Orlando

Cylinder Head Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Remove the intake manifold. Refer to Inlet Manifold Replacement .
2. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement : 2.0L Diesel LNP  → 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH .
3. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal : LDE, LED, LFJ, LXV, 2H0, LUW, LFH .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
7. Lower the vehicle.



8. Set crankshaft balancer in direction of engine rotation to "cylinder 1 TDC of combustion stroke" (1).



9. Prepare the right half of the EN-6340 locking tool.

9.1.	Remove the 2 bolts (2).

9.2.	Remove the front panel (1)




10. Install the EN-6340 locking tool into the camshaft adjusters.

Note: The spot type marking (4) on the inlet camshaft adjuster does not correspond to the groove of EN-6340-left locking tool during this process but must be somewhat above as shown.

•	Install the EN-6340-left locking tool (1) in the camshaft adjusters as shown.

Note: The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340-right locking tool .

•	Install EN-6340-right locking tool (2) in the camshaft adjusters as shown.

11. Remove EN-6340 locking tool.
12. Raise the vehicle.



13. Remove the bolt (1).



14. Install EN-6625 locking device (2) to block the crankshaft.
15. Install the bolt (1).
16. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

17. Assemble the CH-49290 support tool (1) according to the details provided in the SPX installation manual.
18. Support the CH-904 base frame on a jack.
19. Support the CH-49290 support tool on the CH-904 base frame .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

20. Install the CH-49290 support tool (1) according to the details provided in the SPX installation manual.
21. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement .
22. Remove the timing belt centre front cover. Refer to Timing Belt Centre Front Cover Removal .
23. Remove the timing belt lower front cover. Refer to Timing Belt Lower Front Cover Removal .



24. Loosen the timing belt tensioner bolt.
25. Apply tension to the drive belt tensioner (2) in the direction of the arrow, using an Allen key (1).
26. Install the EN-6333 locking pin (3).



27. Remove the timing belt tensioner bolt (1) and the timing belt tensioner (2).
28. Remove the camshaft cover. Refer to Camshaft Cover Replacement : 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH .
29. Remove the 2 camshaft position sensor. Refer to Camshaft Position Sensor Replacement : LDE, LXV, LUW, 2H0 and LFH .
30. Remove the 2 camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement .
31. Remove the 2 camshaft position actuator adjusters. Refer to Camshaft Position Actuator Adjuster Removal .
32. Remove the timing belt rear cover. Refer to Timing Belt Rear Cover Removal .
33. Remove engine coolant thermostat housing. Refer to Engine Coolant Thermostat Replacement : 2.0L Diesel LNP  → 1.6L LDE, LXV, 1.8L LUW, 2H0 and LFH .



34. Remove the 10 cylinder head bolts in sequence as shown, using the EN-45059 sensor kit .

34.1.

Loosen the 10 bolts 90°.

34.2.

Loosen the 10 bolts 180°.

35. Remove the cylinder head and place on a suitable base.
36. Remove and discard the cylinder head gasket.

1. Clean the sealing surfaces.
2. Inspect for plane surface.

2.1.	Cylinder block, cylinder head

2.2.	Straight-edge, feeler gage

3. Install a NEW cylinder head gasket.



4. Install the cylinder head.

Caution: Refer to Fastener Caution in the Preface section.

Note: Note the correct tightening sequence.

5. Install 10 NEW cylinder head bolts (1).
6. Tighten the bolts in 5 passes. Use the EN-45059 sensor kit .

6.1.	First pass to 25 N·m (18 lb ft)

6.2.	Second pass to 90°

6.3.	Third pass to 90°

6.4.	Fourth pass to 90°

6.5.	Fifth pass to 45°

7. Install engine coolant thermostat housing. Refer to Engine Coolant Thermostat Replacement : 2.0L Diesel LNP  → 1.6L LDE, LXV, 1.8L LUW, 2H0 and LFH .
8. Install the timing belt rear cover. Refer to Timing Belt Rear Cover Installation .
9. Install the camshaft position actuator adjuster. Refer to Camshaft Position Actuator Adjuster Installation .
10. Install the camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement .
11. Install the 2 camshaft position sensor. Refer to Camshaft Position Sensor Replacement : LDE, LXV, LUW, 2H0 and LFH .
12. Install the camshaft cover. Refer to Camshaft Cover Replacement : 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH .
13. Clean the timing belt tensioner thread.



14. Install the timing belt tensioner (2).
15. Install the timing belt tensioner bolt (3).



16. Apply tension to the drive belt tensioner (2) in the direction of the arrow, using an Allen key (1).
17. Remove the EN-6333 locking pin (3).

Note: The timing belt tensioner moves automatically to the correct position.

18. Release tension on timing belt tensioner.

Caution: Refer to Fastener Caution in the Preface section.

19. Tighten the timing belt tensioner bolt to 20 N·m (15 lb ft).
20. Install the timing belt lower front cover. Refer to Timing Belt Lower Front Cover Installation .
21. Install the timing belt centre front cover. Refer to Timing Belt Centre Front Cover Installation .
22. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement .
23. Raise the vehicle.



24. Lower the CH-49290 support tool (1) with the CH-904 base frame and a jack.
25. Remove the CH-49290 support tool from the CH-904 base frame .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

26. Disassemble the CH-49290 support tool (1) according to the details provided in the SPX installation manual.
27. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation .



28. Remove bolt (1).
29. Remove EN-6625 locking device (2) to block the crankshaft.



30. Install the bolt (1) and tighten to 75 N·m (55 lb ft).
31. Lower the vehicle.



32. Check the timing

Note: Note the marking at the camshaft sprockets.

•	Turn the crankshaft 720° in the direction of engine rotation by the bolt on the crankshaft balancer.

Note: The spot type marking (4) on the inlet camshaft adjuster does not correspond to the groove of EN-6340-left locking tool during this process but must be somewhat above as shown.

•	Install EN-6340-left locking tool (1) into the camshaft adjusters as shown.

Note: The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340-right locking tool .

•	Install EN-6340-right locking tool (2) into the camshaft adjusters as shown.

•	Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .





Note: Note the marking at the crankshaft balancer and the cover.

33. Control the crankshaft balancer position.

Markings on torsional crankshaft balancer (1) and lower cover (1) must align.

34. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
35. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
36. Lower the vehicle.
37. Remove the EN-6340 locking tool.
38. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Installation : LDE, LED, LFJ, LXV, 2H0, LUW, LFH .
39. Install the exhaust manifold. Refer to Exhaust Manifold Replacement : 2.0L Diesel LNP  → 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH .
40. Install the inlet manifold. Refer to Inlet Manifold Replacement .
41. Fill the cooling system. Refer to Cooling System Draining and Filling .
42. Check and correct the engine oil.