Mitsubishi Car 1999-05

Cylinder Head 2

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Removal & Installation



2.0L Engine
  1. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the engine under cover. Remove the air cleaner assembly.
  4.  
  5. Remove the exhaust manifold. Remove the water hose and pipe. Disconnect the accelerator cable connection.
  6.  
  7. Disconnect the air conditioning compressor connector, power steering oil pressure switch connector and the crankshaft position sensor connector.
  8.  
  9. Disconnect the manifold absolute pressure sensor connector, EVAP solenoid connector and EGR solenoid valve connector.
  10.  
  11. Disconnect the ignition coil connector, injector connector and throttle position sensor connector.
  12.  
  13. Disconnect the idle air control motor connector, engine coolant temperature sensor connector and the camshaft position sensor connector.
  14.  
  15. Disconnect the knock sensor connector, engine coolant temperature gauge unit connector and the heated oxygen sensor connector.
  16.  
  17. Disconnect the brake booster vacuum hose. Disconnect the high pressure hose connection. Remove the timing belt upper cover.
  18.  
  19. Turn the crankshaft clockwise, align the timing marks on the camshaft sprocket to position number one piston to TDC of its compression stroke. Never rotate the crankshaft in the counterclockwise direction.
  20.  
  21. Remove the timing belt under cover rubber plug, using tool MD998738. Screw the tool in until it contacts the timing belt tensioner arm.
  22.  
  23. Secure the camshaft and valve timing belt, with wire to prevent slippage between the camshaft sprocket and valve timing belt. Remove the camshaft sprocket. Do not turn the crankshaft after the camshaft sprocket is removed.
  24.  
  25. Remove the intake manifold stay connecting bolts.
    NOTE
    Be careful not to damage or deform the plug guides when removing the cylinder head bolts. Plug guides cannot be replaced separately.

  26.  
  27. Loosen all cylinder head bolts in two or three steps and in the proper bolt removal sequence. Remove the cylinder head from the engine. Discard the cylinder head gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-Lancer 2.0L and 2.4L engines

  28.  

To install:

  1. Thoroughly clean the mating surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block.
  4.  
  5. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Apply a small amount of engine oil to the thread section and washer of the bolt.
  6.  
  7. Position the cylinder head on the engine. Install and torque the retaining bolts to specification and in the proper sequence.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence- Lancer 2.0L and 2.4L engines

  8.  
  9. Continue the installation in the reverse order of the removal procedure.
  10.  
  11. Fill the engine with the proper grade and type engine oil.
  12.  
  13. Fill the cooling system with the proper grade and type engine coolant.
  14.  
  15. Start the engine and check for leaks.
  16.  
  17. Roadtest the vehicle.
  18.  

2.0L Non-Turbo Engines
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant and oil into suitable containers.
  6.  
  7. Remove the air cleaner and air intake duct.
  8.  
  9. Tag and detach the connectors from the following components:
    1. A/C compressor
    2.  
    3. Power steering pressure switch
    4.  
    5. Heated oxygen sensor
    6.  
    7. Engine coolant temperature gauge sender
    8.  
    9. Engine coolant temperature sensor
    10.  
    11. MAP sensor
    12.  
    13. Intake air temperature sensor
    14.  
    15. Throttle position sensor
    16.  
    17. Idle air control (IAC) motor
    18.  
    19. Injector harness
    20.  
    21. Ignition coil
    22.  
    23. Camshaft position sensor
    24.  
    25. EGR solenoid valve
    26.  

  10.  
  11. Disconnect the accelerator cable from the throttle body.
  12.  
  13. Detach the heater hoses from the rear of the engine.
  14.  
  15. Disconnect the fuel lines from the fuel supply rail.
  16.  
  17. Detach the purge air hose and the brake booster vacuum hose connections.
  18.  
  19. Unfasten the overflow tube connection.
  20.  
  21. Mark the position of the clamp on the hose and disconnect the upper radiator hose and the water hose connections.
  22.  
  23. Remove the timing belt, as outlined later in this section.
  24.  
  25. Remove the intake manifold stay.
  26.  
  27. Remove the intake and exhaust camshafts.
  28.  
  29. Disconnect the exhaust pipe connection from the exhaust manifold.
  30.  
  31. Unfasten the cylinder head mounting bolts, then remove the cylinder head from the vehicle.

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head mounting-1999 2.0L non-turbo engines

  32.  

To install:

  1. Thoroughly clean the cylinder head and engine block sealing surfaces. Check the deck and the cylinder head for warpage.
  2.  
  3. Clean the cylinder head bolts and inspect them for stretching. If the bolt appears to by stretched, replace it.

    Click image to see an enlarged view

    Fig. If the cylinder head bolts are stretched, replace them. Never reuse stretched head bolts

  4.  
  5. Place a new head gasket on the engine block and carefully place the cylinder head on the engine.
  6.  
  7. Coat the threads of the bolts with clean engine oil and install the bolts finger tight in the engine block. The short bolts go in the corners.
  8.  
  9. Tighten the cylinder head bolts as follows:
    1. Tighten the center bolts 1 through 6 to 25 ft. lbs. (33 Nm) then Tighten the outer bolts 7 through 10 to 20 ft. lbs. (27 Nm)
    2.  
    3. Tighten the center bolts 1 through 6 to 50 ft. lbs. (67 Nm) then Tighten the outer bolts 7 through 10 to 20 ft. lbs. (27 Nm)
    4.  
    5. Tighten the center bolts 1 through 6 to 50 ft. lbs. (67 Nm) then Tighten the outer bolts 7 through 10 to 20 ft. lbs. (27 Nm)

      Turn all fasteners 1 through 10 1 / 4 turn (90°) more in sequence. Do not use a torque wrench for this step.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-1999 2.0L non-turbo engine

       

    6.  

  10.  
  11. Use a new gasket and connect the front exhaust pipe to the exhaust manifold.
  12.  
  13. Install the camshafts.
  14.  
  15. Install the timing belts.
  16.  
  17. Install the intake manifold stay.
  18.  
  19. Connect the upper radiator hose. Install the clamp in the original position.
  20.  
  21. Attach the water hose to the water pipe.
  22.  
  23. Connect the overflow tube.
  24.  
  25. Attach the brake booster vacuum hose and purge air hose connection.
  26.  
  27. Use a new O-ring and connect the fuel lines to the fuel supply rail.
  28.  
  29. Connect the heater hose.
  30.  
  31. Attach all electrical connectors, as tagged during removal.
  32.  
  33. Install and adjust the accelerator cable.
  34.  
  35. Install the air intake duct and the air cleaner assembly.
  36.  
  37. Refill the engine with oil and coolant. Replace the oil filter.
  38.  
  39. Turn the ignition to the ON position and check for fuel leaks. Then start the engine and check for coolant leaks and proper operation.
  40.  

2.0L Turbo Engines
  1. Properly relieve the fuel system pressure.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant and engine oil into suitable containers.
  6.  
  7. Disconnect the accelerator cable and remove the mounting bracket.
  8.  
  9. Detach the intake air duct (hose) from the throttle body.
  10.  
  11. Tag and detach the electrical connector from the following components:
    1. Idle air control (IAC) motor
    2.  
    3. Knock sensor
    4.  
    5. Heated oxygen sensor
    6.  
    7. Engine coolant temperature gauge sender
    8.  
    9. Engine coolant temperature sensor
    10.  
    11. Ignition module (power transistor)
    12.  
    13. Throttle position sensor
    14.  
    15. Condenser
    16.  
    17. Manifold differential pressure sensor
    18.  
    19. Fuel injectors
    20.  
    21. Ignition coil
    22.  
    23. Camshaft position sensor
    24.  
    25. Crankshaft position sensor
    26.  
    27. A/C compressor
    28.  
    29. Engine control wiring harness

      Click image to see an enlarged view

      Fig. Make sure to label all electrical connectors before detaching them-1999 2.0L turbo engine

    30.  

  12.  
  13. Remove the engine center cover. Tag and disconnect the spark plug wires.
  14.  
  15. Disconnect the brake booster vacuum hose.
  16.  
  17. Detach the fuel lines from the fuel supply rail.
  18.  
  19. Disconnect the by-pass hose and the water hose connections.
  20.  
  21. Disconnect the vacuum hoses, breather hose and the PCV hose.
  22.  
  23. Remove the timing belt, as outlined later in this section.
  24.  
  25. Remove the power steering pump.
  26.  
  27. Remove the cylinder head cover and the semi-circular packing.
  28.  
  29. Remove the heat protector.
  30.  
  31. Mark the position of the hose clamps on the hoses and disconnect the water hoses and the radiator hoses.
  32.  
  33. Remove the thermostat housing and the O-ring.
  34.  
  35. Remove the intake manifold stay.
  36.  
  37. Remove the turbocharger assembly from the exhaust manifold.
  38.  
  39. Gradually loosen the cylinder head bolts in two or three steps using the specified sequence and remove the bolts.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-1999 2.0L turbo engine

  40.  
  41. Remove the cylinder head and the gasket. Discard the gasket and replace with a new one during installation.

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head mounting and related components-1999 2.0L turbo engines

  42.  

To install:

  1. Thoroughly clean the deck surface of the engine block and the sealing surface of the cylinder head. Check the cylinder head for warpage.
  2.  
  3. Measure the length of the cylinder head bolts from below the head to the end, if the bolt measures more than 3.913 in. (99.4 mm), replace the bolt.
  4.  
  5. Install a new gasket on the engine block with the identification mark facing upwards.
  6.  
  7. Carefully place the cylinder head on the engine. Apply clean engine oil to the bolts and install the bolts finger tight.
  8.  
  9. Tighten the bolts using the following procedure:
    1. Tighten the bolts in sequence to 58 ft. lbs. (78 Nm).
    2.  
    3. Loosen the bolts completely in the reverse order.
    4.  
    5. Tighten the bolts in sequence to 15 ft. lbs. (20 Nm).
    6.  
    7. Make a paint mark on the head of the bolt and the cylinder head at the same spot. Tighten the bolt 90° or 1 / 4 turn from the mark.
    8.  
    9. Tighten the bolt an additional 90° or 1 / 4 turn so that the mark on the head of the bolt is opposite the original mark on the cylinder head.

      Click image to see an enlarged view

      Fig. Cylinder head bolt torque sequence-1999 2.0L turbo engine

    10.  

  10.  
  11. Use a new gasket and install the turbocharger to the exhaust manifold.
  12.  
  13. Install the intake manifold stay.
  14.  
  15. Install the thermostat housing and connect the hoses. Align the matchmarks and install the clamps.
  16.  
  17. Install the heat protector.
  18.  
  19. Apply sealant to the semi-circular packing and install it on the cylinder head.
  20.  
  21. Apply sealant at the front of the cylinder head where the camshaft oil seal retainer and the cylinder head come together and install the cylinder head cover using a new gasket.
  22.  
  23. Install the power steering pump.
  24.  
  25. Install the timing belt.
  26.  
  27. Connect the PCV, breather and vacuum hoses.
  28.  
  29. Connect the water hose and the by-pass hose.
  30.  
  31. Use a new O-ring and connect the lines to the fuel supply rail. Apply a small amount of engine oil to the new O-ring.
  32.  
  33. Connect the brake booster vacuum hose.
  34.  
  35. Connect the spark plug wires and install the center cover.
  36.  
  37. Attach all of the connectors, as tagged during removal.
  38.  
  39. Connect the intake air hose to the throttle body.
  40.  
  41. Connect and adjust the accelerator cable.
  42.  
  43. Refill the engine with coolant.
  44.  
  45. Replace the oil filter and refill the engine with the proper amount of oil.
  46.  
  47. Connect the negative battery cable, start the engine and check for fuel, coolant and oil leaks.
  48.  

2.4L Engine
  1. Properly relieve the fuel system pressure.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant and engine oil into suitable containers.
  6.  
  7. Disconnect the air intake hose.
  8.  
  9. Detach the accelerator cable. Remove cable mounting brackets and position the cable aside.
  10.  
  11. Remove the breather hose.
  12.  
  13. At the throttle body, tag and disconnect the three small vacuum hoses, the coolant hoses, and the brake booster vacuum hose.
  14.  
  15. Disconnect and plug the high pressure fuel line.
  16.  
  17. Disconnect and plug the fuel return hose.
  18.  
  19. Tag and detach the connectors from the following components: the oxygen sensor, engine coolant temperature sensor, the engine coolant temperature gauge unit and the engine coolant temperature switch on vehicles with air conditioning.
  20.  
  21. Disconnect the ISC motor, throttle position sensor, distributor, fuel injectors, noise filter, EGR temperature sensor, ground cable and engine control wiring harness.
  22.  
  23. Tag and remove the spark plug cables.
  24.  
  25. At the thermostat case assembly, remove the coolant hoses and unbolt the thermostat case from the engine.
  26.  
  27. Remove the upper timing belt cover. Align all timing marks.
  28.  
  29. Secure the timing belt to the camshaft sprocket using a piece of cord so the position of the camshaft sprocket does not move.
    WARNING
    After removing the camshaft sprocket, do NOT rotation the crankshaft.

  30.  
  31. Use the special tool shown in the accompanying figure to remove the camshaft sprocket with the timing belt attached.

    Click image to see an enlarged view

    Fig. Tie a piece of cord around the camshaft sprocket and timing belt so the sprocket doesn-t move-2.4L engine



    Click image to see an enlarged view

    Fig. Use the proper tool to remove the camshaft sprocket with the belt attached-2.4L engine

  32.  
  33. Remove the valve cover and the half-round seal.
  34.  
  35. Disconnect the intake manifold stay bracket from the intake manifold.
  36.  
  37. Remove the exhaust pipe self-locking nuts and separate the exhaust pipe from the exhaust manifold. Discard the gasket.
  38.  
  39. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward, as shown in the accompanying figure. Lift off the cylinder head assembly and remove the head gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.4L engine

  40.  

To install:

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks at the front top (upward) position. Make sure the gasket has the proper identification mark for the engine. Do not use sealer on the gasket.
  4.  
  5. Inspect the cylinder head bolts shank length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Install the washer onto the bolt so the chamfer on the washer faces towards the head of the bolt.

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-2.4L engines

  6.  
  7. Carefully install the cylinder head on the block and tighten the cylinder head bolts as follows:
    1. Following the proper tightening sequence, tighten the cylinder head bolts to 58 ft. lbs. (78 Nm).
    2.  
    3. Loosen all bolts completely.
    4.  
    5. Torque bolts to 15 ft. lbs. (20 Nm).
    6.  
    7. Tighten bolts an additional 1 / 4 turn.
    8.  
    9. Tighten bolts an additional 1 / 4 turn.
    10.  

  8.  
  9. Install the new exhaust pipe gasket and connect the exhaust pipe to the manifold. Tighten the self-locking bolts to 33 ft. lbs. (44 Nm).
  10.  
  11. Install the thermostat case and tighten the mounting bolts to 18 ft. lbs. (24 Nm).
  12.  
  13. Connect the coolant hoses to the thermostat case.
  14.  
  15. Apply sealer to the perimeter of the half-round seal and to the lower edges of the half-round portions of the belt-side of the new gasket. Install the valve cover.
  16.  
  17. Connect the intake manifold stay and tighten the mounting bolts to 22 ft. lbs. (30 Nm).
  18.  
  19. Install the timing belt and all related items.
  20.  
  21. Connect or install all previously disconnected hoses, cables and electrical connections, as tagged during removal.
  22.  
  23. Install the spark plug cable center cover.
  24.  
  25. Replace the O-rings and connect the fuel lines.
  26.  
  27. Install the air cleaner and intake hose. Connect the breather hose.
  28.  
  29. Replace the engine oil and oil filter.
  30.  
  31. Fill the system with coolant.
  32.  
  33. Connect the negative battery cable, run the vehicle until the thermostat opens, and fill the radiator completely.
  34.  
  35. Check and adjust the idle speed and ignition timing.
  36.  
  37. Check for leaks and road test for proper operation.
  38.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner with all air intake hoses.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Accelerator cable
     
    Cable mounting brackets and position the cable aside
     
    Breather hose
     
    Vacuum lines at the throttle body, label for identification
     
    High pressure fuel line, plug
     
    Fuel return hose, plug
     

  10.  
  11. Disconnect the following connectors:

    Air conditioning compressor
     
    Power steering pressure switch
     
    Heated Oxygen (HO 2 S) sensor
     
    Engine Coolant Temperature (ECT) gauge sender
     
    ECT sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Intake Air Temperature (IAT) sensor
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Injector harness
     
    Ignition coil
     
    Camshaft Position (CMP) sensor
     
    Exhaust Gas Recirculation (EGR) solenoid valve
     

  12.  
  13. Remove or disconnect the following:

    Spark plug wire cover and wires
     
    Coolant hoses and unbolt the thermostat case from the engine, at the thermostat case assembly
     
    Upper timing belt cover
     

  14.  
  15. Align all timing marks.
  16.  
  17. Secure the timing belt to the camshaft sprocket with cord or a wire tie.
  18.  
  19. Remove or disconnect the following:

    Camshaft sprocket
     
    Valve cover and the half-round seal
     
    Intake manifold stay bracket from the intake manifold

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2000-2003 Eclipse and Galant 2.4L engine

     
    Exhaust pipe self-locking nuts and separate the exhaust pipe from the exhaust manifold. Discard the gasket.
     

  20.  
  21. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward. Lift off the cylinder head assembly and remove the head gasket.
  22.  

To install:

  1. Thoroughly clean the mating surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks at the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Install the washer onto the bolt so the chamfer on the washer faces towards the head of the bolt.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-2000-2003 Eclipse and Galant 2.4L engine

  6.  
  7. Carefully install the cylinder head on the block and tighten the cylinder head bolts as follows:
    1. Following the proper tightening sequence, tighten the cylinder head bolts to 58 ft. lbs. (78 Nm).
    2.  
    3. Loosen all bolts completely.
    4.  
    5. Torque bolts to 15 ft. lbs. (20 Nm).
    6.  
    7. Tighten bolts an additional 1 / 4 turn.
    8.  
    9. Tighten bolts an additional 1 / 4 turn.
    10.  

  8.  
  9. Install or connect the following:

    New exhaust pipe gasket and connect the exhaust pipe to the manifold. Tighten the bolts to 33 ft. lbs. (44 Nm).
     
    Thermostat case and tighten the mounting bolts to 18 ft. lbs. (24 Nm)
     
    Coolant hoses to the thermostat case
     

  10.  
  11. Apply sealer to the perimeter of the half-round seal and to the lower edges of the half-round portions of the belt-side of the new gasket. Install the valve cover.

    Click image to see an enlarged view

    Fig. Secure the timing belt to the camshaft sprocket and remove the sprocket-2000-2003 Eclipse and Galant 2.4L engine

  12.  
  13. Install or connect the following:

    Camshaft sprocket with the timing belt attached. Remove the cord or wire tie.
     
    Upper timing belt cover
     
    Intake manifold stay and tighten the mounting bolts to 22 ft. lbs. (30 Nm)
     

  14.  
  15. Connect the following connectors:

    Air conditioning compressor
     
    Power steering pressure switch
     
    HO 2 S sensor
     
    ECT gauge sender
     
    ECT sensor
     
    MAP sensor
     
    IAT sensor
     
    TP sensor
     
    IAC motor
     
    Injector harness
     
    Ignition coil
     
    CMP sensor
     
    EGR solenoid valve
     

  16.  
  17. Remove or disconnect the following:

    Spark plug wires and cover
     
    Fuel lines using new O-rings
     
    Air cleaner and intake hose
     
    Breather hose
     

  18.  
  19. Fill the cooling system.
  20.  
  21. Connect the negative battery cable
  22.  

  1. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the air cleaner assembly. Drain the engine oil. If equipped, remove the strut tower bar.
  4.  
  5. Remove the thermostat case assembly. Remove the front exhaust pipe.
  6.  
  7. Disconnect the accelerator cable connection, purge hose connection and brake booster vacuum hose.
  8.  
  9. Disconnect the ignition coil connector, injector connector and manifold absolute pressure sensor connector.
  10.  
  11. Disconnect the throttle position sensor connector, heated front oxygen sensor connector and the capacitor connector.
  12.  
  13. Disconnect the engine coolant temperature sensor, camshaft position sensor connector and the knock sensor connector.
  14.  
  15. Disconnect the engine coolant temperature gauge unit connector, the idle air control motor connector and the EVAP solenoid valve connector.
  16.  
  17. Disconnect the EGR vacuum regulator solenoid valve connector, the fuel high pressure hose connection, fuel return hose connection and the pressure hose connection.
  18.  
  19. Remove the engine oil dipstick and dipstick guide. Remove the spark plug cables and ignition coil.
  20.  
  21. Remove the upper radiator hose. Remove the PCV valve hose connection and breather hose connection.
  22.  
  23. Remove the rocker arm cover. Remove the spark plug guide oil seal. Remove the water hose connection.
  24.  
  25. Remove the timing belt.
  26.  
  27. Remove the power steering pressure switch connector. Remove the power steering pump and bracket assembly, position the unit to the side as not to interfere with removal of the cylinder head.
  28.  
  29. Remove the exhaust manifold bracket.
    NOTE
    Be careful not to damage or deform the plug guides when removing the cylinder head bolts. Plug guides cannot be replaced separately.

  30.  
  31. Loosen all cylinder head bolts in two or three steps and in the proper bolt removal sequence. Remove the cylinder head from the engine. Discard the cylinder head gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2004-2005 Eclipse 2.4L engine

  32.  

To install:

  1. Thoroughly clean the mating surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block.
  4.  
  5. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Apply a small amount of engine oil to the thread section and washer of the bolt.
  6.  
  7. Position the cylinder head on the engine. Install and torque the retaining bolts to specification and in the proper sequence.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-2004-2005 Eclipse 2.4L engine

  8.  
  9. Continue the installation in the reverse order of the removal procedure.
  10.  
  11. Fill the engine with the proper grade and type engine oil.
  12.  
  13. Fill the cooling system with the proper grade and type engine coolant.
  14.  
  15. Start the engine and check for leaks.
  16.  
  17. Roadtest the vehicle.
  18.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner with all air intake hoses.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Accelerator cable
     
    Cable mounting brackets and position the cable aside
     
    Breather hose
     
    Vacuum lines at the throttle body, label for identification
     
    High pressure fuel line and plug the line to avoid contamination
     
    Fuel return hose and plug the hose to avoid contamination
     

  10.  
  11. Disconnect the following connectors:

    Air conditioning compressor
     
    Power steering pressure switch
     
    Heated Oxygen (HO 2 S) sensor
     
    Engine Coolant Temperature (ECT) gauge sender
     
    ECT sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Intake Air Temperature (IAT) sensor
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Injector harness
     
    Ignition coil
     
    Camshaft Position (CMP) sensor
     
    Exhaust Gas Recirculation (EGR) solenoid valve
     

  12.  
  13. Remove or disconnect the following:

    Spark plug wire cover and wires
     
    Coolant hoses and unbolt the thermostat case from the engine, at the thermostat case assembly
     
    Upper timing belt cover
     

  14.  
  15. Align all timing marks.
  16.  
  17. Secure the timing belt to the camshaft sprocket with cord or a wire tie.
  18.  
  19. Remove or disconnect the following:

    Camshaft sprocket
     
    Valve cover and the half-round seal
     
    Intake manifold stay bracket from the intake manifold
     
    Exhaust pipe self-locking nuts and separate the exhaust pipe from the exhaust manifold. Discard the gasket.
     

  20.  
  21. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward. Lift off the cylinder head assembly and remove the head gasket.
  22.  

To install:

  1. Thoroughly clean the mating surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks at the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Install the washer onto the bolt so the chamfer on the washer faces towards the head of the bolt.
  6.  
  7. Carefully install the cylinder head on the block and tighten the cylinder head bolts as follows:
    1. Following the proper tightening sequence, tighten the cylinder head bolts to 58 ft. lbs. (78 Nm).
    2.  
    3. Loosen all bolts completely.
    4.  
    5. Torque bolts to 15 ft. lbs. (20 Nm).
    6.  
    7. Tighten bolts an additional 1 / 4 turn.
    8.  
    9. Tighten bolts an additional 1 / 4 turn.
    10.  

  8.  
  9. Install or connect the following:

    New exhaust pipe gasket and connect the exhaust pipe to the manifold. Tighten the bolts to 33 ft. lbs. (44 Nm).
     
    Thermostat case and tighten the mounting bolts to 18 ft. lbs. (24 Nm)
     
    Coolant hoses to the thermostat case
     

  10.  
  11. Apply sealer to the perimeter of the half-round seal and to the lower edges of the half-round portions of the belt-side of the new gasket. Install the valve cover.
  12.  
  13. Install or connect the following:

    Camshaft sprocket with the timing belt attached. Remove the cord or wire tie.
     
    Upper timing belt cover
     
    Intake manifold stay and tighten the mounting bolts to 22 ft. lbs. (30 Nm)
     

  14.  
  15. Connect the following connectors:

    Air conditioning compressor
     
    Power steering pressure switch
     
    HO 2 S sensor
     
    ECT gauge sender
     
    ECT sensor
     
    MAP sensor
     
    IAT sensor
     
    TP sensor
     
    IAC motor
     
    Injector harness
     
    Ignition coil
     
    CMP sensor
     
    EGR solenoid valve
     

  16.  
  17. Remove or disconnect the following:

    Spark plug wires and cover
     
    Fuel lines using new O-rings
     
    Air cleaner and intake hose
     
    Breather hose
     

  18.  
  19. Fill the cooling system.
  20.  
  21. Connect the negative battery cable
  22.  

  1. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the ECM, if the vehicle is equipped with manual transaxle. Remove the PCM if the vehicle is equipped with automatic transaxle.
  4.  
  5. Remove the air cleaner assembly. Remove the battery and tray.
  6.  
  7. Disconnect the control wiring harness, radiator hose lower clamp and the water hose clamp.
  8.  
  9. Disconnect the EVAP hose connection. Disconnect the brake booster vacuum hose, pressure hose clamp and knock sensor connector.
  10.  
  11. Remove the engine oil dipstick and dipstick guide. Remove the intake manifold stay.
  12.  
  13. Remove the exhaust manifold. Remove the timing belt upper cover. Remove the engine front mounting bracket.
  14.  
  15. Turn the crankshaft clockwise, align the timing marks on the camshaft sprocket to position number one piston to TDC of its compression stroke. Never rotate the crankshaft in the counterclockwise direction.
  16.  
  17. Remove the timing belt under cover rubber plug, using tool MD998738. Screw the tool in until it contacts the timing belt tensioner arm.
  18.  
  19. Secure the camshaft and valve timing belt, with wire to prevent slippage between the camshaft sprocket and valve timing belt. Remove the camshaft sprocket. Do not turn the crankshaft after the camshaft sprocket is removed.
  20.  
  21. Remove the upper radiator hose connection, water cooler hose connection, if equipped with automatic transaxle and water hose connection. Disconnect the high pressure hose connection.
  22.  
  23. Remove the valve cover.
  24.  
  25. Loosen all cylinder head bolts in two or three steps and in the proper bolt removal sequence. Remove the cylinder head from the engine. Discard the cylinder head gasket.
    NOTE
    If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it with a magnet.



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2004-2005 Galant 2.4L engine

  26.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2004-2005 Galant 2.4L engine

  1. Thoroughly clean the mating surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block. Position the gasket on the block so that the identification mark -381- is at the top surface and on the exhaust side.
  4.  
  5. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Apply a small amount of engine oil to the thread section and washer of the bolt.
  6.  
  7. Position the cylinder head on the engine. Install and torque the retaining bolts to specification and in the proper sequence.
  8.  
  9. Torque the camshaft bolt to 58-72 ft. lbs. (80-98 Nm)
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. Fill the engine with the proper grade and type engine oil.
  14.  
  15. Fill the cooling system with the proper grade and type engine coolant.
  16.  
  17. Initialize the ECM, if equipped with manual transaxle or the PCM if equipped with automatic transaxle by turning the ignition switch ON then OFF. Keep it off for at least ten seconds.
  18.  
  19. Start the engine and check for leaks.
  20.  
  21. Roadtest the vehicle.
  22.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the battery and tray.
  10.  
  11. Disconnect the control wiring harness, radiator hose lower clamp and the water hose clamp.
  12.  
  13. Disconnect the EVAP hose connection. Disconnect the brake booster vacuum hose, pressure hose clamp and knock sensor connector.
  14.  
  15. Remove the engine oil dipstick and dipstick guide. Remove the intake manifold stay.
  16.  
  17. Remove the exhaust manifold. Remove the timing belt upper cover. Remove the engine front mounting bracket.
  18.  
  19. Turn the crankshaft clockwise, align the timing marks on the camshaft sprocket to position number one piston to TDC of its compression stroke. Never rotate the crankshaft in the counterclockwise direction.
  20.  
  21. Remove the timing belt under cover rubber plug, using tool MD998738. Screw the tool in until it contacts the timing belt tensioner arm.
  22.  
  23. Secure the camshaft and valve timing belt, with wire to prevent slippage between the camshaft sprocket and valve timing belt. Remove the camshaft sprocket. Do not turn the crankshaft after the camshaft sprocket is removed.
  24.  
  25. Remove the upper radiator hose connection, water cooler hose connection, if equipped with automatic transaxle and water hose connection. Disconnect the high pressure hose connection.
  26.  
  27. Remove the valve cover.
  28.  
  29. Loosen all cylinder head bolts in two or three steps and in the proper bolt removal sequence. Remove the cylinder head from the engine. Discard the cylinder head gasket.
    NOTE
    If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it with a magnet.

  30.  

To install:

  1. Thoroughly clean the mating surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block. Position the gasket on the block so that the identification mark -381- is at the top surface and on the exhaust side.
  4.  
  5. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Apply a small amount of engine oil to the thread section and washer of the bolt.
  6.  
  7. Position the cylinder head on the engine. Install and torque the retaining bolts to specification and in the proper sequence.
  8.  
  9. Torque the camshaft bolt to 58-72 ft. lbs. (80-98 Nm)
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. Fill the engine with the proper grade and type engine oil.
  14.  
  15. Fill the cooling system with the proper grade and type engine coolant.
  16.  
  17. Start the engine and check for leaks.
  18.  
  19. Roadtest the vehicle.
  20.  

3.0L Engine
  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Air intake hose
     
    Exhaust manifold
     
    Air intake plenum and intake manifold
     
    Timing belt
     
    Camshaft sprockets and the rear timing belt cover
     
    Power steering pump bracket. If removing the rear head, remove the alternator brace.
     
    Water inlet pipe
     
    Purge pipe assembly
     
    Valve cover
     

  6.  
  7. Loosen all cylinder head bolts in two or three steps and in the proper bolt removal sequence. Remove the cylinder head from the engine. Discard the cylinder head gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2002-2005 Eclipse and 2002-2003 Galant 3.0L engine

  8.  

To install:

  1. Thoroughly clean the sealing surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block making sure the identification mark on the cylinder head gasket is in the front top (upward) location. Do not use sealer on the gasket.
  4.  
  5. Carefully install the cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Torque the cylinder head bolts to specification.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-2002-2005 Eclipse and 2002-2003 Galant 3.0L engine

  6.  
  7. Apply sealer to the lower edges of the half-round portions and install the valve cover. Tighten valve cover bolts to 84 inch lbs. (9 Nm).
  8.  
  9. Install or connect the following:

    Purge pipe assembly
     
    Water inlet pipe
     
    Power steering pump bracket and alternator brace
     
    Rear timing belt cover and camshaft sprockets.
     
    Timing belt
     
    Intake manifold, air intake plenum and exhaust manifold, using new gaskets
     
    Air intake hose
     

  10.  
  11. Fill the system with coolant.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine.
  16.  
  17. Once the vehicle has cooled, recheck the coolant level.
  18.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Air intake hose
     
    Exhaust manifold
     
    Air intake plenum and intake manifold
     
    Timing belt
     
    Camshaft sprockets and the rear timing belt cover
     
    Power steering pump bracket. If removing the rear head, remove the alternator brace.
     
    Water inlet pipe
     
    Purge pipe assembly
     
    Valve cover
     

  8.  
  9. Loosen all cylinder head bolts in two or three steps and in the proper bolt removal sequence. Remove the cylinder head from the engine. Discard the cylinder head gasket.
  10.  

To install:

  1. Thoroughly clean the sealing surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block making sure the identification mark on the cylinder head gasket is in the front top (upward) location. Do not use sealer on the gasket.
  4.  
  5. Carefully install the cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Torque the cylinder head bolts to specification.
  6.  
  7. Apply sealer to the lower edges of the half-round portions and install the valve cover. Tighten valve cover bolts to 84 inch lbs. (9 Nm).
  8.  
  9. Install or connect the following:

    Purge pipe assembly
     
    Water inlet pipe
     
    Power steering pump bracket and alternator brace
     
    Rear timing belt cover and camshaft sprockets. Torque the retaining bolt to 65 ft. lbs. (90 Nm).
     
    Timing belt
     
    Intake manifold, air intake plenum and exhaust manifold, using new gaskets
     
    Air intake hose
     

  10.  
  11. Fill the system with coolant.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine.
  16.  
  17. Check and adjust the idle speed and ignition timing.
  18.  
  19. Once the vehicle has cooled, recheck the coolant level.
  20.  

DOHC Engine
  1. Relieve fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the air intake hoses.
  2.  
  3. Remove air intake plenum and intake manifold.
  4.  
  5. Remove the exhaust manifold.
  6.  
  7. Remove the timing belt. Refer to the timing belt procedure in this section.
  8.  
  9. Remove the breather hose.
  10.  
  11. Remove the spark plug wire center cover and remove the spark plug wires.
  12.  
  13. Remove the rocker covers.
  14.  
  15. Remove the intake camshaft sprockets.
  16.  
  17. Remove the rear timing belt cover.
  18.  
  19. Remove the ignition coil assembly.
  20.  
  21. Disconnect all water hoses from the thermostat housing and remove the housing.
  22.  
  23. Disconnect the water inlet from the front head.
  24.  
  25. Loosen the cylinder head mounting bolts in the reverse of the torque sequence and loosen the bolts in three steps. Lift off the cylinder head assembly and remove the head gasket.
  26.  

To install:

  1. Thoroughly clean the sealing surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Carefully install the cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Using three even steps, torque the head bolts in sequence, to 76-83 ft. lbs. (105-115 Nm).
  6.  



Click image to see an enlarged view

Fig. Tighten the cylinder head bolts according to the sequence shown-3.0L (SOHC and DOHC) engines



Click image to see an enlarged view

Fig. Rocker cover bolt torque sequence-Diamante 3.0L DOHC engine

  1. Install new O-ring and connect the water inlet to the head. Tighten the mounting bolt to 9-11 ft. lbs. (12-15 Nm).
  2.  
  3. Replace the gaskets and install the thermostat housing. Tighten the mounting bolts to 12-14 ft. lbs. (17-20 Nm).
  4.  
  5. Using new hose clamps, connect the hoses to the thermostat housing.
  6.  
  7. Install the ignition coil and torque the mounting bolts to 7 ft. lbs. (10 Nm).
  8.  
  9. Install the rear timing belt cover and torque the mounting bolts to 17 ft. lbs. (24 Nm).
  10.  
  11. Install the intake camshaft sprockets. Tighten the retaining bolt to 65 ft. lbs. (90 Nm).
  12.  
  13. Apply sealer to the lower edges of the valve cover. Tighten the bolts in the proper sequence to 44-51 inch lbs. (5-6 Nm).
  14.  
  15. Connect the spark plug wires and install the center cover. Tighten the bolts that secure the center cover to 27 inch lbs. (3 Nm)
  16.  
  17. Install the breather hose.
  18.  
  19. Install the timing belt. Refer to the timing belt procedure in this section.
  20.  
  21. Install the exhaust manifold assembly.
  22.  
  23. Using all new gaskets, install the intake manifold and air intake plenum.
  24.  
  25. Install the air intake hoses.
  26.  
  27. Change the engine oil and oil filter.
  28.  
  29. Fill the system with coolant.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Adjust the accelerator cable.
  34.  
  35. Start the engine.
  36.  
  37. Check and adjust the idle speed and ignition timing.
  38.  
  39. Once the vehicle has cooled, recheck the coolant level.
  40.  

SOHC Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the air intake hose.
  2.  
  3. Remove the exhaust manifold.
  4.  
  5. Remove the air intake plenum and intake manifold.
  6.  
  7. Remove the timing belt. Refer to the timing belt procedure in this section.
  8.  
  9. Remove the camshaft sprockets and the rear timing belt cover.
  10.  
  11. Remove the power steering pump bracket. If removing the rear head, remove the alternator brace.
  12.  
  13. Disconnect the water inlet pipe.
  14.  
  15. Remove the purge pipe assembly.
  16.  
  17. Remove the valve cover.
  18.  
  19. Using the reverse sequence of the installation sequence, loosen the cylinder head mounting bolts in three steps. Lift off the cylinder head assembly and remove the head gasket.
  20.  

To install:

  1. Thoroughly clean the sealing surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block making sure the identification mark on the cylinder head gasket is in the front top (upward) location. Do not use sealer on the gasket.
  4.  
  5. Carefully install the cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Using three even steps, torque the head bolts in sequence, to 76-83 ft. lbs. (105-115 Nm).
  6.  
  7. Apply sealer to the lower edges of the half-round portions and install the valve cover. Tighten valve cover bolts to 7 ft. lbs. (9 Nm).
  8.  
  9. Install the purge pipe assembly.
  10.  
  11. Connect the water inlet pipe.
  12.  
  13. Install the power steering pump bracket and alternator brace.
  14.  
  15. Install the rear timing belt cover and camshaft sprockets. Torque the retaining bolt to 65 ft. lbs. (90 Nm).
  16.  
  17. Install the timing belt. Refer to the timing belt procedure in this section.
  18.  
  19. Using all new gaskets, install the intake manifold, air intake plenum and exhaust manifold.
  20.  
  21. Install the air intake hose.
  22.  
  23. Fill the system with coolant.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Start the engine.
  28.  
  29. Check and adjust the idle speed and ignition timing.
  30.  
  31. Once the vehicle has cooled, recheck the coolant level.
  32.  

3.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the timing belt. Refer to the timing belt procedure in this section.
  2.  
  3. Remove the intake and exhaust manifolds.
  4.  
  5. Remove the spark plug wires.
  6.  
  7. Remove the cylinder head covers.
  8.  
  9. Remove the timing belt rear center cover.
  10.  
  11. Loosen the cylinder head bolts gradually in three stages, in the opposite of the installation sequence.
  12.  
  13. Remove the cylinder head.
  14.  

To install:

  1. Clean the cylinder head and mounting surface on the engine block.
  2.  
  3. Install the cylinder head using a new gasket.
  4.  
  5. Tighten the bolts in sequence using three stages to 76-83 ft. lbs. (103-113 Nm).
  6.  



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.5L engine

  1. Install the timing belt rear center cover.
  2.  
  3. Install the cylinder head covers using new gaskets. Tighten the bolts to 2-3 ft. lbs. (3-4 Nm).
  4.  
  5. Install the spark plug wires.
  6.  
  7. Install the intake and exhaust manifolds.
  8.  
  9. Install the timing belt. Refer to the timing belt procedure in this section.
  10.  
  11. Install any remaining components.
  12.  
  13. Refill the cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  

3.8L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the intake manifold. Remove the exhaust manifolds. Remove the timing belt.
  8.  
  9. Remove the thermostat housing. Disconnect the PCV hose connection. Remove the PCV valve.
  10.  
  11. Disconnect the ignition coil connector and remove the ignition coil.
  12.  
  13. Disconnect the engine control wiring harness clamp. Remove the harness bracket.
  14.  
  15. Remove the rocker arm covers and gaskets. Remove the camshaft position sensor connector.
  16.  
  17. Remove the engine oil control valve connector. Remove the grounding bolt. Remove the engine oil dipstick assembly.
  18.  
  19. Remove the camshaft sprockets, using tool MB990767 or equivalent. Remove the timing belt rear center cover.
  20.  
  21. Remove the power steering oil pump assembly and position it to the side. Remove the power steering oil pump bracket bolt. Remove the engine oil control valve connector.
  22.  
  23. Loosen all cylinder head bolts in two or three steps and in the proper bolt removal sequence. Remove the cylinder head from the engine. Discard the cylinder head gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2004-2005 Galant 3.8L engine

  24.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2004-2005 Galant 3.8L engine

  1. Thoroughly clean the sealing surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block making sure the identification mark on the cylinder head gasket is in the front top (upward) location. Do not use sealer on the gasket.
  4.  
  5. Carefully install the cylinder head on the block. Be sure the head bolt washers are installed with the beveled side facing upward. Torque the cylinder head bolts to specification.
  6.  

Evolution
  1. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the engine under cover. Remove the side cover.
  4.  
  5. Drain the engine oil. Remove the strut tower bar assembly. Remove the air cleaner assembly.
  6.  
  7. Remove the turbocharger bypass valve assembly, air bypass hose, air hose, air pipe and secondary air hose.
  8.  
  9. Remove the battery. Disconnect the accelerator cable. Remove the rocker cover center cover.
  10.  
  11. Remove the radiator. Remove the front axle crossmember bar. Remove the front exhaust pipe. Remove the starter.
  12.  
  13. Remove the timing belt.
  14.  
  15. Disconnect the control wiring harness and ground cable connector.
  16.  
  17. Disconnect the EGR vacuum regulator solenoid valve connector, EGR vacuum regulator solenoid valve and bracket assembly and the brake booster vacuum hose.
  18.  
  19. Remove the engine oil dipstick and dipstick guide. Remove the purge hose connection. Remove the alternator brace bolt. Remove the battery wiring harness connection.
  20.  
  21. Remove the intake manifold stay. Remove the eye bolt, gasket, check valve assembly, oil feeder control valve pipe and filter.
  22.  
  23. Remove the oil pipe joint, gasket, oil return tube, oil return tube gasket and turbocharger bracket.
  24.  
  25. Remove the water outlet fitting and thermostat case assembly.
  26.  
  27. Remove the rocker arm cover, water return hose connector, heater hose connection and fuel line return hose connection.
  28.  
  29. Disconnect the fuel high pressure hose connection and remove the O-ring.
  30.  
  31. Loosen all cylinder head bolts in two or three steps and in the proper bolt removal sequence. Remove the cylinder head from the engine. Discard the cylinder head gasket.
    NOTE
    If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it with a magnet.



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-Evolution

  32.  

To install:

  1. Thoroughly clean the mating surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block. Position the gasket on the block so that the identification mark -63- is at the top surface and on the exhaust side.
  4.  
  5. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Apply a small amount of engine oil to the thread section and washer of the bolt.
  6.  
  7. Position the cylinder head on the engine. Install and torque the retaining bolts to specification and in the proper sequence.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-Evolution

  8.  

 
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