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In-vehicle Repair|Oil Pan > < Exhaust Manifold

Galaxy 2000.75 (04.2000-02.2006)

Engine - 2.8L - Cylinder Head Galaxy 2000.75 (04/2000-02/2006)
In-vehicle Repair

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

Alignment Plate, Camshaft

303-696 (21-249)

Wrench, Crankshaft

303-697 (21-250)
Materials
Name
Specification
Engine oil
ACEA A3/B3 
Sealer
AMV 188 001 02 

Removal

  1. Remove the valve cover.
    For additional information, refer to Valve Cover in this section.

  1. Detach the battery junction box (BJB) from the radiator grille opening panel reinforcement.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Disconnect the oil level and temperature sensor electrical connector.

  1. Detach the wiring harness from the brackets (engine shown removed for clarity).

  1. Disconnect the exhaust downpipe from the exhaust manifold (six nuts).
    • Discard the gaskets.

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Rotate the engine until piston No. 1 is at top dead center (TDC).
  1. Lower the vehicle.

  1. Detach the knock sensor (KS) electrical connector from the bracket.

  1. Detach the wiring harness from the bracket.
  1. NOTE:
    NOTE:Use a suitable wooden block to support the engine.
    Position a trolley jack with the wooden block under the oil pan and raise the engine so that the engine front mount is free from load.

  1. NOTE:
    NOTE:Do not remove the engine front mount bracket nuts and bolts.
    Loosen the engine front mount bracket nuts and bolts.
    1. Detach the ground cable.
    1. Loosen the nuts and bolts.

  1. Remove the accessory drive belt tensioner.

  1. Detach the wiring harness bracket from the cylinder head.

  1. Detach the secondary air injection (AIR) pipe and the low pressure pipe from the secondary air injection valve.

  1. NOTE:
    NOTE:Mark the positions of the electrical connectors.
    Disconnect the camshaft position (CMP) sensor electrical connectors, and the intake and exhaust camshaft control valve electrical connectors.

  1. Using the special tool, disconnect the coolant hoses from the thermostat housing.

  1. Disconnect the engine coolant temperature (ECT) sensor electrical connector.

  1. Disconnect the engine cooling fan temperature switch electrical connector.

  1. Using the special tool, disconnect the coolant hose from the cylinder head.

  1. Remove the timing chain tensioner.

  1. Remove the timing chain upper cover.
    • Discard the gaskets.

  1. Remove the timing chain upper guide.

  1. NOTE:
    NOTE:Use an open ended wrench to prevent the camshaft from turning.
    Remove the exhaust camshaft adjuster.

  1. NOTE:
    NOTE:Using a suitable piece of wire, prevent the timing chain from dropping into the timing case.
    Detach the timing chain from the intake camshaft adjuster.

  1. Disconnect the fuel injector electrical connectors.

  1. CAUTION:
    CAUTION:The cylinder head must have cooled to below 30°C before removing.
    CAUTION:
    CAUTION:Loosen the cylinder head bolts in the sequence shown.
    Remove the cylinder head.
    • Discard the gasket.

Installation

  1. Raise and support the vehicle. For additional information, refer to Section  100-00 General Information.
  1. NOTE:
    NOTE:Guide the timing chain when rotating the crankshaft.
    NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Rotate the engine until piston No. 1 is 25 mm before top dead center (TDC).
  1. Lower the vehicle.
  1. Clean the mating faces of the cylinder head and the cylinder block.

  1. NOTE:
    NOTE:Note the position of the locating sleeves in cylinder block holes 12 and 20.
    NOTE:
    NOTE:The correct location of the bolts (different bolt lengths).
    NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:The inscription of the cylinder head gasket must be legible.
    Install the cylinder head.
    • Tighten the bolts in the sequence shown in four stages.

        • 1. Stage 1: 30 Nm

        2. Stage 2: 50 Nm

        3. Stage 3: 90 degrees

        4. Stage 4: 90 degrees

  1. Connect the fuel injector electrical connectors.

  1. Install the special tool.
  1. Raise and support the vehicle. For additional information, refer to Section  100-00 General Information.

  1. NOTE:
    NOTE:Guide the timing chain when rotating the crankshaft.
    NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Rotate the engine until piston No. 1 is at TDC.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:The silver colored link of the timing chain must align with the arrow on the intake camshaft adjuster.
    CAUTION:
    CAUTION:The arrow on the intake camshaft adjuster must align with the mark on the camshaft control housing.
    Attach the timing chain to the intake camshaft adjuster.

  1. Rotate the camshaft position (CMP) signal generating disc clockwise until it stops.

  1. CAUTION:
    CAUTION:The silver colored link of the timing chain must align with the arrow on the exhaust camshaft adjuster.
    CAUTION:
    CAUTION:The arrow on the exhaust camshaft adjuster must align with the mark on the camshaft control housing.
    Install the exhaust camshaft adjuster.

  1. Remove the special tool.

  1. NOTE:
    NOTE:Install a new camshaft adjuster retaining bolts.
    NOTE:
    NOTE:Use an open ended wrench to prevent the camshafts from turning.
    Install both camshaft adjuster retaining bolts (exhaust camshaft retaining bolt shown).
    • Tighten the bolt in two stages.
    • Stage 1: 60 Nm
    • Stage 2: 90 degrees

  1. Install the timing chain guide.

  1. Apply sealer into the bore of the cylinder head gasket and to the mating faces of the timing chain upper cover.

  1. Install the timing chain upper cover.
    1. Tighten the bolts.
    1. Tighten the bolts

  1. Install the timing chain tensioner.

  1. Using the special tool, connect the coolant hose to the cylinder head.

  1. Connect the engine cooling fan temperature switch electrical connector.

  1. Connect the engine coolant temperature (ECT) sensor electrical connector.

  1. Using the special tool, connect the coolant hoses to the thermostat housing.

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Rotate the engine two revolutions until piston No. 1 is at TDC.

  1. CAUTION:
    CAUTION:The silver colored link of the timing chain must align with the arrow on the exhaust camshaft adjuster.
    CAUTION:
    CAUTION:The arrow on the exhaust camshaft adjuster must align with the mark on the camshaft control housing.
    CAUTION:
    CAUTION:The silver colored link of the timing chain must align with the arrow on the intake camshaft adjuster.
    CAUTION:
    CAUTION:The arrow on the intake camshaft adjuster must align with the mark on the camshaft control housing.
    Check the position of the intake camshaft adjuster in relation to the exhaust camshaft adjuster.
    • The distance between the arrows on the camshaft adjusters must be 16 rollers of the timing chain.

  1. Connect the CMP sensors, intake and exhaust camshaft control valve electrical connectors.

  1. Attach the secondary air injection (AIR) pipe and the low pressure pipe to the secondary air injection valve.

  1. Attach the wiring harness bracket to the cylinder head.

  1. Install the accessory drive belt tensioner.

  1. Tighten the engine front mount nuts and bolts.
    1. Tighten the nuts and bolts.
    1. Attach the ground cable.
  1. Remove the trolley jack and the wooden block.

  1. Attach the wiring harness to the bracket.

  1. Attach the knock sensor (KS) electrical connector to the bracket.
  1. Raise and support the vehicle. For additional information, refer to Section  100-00 General Information.

  1. NOTE:
    NOTE:Install new exhaust flange gaskets.
    Connect the exhaust downpipe to the exhaust manifold (six nuts).

  1. Attach the wiring harness to the brackets (engine shown removed for clarity).

  1. Connect the oil level and temperature sensor electrical connector.
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.
  1. Lower the vehicle.
  1. Attach the battery junction box (BJB) to the radiator grille opening panel reinforcement.
  1. Drain the engine oil.
    • Allow the oil to drain into a suitable container.
    • Discard the oil drain plug washer.

  1. NOTE:
    NOTE:Install a new oil drain plug washer.
    Install the oil drain plug.

  1. Install the engine undershield (two nuts and four bolts).
  1. Lower the vehicle.
  1. Install the valve cover.
    For additional information, refer to Valve Cover in this section.
  1. Fill the engine with engine oil.
  1. Fill the engine cooling system. For additional information, refer to Section  303-03A Engine Cooling / 303-03B Engine Cooling.

In-vehicle Repair|Oil Pan > < Exhaust Manifold