Volkswagen Cars 2000-05

Cylinder Head 3

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Removal & Installation



2.8L (Aha/Atq) Engine

NOTE
This procedure is for removing the left cylinder head, the right cylinder head service is similar.



Before servicing the vehicle, refer to the Precautions section.
 
Place the lock carrier into the service position as follows:
  1. Remove or disconnect:
  2.  

  1. Front bumper.
  2.  
  3. Any wiring or connector that would inhibit locking the carrier.
  4.  
  5. 3 quick-release screws on the front noise insulation panel.
  6.  
  7. Air guide between the lock carrier and the air filter.
  8.  
  9. If installed, retaining clamps for the wiring harness at the left side of the radiator frame.
  10.  
  11. No. 2 bolts and install Support 3369 or equivalent.
  12.  
  13. Remaining bolts and pull the lock carrier out to the stop.
  14.  
  15. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
  16.  

 
Remove or disconnect:

Negative battery cable.
 
Engine cover and under cover.
 
Accessory drive belt.
 
Timing belt.
 
Left and right front exhaust pipes from the manifold.
 
Exhaust system from the transaxle bracket.
 
Coolant.
 
Coolant expansion tank.
 
Crankshaft housing ventilation hose from the valve cover.
 
Intake air duct between the MAF sensor and elbow.
 
Intake Manifold Tuning (IMT) valve and IAT sensor electrical connectors.
 
Vacuum hoses from the cruise control diaphragm and fuel pressure regulator.
 
Cruise control vacuum diaphragm and throttle control linkage from the throttle body.
 
ECT and CMP sensor electrical connector.
 
Tie wraps for the wiring harnesses and position the wires to the rear.
 
Any remaining connectors and hoses that would interfere with the cylinder head removal.
 
Fuel supply and return lines.
 
4 bolts mounting the fuel rail to the intake manifold.
 
Fuel rail from the intake manifold.
 

 
Install Camshaft Locator Bar 3391, or equivalent, onto the camshaft sprocket.
 
Loosen the 2 bolts for the camshaft and back out approximately 5 turns.
 
Remove the Camshaft Locating Bar 3391.
 
Using Camshaft Gear Puller T40001, or equivalent, remove the camshaft sprocket.
 
Remove or disconnect:
  1. Spark plug connectors.
  2.  
  3. Ignition coil bracket and position it aside with the coils.
  4.  
  5. Intake manifold.
  6.  
  7. Timing belt rear cover.
  8.  
  9. Coolant hoses related to the cylinder head service.
  10.  
  11. Valve cover.
  12.  

 
Using Polydrive Special tool 3452, or equivalent, loosen, then remove the cylinder head bolts in the reverse order of the tightening sequence.
 


Click image to see an enlarged view

Fig. To remove and install the cylinder head bolts, use the Polydrive Special tool 3452 with a 10mm socket-2.8L (AHA/ATQ) engine


To install:



Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.8L (AHA/ATQ) engine


NOTE
The bolt holes in the engine block MUST be clean and free of debris and fluid. Always replace the cylinder head bolts.



Set the crankshaft and camshaft to TDC for cylinder No. 3.
 
Install or connect:

Head gasket, making sure that the part No. or the word -OBEN- is facing the cylinder head.
 
Cylinder head and tighten the head bolt hand-tight.
 
New cylinder head bolts in sequence in 2 steps:
 
Tighten all bolts to 44 ft. lbs. (60 Nm).
 
Tighten all bolts an additional12
 

 


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

  1. Timing belt rear cover.
  2.  
  3. Any coolant hoses that were removed.
  4.  
  5. Intake manifold.
  6.  
  7. Ignition coil bracket with the coil attached.
  8.  
  9. Camshaft sprocket. Retaining bolt: 41 ft. lbs. (55 Nm).
  10.  
  11. Camshaft Locating Bar 3391, tighten the 2 bolts for the camshafts, then remove the tool.
  12.  
  13. Fuel rail to the intake manifold.
  14.  
  15. Fuel supply and return lines.
  16.  
  17. All hoses, vacuum lines and electrical connectors.
  18.  
  19. Any tie wraps that were cut during the removal steps.
  20.  
  21. Exhaust system.
  22.  
  23. Coolant expansion tank and fill the cooling system.
  24.  
  25. Timing belt.
  26.  
  27. Accessory drive belt.
  28.  



Return the lock carrier to the normal position.
 
Connect the negative battery cable.
 
Install the engine cover and under cover.
 

2.8L (Atq) Engine

NOTE
This procedure is for removing the left cylinder head, the right cylinder head service is similar.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Place the lock carrier into the service position as follows:
    1. Remove or disconnect:

      Front bumper.
       
      Any wiring or connector that would inhibit locking the carrier.
       
      3 quick-release screws on the front noise insulation panel.
       
      Air guide between the lock carrier and the air filter.
       
      If installed, retaining clamps for the wiring harness at the left side of the radiator frame.
       
      No. 2 bolts and install Support 3369 or equivalent.
       
      Remaining bolts and pull the lock carrier out to the stop.
       

    2.  
    3. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
    4.  

  4.  
  5. Remove or disconnect:

    Negative battery cable.
     
    Engine cover and under cover.
     
    Accessory drive belt.
     
    Timing belt.
     
    Left and right front exhaust pipes from the manifold.
     
    Exhaust system from the transaxle bracket.
     
    Coolant.
     
    Coolant expansion tank.
     
    Crankshaft housing ventilation hose from the valve cover.
     
    Intake air duct between the MAF sensor and elbow.
     
    Intake Manifold Tuning (IMT) valve and IAT sensor electrical connectors.
     
    Vacuum hoses from the cruise control diaphragm and fuel pressure regulator.
     
    Cruise control vacuum diaphragm and throttle control linkage from the throttle body.
     
    ECT and CMP sensor electrical connector.
     
    Tie wraps for the wiring harnesses and position the wires to the rear.
     
    Any remaining connectors and hoses that would interfere with the cylinder head removal.
     
    Fuel supply and return lines.
     
    4 bolts mounting the fuel rail to the intake manifold.
     
    Fuel rail from the intake manifold.
     

  6.  
  7. Install Camshaft Locator Bar 3391, or equivalent, onto the camshaft sprocket.
  8.  
  9. Loosen the 2 bolts for the camshaft and back out approximately 5 turns.
  10.  
  11. Remove the Camshaft Locating Bar 3391.
  12.  
  13. Using Camshaft Gear Puller T40001, or equivalent, remove the camshaft sprocket.
  14.  
  15. Remove or disconnect:

    Spark plug connectors.
     
    Ignition coil bracket and position it aside with the coils.
     
    Intake manifold.
     
    Timing belt rear cover.
     
    Coolant hoses related to the cylinder head service.
     
    Valve cover.
     

  16.  
  17. Using Polydrive Special tool 3452, or equivalent, loosen, then remove the cylinder head bolts in the reverse order of the tightening sequence.

    Click image to see an enlarged view

    Fig. To remove and install the cylinder head bolts, use the Polydrive Special tool 3452 with a 10mm socket-2.8L (ATQ) engine

  18.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.8L (ATQ) engine


NOTE
The bolt holes in the engine block MUST be clean and free of debris and fluid. Always replace the cylinder head bolts.

  1. Set the crankshaft and camshaft to TDC for cylinder No. 3.
  2.  
  3. Install or connect:

    Head gasket, making sure that the part No. or the word -OBEN- is facing the cylinder head.
     
    Cylinder head and tighten the head bolt hand-tight.
     
    New cylinder head bolts in sequence in 2 steps:
     

    1. Tighten all bolts to 44 ft. lbs. (60 Nm).
    2.  
    3. Tighten all bolts an additional 1 / 2 turn (180°).
      NOTE
      It is not necessary to retighten the cylinder head bolts.



      Timing belt rear cover.
       
      Any coolant hoses that were removed.
       
      Intake manifold.
       
      Ignition coil bracket with the coil attached.
       
      Camshaft sprocket. Retaining bolt: 41 ft. lbs. (55 Nm).
       
      Camshaft Locating Bar 3391, tighten the 2 bolts for the camshafts, then remove the tool.
       
      Fuel rail to the intake manifold.
       
      Fuel supply and return lines.
       
      All hoses, vacuum lines and electrical connectors.
       
      Any tie wraps that were cut during the removal steps.
       
      Exhaust system.
       
      Coolant expansion tank and fill the cooling system.
       
      Timing belt.
       
      Accessory drive belt.
       

    4.  

  4.  
  5. Return the lock carrier to the normal position.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Install the engine cover and under cover.
  10.  

2.8L (Bdf) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  14.  
  15. Remove the ignition coils using T10094 extractor.

    Remove or disconnect:
     

    1. Connector from throttle valve control module.
    2.  
    3. Coolant hoses from throttle valve control module and plug hose ends.
    4.  
    5. All vacuum lines at cylinder head.
    6.  
    7. Center support between intake manifold and heat shield/exhaust manifold.
    8.  
    9. Pressure hose at combination valve and connecting hose at cylinder head cover.
    10.  
    11. Unclip pressure hose and all other lines from retainers at intake manifold and at cylinder head cover.
    12.  
    13. Intake manifold supports at both sides at bracket from heat shield/exhaust manifold.
    14.  
    15. Secondary Air Injection (AIR) pump motor.
    16.  
    17. Dipstick and dipstick tube.
    18.  
    19. Intake manifold with throttle valve control module.
    20.  
    21. Cylinder head cover.
    22.  
    23. Fuel supply and return lines.
    24.  
    25. Coolant temperature sensor.
    26.  
    27. All remaining harness connectors and vacuum lines at cylinder head.
    28.  
    29. Thermostat housing.
    30.  
    31. Exhaust pipe from exhaust manifold.
    32.  
    33. Timing chain.
    34.  

  16.  
  17. Using Polydrive Special tool 3452, or equivalent, loosen, then remove the cylinder head bolts in the proper sequence.
  18.  
  19. Remove the cylinder head.
  20.  


    Click image to see an enlarged view

    Fig. To remove and install the cylinder head bolts, use the Polydrive Special tool 3452 with a 10mm socket-2.8L (BDF) engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.8L (BDF) engine


To install:


NOTE
The bolt holes in the engine block MUST be clean and free of debris and fluid. Always replace the cylinder head bolts.

  1. Set the crankshaft and camshaft to TDC for cylinder No. 1.
  2.  
  3. Install or connect:
    1. Head gasket, making sure that the part No. faces up.
    2.  

  4.  


NOTE
Make sure dowel sleeves in cylinder block bore 12 and 20 are inserted and the cylinder head gasket is secured. The longer cylinder head bolts go into the center bores.



Cylinder head and tighten the head bolt hand-tight.
 
New cylinder head bolts in reverse of the removal sequence in 4 steps:
 
Tighten all bolts to 22 ft. lbs. (30 Nm).
 
Tighten all bolts to 37 ft. lbs. (50 Nm).
 
Tighten all bolts an additional12
 


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

  1. Installation is the reverse of the removal procedure using the following torque values.

    Camshaft roller chain adjusting bolt: 30 ft. lbs. (40 Nm).
     
    Camshaft adjuster: 88 inch lbs. (10 Nm).
     
    Drive belt tensioner bolt: 88 inch lbs. (10 Nm).
     
    Exhaust pipe and exhaust manifold nuts: M8 18 ft. lbs. (25 Nm), M10 30 ft. lbs. (40 Nm).
     
    Intake manifold bolts: 18 ft. lbs. (25 Nm).
     
    Thermostat housing bolt: 88 inch lbs. (10 Nm).
     
    Valve cover bolts: 88 inch lbs. (10 Nm).
     

  2.  
  3. Connect the negative battery cable.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  14.  
  15. Remove the ignition coils using T10094 extractor.
    1. Remove or disconnect:

      Connector from throttle valve control module.
       
      Coolant hoses from throttle valve control module and plug hose ends.
       
      All vacuum lines at cylinder head.
       
      Center support between intake manifold and heat shield/exhaust manifold.
       
      Pressure hose at combination valve and connecting hose at cylinder head cover.
       
      Unclip pressure hose and all other lines from retainers at intake manifold and at cylinder head cover.
       
      Intake manifold supports at both sides at bracket from heat shield/exhaust manifold.
       
      Secondary Air Injection (AIR) pump motor.
       
      Dipstick and dipstick tube.
       
      Intake manifold with throttle valve control module.
       
      Cylinder head cover.
       
      Fuel supply and return lines.
       
      Coolant temperature sensor.
       
      All remaining harness connectors and vacuum lines at cylinder head.
       
      Thermostat housing.
       
      Exhaust pipe from exhaust manifold.
       
      Timing chain.
       

    2.  

  16.  
  17. Using Polydrive Special tool 3452, or equivalent, loosen, then remove the cylinder head bolts in the proper sequence.
  18.  
  19. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. To remove and install the cylinder head bolts, use the Polydrive Special tool 3452 with a 10mm socket-2.8L (BDF) engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.8L (BDF) engine

  20.  

To install:


NOTE
The bolt holes in the engine block MUST be clean and free of debris and fluid. Always replace the cylinder head bolts.

  1. Set the crankshaft and camshaft to TDC for cylinder No. 1.
  2.  
  3. Install or connect:
    NOTE
    Make sure dowel sleeves in cylinder block bore 12 and 20 are inserted and the cylinder head gasket is secured. The longer cylinder head bolts go into the center bores.



    Head gasket, making sure that the part No. faces up.
     



    Cylinder head and tighten the head bolt hand-tight.
     
    New cylinder head bolts in reverse of the removal sequence in 4 steps:
     

    1. Tighten all bolts to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten all bolts to 37 ft. lbs. (50 Nm).
    4.  
    5. Tighten all bolts an additional 1 / 2 turn (180°), using 2 steps of 90° each.
      NOTE
      It is not necessary to retighten the cylinder head bolts.

    6.  

  4.  
  5. Installation is the reverse of the removal procedure using the following torque values.

    Camshaft roller chain adjusting bolt: 30 ft. lbs. (40 Nm).
     
    Camshaft adjuster: 88 inch lbs. (10 Nm).
     
    Drive belt tensioner bolt: 88 inch lbs. (10 Nm).
     
    Exhaust pipe and exhaust manifold nuts: M8 18 ft. lbs. (25 Nm), M10 30 ft. lbs. (40 Nm).
     
    Intake manifold bolts: 18 ft. lbs. (25 Nm).
     
    Thermostat housing bolt: 88 inch lbs. (10 Nm).
     
    Valve cover bolts: 88 inch lbs. (10 Nm).
     

  6.  
  7. Connect the negative battery cable.
  8.  

2.8L V6 Engines

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

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

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

2.8L V6 SOHC Engine:



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

2.8L 5V V6 DOHC Engine:



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

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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

To install:

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



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

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

2.8L Vr6

This procedure requires special tool 3268 or equivalent. This is a setting tool that holds the camshafts in the correct position for installing the timing chains. Before removing the cylinder head, be sure new bolts are available. The cylinder head bolts are made to stretch and cannot be used again.

  1. Disconnect the battery cables and remove the battery.
  2.  
  3. Disconnect the wiring and vacuum lines as required to remove the air cleaner, Mass Air Flow (MAF) sensor and duct.
  4.  
  5. Open the radiator cap and remove the drain plug from the coolant pipe below the intake manifold to drain the cooling system.
  6.  
  7. Remove the engine trim cover. Remove the distributor cap, ignition wires and wire guide as an assembly.
  8.  
  9. Disconnect the throttle cable. Label and disconnect the wiring and vacuum lines from the intake manifold and remove the upper manifold.
  10.  
  11. The injectors and fuel rail assembly may be left on the manifold. Disconnect the fuel supply and return lines and the wiring connector for the injectors.
  12.  
  13. Disconnect the radiator and heater hoses.
  14.  
  15. Thread a long 8 x 10mm bolt into the accessory drive belt tensioner to release the tension. Move the tensioner only as required to remove the belt.
  16.  
  17. Remove the alternator and the belt tensioner.
  18.  
  19. Remove the heatshield and the bolts to disconnect the 2 piece exhaust manifold from the engine. Note the position of the gaskets.
  20.  
  21. Remove the distributor and the timing chain tensioner bolt from the timing chain cover.
  22.  
  23. Remove the cylinder head cover, upper timing chain cover and the retaining plate.
  24.  
  25. If possible, rotate the crankshaft to TDC of No. 1 piston. Clean the oil off the chain and sprockets and mark the direction of rotation for assembly.
  26.  
  27. Hold the camshafts at the flats with a 24mm wrench and remove the bolts to remove the sprockets and chain. Note the position of the distributor drive on the short camshaft.
  28.  


WARNING
Do not use the setting tool to hold the camshafts when removing or installing the sprocket bolts. The camshafts and the tool will be damaged.

  1. Carefully check to be sure all necessary wires, hoses and brackets and components have been removed.
  2.  
  3. Loosen the cylinder head bolts in the reverse of the torque sequence. Remove and discard the bolts.
  4.  
  5. Remove the cylinder head.
  6.  

To install:

  1. Carefully clean the old gasket material from the head and the block. Before reinstalling the head, check the flatness of the head and block in both width and length, then diagonally from each corner. Maximum allowable distortion is 0.004 in. (0.1mm).
  2.  
  3. If the new head gasket already has sealant in the small holes at the timing chain end, remove the sealant. Apply a silicone sealer to the timing chain end and install the gasket onto the block with the word TOP or OPEN facing up.
  4.  
  5. Fit the cylinder head over the locating dowels and set the head onto the engine. Install new bolts and hand-tighten them. Do not attempt to re-use the old bolts.
  6.  
  7. Tighten the bolts in sequence as described in the following steps:
    1. Tighten all bolts to 30 ft. lbs. (40 Nm).
    2.  
    3. Tighten all bolts to 44 ft. lbs. (60 Nm).
    4.  
    5. Tighten all bolts an additional 1 / 4 turn (90°).
    6.  
    7. Tighten all bolts an additional 1 / 4 turn (90°).
    8.  

  8.  



Click image to see an enlarged view

Fig. Be sure to tighten the cylinder head bolts in the sequence shown-2.8L (AAA) engine

  1. Be sure the crankshaft is at TDC on No. 1 piston. Install the setting tool to lock the camshafts in place, then install the timing chain and sprockets. Be sure they are positioned to rotate in the original direction.
  2.  
  3. Hold the camshaft with a 24mm wrench and install the sprocket bolt. Be sure the distributor drive is correctly positioned and tighten the bolts to 74 ft. lbs. (100 Nm).
  4.  
  5. Install the tensioner shoe and temporarily install the upper timing chain cover. Install the tensioner bolt and remove the setting tool. Rotate the crankshaft 4 full turns and stop at TDC of No. 1 piston. The setting tool should fit into the camshafts.
  6.  
  7. Remove the tensioner bolt and upper timing chain cover again. Apply new sealant as required, install the cover and tighten the bolts to 82 inch lbs. (10 Nm). Install the tensioner bolt and tighten to 15 ft. lbs. (20 Nm).
  8.  
  9. Install the cylinder head cover.
  10.  
  11. Use new gaskets and install the intake and exhaust manifolds. Tighten the nuts and bolts to 18 ft. lbs. (25 Nm).
  12.  
  13. Install the alternator belt and adjust tension.
  14.  
  15. Install the accessory drive belt and adjust tension.
  16.  
  17. Connect the radiator and heater hoses.
  18.  
  19. Install the injectors, fuel rail assembly and manifold. Connect the fuel supply and return lines. Connect the wiring connector for the injectors.
  20.  
  21. Install the upper manifold. Tighten the manifold bolts to 18 ft. lbs. (25 Nm).
  22.  
  23. Connect the wiring and vacuum lines disconnected from the intake manifold. Connect the throttle cable.
  24.  
  25. Install the distributor cap, ignition wires and wire guide as an assembly. Install the engine trim cover.
  26.  
  27. Disconnect the battery cables and remove the battery.
  28.  
  29. Refill and bleed the cooling system.
  30.  
  31. When everything has been properly installed and connected, be sure to change the oil and filter before starting the engine.
  32.  

4.0L Engine

NOTE
This procedure is for removing the left cylinder head, the right cylinder head service is similar.



Before servicing the vehicle, refer to the Precautions section.
 
Disconnect the negative battery cable.
 
Remove the engine top cover.
 
Remove the engine insulation cover.
 
Drain the engine coolant into an approved container.
 
Disconnect the coolant hoses at the radiator.
 
Remove or disconnect:
  1. Upper intake manifold.
  2.  

 
Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
 
Remove the ignition coils using T10094 extractor.
 
Remove or disconnect:
  1. Cylinder head cover
  2.  
  3. Fuel rail with injectors.
  4.  
  5. Lower intake manifold spacer.
  6.  

 


NOTE
Cover intake ports to prevent debris from entering.



Coolant pipes.
 
Intake pipes.
 

  1. Turn the crankshaft until no. 1 cylinder is at TDC. Mark on crankshaft damper must align with mark on cylinder block joint.
  2.  
  3. Remove the camshaft chain tensioner.
  4.  
  5. Remove the timing chain upper cover.
  6.  
  7. Remove the timing chain lower cover.
  8.  
  9. Mark the timing chain rotation direction for installation.
  10.  
  11. Remove the exhaust camshaft adjuster bolts.
  12.  
  13. Remove the intake camshaft adjuster bolts.
  14.  
  15. Remove the camshaft adjusters together with the timing chain.
  16.  
  17. Remove the timing chain guide rail.
  18.  
  19. Remove the cylinder head bolts in the proper sequence, and remove the cylinder head.
  20.  


    Click image to see an enlarged view

    Fig. Locating TDC alignment marks-4.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence bank 1-4.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence bank 2-4.0L engine


To install:


NOTE
The bolt holes in the engine block MUST be clean and free of debris and fluid. Always replace the cylinder head bolts.



Set the crankshaft and camshaft to TDC for cylinder No. 1.
 
Install or connect:

Head gasket, making sure that the part No. faces up.
 

 


NOTE
Make sure the longer cylinder head bolts are inserted into the middle holes of the cylinder head.



Cylinder head and tighten the head bolts hand-tight.
 
New cylinder head bolts in reverse of the removal sequence in 4 steps:
 
Tighten all bolts to 22 ft. lbs. (30 Nm).
 
Tighten all bolts to 37 ft. lbs. (50 Nm).
 
Tighten all bolts an additional12
 


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

  1. Installation is the reverse of the removal procedure using the following torque values.
    1. Timing chain guide rail bolt: 88 inch lbs. (10 Nm).
    2.  
    3. Camshaft adjuster bolt: 44 ft. lbs. (60 Nm) plus 90°.
    4.  
    5. Lower timing chain cover bolts: 15 ft. lbs. (20 Nm).
    6.  
    7. Upper timing chain cover bolts: 88 inch lbs. (10 Nm).
    8.  
    9. Timing chain tensioner bolts: 88 inch lbs. (10 Nm).
    10.  
    11. Intake manifold bolts: 88 inch lbs. (10 Nm).
    12.  
    13. Fuel rail bolts: 88 inch lbs. (10 Nm).
    14.  

  2.  
  3. Connect the negative battery cable.
  4.  


NOTE
This procedure is for removing the left cylinder head, the right cylinder head service is similar.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Remove or disconnect:

    Upper intake manifold.
     

  14.  
  15. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  16.  
  17. Remove the ignition coils using T10094 extractor.
  18.  
  19. Remove or disconnect:
    NOTE
    Cover intake ports to prevent debris from entering.



    Cylinder head cover
     
    Fuel rail with injectors.
     
    Lower intake manifold spacer.
     



    Coolant pipes.
     
    Intake pipes.
     

  20.  
  21. Turn the crankshaft until no. 1 cylinder is at TDC. Mark on crankshaft damper must align with mark on cylinder block joint.
  22.  
  23. Remove the camshaft chain tensioner.
  24.  
  25. Remove the timing chain upper cover.
  26.  
  27. Remove the timing chain lower cover.
  28.  
  29. Mark the timing chain rotation direction for installation.
  30.  
  31. Remove the exhaust camshaft adjuster bolts.
  32.  
  33. Remove the intake camshaft adjuster bolts.
  34.  
  35. Remove the camshaft adjusters together with the timing chain.
  36.  
  37. Remove the timing chain guide rail.
  38.  
  39. Remove the cylinder head bolts in the proper sequence, and remove the cylinder head.

    Click image to see an enlarged view

    Fig. Locating TDC alignment marks-4.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence bank 1-4.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence bank 2-4.0L engine

  40.  

To install:


NOTE
The bolt holes in the engine block MUST be clean and free of debris and fluid. Always replace the cylinder head bolts.

  1. Set the crankshaft and camshaft to TDC for cylinder No. 1.
  2.  
  3. Install or connect:
    NOTE
    Make sure the longer cylinder head bolts are inserted into the middle holes of the cylinder head.



    Head gasket, making sure that the part No. faces up.
     



    Cylinder head and tighten the head bolts hand-tight.
     
    New cylinder head bolts in reverse of the removal sequence in 4 steps:
     

    1. Tighten all bolts to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten all bolts to 37 ft. lbs. (50 Nm).
    4.  
    5. Tighten all bolts an additional 1 / 2 turn (180°), using 2 steps of 90° each.
      NOTE
      It is not necessary to retighten the cylinder head bolts.

    6.  

  4.  
  5. Installation is the reverse of the removal procedure using the following torque values.

    Timing chain guide rail bolt: 88 inch lbs. (10 Nm).
     
    Camshaft adjuster bolt: 44 ft. lbs. (60 Nm) plus 90°.
     
    Lower timing chain cover bolts: 15 ft. lbs. (20 Nm).
     
    Upper timing chain cover bolts: 88 inch lbs. (10 Nm).
     
    Timing chain tensioner bolts: 88 inch lbs. (10 Nm).
     
    Intake manifold bolts: 88 inch lbs. (10 Nm).
     
    Fuel rail bolts: 88 inch lbs. (10 Nm).
     

  6.  
  7. Connect the negative battery cable.
  8.  

 
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