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| Both sides previous revision Previous revision Next revision | Previous revision | ||
| articles:m104_head_gasket_replacement [2024/03/01 05:55] – john5788 | articles:m104_head_gasket_replacement [2024/04/26 05:55] (current) – john5788 | ||
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| - Set engine position to TDC | - Set engine position to TDC | ||
| - | ===== Front Cover, Belt, and Accessories ===== | + | ===== Remove |
| - Remove false firewall | - Remove false firewall | ||
| + | - Remove wire harness holder | ||
| - Remove valve cover | - Remove valve cover | ||
| - Remove and disconnect smog pump / EGR switchover vacuum valve | - Remove and disconnect smog pump / EGR switchover vacuum valve | ||
| Line 42: | Line 43: | ||
| - Remove chain tensioner | - Remove chain tensioner | ||
| - Remove camshaft chain sprocket | - Remove camshaft chain sprocket | ||
| + | |||
| + | ===== Remove Exhaust Manifold ===== | ||
| + | - Remove smog pump / alternator bracket from engine block | ||
| + | - Remove EGR valve | ||
| + | - Disconnect pipe at rear | ||
| + | - Disconnect pipe at manifold | ||
| + | - Remove fasteners at flange and remove | ||
| + | - Disconnect both downpipes from exhaust manifolds underneath car | ||
| + | - Remove downpipes support clamp at transmission | ||
| + | - Remove copper self locking nuts securing exhaust manifolds to cylinder head | ||
| + | - Remove exhaust manifold | ||
| + | |||
| + | ===== Remove Intake Manifold ===== | ||
| + | - Disconnect fuel injectors wire plugs | ||
| + | - Disconnect resonance flap wire plug | ||
| + | - Bleed pressure from fuel rail using test port schrader valve | ||
| + | - Disconnect fuel supply and fuel return hoses | ||
| + | - Remove 5 screws holding fuel rail to intake manifold | ||
| + | - Pull fuel rail off | ||
| + | - Remove remaining screws on intake manifold | ||
| + | - Loosen hose clamps connecting upper and lower manifolds | ||
| + | - Pull air intake away from cylinder head slightly | ||
| + | - Reach down between gap and disconnect knock sensor below cylinder 5 | ||
| + | - Remove air intake manifold | ||
| + | |||
| + | ===== Remove Cylinder Head ===== | ||
| + | - Remove EGR support bracket | ||
| + | - Loosen hose clamp on coolant hose at back of cylinder head and pull off hose | ||
| + | - Remove cylinder head bolts, starting with bolt #14 on the outside working towards the center | ||
| + | - Lift cylinder head off engine block. Cylinder head weight approximately 80 lb. | ||
| + | |||
| + | |||
| + | ===== Installing Cylinder Head ===== | ||
| + | - Clean mating surfaces and check for flatness. | ||
| + | - 0.004" tolerance between front and rear of engine block / cylinder head mating surface | ||
| + | - Clean cylinder head bolt holes | ||
| + | - Set engine timing to 30 degrees BTDC. | ||
| + | - Pistons are in position such that valves will not interfere when adjusted later | ||
| + | - Install new head gasket | ||
| + | - Install cylinder head | ||
| + | - Torque cylinder head bolts | ||
| + | - Lightly coat threads with engine oil for wet torque | ||
| + | - Follow tightening stages, order, and torque specs | ||
| + | - 1st stage: 55 Nm | ||
| + | - 2nd stage: 90 degrees | ||
| + | - 3rd stage: 90 degrees | ||