Cylinder Head Replacement (1.4L LUH and LUJ)
Special Tools
• |
EN-470-B
Angular Torque Wrench |
• |
EN-955-1
Fixing Pin from EN-955 Kit |
For equivalent regional tools, refer to
Special Tools .
Removal Procedure
3. |
Remove the engine sight
shield. |
8. |
Remove the engine control
module wiring harness (1) from camshaft cover: |
|
• |
Disconnect the intake camshaft
position sensor wiring harness plug (7). |
|
• |
Disconnect the intake camshaft
position actuator solenoid valve wiring harness plug (6).
|
|
• |
Disconnect the exhaust
camshaft position sensor wiring harness plug (4). |
|
• |
Disconnect the exhaust
camshaft position actuator solenoid valve wiring harness plug
(5). |
|
• |
Disconnect the engine coolant
temperature sensor wiring harness plug (3). |
9. |
Place a drain pan underneath
the vehicle. |
10. |
Remove the oil cooler inlet
hose clamp and the oil cooler inlet hose (1). |
11. |
Remove the radiator inlet hose
clamp and the radiator inlet hose (4). |
12. |
Remove the engine coolant air
bleed hose (2). |
13. |
Disconnect the engine coolant
temperature sensor wiring harness plug (3). |
15. |
Remove the ground cable bolt
(2) and the ground cable (1). |
16. |
Unclip the radiator outlet
hose quick connector clamp (2). |
17. |
Remove the radiator outlet
hose (3) from the engine coolant thermostat housing (1).
|
21. |
Remove 5 engine front cover
bolts (1, 2). |
22. |
Remove 3 water pump bolts
(3). |
29. |
Remove the timing chain
tensioner plug (1) from the engine front cover. |
|
Note: Remove and
reinstall the EN-953-A fixing tool for this
step.
|
30. |
Install a wrench (1) to the
hexagon of the intake camshaft and rotate it in direction of the
arrow to apply tension to the timing chain and hold. |
31. |
Install EN-955-1
pin (2) to the timing chain tensioner bore (1) to secure it
in place. |
32. |
Remove the wrench from the
intake camshaft. |
33. |
Remove 2 upper timing chain
guide bolts (1). |
34. |
Remove upper timing chain
guide (2). |
35. |
Loosen the intake camshaft
sprocket bolt (2) while holding the hexagon of intake camshaft
sprocket with a wrench (1). |
36. |
Loosen the exhaust camshaft
sprocket bolt while holding with a wrench. |
37. |
Remove the 2 camshaft sprocket
bolts (2) and the 2 camshaft position exciter wheels (1).
|
38. |
Remove the 2 camshaft
sprockets (2) along with the timing chain (1) and place it in the
engine front cover. |
39. |
Loosen the 12 cylinder head
bolts in the sequence as shown. Use the following procedure:
|
|
39.1 |
Loosen the cylinder head bolts
90° . |
|
39.2 |
Loosen the cylinder head bolts
180° . |
40. |
Remove and DISCARD the 12
cylinder head bolts. |
41. |
Move the cylinder head
assembly slightly in direction of the transmission. |
|
Note: Mind the timing
chain tensioner and the timing chain guide pin.
|
|
Note: A second
technician is required.
|
42. |
Remove the cylinder head
assembly. |
43. |
Remove the cylinder head
gasket. |
44. |
Remove the assembly parts from
cylinder head: |
|
• |
Remove the EN-953-A
fixing tool . |
|
• |
Remove the 3 engine lift
brackets. |
Installation Procedure
1. |
Install the cylinder head
assembly parts: |
|
• |
Install the 3 engine lift
brackets. |
|
• |
Install the 3 engine lift
bracket bolts and tighten to 22 N·m (16 lb
ft) . |
|
Note: Adjust the camshafts
using the hexagon and a wrench.
|
|
|
|
|
• |
Install the EN-953-A
fixing tool . |
2. |
Cut the 2 elastomer sealing
lips (1) from engine front cover gasket. |
3. |
Bend down the engine front
cover gasket at the predetermined breaking points (arrows).
|
4. |
Clean sealing surfaces of
engine front cover and engine block from grease and old gasket
material. |
|
Note: The thickness
of the sealing bead should be 2 mm (0.0787 in)
.
|
|
Note: Mind the
marking on the cylinder head gasket for top side.
|
7. |
Install the cylinder head
gasket to engine block. |
8. |
Install 2 engine front cover
bolts (1) in order to guide the NEW upper engine front cover
gasket. |
9. |
Install the NEW upper engine
front cover gasket. |
10. |
Apply sealing compound to the
shown areas (2). The thickness of the sealing bead should be
2 mm (0.0787 in) . |
|
Note: A second
technician is required. Guide the timing chain guide pin (2) to the
timing chain guide and the timing chain tensioner (1) with the
installed fixing pin through the timing chain tensioner plug bore
in engine front cover.
|
11. |
Install the cylinder head
(3). |
12. |
Loosely install 12 NEW
cylinder head bolts. |
13. |
Adjust the cylinder head to
the engine front cover. Use a rubber mallet. |
14. |
Locate the engine front cover
to cylinder head by installing 3 bolts (1). |
15. |
Tighten the 3 bolts (1) to
8 N·m (71 lb in) . |
16. |
Tighten the cylinder head
bolts in the sequence as shown and in the following order:
|
|
16.1 |
Tighten the cylinder head
bolts to 35 N·m (26 lb ft) . |
|
16.2 |
Tighten the cylinder head
bolts an additional 180° . Use
EN-470-B wrench . |
17. |
Loosen the 3 bolts from engine
front cover. |
18. |
Install the 5 remaining bolts
to engine front cover and water pump. |
19. |
Tighten the 5 engine front
cover bolts (1, 2) to 8 N·m (71 lb in)
. |
20. |
Tighten the 3 water pump bolts
(3) to 8 N·m (71 lb in) . |
26. |
Install the 2 camshaft
sprockets (2) along with the timing chain (1). |
|
Note: Camshaft
position exciter wheels should stay rotatable.
|
27. |
Install the 2 camshaft
position exciter wheels (1) and the 2 camshaft sprocket bolts
(2). |
29. |
Rotate the crankshaft for
720° and check the engine timing again. Repeat the adjustment
procedure if necessary. |
34. |
Connect radiator outlet hose
(3) to engine coolant thermostat housing (1). Clip quick connector
(2). |
35. |
Install the ground cable (1)
and the ground cable bolt (2) and tighten to 20 N·m
(15 lb ft) . |
36. |
Install the radiator inlet
hose (4) and the radiator inlet hose clamp to the water
outlet. |
37. |
Install the oil cooler inlet
hose (1) and the oil cooler inlet hose clamp to the water
outlet. |
38. |
Connect the engine coolant air
bleed hose (2) to the water outlet. |
39. |
Connect the engine coolant
temperature sensor wiring harness plug (3). |
41. |
Install the engine control
module wiring harness to the camshaft cover: |
|
• |
Connect the engine coolant
temperature sensor wiring harness plug (3). |
|
• |
Connect the exhaust camshaft
position actuator solenoid valve wiring harness plug (5).
|
|
• |
Connect the exhaust camshaft
position sensor wiring harness plug (4). |
|
• |
Connect the intake camshaft
position actuator solenoid valve wiring harness plug (6).
|
|
• |
Connect the intake camshaft
position sensor wiring harness plug (7). |
45. |
Install the engine sight
shield. |
48. |
Check and correct engine
oil. |
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