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    2004 Chevrolet Cavalier 2.2L SFI DOHC 4cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    Volvo Truck 2003-05

    Cylinder Head

    Print

    Removal & Installation



    8-Cylinder Engines
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove intake manifold. Refer to Intake Manifold removal and installation.
    4.  
    5. Remove air induction pipe.
    6.  
    7. Remove ignition coils on the left and right banks, refer to Ignition Coil Pack removal and installation.
    8.  
    9. Remove camshaft covers, refer to Camshaft Covers removal and installation.
    10.  
    11. Remove timing chain and sprockets, refer to Timing Chain and Sprockets removal and installation.
    12.  
    13. Remove camshafts, refer to Camshaft and Valve Lifters removal and installation.
    14.  

    Left Cylinder Head

    This procedure will expose the left cylinder head, cylinders 2, 4, 6 and 8 (Bank 2).

    1. Disconnect or remove:

      Cable harness from the engine bracket
       
      Connector for the camshaft position sensor
       
      Vacuum valve
       
      Hose clip for the coolant hose

      Click image to see an enlarged view

      Fig. Hose clamp location for removal-8-Cylinder Engine

      Hose clamp location for removal-8-Cylinder Engine
       

    2.  
    3. Remove M6 bolt and heat shield around connector.

      Click image to see an enlarged view

      Fig. Heat shield location-8-Cylinder Engine

      Heat shield location-8-Cylinder Engine

      Click image to see an enlarged view

      Fig. Alternator upper mounting bolt location-8-Cylinder Engine

      Alternator upper mounting bolt location-8-Cylinder Engine
    4.  
    5. Remove the M8 upper mounting bolt from the alternator.
    6.  
    7. To remove the exhaust manifold:

      Remove the two M8 bracket bolts
       
      Remove the eight M8 nuts from the exhaust manifold
       
      Discard the exhaust manifold gasket

      Click image to see an enlarged view

      Fig. Exhaust bracket and bolt location for removal (Bank 2)-8-Cylinder Engine

      Exhaust bracket and bolt location for removal (Bank 2)-8-Cylinder Engine

      Click image to see an enlarged view

      Fig. Exhaust manifold bolt removal (Bank 2)-8-Cylinder Engine

      Exhaust manifold bolt removal (Bank 2)-8-Cylinder Engine
       

    8.  

    When replacing or working on the cylinder head, lift out the lifters using a magnet or suction cup. Make note of the positions. Also, take care not to damage the mating surfaces when removing the cylinder head.

    1. Remove the ten M12 bolts in the cylinder head.
    2.  
    3. Remove cylinder head.
    4.  
    5. Discard the cylinder head gasket.

      To install:
       

    6.  
    7. Clean and check the gasket faces:

      The coolant bypass channel
       
      The intake manifold
       
      The cylinder block
       
      Camshaft cover
       

    8.  
    9. Carefully blow the oil ducts clean.
      NOTE
      Check that all studs at the exhaust ports are tightened.

    10.  
    11. Install:

      New exhaust manifold gasket. Lubricate the studs using paste 116 1408
       
      New cylinder head gasket. Apply sealing compound 307 57050 to both sides
       
      The cylinder head
       
      New bolts in cylinder head. Lubricate the bolts
       

    12.  
    13. Tighten the cylinder head bolts in a circle from the inside and outwards. Use protractor 951 2050. Tighten in two steps:
      1. Step 1 to 30 ft. lbs. (40 Nm).
      2.  
      3. Step 2 angle tighten to 90°

        Click image to see an enlarged view

        Fig. Cylinder head torque sequence-8-Cylinder Engine

        Cylinder head torque sequence-8-Cylinder Engine
      4.  

    14.  
    15. Install the valve lifters.
      NOTE
      If the cylinder head has been replaced, the valve clearance must be adjusted. Refer to Valve Lash adjustment.

    16.  
    17. Lubricate and install valve lifters.
    18.  
    19. Install or connect:

      Exhaust manifold and tighten the eight M8 nuts to 18 ft. lbs. (24 Nm)
       
      Two M8 bolts for the exhaust manifold bracket and tighten to 18 ft. lbs. (24 Nm)
       
      The M8 upper mounting bolt from the alternator and tighten to 18 ft. lbs. (24 Nm)
       
      Heat shield and M6 bolt, tighten to 88 inch lbs. (10 Nm)
       
      Connector for camshaft position sensor
       
      Cable harness on the engine bracket
       
      Vacuum valve
       
      Hose clip for the coolant hose
       
      Camshafts
       
      Timing chain and sprockets
       
      Camshaft cover
       
      Ignition coils
       
      Intake manifold, refer to Intake Manifold removal and installation.
       

    20.  

    Right Cylinder Head

    This procedure will expose the right cylinder head, cylinders 1, 3, 5 and 7 (Bank 1).

    1. Disconnect or remove:

      Hose clamp for the upper coolant hose
       
      Electrical connectors for the camshaft position sensors
       
      Coolant hoses and place them to one side

      Click image to see an enlarged view

      Fig. Coolant hose location-8-Cylinder Engine

      Coolant hose location-8-Cylinder Engine
       

    2.  
    3. Remove the two M8 upper bolts holding the water pump

      Click image to see an enlarged view

      Fig. Water pump location-8-Cylinder Engine

      Water pump location-8-Cylinder Engine
    4.  
    5. Remove the M8 bolt and two M8 nuts attaching coolant pipes illustrated in the graphic.

      Click image to see an enlarged view

      Fig. Coolant pipe removal-8-Cylinder Engine

      Coolant pipe removal-8-Cylinder Engine
    6.  
    7. Remove exhaust manifold:
      1. Remove the two M8 bolts holding the bracket to the manifold.
      2.  
      3. Remove the eight M8 nuts holding the flanged joint to the manifold.
        NOTE
        Discard the exhaust manifold gasket.



        Click image to see an enlarged view

        Fig. Bracket bolt removal on exhaust manifold-8-Cylinder Engine

        Bracket bolt removal on exhaust manifold-8-Cylinder Engine

        Click image to see an enlarged view

        Fig. Flanged joint removal-8-Cylinder Engine

        Flanged joint removal-8-Cylinder Engine
      4.  

    8.  

    When replacing or working on the cylinder head, lift out the lifters using a magnet or suction cup. Make note of the positions. Also, take care not to damage the mating surfaces when removing the cylinder head.

    1. Remove the ten M12 bolts in the cylinder head.
    2.  
    3. Remove cylinder head.
    4.  
    5. Discard the cylinder head gasket.

      To install:
       

    6.  
    7. Clean and check the gasket faces:

      The coolant bypass channel
       
      The intake manifold
       
      The cylinder block
       
      Camshaft cover
       

    8.  
    9. Carefully blow the oil ducts clean.
      NOTE
      Check that all studs at the exhaust ports are tightened.

    10.  
    11. Install:

      New exhaust manifold gasket. Lubricate the studs using paste 116 1408
       
      New cylinder head gasket. Apply sealing compound 307 57050 to both sides
       
      The cylinder head
       
      New bolts in cylinder head. Lubricate the bolts
       

    12.  
    13. Tighten the cylinder head bolts in a circle from the inside and outwards. Use protractor 951 2050. Tighten in two steps:
      1. Step 1 to 30 ft. lbs. (40 Nm).
      2.  
      3. Step 2 angle tighten to 90°

        Click image to see an enlarged view

        Fig. Cylinder head torque sequence-8-Cylinder Engine

        Cylinder head torque sequence-8-Cylinder Engine
      4.  

    14.  
    15. Install the valve lifters.
      NOTE
      If the cylinder head has been replaced, the valve clearance must be adjusted. Refer to Valve Lash adjustment.

    16.  
    17. Lubricate and install valve lifters.
    18.  
    19. Install:

      Exhaust manifold flanged joint and tighten the eight M8 nuts to 18 ft. lbs. (24 Nm)
       
      Two M8 bolts for the exhaust manifold bracket and tighten to 18 ft. lbs. (24 Nm)
       
      The M8 bolt and two M8 nuts attaching coolant pipes and tighten to 18 ft. lbs. (24 Nm)
       
      Two M8 upper bolts holding the water pump and tighten to 18 ft. lbs. (24 Nm)
       
      Coolant hoses and clamps
       
      Camshafts
       
      Timing chain and sprockets
       
      Camshaft cover
       
      Ignition coils
       
      Air induction pipe.
       
      Intake manifold, refer to Intake Manifold removal and installation.
       

    20.  

    5-Cylinder Engines
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Air intake assembly
       
      Accessory drive belts
       
      Front cover
       
      Timing belt
       
      Exhaust manifold
       
      Fuel supply manifold covers
       
      Fuel line retainers
       

    6.  
    7. Install fuel injector holders on the injectors.

      Fuel pressure regulator vacuum hose
       
      Fuel supply manifold with injectors attached
       
      Ignition coils
       
      Cooling fan
       
      Intake manifold with turbocharger attached
       
      Upper radiator hose
       
      Camshaft sprockets
       
      Rear timing cover
       
      Camshaft Position (CMP) sensor, if equipped
       
      Extension arm and brackets
       
      Cylinder head cover
       
      Camshafts
       
      Coolant pipe
       
      Cylinder head

      Click image to see an enlarged view

      Fig. Cylinder head loosening sequence-5-cylinder engine

      Cylinder head loosening sequence-5-cylinder engine
       

    8.  

    To install:

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-5-cylinder engines

    Cylinder head torque sequence-5-cylinder engines

    1. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows:
      1. Step 1: 15 ft. lbs. (20 Nm)
      2.  
      3. Step 2: 44 ft. lbs. (60 Nm)
      4.  
      5. Step 3: Plus 130°
      6.  

    2.  
    3. Install or connect the following:

      Coolant pipe
       
      Camshafts
       
      Upper cylinder head. Tighten the bolts to 13 ft. lbs. (17 Nm).
       
      Extension arm and brackets
       
      CMP sensor, if equipped
       
      Distributor, if equipped
       
      Rear timing cover
       
      Camshaft sprockets
       
      Upper radiator hose
       
      Intake manifold
       
      Cooling fan
       
      Fuel supply manifold with injectors attached and remove the injector holders
       
      Fuel pressure regulator vacuum hose
       
      Fuel line retainers
       
      Fuel supply manifold covers
       
      Exhaust manifold
       
      Timing belt
       
      Front cover
       
      Accessory drive belts
       
      Air intake assembly
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system.
    6.  
    7. Start the engine and check for leaks.
    8.  

    6-Cylinder Engine
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Disconnect the battery negative lead.
    4.  
    5. Remove the radiator breather tube at the expansion tank
    6.  
    7. Install lock grip pliers
    8.  
    9. Install the cover from the expansion tank.
    10.  
    11. Lift up the servo reservoir and place it on top of the engine.
      NOTE
      Ensure that the oil does not leak from the ventilation hole in the filler cap.

    12.  
    13. Seal the hose between the expansion tank and the radiator.
    14.  
    15. Disconnect the hose at the tank. Lift up the expansion tank and place it on top of engine.
    16.  
    17. Remove the turbocharger.
    18.  
    19. Remove:

      The ground strip between the cylinder head and the engine
       
      The upper engine coolant hose between the engine and radiator
       
      The solenoid valve (turbocharger control system) from the air cleaner
       
      The air cleaner intake from the connection on the front cover plate
       
      Air cleaner assembly
       
      Torque rod for cross stay
       
      The upper timing cover
       
      The cover over the ignition coils
       
      The front timing cover.
       

    20.  
    21. Relieve the load from the belt tensioner. Remove the auxiliary belt.
    22.  
    23. Drain the fuel line.
    24.  
    25. Remove:

      The brake vacuum hose from the intake manifold
       
      The charge air pipe from the electronic throttle module
       
      The dip stick pipe from the intake manifold
       
      The pipe bolt for the crankcase ventilation connection at the intake manifold
       
      The protective cover over the nozzle connectors
       
      The fuel rail mounting bolts.
       

    26.  
    27. Spray penetrating oil around the injector connectors on the intake manifold. Gently work the fuel rail and injectors loose.
    28.  
    29. Separate the fuel line quick-release connector under the intake manifold. Use tool 951 2666, or equivalent. Carefully put the fuel rail to one side.
    30.  
    31. Remove the EVAP hose from the intake manifold.
    32.  
    33. Remove:

      The camshaft position sensor housing and trigger wheels
       
      The pipe bolt at the rear edge of the cylinder head for the water heated crankcase ventilation
       
      The clamps for the high tension wiring and positive cable.
       
      The bolt that holds the inlet pipe for the coolant pump on the cylinder block
       
      The two bolts for the connector between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.
       

    34.  
    35. Remove the nuts from the cover on the fender liner.
    36.  
    37. Position the upper timing cover.
    38.  
    39. Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond.
    40.  
    41. Remove the upper timing cover.
    42.  
    43. Remove:
      NOTE
      Mark up the ignition coils before removal.



      The variable valve timing solenoid connectors
       
      The connector for the coolant temperature sensor
       
      The bolts for the ignition coils and the two ground terminals.
       

    44.  
    45. Lift up and place the ignition coils and wiring to one side.
    46.  
    47. Slacken off the center bolt for the belt tensioner slightly.
    48.  
    49. Hold the center bolt still. Turn the tensioner eccentric clockwise to 10 o'clock using a 6mm Allen key.
    50.  
    51. Remove the timing belt.
    52.  
    53. Install tool 999 5452, or equivalent, at the rear of the camshafts.

      Click image to see an enlarged view

      Fig. Tool 9995452 installed

      Tool 9995452 installed
    54.  
    55. Remove the center plugs for the variable valve timing units.
      NOTE
      Collect any oil spills using paper under the plugs.

    56.  
    57. Remove the variable valve timing unit center bolts.
    58.  
    59. Pull or work off the variable valve timing units and timing gear pulley.
    60.  
    61. Remove tool 999 5452.
    62.  
    63. Remove:

      The bolt for the thermostat housing cable duct
       
      bolts holding the thermostat housing to the cylinder head. Lift out the thermostat housing, gasket and cable duct
       
      The bolt holding the inner timing cover to the cylinder head.
       
      Spark plugs for cylinders 2 and 5. Install tool 999 5454, or equivalent. Leave a 0.079- 0.118 inch (2-3mm) gap to the camshaft cover. Ensure that the bolt in the spark plug well is fully tightened

      Click image to see an enlarged view

      Fig. Tool 9995454 installed

      Tool 9995454 installed
       
      Variable valve timing solenoid
       
      The bolts holding the camshaft cover to the cylinder head.
       

    64.  
    65. Use to lift the cover from the cylinder head. Install the pliers at the stop lugs.
    66.  
    67. Start with cylinder 1 and work alternately backward.
    68.  
    69. Slacken off the wing nuts approximately 2 turns.
    70.  
    71. Repeat the procedure with the pliers.
    72.  
    73. Carefully press out the front and rear camshaft seals.
    74.  
    75. Remove the seals.
    76.  
    77. Remove:
      CAUTION
      Mark up and position the lifters so that their original positions can be established.



      Tools 999 5454
       
      The camshaft cover
       
      The camshafts.
       

    78.  
    79. Lift out the valve lifters. Use a suction cup.
    80.  
    81. Position the valve lifters on a piece of paper to drain.
    82.  
    83. Remove the bolts holding the cylinder head on the cylinder block.
    84.  
    85. Start at the sides and work alternately towards the center.
      NOTE
      Do not damage the mating surfaces.

    86.  
    87. Remove:

      The intake manifold and gasket
       
      The coolant outlet pipe.

      Click image to see an enlarged view

      Fig. Cylinder head loosening sequence-6-cylinder engine

      Cylinder head loosening sequence-6-cylinder engine
       

    88.  

    To install:

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-6-cylinder engines

    Cylinder head torque sequence-6-cylinder engines

    To install:

    1. Clean the gasket surfaces of:

      The manifold. Check that the studs are tightened
       
      The coolant bypass channel
       
      The coolant outlet pipe
       
      The intake manifold
       
      The cylinder block
       
      Camshaft cover
       

    2.  
    3. Blow the oil ducts clean.
    4.  
    5. Remove the starter motor mounting bolts. Pull out the starter motor and place to one side.
    6.  
    7. Remove the blind cover plug.
    8.  
    9. Turn the crankshaft clockwise slightly. Install the crankshaft stop 999 5451, or equivalent. Ensure that it bottoms out against the cylinder block.
    10.  
    11. Turn the crankshaft counter-clockwise until it stops against the crankshaft stop.
    12.  
    13. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
    14.  
    15. Install a new cylinder head gasket.
    16.  
    17. Install the cylinder head.
    18.  
    19. Use new bolts. Lubricate and install all the bolts.
    20.  
    21. Tighten the bolts in the order illustrated. See the torque chart at the beginning of this chapter.
    22.  
    23. When installing a new cylinder head, the valve clearance must be set.
      CAUTION
      Make sure that the lifters are in the same position as before.

    24.  
    25. Lubricate the valve lifter wells and the lifters. Install all the valve lifters.
    26.  
    27. Lubricate the camshaft bearing positions.
    28.  
    29. Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line.
    30.  
    31. Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line.
      NOTE
      Ensure that no liquid gasket gets into the oil ducts.

    32.  
    33. Install new O-rings around the spark plug wells at the cylinder head.
    34.  
    35. Apply liquid gasket 11 61,059, or equivalent, to the camshaft cover. Use a roller. The surface must be completely covered without any excess.
    36.  
    37. Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.
    38.  
    39. Install the camshaft cover. Install 2 press tools 999 5454, or equivalent.
    40.  
    41. Tighten the camshaft cover bolts alternately, keeping it parallel to the cylinder head using the press tools.
    42.  
    43. Install all the bolts and tighten.
    44.  
    45. Install the variable valve timing solenoid using a new gasket.
    46.  
    47. Remove the press tools.
    48.  
    49. Install the spark plugs.
    50.  
    51. Lubricate the surface of the seal that the camshaft rotates against.
    52.  
    53. Using a drift, press in the seal until the drift bottoms out.
      NOTE
      If there are grooves worn into the camshaft, the seal can be pressed in a further 0.078 inch (2mm) by reversing the sleeve on the tool.

    54.  
    55. Using camshaft tool 999 5452, or equivalent, separate the camshaft adjustment tool into two units.
      CAUTION
      The camshafts must not be turned more than is listed in the text below. The valves may be damaged.

    56.  
    57. Install the exhaust camshaft section of the adjustment tool. Screw into the rear edge of the camshaft.
    58.  
    59. Carefully turn the camshaft adjustment tool clockwise (as viewed from the back of the engine) until the camshaft adjustment tool is parallel with the join between the cylinder head and camshaft cover.
    60.  
    61. Install the intake camshaft section of the adjustment tool.
    62.  
    63. Screw into the rear edge of the camshaft.
    64.  
    65. Carefully turn the camshaft adjustment tool counter-clockwise until it is in contact with the exhaust camshaft section of the camshaft adjustment tool.
    66.  
    67. Screw the adjustment tool sections together into one.
    68.  
    69. Check that the bolts retaining the adjustment tool to the camshafts and the bolts holding the tool together are well tightened.
    70.  
    71. Lubricate the surface of the seal that the camshaft rotates against.
    72.  
    73. Use the mounting bolts for the variable valve timing unit.
    74.  
    75. Using drift 999 5718, or equivalent, tighten the bolts until the drift bottoms out.
    76.  
    77. Install:

      The bolt holding the inner timing cover to the cylinder head
       
      The thermostat housing and cable duct. Use a new gasket
       
      The bolt for the thermostat housing cable duct.
       

    78.  
    79. Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 18 ft. lbs. (24 Nm).
    80.  
    81. Spin the tension pulley and listen for noise. When replacing, bolt the tension pulley into place using the center bolt. Screw in the center bolt by hand.

      Click image to see an enlarged view

      Fig. Allen hole positioned at 10:00 o-clock

      Allen hole positioned at 10:00 o-clock
    82.  
    83. Ensure that the tensioner fork is centered over the cylinder block rib/bracket. Ensure that the Allen hole on the eccentric is at 10 o'clock.
    84.  
    85. Slacken off, but do not remove the bolts which secure the timing gear pulley to the VVT unit.
    86.  
    87. Press the variable valve timing unit and timing gear onto the camshaft.

      Click image to see an enlarged view

      Fig. Installing the VVT unit

      Installing the VVT unit
    88.  
    89. Install the center bolt which secures the variable valve timing unit to the camshaft. Tighten slightly.
    90.  
    91. Turn the variable valve timing unit counter-clockwise as far as it will go. Slacken off the center bolt.
    92.  
    93. Position the upper timing cover.
    94.  
    95. Turn the timing gear pulley clockwise until the bolts at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover.
      NOTE
      Do not turn counter clockwise during this procedure.

    96.  
    97. Check that the timing gear pulley is still in the limit position in the oval holes.
    98.  
    99. Tighten the center bolt in the VVT unit to 89 ft. lbs. (120 Nm). Check that the variable valve timing unit does not rotate when tightening.
    100.  
    101. Install and tighten the center plug.
    102.  
    103. Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond.
    104.  
    105. Slacken off, but do not remove the bolts which secure the timing gear pulley to the VVT unit.
    106.  
    107. Press the variable valve timing unit/timing gear onto the camshaft.
    108.  
    109. Install the center bolt which secures the variable valve timing unit to the camshaft. Tighten slightly.
    110.  
    111. Turn the variable valve timing unit counter-clockwise as far as it will go.
    112.  
    113. Slacken off the center bolt.
    114.  
    115. Turn the timing gear pulley clockwise until the bolts at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 2 cogs before the marking on the upper timing cover.
      NOTE
      Do not turn counter clockwise during this procedure.

    116.  
    117. Check that the timing gear pulley is still in the limit position in the oval holes.
    118.  
    119. Tighten the center bolt in the VVT unit to 89 ft. lbs. (120 Nm). Check that the variable valve timing unit does not rotate when tightening.
    120.  
    121. Install and tighten the center plug.
    122.  
    123. Turn the variable valve timing unit clockwise to the limit position.
    124.  
    125. Turn the timing gear pulley so that the markings correspond.
    126.  
    127. Tighten the timing belt tensioner center bolt. Tighten to 44 inch lbs. (5 Nm).
    128.  
    129. Install the timing belt in the following order:

      Crankshaft
       
      The idler pulley
       
      Intake cam
       
      Exhaust cam
       
      Water pump
       
      Tension pulley.
       

    130.  
    131. The variable valve timing unit does not have a return spring and is easily dislodged when reinstalling the timing belt. Check that the markings correspond.
      NOTE
      Adjust the timing gear pulleys so that the bolts are not at the limit positions in any of the oval holes.

    132.  
    133. This adjustment is to be made with a cold engine. A suitable temperature is approximately 68°F (20°C).
    134.  
    135. At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
    136.  
    137. The illustration shows the position of the indicator at different engine temperatures.
    138.  
    139. Hold the center bolt secure and turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position.
    140.  
    141. Turn the eccentric back so that the indicator reaches the marked position in the center of the window.
    142.  
    143. Remember to hold the center bolt secure at the same time.
    144.  
    145. Hold the eccentric secure and tighten the center bolt. Tighten to 18 ft. lbs. (25 Nm).
    146.  
    147. Check that the indicator is in the correct position.
    148.  
    149. Check:

      That the timing gear pulley is still in the limit position in the oval holes
       
      The timing gear pulley so that the markings line up with the upper timing cover.
       

    150.  
    151. Tighten the bolts for the timing gear pulleys.
    152.  
    153. Remove:

      Camshaft adjustment tools 999 5451

      Click image to see an enlarged view

      Fig. Camshaft adjustment tools installed

      Camshaft adjustment tools installed
       
      Crankshaft stop 999 5452
       

    154.  
    155. Install the plug with a new blind cover plug. Tighten to 30 ft. lbs. (40 Nm).
    156.  
    157. Press the timing belt to check that the indicator on the tensioner moves easily.
    158.  
    159. Position the upper timing cover.
    160.  
    161. Turn the crankshaft two turns. Check that the markings on the crankshaft timing gear pulley and the camshaft timing gear pulley match up with the markings on the oil pump and upper timing cover respectively.
    162.  
    163. Check that the indicator on the belt tensioner is within the marked position.
    164.  
    165. Remove the upper timing cover.
    166.  
    167. Install:
      CAUTION
      The trigger wheel can only be installed in one way



      The trigger wheel.
       



      The camshaft position sensor housing
       
      The pipe bolt for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 19 ft. lbs. (26 Nm).
       
      The ignition coils according to the earlier markings
       
      The connector for the engine coolant temperature sensor
       
      The connectors for the variable valve timing solenoid
       
      The bolts for the 2 ground terminals between ignition coils 1 and 2 and 5 and 6.
       
      The starter motor
       
      The throttle body connector to the engine wiring
       
      The charge air pipe to the throttle body. Tighten the clamp
       
      The brake vacuum hose to the intake manifold
       
      The pipe bolts at the underside of the intake pipe for the water heated crankcase ventilation. Tighten to 19 ft. lbs. (26 Nm)
       
      The dip stick pipe onto the intake manifold.
       
      The fuel rail. Use new bolts. Tighten to 88 inch lbs. (10 Nm). Press the quick-release connector for the fuel pressure line until it clicks
       
      The clamps that hold the injector wiring and the positive cable to the rear edge of the cylinder head
       
      The protective cover over the nozzle connectors
       
      The upper engine coolant hose to the cylinder head and radiator. Tighten the clamp.
       
      The inlet pipe for the coolant pump to the cylinder head. Use a new gasket
       
      The bolt which secures the coolant pump inlet pipe to the cylinder block
       
      The turbocharger.
       
      The bracket for the torque rod
       
      The upper bolt securing the automatic transaxle dip stick pipe to the engine
       
      The ground strip between the right frame member and the cylinder head
       
      The cable duct on the inside of the right suspension turret
       
      The front timing cover.
       
      Expansion tank. Connect the connector to the coolant level sensor
       
      The hose to the expansion tank from the radiator. Secure the clamp and remove the lock grip pliers.
       
      Connect the connector to the ABS sensor
       
      The servo reservoir. Ensure that the hoses are correctly positioned.
       
      The upper timing cover
       
      The cover over the ignition coils
       
      The plastic intake pipe over the engine. Adjust and tighten the intake pipe at the turbocharger. Tighten the clamps and mounting bolts on the plastic pipe
       
      The plastic charge air pipe over the engine. Tighten the clamps and mounting bolts
       
      The hose between the charge air cooler and the plastic charge air pipe over the engine. Tighten the clamps
       
      The crankcase ventilation hose to the PTC resistor in the plastic intake pipe over the engine. Use a new clamp
       
      The connector for the PTC resistor
       
      The protective cover over the PTC resistor
       
      The EVAP hose to the plastic intake pipe
       
      The air cleaner assembly
       
      The plastic intake pipe to the mass air flow sensor. Tighten the clamp
       
      The connector to the mass air flow sensor. Clamp the wiring at the front of the air cleaner
       
      The turbocharger control valve to the mounting on the air cleaner
       
      The blue marked hose and the turbocharger control system to the intake manifold
       
      The red marked hose and turbocharger control system to the charge air pipe
       
      The yellow marked hose and turbocharger control system to the pressure regulators
       
      The cross stay between the suspension turrets
       
      The suspension turret covers. Clamp the servo hose to the right mounting on the engine stabilizer brace
       
      The battery negative lead.
       

    168.  
    169. Replace the oil and oil filter if necessary.
    170.  
    171. Check:

      The engine oil level
       
      The servo oil level
       
      The coolant level.
       
      The engine for leaks
       
      The oil level in the transaxle
       
      The coolant level
       

    172.  

     
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