Cylinder Head Assembly: Service and Repair

Cylinder Head Replacement

Tools Required
J 45059 Angle Meter

Removal Procedure
1. Remove the exhaust manifold.
2. Remove the timing chain and sprockets.





3. Remove the cylinder head bolts.Discard the bolts.





4. Remove the cylinder head.
5. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.





6. Remove the cylinder head gasket.Discard the gasket.
7. Remove all remaining gasket material from the engine block.
8. Inspect the cylinder head gasket mating surface on the engine block.
9. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection.
10. Disassemble the cylinder head if necessary. Refer to Cylinder Head Disassemble.

Installation Procedure

Important: Ensure number 1 cylinder is at top dead center.

1. Assemble the cylinder head if necessary. Refer to Cylinder Head Assemble.





2. Install the dowel pins, cylinder head locator, if necessary.
3. Position a NEW cylinder head gasket to the engine block.





4. Important: Ensure all wires, components, etc. are out of the way when installing the cylinder head.

Install the cylinder head.





5. Notice: This component uses torque-to-yield bolts. When servicing this component do not reuse the bolts, New torque-to-yield bolts must be installed. Reusing used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.

Install NEW cylinder head bolts.





6. Notice: Refer to Fastener Notice in Service Precautions.

Tighten the NEW cylinder head bolts in the following sequence:
1 Tighten the cylinder head bolts (1-10) in sequence to 30 Nm (22 ft. lbs.). Use the J 45059 to rotate the cylinder head bolts (1-10) in sequence an additional 155 degrees.
2 Tighten the (2 Short) end bolts (12-13) to 7 Nm (62 inch lbs.). Use the J 45059 to rotate the short cylinder head end bolts (12-13) an additional 60 degrees.
3 Tighten the (1 Long) end bolt (11) to 7 Nm (62 inch lbs.). Use the J 45059 to rotate the long cylinder head end bolt (11) an additional 120 degrees.
7. Install the timing chain and sprockets.
8. Install the exhaust manifold.