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Cylinder Head Replacement (LLU/A16LET)

Cylinder Head Replacement (LLU/A16LET)

Removal Procedure


1. Remove the turbocharger. Refer to Turbocharger Replacement .

2. Remove the thermostat housing from the cylinder head. Refer to Engine Coolant Thermostat Housing Replacement (LAU/A28NER) Engine Coolant Thermostat Housing Replacement (LLU/A16LET) .

3. Remove the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (LLU/A16LET) .

4. Remove the brake booster vacuum pipe from the intake manifold. Refer to Power Brake Booster Vacuum Pipe Replacement .

5. Relief the fuel pressure. Refer to Fuel Pressure Relief .

6.
Note

Secure the fuel pipes with a cable tie.


Remove the fuel feed pipe and the fuel return pipe from the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .

7. Remove vacuum hose from the intake manifold.

8. Remove the wiring harness from the intake manifold.

9. Remove the camshaft cover from the cylinder head. Refer to Camshaft Cover Replacement .

10. Remove the timing belt. Refer to Timing Belt Replacement (LLU/A16LET) .

11. Install the engine support fixture (orange tool). Refer to Engine Support Fixture (Bridge Retainer Frame LLU/A16LET) Engine Support Fixture (Engine Bridge, Retainer Frame-LLU/A16) .

12. Remove the engine mount. Refer to Engine Mount Bracket Replacement .

13. Remove the camshaft exhaust sprocket. Refer to Camshaft Exhaust Sprocket Replacement (LLU/A16LET) .

14. Remove the camshaft intake sprocket. Refer to Camshaft Intake Sprocket Replacement (LDE/A16XER, 2H0/A18XER) .

15. Remove the timing belt rear cover. Refer to Timing Belt Rear Cover Replacement .

16. Remove the 10 cylinder head fasteners in sequence as shown.


• Loosen the 10 bolts 90 degrees .

• Loosen the 10 bolts 180 degrees .

17.
Note

Place the cylinder head on a suitable base.


With the aid of an assistant remove the cylinder head.

18. Remove the cylinder head gasket.


Installation Procedure


1. Clean the sealing surfaces.

2. Check the cylinder head and the cylinder block for plan surface. Refer to Cylinder Head Cleaning and Inspection .

3. Install a NEW cylinder head gasket.

4. With the aid of an assistant install the cylinder head.

5. Install 10 NEW cylinder head fasteners (1).


6. Refer to Fastener Caution .

Note

Note the correct tightening sequence.


Tighten the fasteners of the cylinder head in 5 passes.

• First pass in sequence to 25 Nm (18 lb ft)

• Second pass to 90 degrees

• Third pass to 90 degrees

• Fourth pass to 90 degrees

• Fifth pass to 45 degrees

7. Clean the 4 threads of the timing rear cover.

8. Install the timing belt rear cover. Refer to Timing Belt Rear Cover Replacement .

9. Clean the thread of the timing belt tensioner.

10. Install the camshaft intake sprocket. Refer to Camshaft Intake Sprocket Replacement (LDE/A16XER, 2H0/A18XER) .

11. Attach the camshaft exhaust sprocket. Refer to Camshaft Exhaust Sprocket Replacement (LLU/A16LET) .

12. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement .

13. Remove the engine support fixture (orange tool). Refer to Engine Support Fixture (Bridge Retainer Frame LLU/A16LET) Engine Support Fixture (Engine Bridge, Retainer Frame-LLU/A16) .

14. Install the timing belt. Refer to Timing Belt Replacement (LLU/A16LET) .

15. Install the camshaft cover to the cylinder head. Refer to Camshaft Cover Replacement .

16. Install the wiring harness to the intake manifold.

17. Install vacuum hose to the intake manifold.

18. Install the fuel feed pipe and the fuel return pipe to the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .

19. Install the brake booster vacuum pipe to the intake manifold. Refer to Power Brake Booster Vacuum Pipe Replacement .

20. Install the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (LLU/A16LET) .

21. Install the thermostat housing to the cylinder head. Refer to Engine Coolant Thermostat Housing Replacement (LAU/A28NER) Engine Coolant Thermostat Housing Replacement (LLU/A16LET) .

22. Install the turbocharger. Refer to Turbocharger Replacement .