• - it is not necessary to remove the engine to remove the cylinder head
  • - to prevent damage to the paintwork of the wings of the body, it is necessary to use a special coating
  • - to prevent damage to the cylinder head, wait until the engine cools down before removing it

When removing the metal cylinder head gasket, be careful not to miss it or damage the contact surface of the block with the head.

When disconnecting a wire, apply force directly to the connector, not the wire.

To avoid incorrect connection, it is necessary to put labels on all wires.

Turn the crankshaft pulley to set the piston of the first cylinder to the top dead center (TDC) position.

1. Disconnect the negative and positive terminals (A) from the battery.

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Remove the engine cover (A).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Remove the duct (A).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Disconnect the vent hose (A), vacuum hose (B), ECM connector (C), and remove the air filter assembly.

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Remove the bottom cover (A).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Unscrew the drain plug and drain the coolant.

Remove the upper radiator hose (A) and the lower hose (B).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Remove the heater hose (A).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Disconnect the VIS connector (A), OPS(B), knock sensor (C) and A/C switch connector.

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Disconnect the intake valve connector (A).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Disconnect the injector connectors (A) and ignition coils (B).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Disconnect the electronic timing control connectors (A) from the MAP sensor (B).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Disconnect the connectors for the idle control (A), throttle position sensor (B), and mass air flow sensor (C), then remove the cable.

Removing and installing the cylinder head of the 2.0 liter engine - G4KD and 2.4 liter - G4KE

Disconnect the camshaft position sensor (A), fuel hose (B), brake booster vacuum hose (C) and positive crankcase breather hose (D) connectors.

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Disconnect the connector from the positive crankcase breather hose (A), electronic ignition timing control (B), capacitor (C), crankshaft position sensor (D), camshaft position sensor (E), and brake booster vacuum hose (F).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Remove thermostat assembly (A).

Remove the timing chain.

Remove the intake and exhaust manifolds.

Remove the intake and exhaust sprockets.

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Remove the camshaft.

- Remove the front camshaft bearing cover (A).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

- Remove the upper bushing of the exhaust camshaft (A).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

- Remove the insert cover (A) as shown.

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

- Remove the camshaft (A).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

- Remove the lower exhaust camshaft bearing (A).

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KERemoving and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Remove the oil pressure control valve (A)

Remove the exhaust valve.

Remove the cylinder head bolts, then remove the cylinder head.

Using the special tool, remove the 10 cylinder head bolts in the order shown.

Incorrect installation may result in damage to the cylinder head.

- Remove the cylinder head from the guide pin on the cylinder block and place it on wooden blocks.

Be careful not to damage the contact surfaces of the head and cylinder block.

Remove the cylinder head gasket.

Installing the cylinder head

  • - Rinse all parts before installation.
  • - Always use new cylinder head gasket and exhaust and intake manifold gaskets
  • - Always use new cylinder head bolts
  • - The cylinder head gasket is metal, you must be careful not to bend it before installation.
  • - PTurn the crankshaft clockwise to set the piston of the first cylinder to the TDC position.

Removing and installing the cylinder head of the 2.0L engine - G4KD and 2.4L - G4KE

Set filter.

Keep the filter clean

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Install the cylinder head gasket (A) on the cylinder block.

  • - Pay attention to the installation order.
  • - Apply sealant to the mark (B).
  • - After applying the sealant, the block head must be installed within 5 minutes.

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Install the block head carefully so as not to damage the gasket.

Install the cylinder head bolts.

  • - Apply a thin coat of engine oil to the threads and under the cylinder head bolt heads.
  • - Using a hex wrench, screw in and tighten the 10 head bolts and washers in the order shown in the figure. Tightening torque: 34.3 Nm + 90˚ + 90˚.

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Install the valves. Tightening torque: 9.8 - 11.8 Nm.

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

  • - Do not damage or drop the valve.
  • - keep the filter clean.
  • - When the valves are installed on the engine, do not move the engine while holding the valve bracket.

Install camshafts.

Apply a thin layer of engine oil to the camshaft bearings.

- Install the lower exhaust camshaft bearing (A).

- Install camshafts (A).

- Install the upper exhaust camshaft bearing (A).

Install the bearing caps in their original position.

Torque order: group A -> group B - > group C.

Tightening torque:

  • step 1: M6: 5.9 Nm, M8: 14.7 Nm,
  • step 2: M6: 10.8 - 12.7 Nm, M8: 27.5 - 31.4 Nm.

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Install the thermostat assembly (A). Tightening torque for bolts and nuts: 18.6 - 23.5 Nm.

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

First install the thermostat assembly and the water inlet hose to the water pump, then tighten the inlet hose nuts.

- Always use new O-rings.

Install the timing chain.

Check valve clearance.

10. Install the cylinder head cover.

  • - Cured sealant located on the top surface between the chain cover and the head of the block must be removed before installing the head cover.
  • - After applying the sealant, the assembly must be completed within 5 minutes. The thickness of the sealant strip is 2.5 mm.

  • - Crimping and blowing is necessary no more than 30 minutes after installing the cover.
  • - Screw in the cylinder head bolts in the following way:

Tightening torque: step 1: 3.9 - 5.9 Nm, step 2: 7.8 - 9.8 Nm.

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Do not reuse the cylinder head gasket.

Install intake and exhaust manifolds.

Connect the connectors of the positive crankcase ventilation hose (A), electronic ignition timing control (B), capacitor (C), crankshaft position sensor (D), camshaft position sensor (E), and brake booster vacuum hose.

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Connect the brake booster vacuum hose (D), the positive crankcase ventilation hose (C), the fuel hose (B), the camshaft position sensor (A).

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Connect the connectors of the ETC and the absolute air pressure sensor (B).

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Connect the connectors for the idle air control (A), throttle position sensor (B), and mass air flow sensor (C), then connect the connectors for the throttle cable harness (D).

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Connect the injector connectors (A), throttle position sensor (B).

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Connect the control valve connector (A)

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE

Connect VIS(A), OPS(B), knock sensor (C) and compressor switch (D) connectors

Install the heater hose (A).

 installation of the cylinder head of the engine with a volume of 2.0 liters - G4KD and 2.4 liters - G4KE