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Cylinder Head, Remove and Install
Caution
Only remove cylinder head with engine cold (room
temperature).
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 Remove
Disconnect ground cable from battery.
Open coolant drain bolt on radiator – collect coolant.
Disconnect all wiring harness plugs and hose connections from
intake manifold – see operation "Intake Manifold, Remove and
Install".
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Disconnect wiring harness plug (1) from exhaust gas
recirculation solenoid valve, wiring harness plug (2) from coolant
temperature sender, wiring harness plug (3) from coolant
temperature sensor.
Unclip cable bundle from bracket.
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Remove
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For X 20 XEV: Disconnect wiring harness plug (1) from DIS
ignition module and wiring harness plug (2) from tank vent
valve.
For Y 22 XE and Z 22 XE: Disconnect wiring harness plug from
ignition module.
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Remove coolant hose (1) from coolant flange (DIS ignition module
adapter).
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I AT:
- Disconnect wiring harness plug (1) from output speed sensor
and
- wiring harness plug (2) from transmission casing (7 pin).
- For X 20 XEV: Disconnect wiring harness plug (3) from oxygen
sensor.
- For Y 22 XE and Z 22 XE: Disconnect oxygen sensor wiring
harness plug – see operation "Oxygen Sensor, Remove and
Install (Y 22 XE, Z 22 XE)".
- wiring harness plug (4) from intermediate housing (4-pin),
- wiring harness plug (5) from selector lever position
switch.
II MT:
- Disconnect wiring harness plug (1) from reversing lamp
switch.
- For X 20 XEV: Disconnect wiring harness plug (2) from oxygen
sensor.
- For Y 22 XE and Z 22 XE: Disconnect oxygen sensor wiring
harness plug – see operation "Oxygen Sensor, Remove and
Install (Y 22 XE, Z 22 XE)".
Remove front exhaust pipe.
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Detach coolant hose (1) and (2) from coolant flange.
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Remove upper coolant hose (1) from thermostat housing.
For X 20 XEV: Detach air duct hose from secondary air non-return
valve.
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Remove crankcase ventilation hose (1) from cylinder head cover
and crankcase ventilation flange from cylinder block.
Remove camshafts – see operation "Camshafts, Remove and
Install".
Remove fastening bolts (2) for rear toothed belt cover from
cylinder head.
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Remove cylinder head bolts in illustrated sequence with KM-2355.
Loosen cylinder head bolts first 1/4, then 1/2 turn and remove.
Remove cylinder head from cylinder block.
 Clean
Clean sealing surfaces, bores and threads of cylinder head bolts
and remove gasket residue.
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Inspect
Check cylinder head and cylinder block for plane surface –
see operations "Cylinder Head, Check for Plane Surface" and
"Cylinder Block, Check for Plane Surface".
Install
Place new cylinder head gasket on cylinder block – code
"OBEN/TOP" on top and towards timing side of engine.
Place cylinder head on cylinder block.
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Attach cylinder head to cylinder block with new cylinder head
bolts.
Tighten cylinder head bolts in sequence shown with KM-2355
– use MKM-610 and KM-470-B.
Cylinder head to cylinder block – tightening torque 25 Nm
/ 18.5 lbf. ft. + 90° + 90° + 90°+ 15°.
Fasten rear toothed belt cover to cylinder head –
tightening torque 8 Nm / 6 lbf. ft.
Install camshafts – see operation "Camshafts, Remove and
Install".
Attach crankcase ventilation flange with new gasket to cylinder
block – tightening torque 25 Nm / 18 lbf. ft. Attach
crankcase ventilation hose to cylinder head cover.
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For X 20 XEV: Attach air duct hose to secondary air non-return
valve.
Attach coolant hose to thermostat housing and coolant hoses to
coolant flange.
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I AT:
- Attach wiring harness plug (1) to output speed sensor and
- wiring harness plug (2) to transmission casing (7 pin).
- For X 20 XEV: Connect wiring harness plug (3) to oxygen
sensor.
- For Y 22 XE and Z 22 XE: Connect oxygen sensor wiring harness
plug – see operation "Oxygen Sensor, Remove and Install (Y 22
XE, Z 22 XE)".
- wiring harness plug (4) to intermediate housing (4-pin),
- wiring harness plug (5) to selector lever position switch.
II MT:
- Attach wiring harness plug (1) to reversing lamp switch.
- For X 20 XEV: Connect wiring harness plug (2) to oxygen
sensor.
- For Y 22 XE and Z 22 XE: Connect oxygen sensor wiring harness
plug – see operation "Oxygen Sensor, Remove and Install (Y 22
XE, Z 22 XE)".
Install front exhaust pipe.
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Attach coolant hose to coolant flange (DIS ignition module
adapter).
For Y 22 XE: Connect wiring harness plug to ignition module.
For X 20 XEV and Z 22 XE: Connect wiring harness plug to tank
vent valve and wiring harness plug to DIS ignition module.
Clip cable bundle to bracket. Attach wiring harness plug (3) to
coolant temperature sensor, wiring harness plug (2) to coolant
temperature sender and wiring harness plug (1) to exhaust gas
recirculation solenoid valve.
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Attach all wiring harness plugs and hose connections to intake
manifold – see operation "Intake Manifold, Remove and
Install".
Close coolant drain bolt on radiator. Connect ground cable to
battery.
Inspect
Top up and bleed cooling system – see operation "Cooling
System, Top up and Bleed" and "Cooling System, Check for
Leaks".
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