Cylinder Head Assembly: Service and Repair

Cylinder Head Replacement

Special Tools

* EN-38188 - Cylinder Head Broken Bolt Extractor Kit

* EN-45059 - Angle Meter

For equivalent regional tools, refer to Special Tools (LDK, LHU) Special Tools (LDK, LHU).

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).

3. Remove the camshaft cover. Refer to Camshaft Cover Replacement Service and Repair

4. Remove the intake manifold. Refer to Intake Manifold Replacement Intake Manifold Replacement.

5. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement (LUK or LEA) Service and RepairExhaust Manifold Replacement (LDK or LHU) Service and Repair.

6. Remove the camshaft timing chain. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement Service and Repair.





7. Remove the cylinder head bolts opposite to the block fastener sequence.





8. Remove the cylinder head (1) and the cylinder head gasket (2) from the block.

9. Clean all of the gasket surfaces. Refer to Cylinder Head Cleaning and Inspection (LDK, LHU)

Installation Procedure





Note:
Do not use any sealing material.

1. Install the cylinder head gasket (1) to the cylinder block (2). On right side pay attention to the cylinder head lock pin (3).





2. Ensure the number 1 cylinder is at top dead center (TDC).

Setting up the crankshaft balancer mark (1) to the oil pump housing mark (2).





Note:
Always use NEW cylinder head fasteners.

3. Install the cylinder head.

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install NEW cylinder head fasteners.

* Tighten the fastener in sequence to 30 Nm (22 lb ft).

* Tighten the fastener in additional 155 degreesin sequence using the EN-45059 - angle meter.





5. Install the front cylinder head fastener (1) and tighten to 35 Nm (26 lb ft).

6. Install camshaft timing chain. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement Service and Repair.

7. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (LUK or LEA) Service and RepairExhaust Manifold Replacement (LDK or LHU) Service and Repair.

8. Install the intake manifold. Refer to Intake Manifold Replacement Intake Manifold Replacement.

9. Install camshaft cover. Refer to Camshaft Cover Replacement Service and Repair

10. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).

11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.