For 1990-2009 cars

#### Special Tools

• | GE-571-B Dial Gage

• | EN-45059 Torque Angle Sensor Kit

For equivalent regional tools, refer to Special Tools .

### Removal Procedure

1. Remove the air cleaner outlet front duct. Refer to Air Cleaner Outlet Front Duct Replacement .
2. Remove the catalytic converter. Refer to Catalytic Converter Replacement .
3. Remove the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement .
4. Remove the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement .
5. Remove the camshaft cover. Refer to Camshaft Cover Replacement .
6. Remove the timing belt. Refer to Timing Belt Replacement .
7. Remove oil level indicator tube. Refer to Oil Level Indicator and Tube Removal .
8. Remove the coolant temperature sensor wiring harness plug (1).
9. Remove intake air pressure and temperature sensor wiring harness plug (3).
10. Remove the wiring harness (2).
11. Remove radiator inlet hose clamp (6).
12. Remove the radiator inlet hose (7).
13. Remove the fuel hose -- fuel injection pump to fuel feed block. Refer to Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block .
14. Remove the wiring harness plug (2) from electronic throttle actuator control module (1).
15. Loosen the charge air cooler outlet air hose clamp.
16. Remove the charge air cooler outlet hose (3) from the throttle body (1).
17. Remove the 2 hose clamps (2).
18. Remove the EGR manifold cooling return hose (1).
19. Remove the 2 hose clamps (1).
20. Remove the EGR manifold cooling feed hose (2).
21. Remove the charge air cooler inlet hose clamp (3).
22. Remove the charge air cooler inlet hose (2) from the turbocharger (1).
23. Loosen the 10 cylinder head bolts as shown in the graphic.
24. Remove the 10 cylinder head bolts (1).
25. Remove the cylinder head (3) .
26. Remove the cylinder head gasket (2).

### Disassemble Procedure

1. Remove the exhaust gas recirculation valve pipe. Refer to Exhaust Gas Recirculation Valve Pipe Removal .
2. Remove the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Removal .
3. Remove the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Removal .
4. Remove the intake manifold. Refer to Intake Manifold Removal .
5. Remove the exhaust manifold. Refer to Exhaust Manifold Removal .
6. Remove the glow plug. Refer to Glow Plug Removal .
7. Remove the camshaft. Refer to Camshaft Removal .
8. Remove the 8 valve rocker arms (4, 1).
9. Remove the 8 valve lifter bridges (2, 3)
10. Remove the 16 valves. Refer to Cylinder Head Disassemble .

### Cleaning Procedure

1. Clean the cylinder head surface.
2. Clean the engine block surface.
3. Clean the engine block bolt holes.

### Assemble Procedure

1. Install the 16 valves. Refer to Cylinder Head Assemble .
2. Install the 8 valve lifter bridges (2, 3).
3. Install the 8 valve rocker arms (4, 1).
4. Install the camshaft. Refer to Camshaft Installation .
5. Install the glow plugs. Refer to Glow Plug Installation .
6. Install the exhaust manifold. Refer to Exhaust Manifold Installation .
7. Install the intake manifold. Refer to Intake Manifold Installation .
8. Install the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Installation .
9. Install the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Installation .
10. Install the exhaust gas recirculation valve pipe. Exhaust Gas Recirculation Valve Pipe Installation .

### Installation Procedure

1. Align the TDC of the piston (1).
2. Clean the cylinder block sealing surface and piston (1).
3. Measure the piston projection thickness (2) using the GE-571-B gage (3).
4. Repeat the measuring process on the other cylinders and average the measured piston projection values.
5. Choose the cylinder head gasket specifications:

• | Piston Protrusion 0.194-0.337 mm (0.008-0.013 in)

| Gasket Thickness 1.1 mm (0.043 in)

• | Piston Protrusion 0.337-0.44 mm (0.013-0.017 in)

| Gasket Thickness 1.2 mm (0.047 in)

• | Piston Protrusion 0.44-0.542 mm (0.017-0.021 in)

| Gasket Thickness 1.3 mm (0.051 in)

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

6. Clean the cylinder head bolt holes.
7. Install a NEW cylinder head gasket (2).
8. Install the cylinder head (3).

Caution: Refer to Fastener Caution in the Preface section.

Note: Always use new cylinder head bolts.

9. Install the 10 NEW cylinder head bolts.
10. Tighten the 10 cylinder head bolts in a sequence as shown in the graphic.
11. Tighten the 10 NEW cylinder head bolts in three passes:

11.1. | First pass in sequence to 65 N·m (48 lb ft) .

11.2. | Second pass in sequence to an additional 120 degrees using the EN-45059 angle sensor .

11.3. | Third pass in sequence to an additional 120 degrees using the EN-45059 angle sensor .

12. Install the charge air cooler inlet hose (2) to the turbocharger (1).
13. Install the charge air cooler inlet hose clamp (3).
14. Install the EGR manifold cooling feed hose (2).
15. Install the 2 hose clamps (1).
16. Install the EGR manifold cooling return hose (1).
17. Install the 2 hose clamps (2).
18. Install the charge air cooler outlet hose (3) to the throttle body (1).
19. Install the charge air cooler outlet air hose clamp.
20. Install the wiring harness plug (2) to the electronic throttle actuator control module (1).
21. Install the fuel hose -- fuel injection pump to fuel feed block. Refer to Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block .
22. Install the radiator inlet hose (7).
23. Install radiator inlet hose clamp (6).
24. Install the wiring harness (2).
25. Install the coolant temperature sensor wiring harness plug (1).
26. Install intake air pressure and temperature sensor wiring harness plug (3).
27. Install oil level indicator tube. Refer to Oil Level Indicator and Tube Installation .
28. Install the timing belt. Refer to Timing Belt Replacement .
29. Install the camshaft cover. Refer to Camshaft Cover Replacement .
30. Install the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement .
31. Install the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement .
32. Install the catalytic converter. Refer to Catalytic Converter Replacement .
33. Install the air cleaner outlet front duct. Refer to Air Cleaner Outlet Front Duct Replacement .