Audi Cars 1999-05

Cylinder Head 2

Print

Removal & Installation



1.8L Engine
  1. Turn the ignition switch to the OFF position, and then disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the accessory drive belt, then the engine driven cooling fan.
  6.  
  7. Drain the engine coolant into a suitable container.
  8.  
  9. Remove the intake manifold.
  10.  
  11. Label and detach the following lines and electrical connectors:
  12.  


    Wastegate bypass regulator valve
     
    Evaporative Emission (EVAP) canister purge regulator valve
     
    Power outage stage
     
    Mass Air Flow (MAF) sensor
     

  13. Remove the air cleaner housing.
  14.  
  15. Detach the Engine Coolant Temperature (ETC) and the temperature II sensor harness connector.
  16.  
  17. Label and detach all connections from the cylinder head and position them aside.
  18.  
  19. Remove the crankcase breather line.
  20.  
  21. Disconnect the oil supply line at the cylinder head.
  22.  
  23. Remove the exhaust manifold heat shield.
  24.  
  25. Unbolt the turbocharger from the exhaust manifold.
  26.  
  27. Disconnect the coolant hose to the heat exchanger at the rear of the cylinder head.
  28.  
  29. Remove the upper timing belt cover.
  30.  
  31. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at Top Dead Center (TDC).
  32.  
  33. Using Torx® wrench T45, loosen the timing belt tensioner.
  34.  
  35. Push down on the tensioner, and remove the belt from the camshaft gear.
  36.  
  37. Remove the Torx® bolt and swing the tensioner assembly bracket forward.
  38.  
  39. Remove the valve cover.
  40.  
  41. Remove the cylinder head bolts in sequence, as shown.
  42.  
  43. Remove the cylinder head, and then clean the gasket mating surfaces.
  44.  
  45. Clean and dry out the cylinder head bolt holes.
  46.  



Click image to see an enlarged view

Fig. Cylinder head bolt LOOSENING sequence-1.8L Engine



Click image to see an enlarged view

Fig. Cylinder head bolt TIGHTENING sequence-1.8L Engine



Click image to see an enlarged view

Fig. An exploded view of the 1.8L cylinder head and its related components

To install:


WARNING
Always replace the cylinder head bolts. Always replace self-locking nuts, bolts, gaskets and O-rings. Do NOT remove the new head gasket from the package until immediately before installing.

  1. Before installing the cylinder head, set the crankshaft and camshaft to TDC for the No. 1 cylinder.
  2.  
  3. Loosen the turbocharger support bracket to reduce the likelihood of any tension while installing the cylinder head.
  4.  
  5. Install the head gasket with the part number visible from the intake side.
  6.  
  7. Install the cylinder head.
  8.  
  9. Install the new cylinder head bolts and tighten in sequence by hand.
  10.  
  11. Torque the new cylinder head bolts following the tightening sequence in four steps:
  12.  
  13. Step 1: 30 ft. lbs. (40 Nm)
  14.  
  15. Step 2: 44 ft. lbs. (60 Nm)
  16.  
  17. Step 3: additional 1 / 4 turn (90°)
  18.  
  19. Step 4: additional 1 / 4 turn (90°)
  20.  


NOTE
It is not necessary to retighten the cylinder head bolts.

  1. Using new gaskets, install the turbocharger to the exhaust manifold, coat the bolts with Hot Bolt Paste G 052 112 A3, or equivalent, then tighten the mounting bolts to 26 ft. lbs. (35 Nm). Tighten the turbo support bracket mounting bolts to 33 ft. lbs. (40 Nm).
  2.  
  3. Install the valve cover.
  4.  
  5. Install the timing belt.
  6.  
  7. Install the accessory drive belts.
  8.  
  9. Install the exhaust manifold heat shield.
  10.  
  11. Connect the oil supply lines to the cylinder head and tighten the retaining straps to 15 ft. lbs. (20 Nm).
  12.  
  13. Install the crankcase breather.
  14.  
  15. Attach any items removed during disassembly.
  16.  
  17. Connect the coolant temperature sensors, and install the air cleaner housing.
  18.  
  19. Fill the engine with coolant and bleed as necessary. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the 1-touch opening/closing function.
  24.  
  25. Check the oil level before starting the engine and top off as necessary.
  26.  
  27. Set the clock to the correct time.
  28.  
  29. Check and clear any stored Diagnostic Trouble Codes (DTCs) as necessary, using an appropriate scan tool.
  30.  
  31. Install the hood lock carrier assembly and front bumper.
  32.  
  33. Adjust the headlights.
  34.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the front bumper if necessary for access.
  4.  
  5. Place the hood lock carrier into the service position.
  6.  
  7. Turn the ignition switch to the OFF position.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Cooling fan
     

  10.  
  11. Drain the engine coolant.
  12.  
  13. Remove or disconnect the following:

    Intake manifold
     
    Accessory drive belts
     
    Wastegate bypass regulator valve
     
    Evaporative Emissions (EVAP) canister purge regulator valve
     
    Power outage stage
     
    Mass Air Flow (MAF) sensor
     
    Air cleaner housing
     
    Engine Temperature Control (ETC) and the temperature II sensor harness connector
     
    All connections from the cylinder head
     
    Crankcase breather line
     
    Oil supply line at the cylinder head
     
    Exhaust manifold heat shield
     
    Turbocharger from the exhaust manifold
     
    Coolant hose to the heat exchanger at the rear of the cylinder head
     
    Upper timing belt cover
     

  14.  
  15. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at TDC.
  16.  
  17. Using Torx® wrench T45, loosen the timing belt tensioner.
  18.  
  19. Push down on the tensioner and remove the belt from the camshaft gear.
  20.  
  21. Remove or disconnect the following:

    Torx® bolt and swing the tensioner assembly bracket forward
     
    Valve cover
     
    Cylinder head bolts, in sequence, as shown
     
    Cylinder head
     

  22.  
  23. Clean the gasket mating surfaces.
  24.  
  25. Clean and dry out the cylinder head bolt holes.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-A4 1.8L engine

  26.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-A4 1.8L engine


NOTE
Always replace the cylinder head bolts, self-locking nuts, bolts, gaskets and O-rings.

  1. Before installing the cylinder head, set the crankshaft and camshaft to TDC for the No. 1 cylinder.
  2.  
  3. Loosen the turbocharger support bracket to reduce the likelihood of any tension while installing the cylinder head.
  4.  
  5. Install or connect the following:

    Head gasket with the part number visible from the intake side
     
    Cylinder head
     
    New cylinder head bolts, tighten by hand
     

  6.  
  7. Tighten the new cylinder head bolts in sequence in 2 steps:
    1. Step 1: Exc. 2004, 44 ft. lbs. (60 Nm); on 2004, 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Plus 180 degrees
    4.  

  8.  
  9. Install or connect the following:

    Turbocharger to the exhaust manifold using new gaskets and the bolts coated with Hot Bolt Paste G 052 112 A3. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Turbo support bracket. Torque the bolts to 33 ft. lbs. (40 Nm).
     
    Valve cover
     
    Timing belt
     
    Accessory drive belts
     
    Exhaust manifold heat shield
     
    Oil supply lines to the cylinder head. Torque the retaining straps to 15 ft. lbs. (20 Nm).
     
    Crankcase breather
     
    Coolant temperature sensors
     
    Air cleaner housing
     

  10.  
  11. Fill the engine with coolant and bleed, if necessary.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one touch opening/closing function.
  16.  
  17. Check the oil level before starting the engine and top off, as necessary.
  18.  
  19. Install the hood lock carrier assembly and front bumper.
  20.  
  21. Adjust the headlights.
  22.  
  23. Start the vehicle, check for leaks and repair if necessary.
  24.  

2.7L Engines

NOTE
On A6 models, the front lock carrier assembly must be placed in the service position. The front bumper must be removed before the lock carrier can be placed in the service position

  1. Drain engine coolant.
  2.  
  3. Properly relieve fuel pressure.
  4.  
  5. Before servicing the vehicle, refer to the precautions section.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Camshaft timing control connector
     
    Injector connectors
     
    Ignition coil connectors
     
    Crankcase breather
     
    Ignition coils
     
    Turbocharger intake hose
     
    Solenoid valve for charge air pressure control
     
    EVAP valve connector
     
    Throttle unit connector
     
    Charge air sensor connector
     
    Intake air temperature sensor connector
     
    Accessory belt
     
    Accessory belt tensioner
     
    Timing belt front covers
     

  8.  
  9. Place crankshaft in TDC position for no. 1 cylinder.
  10.  
  11. Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.
  12.  
  13. Remove or disconnect the following:

    Crankshaft damper
     
    Idler wheel
     
    Belt guard behind vibration damper
     
    Timing belt
     
    Camshaft sprockets
     
    Intake manifold
     
    Coolant brackets and water lines
     
    Heat sensor
     
    Turbocharger from exhaust manifold
     
    Valve covers
     
    Cylinder head bolts by loosening them in the reverse of the tightening sequence
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-2.7L and 2.8L DOHC engine

     

  14.  

To install:

  1. Clean all sealing surfaces. Check cylinder head for distortion. Measure at several locations. The maximum permissible distortion is 0.0039 in. (0.1mm).
  2.  
  3. Before installing cylinder head, place camshaft and crankshaft sprockets in TDC position of no. 3 cylinder.
  4.  
  5. Install or connect the following:

    New cylinder head gasket with the lettering facing toward cylinder head
     
    Cylinder head
     

  6.  
  7. Tighten the cylinder head bolts following the torque tightening sequence in 2 steps as follows:
    1. Step 1: 44 ft. lbs. (60 Nm)
    2.  
    3. Step 2: Plus 180 degrees
    4.  

  8.  
  9. Install or connect the following:

    Valve covers
     
    Turbocharger
     
    Heat sensor
     
    Coolant brackets and water lines
     
    Intake manifold
     
    Camshaft sprockets
     
    Timing belt
     
    Belt guard behind vibration damper
     
    Idler wheel
     
    Crankshaft damper
     
    Timing belt front covers
     
    Accessory belt tensioner
     
    Accessory belt
     
    Intake air temperature sensor connector
     
    Charge air sensor connector
     
    Throttle unit connector
     
    EVAP valve connector
     
    Solenoid valve for charge air pressure control
     
    Turbocharger intake hose
     
    Ignition coils
     
    Crankcase breather
     
    Ignition coil connectors
     
    Injector connectors
     
    Camshaft timing control connector
     

  10.  
  11. Fill and bleed the cooling system, as necessary.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Check all fluid levels and top off as necessary.
  16.  
  17. Operate the engine and check for leaks.
  18.  
  19. Road test the vehicle for proper operation.
  20.  

2.8L Engine

NOTE
On A4 models and A6 models, the front lock carrier assembly must be placed in the service position. The front bumper must be removed before the lock carrier can be placed in the service position

  1. Drain engine coolant.
  2.  
  3. Properly relieve fuel pressure.
  4.  
  5. Before servicing the vehicle, refer to the precautions section.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Lower engine splash shield and position the front lock carrier assembly in the service position
     
    Accessory drive belt
     
    Timing belt
     
    Exhaust pipe from the manifold
     
    Exhaust Gas Recirculation (EGR) valve hose at manifold
     
    Air guide hose between air mass sensor and intake manifold
     
    Spark plug wires
     
    Injector connectors
     
    Crankcase breathers on the left and right cylinder head covers
     
    Fuel feed and return lines
     
    Left side cover for fuel line
     
    Throttle cable
     
    Vacuum hoses from vacuum pump and intake manifold
     
    Idling stabilization valve and throttle valve potentiometer
     
    Vacuum hose on vacuum control unit
     
    Oil pressure sender
     
    Oil pressure switch
     
    Hall sender sensor
     
    EGR valve from the intake manifold
     
    Intake manifold assembly
     
    Coolant pipe at the rear of the cylinder head
     
    Oxygen (O 2 S) sensor
     
    Heat shield on the exhaust manifold
     
    Cylinder head cover
     
    Timing belt rear belt guard
     
    Hydraulic line from reservoir to pump
     
    Cylinder head bolts by loosening them in the reverse of the torque sequence
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-2.7L and 2.8L DOHC engine

     

  8.  

To install:

  1. Clean all sealing surfaces. Check cylinder head for distortion. Measure at several locations. The maximum permissible distortion is 0.0039 in. (0.1mm).
  2.  
  3. Install or connect the following:

    New cylinder head gasket with the lettering facing upwards
     
    Cylinder head
     

  4.  
  5. Tighten the cylinder head bolts following the torque tightening sequence in 2 steps as follows:
    1. Step 1: 44 ft. lbs. (59.8 Nm)
    2.  
    3. Step 2: Plus 180 degrees
    4.  

  6.  
  7. Install or connect the following:

    Timing belt rear belt guard
     
    Cylinder head cover
     
    O 2 S sensor
     
    Heat shield on the exhaust manifold
     
    Intake manifold assembly
     
    EGR valve to the intake manifold
     
    Hall sender sensor
     
    Oil pressure sender
     
    Oil pressure switch
     
    Connectors on idling stabilization valve and throttle valve potentiometer
     
    Vacuum hoses to vacuum pump and intake manifold
     
    Throttle cable
     
    Fuel feed and return lines
     
    Crankcase breather on the cylinder head cover
     
    Spark plug wires and injector connectors
     
    Exhaust manifold
     
    Timing belt and accessory drive belt
     

  8.  
  9. Fill and bleed the cooling system, as necessary.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Check all fluid levels and top off as necessary.
  14.  
  15. Operate the engine and check for leaks.
  16.  
  17. Road test the vehicle for proper operation.
  18.  

2.8L V6 Engines

The 1996 Audi A4 is equipped with the code AFC engine, which is a Single Overhead (SOHC) Camshaft 2.8L V6 engine.

As of 1997, all 1997-00 A4 & 1998-00 Passat models, equipped with a 2.8L V6 engine, use the code AHA engine, which is a Double Overhead (DOHC) Camshaft 2.8L V6 engine with 5 valves per cylinder.

Although both engines are 2.8L 90° V6 designs, the cylinder heads differ. The code AHA engine features 5 valves per cylinder and variable intake camshaft timing. The following is a comparison of the two engines.

2.8L V6 SOHC Engine:



Code: AFC
 
Type: Single Overhead Camshaft (SOHC)
 
Valves per cylinder: 2 (1 intake, 1 exhaust)
 
Camshaft timing: Fixed
 

2.8L 5V V6 DOHC Engine:



Code: AHA
 
Type: Double Overhead Camshaft (DOHC)
 
Valves per cylinder: 5 (3 intake, 2 exhaust)
 
Camshaft timing: Variable intake camshaft
 

  1. Turn the ignition switch to the OFF position, and then disconnect the negative battery cable.
  2.  
  3. Remove the lower engine splash shield.
  4.  
  5. Drain engine coolant into a sealable container.
  6.  
  7. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  8.  
  9. Properly relieve fuel pressure.
  10.  
  11. Remove the accessory drive belt.
  12.  
  13. Remove the timing belt. The vibration damper should remain installed.
  14.  
  15. Remove the exhaust pipe from the manifold.
  16.  
  17. Remove the Exhaust Gas Recirculation (EGR) valve hose at manifold.
  18.  
  19. Remove the air guide hose between air mass sensor and intake manifold.
  20.  
  21. Remove and tag all spark plug wires and injector connectors.
  22.  
  23. Remove the crankcase breathers on the left and right cylinder head covers.
  24.  
  25. Remove the fuel feed and return lines.
  26.  
  27. Remove the left side cover for fuel line.
  28.  
  29. Disconnect the throttle cable.
  30.  
  31. Mark and remove all vacuum hoses from vacuum pump and intake manifold.
  32.  
  33. Disconnect connectors on the idling stabilization valve and throttle valve potentiometer.
  34.  
  35. Disconnect vacuum hose on vacuum control unit.
  36.  
  37. Disconnect connectors on oil pressure sender and oil pressure switch.
  38.  
  39. Disconnect connector for Hall sender sensor.
  40.  
  41. Remove the EGR valve from the intake manifold.
  42.  
  43. Remove the intake manifold assembly.
  44.  
  45. Remove the coolant pipe at the rear of the cylinder head.
  46.  
  47. Remove the Oxygen (O 2 S) sensor.
  48.  
  49. Remove the heat shield on the exhaust manifold.
  50.  
  51. Remove the cylinder head cover.
  52.  
  53. Remove the timing belt rear belt guard. Remove the hydraulic line from reservoir to pump.
  54.  
  55. Loosen the head bolts in the reverse of the installation torque sequence and remove the cylinder head assembly from the engine.
  56.  



Click image to see an enlarged view

Fig. Exploded view of the cylinder head mounting and related components-2.8L V6 SOHC Engine



Click image to see an enlarged view

Fig. Exploded view of the cylinder head mounting and related components-2.8L V6 DOHC Engine



Click image to see an enlarged view

Fig. Cylinder head mounting bolt torque tightening sequence-2.8L V6 SOHC Engine



Click image to see an enlarged view

Fig. Cylinder head mounting bolt torque tightening sequence-2.8L V6 DOHC Engine



Click image to see an enlarged view

Fig. Exploded view of the 2.8L SOHC V6 cylinder head

To install:

  1. Clean all sealing surfaces. Check cylinder head for distortion. Measure at several locations. The maximum permissible distortion is 0.1mm.
  2.  
  3. Install cylinder head gasket. The lettering must face upwards.
  4.  
  5. Install the cylinder head assembly and check the centering pins in the cylinder block.
  6.  
  7. Install cylinder head bolts by hand.
  8.  
  9. Tighten the cylinder head bolts following the torque tightening sequence in 3 steps as follows:
  10.  
    1. Step 1: 44 ft. lbs. (60 Nm)
    2.  
    3. Step 2: 1 / 4 turn (90°)
    4.  
    5. Step 3: 1 / 4 turn (90°)
    6.  



NOTE
It is not necessary to retighten the cylinder head bolts after repairs or as part of inspection service.

  1. Install the timing belt rear belt guard.
  2.  
  3. Install the cylinder head cover.
  4.  
  5. Install the O 2 S sensor, then install the heat shield on the exhaust manifold.
  6.  
  7. Install the intake manifold assembly.
  8.  
  9. Install the EGR valve to the intake manifold.
  10.  
  11. Reconnect the hall sender sensor, oil pressure sender and oil pressure switch.
  12.  
  13. Reconnect connectors on idling stabilization valve and throttle valve potentiometer.
  14.  
  15. Install all vacuum hoses to vacuum pump and intake manifold.
  16.  
  17. Reconnect the throttle cable.
  18.  
  19. Reconnect the fuel feed and return lines.
  20.  
  21. Install the crankcase breather on the cylinder head cover.
  22.  
  23. Install all spark plug wires and injector connectors.
  24.  
  25. Install the exhaust manifold.
  26.  
  27. Install the timing belt and accessory drive belt.
  28.  
  29. Refill and bleed the cooling system, top off as necessary. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Enter the radio security code.
  34.  
  35. Check all fluid levels and top off as necessary. Operate the engine at normal operating temperatures and check for leaks.
  36.  
  37. Road test the vehicle for proper operation.
  38.  

3.0L Engine

NOTE
On 3.0L models, the following procedure is with the engine installed in the vehicle.

  1. Drain engine coolant.
  2.  
  3. Properly relieve fuel pressure.
  4.  
  5. Before servicing the vehicle, refer to the precautions section.
  6.  
  7. Remove or disconnect the following:
    NOTE
    The flex pipes at the front exhaust pipes must not be bent more than 10 degrees. Otherwise they may be damaged.



    Negative battery cable
     
    Intake manifold
     
    Engine covers
     
    Coolant reservoir
     
    Resonator
     
    Fuel rail
     
    Ducting
     
    Solenoid valve holding plate
     
    Connectors from CMP sensors
     
    Ground wire from rear of cylinder head
     
    PS pressure line from pump at RH cylinder head (position aside)
     
    Timing belt
     
    Camshaft gears from both heads
     
    Belt guard
     
    Idler roller and bracket from right head
     
    Timing belt brackets from both heads
     
    Coolant pipes from both heads
     
    Vacuum hose to brake booster
     
    Secondary air injection combination valves
     
    Exhaust manifold to exhaust pipe nuts on both sides
     



    Exhaust pipes from manifold
     
    Cylinder head bolts in proper sequence
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head cover removal sequence-Audi 3.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head removal sequence-3.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.0L engine

     

  8.  

To install:

  1. Clean all sealing surfaces. Check cylinder head for distortion. Measure at several locations. The maximum permissible distortion is 0.0039 in. (0.1mm).
  2.  
  3. Install new cylinder head gasket with the lettering facing toward cylinder head.
  4.  
  5. Install the cylinder head.
  6.  
  7. Tighten the cylinder head bolts following the torque tightening sequence in 2 steps as follows:
    1. Step 1: 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Plus 180 degrees
    4.  

  8.  
  9. Install or connect the following:

    Exhaust pipes
     
    Exhaust pipes to exhaust manifold
     
    Secondary air injection combination valves
     
    Vacuum hose to brake booster
     
    Coolant pipes
     
    Timing belt brackets
     
    Idler roller and bracket to right head
     
    Camshaft gears
     
    Timing belt
     
    Power steering pressure line
     
    Ground wire on left head
     
    Crankshaft and camshaft position sensor connectors
     
    Coolant level warning switch connector at bottom of expansion tank
     
    Coolant hoses at reservoir and reservoir
     
    Solenoid valve holding plate
     
    Ducting
     
    Fuel rail
     
    Resonator
     
    Exhaust manifold
     
    Engine cover
     

  10.  
  11. Fill and bleed the cooling system, as necessary.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Check all fluid levels and top off as necessary.
  16.  
  17. Operate the engine and check for leaks.
  18.  
  19. Road test the vehicle for proper operation.
  20.  

3.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Turn the ignition switch to the OFF position.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Before removing ribbed belt, mark direction of rotation with chalk or a felt pen. If a used belt rotates in the wrong direction when reinstalled, this can result in breakage. When installing belt, ensure it is correctly seated in the pulleys.


    NOTE
    The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To accomplish this, press the engine simultaneously to the left side. If necessary, loosen all bolts of the assembly mounting.


    NOTE
    Replace cylinder head bolts. Replace self locking nuts and bolts that are tightened by turning to a specified angle



    Negative battery cable
     



    Release tension on belt by screwing an M8 x 40 bolt into bore on tensioning element and remove belt
     
    Upper mounting bolt for the alternator
     
    Upper mounting bolts for radiator cowl
     
    Secondary air hose
     
    Center and right-hand noise insulation under engine
     
    Cross piece
     
    Power steering pump from bracket, hang pump from lock carrier with hoses still attached
     
    Secondary air injection pump with bracket
     
    Lower radiator cowl bolts and remove the radiator cowl with fans
     



    Mounting bolt for air conditioning compressor
     
    Secure the air conditioning compressor together with the hoses at front longitudinal member (hoses remain connected)
     
    Alternator
     
    Oil dipstick tube
     
    Vacuum reservoir
     
    Mounting bracket for alternator and air conditioning compressor
     
    Bolts at front of intake manifold
     
    Attach puller T10095A or equivalent to ignition coils and remove coils
     
    Body brace
     
    Air intake hose
     
    Crankcase breather hose
     
    Throttle body
     
    Hose bracket
     
    Rear intake mounting bolts, swing intake manifold forward
     
    Cylinder head cover, remove bolts in sequence

    Click image to see an enlarged view

    Fig. Cylinder head cover bolt removal sequence-TT 3.2L engine

     
    Timing chain from camshafts
     
    Exhaust pipe from manifold
     
    Remove cylinder head bolts in sequence indicated
     
    Attach lifting shackle 3033 or equivalent and carefully lift off cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal and tightening sequence-TT 3.2L engine

     

  8.  
  9. Set camshafts to TDC for number 1 cylinder

    It must be possible to insert camshaft plate T10058 in both camshaft grooves
     

  10.  
  11. Install cylinder head gasket and cylinder head
    NOTE
    The long cylinder head bolts are inserted in the middle bores of the cylinder head

  12.  
  13. Tighten cylinder head bolts in 4 stages using the following sequence:

    1st stage 22 ft. lbs (30 Nm)
     
    2nd stage 37 ft. lbs (50 Nm)
     
    3rd stage 90° (1/4 turn) further
     
    4th stage 90° (1/4 turn) further
     

  14.  
  15. Install or connect the following

    Timing chain
     
    Cylinder head cover
     
    Intake manifold
     

  16.  
  17. Fill the engine with coolant and bleed, if necessary.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Check the oil level before starting the engine and top off, as necessary.
  22.  
  23. Start the vehicle, check for leaks and repair if necessary.
  24.  

4.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Dipstick from LH cylinder head
     
    Intake duct for air cleaner
     
    Fuel supply and return lines
     
    Upper bolt between exhaust manifold and exhaust pipe
     
    Oxygen sensor connectors
     
    Exhaust pipe from LH manifold (loosen double clamps rearward)
     
    Upper LH and RH timing belt guards
     
    Timing belt from camshafts (without moving position)
     
    Lower timing belt guard
     
    Connectors, pipes and coolant lines (mark for position reference)
     
    Cylinder head covers
     
    Left and right knock sensor connectors
     
    Fuel injector harness connectors
     
    Fuel rail, carefully remove along with fuel injectors, and place down to one side
     
    Coolant line at rear between cylinder heads
     
    Intake manifold
     
    Cylinder head bolts, in sequence, following reverse order of tightening sequence
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-4.2L Engines

     

  8.  

To install:

  1. Install the cylinder head with a new gasket and tighten the bolts in sequence as follows:
    1. Step 1: 26 ft. lbs. (35 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Plus 90 degrees
    6.  
    7. Step 4: Plus 90 degrees
    8.  

  2.  
  3. The remainder of the installation is the reverse of the removal procedure.
  4.  

 
label.common.footer.alt.autozoneLogo