely loosen all bolts in the reverse of the tightening order.
  7. Retighten the bolts to 15 ft-lbs (20 Nm) in the sequence shown.
  8. Make a straight line mark across each bolt head and cylinder head. Tighten the cylinder head bolts 90° in the specified order.

    9. CAUTION
    Make sure each bolt is tightened EXACTLY 90°. If a bolt is under-tightened, it might not be correctly fastened, and if it is over-tightened, loosen it fully and retighten it.

  9. Tighten the bolts another 90° in the specified order. Make sure the alignment marks you made on the cylinder head bolts and the cylinder head line up correctly.
  10. Install the rocker arm cover.
  11. Connect the fuel line.
  12. Connect the coolant hose connection.
  13. Connect the upper radiator hose connection.
  14. Install the camshaft sprocket.
  15. Remove the special tool to apply tension to the timing belt.
  16. Remove the tie wraps and verify correct timing mark alignment.
  17. Install the upper timing belt cover.
  18. Install the exhaust manifold from the cylinder head.
  19. Install the intake manifold stay.
  20. Install the battery harness.
  21. Connect the knock sensor.
  22. Install the engine oil dipstick and tube.
  23. Connect the brake booster vacuum hose.
  24. Connect the EVAP hose.
  25. Install the lower radiator hose routing bracket.
  26. Install the battery wiring harness.
  27. Install the control wiring harness.
  28. Connect the accelerator cable.
  29. Install the air cleaner.
  30. Install the engine cover.
  31. Install the strut tower bar.
  32. Refill the cooling system.

Previous Next