Tracker 2000-2004

Cylinder Head

Print

Removal & Installation



1.6L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Air intake pipe
     
    Fuel lines
     
    Upper radiator hose
     
    Coolant bypass hose
     
    Alternator bracket
     
    Intake manifold brackets
     
    Intake manifold
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust manifold heat shield
     
    Exhaust manifold bracket
     
    Exhaust front pipe
     
    Exhaust manifold
     
    A/C compressor
     
    Power steering pump
     
    Front cover
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Camshaft timing sprocket
     
    Rear timing belt cover
     
    Distributor and spark plug wires, if equipped
     
    Ignition coils and wiring, if equipped with Distributorless Ignition System (DIS)
     
    Valve cover
     
    Cylinder head. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-1.6L engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.6L engine

  1. Install the cylinder head with a new gasket.
  2.  
  3. Tighten the bolts in sequence as follows:
    1. Step 1: 26 ft. lbs. (35 Nm)
    2.  
    3. Step 2: 41 ft. lbs. (55 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 26 ft. lbs. (35 Nm)
    8.  
    9. Step 5: 52 ft. lbs. (70 Nm)
    10.  

  4.  
  5. Install or connect the following:

    Valve cover
     
    Ignition coils and wiring, if equipped with DIS
     
    Distributor and spark plug wires, if equipped
     
    Rear timing belt cover
     
    Camshaft timing sprocket
     
    Timing belt
     
    Front cover
     
    Power steering pump
     
    A/C compressor
     
    Exhaust manifold
     
    Exhaust front pipe
     
    Exhaust manifold bracket
     
    Exhaust manifold heat shield
     
    HO 2 S sensor connectors
     
    Intake manifold
     
    Intake manifold brackets
     
    Alternator bracket
     
    Coolant bypass hose
     
    Upper radiator hose
     
    Fuel lines
     
    Air intake pipe
     
    Accessory drive belts
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower brace
     
    Air intake tube
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Evaporative Emission (EVAP) canister purge valve connector and hose
     
    Intake manifold ground cable
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Camshaft Position (CMP) sensor connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Fuel injector connectors
     
    Ignition coils
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Brake booster vacuum hose
     
    Radiator hose
     
    Bypass hose
     
    Heater hose
     
    Fuel lines
     
    Intake manifold bracket
     
    Water pipe
     
    Valve cover
     
    Accessory drive belts
     
    Oil pan
     
    Front cover
     
    Timing chains
     
    Camshafts
     
    Exhaust front pipe
     
    Exhaust manifold bracket
     
    Cylinder head. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-2.0L engines

     

  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.0L engines

  1. Install the cylinder head with a new gasket.
  2.  
  3. Tighten the bolts in sequence as follows:
    1. Step 1: 38 ft. lbs. (52 Nm)
    2.  
    3. Step 2: 61 ft. lbs. (84 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 38 ft. lbs. (52 Nm)
    8.  
    9. Step 5: 76 ft. lbs. (105 Nm)
    10.  
    11. Step 6: 6mm bolt to 96 inch lbs. (8 Nm)
    12.  

  4.  
  5. Install or connect the following:

    Exhaust manifold bracket
     
    Exhaust front pipe
     
    Camshafts
     
    Timing chains
     
    Front cover
     
    Oil pan
     
    Accessory drive belts
     
    Valve cover
     
    Water pipe
     
    Intake manifold bracket
     
    Fuel lines
     
    Heater hose
     
    Bypass hose
     
    Radiator hose
     
    Brake booster vacuum hose
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Ignition coils
     
    Fuel injector connectors
     
    ECT sensor connector
     
    CMP sensor connector
     
    HO 2 S sensor connectors
     
    Intake manifold ground cable
     
    EVAP canister purge valve connector and hose
     
    TP sensor connector
     
    IAC valve connector
     
    EGR valve connector
     
    Air intake tube
     
    Strut tower brace
     
    Negative battery cable
     

  6.  
  7. Fill the crankcase to the correct level.
  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

2.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system and engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Ignition coil covers and ignition coils
     
    Valve covers
     
    Oil pan
     
    Timing chain cover and timing chains
     
    Camshaft Position (CMP) sensor
     
    Camshafts
     
    Exhaust manifolds
     
    Water outlet caps
     
    Cylinder heads. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-2.5L engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L engine

  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 38 ft. lbs. (52 Nm)
    2.  
    3. Step 2: 61 ft. lbs. (84 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 38 ft. lbs. (52 Nm)
    8.  
    9. Step 5: 76 ft. lbs. (105 Nm)
    10.  
    11. Step 6: 6mm bolt to 96 inch lbs. (8 Nm)
    12.  

  2.  
  3. Install or connect the following:

    Water outlet caps
     
    Exhaust manifolds
     
    Camshafts
     
    CMP sensor
     
    Timing chain cover and timing chains
     
    Oil pan
     
    Valve covers
     
    Ignition coil covers and ignition coils
     
    Intake manifold
     
    Negative battery cable
     

  4.  
  5. Fill the crankcase to the correct level
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

 
label.common.footer.alt.autozoneLogo