Orlando

Cylinder Head Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Remove the inlet manifold bracket . Refer to Inlet Manifold Bracket Replacement
2. Remove the exhaust gas recirculation manifold cooling return hose from the thermostat bypass pipe. Refer to Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement : 2.0L Diesel LNP
3. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement
4. Remove the turbocharger. Refer to Turbocharger Replacement
5. Remove the charge air cooler outlet hose from the throttle body module. Refer to Charge Air Cooler Outlet Hose Replacement : LNP and Manual Transmission → LNP and Automatic Transmission
6. Remove the engine water outlet adaptor. Refer to Engine Water Outlet Adaptor Replacement : 2.0L Diesel LNP
7. Remove the inlet camshaft. Refer to Inlet Camshaft Replacement .



8. Remove the camshaft seat guide (1).



9. Loosen the 10 cylinder head retaining bolts in sequence as shown.



10. Remove and DISCARD 10 cylinder head retaining bolts (2).
11. Remove the cylinder head (3) and the gasket (4).
12. Remove the intake manifold. Refer to Inlet Manifold Replacement
13. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement : 2.4L LAF → 2.0L Diesel LNP → 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
14. Remove the hydraulic valve adjusters. Refer to Hydraulic Valve clearance Adjuster Replacement

Note: Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material.

1. Clean the sealing surfaces.
2. Inspect the flatness of cylinder head and cylinder block sealing surfaces.
3. Clean the piston surfaces.

1. Align TDC of piston 1.
2. Measure the piston projection thickness using EN-50437 height gauge .
3. Repeat the measuring process on cylinders 2, 3, 4 and average the measured piston projection values.
4. Choose the cylinder head gasket through below the specifications. Refer to Engine Mechanical Specifications .

1. Install the hydraulic valve lash adjusters. Refer to Hydraulic Valve clearance Adjuster Replacement
2. Install the inlet manifold. Refer to Inlet Manifold Replacement
3. Install the exhaust manifold. Refer to Exhaust Manifold Replacement : 2.4L LAF → 2.0L Diesel LNP → 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH



4. Clean the sealing surfaces.
5. Install the cylinder head (3) and a NEW gasket (4).

Note: Do not tighten the bolts.

6. Install 10 NEW cylinder head retaining bolts (2).

Caution: Refer to Fastener Caution in the Preface section.

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.




7. Tighten the cylinder head retaining bolts (2) in four steps, in a sequence as shown in the illustration above:

•	First step 30 N·m (22 lb ft).

•	Second step 100 N·m (74 lb ft).

•	Third step 90°. Use EN-470-B angle meter .

•	Fourth step 90°. Use EN-470-B angle meter .




8. Install the camshaft seat guide (1).
9. Install the inlet camshaft. Refer to Inlet Camshaft Replacement .
10. Install the engine water outlet adaptor. Refer to Engine Water Outlet Adaptor Replacement : 2.0L Diesel LNP
11. Install the charge air cooler outlet hose to the throttle body module. Refer to Charge Air Cooler Outlet Hose Replacement : LNP and Manual Transmission → LNP and Automatic Transmission
12. Install the turbocharger. Refer to Turbocharger Replacement
13. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement
14. Install the exhaust gas recirculation manifold cooling return hose to the thermostat bypass pipe. Refer to Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement : 2.0L Diesel LNP
15. Install the inlet manifold bracket . Refer to Inlet Manifold Bracket Replacement