Cylinder Head Gasket-RH

Cylinder Head Gasket RH

Service Repair No - 12.29.03

Remove
1. Remove inlet manifold chamber.
2. Remove camshaft timing belt.





3. Release RH H02S multiplug from coolant rail bracket and disconnect multiplug.





4. Remove 4 nuts securing RH exhaust manifold to cylinder head.
5. Remove exhaust manifold, remove and discard gasket.





6. Remove 4 bolts securing RH front timing belt cover backplate to cylinder head and remove backplate.





7. Depress locking collars and release breather hoses from RH camshaft cover and RH inlet manifold.





8. Release 3 locking clips and disconnect 3 multiplugs from plug top coils.
9. Remove bolt securing earth lead to RH camshaft cover and release earth lead.
10. Remove 6 bolts securing plug top coils to camshaft cover and remove coils.





11. Remove 3 nuts and 3 bolts securing ignition coils to LH inlet manifold and release coil earth lead.
12. Remove ignition coils and position aside.





13. Release clip and disconnect coolant bleed hose from RH inlet manifold, position hose aside.





14. Release injector harness clips from injector protection cover.
Protection covers are NOT fitted to NAS vehicles.





15. Remove 2 bolts securing protection cover and RH fuel rail to RH inlet manifold, remove cover.





16. Remove 2 bolts securing fuel rail to LH inlet manifold.
17. Release injectors from manifolds and carefully lay fuel rail and injectors aside.

CAUTION: Always fit plugs to open connections to prevent contamination.





18. Remove 14 bolts and remove RH camshaft cover and gasket.





19. Progressively loosen and remove 8 cylinder head bolts.
20. Remove cylinder head.
21. Remove and discard cylinder head gasket.





22. Fit cylinder liner clamps LRT-12-144 and secure with bolts. Ensure that feet of clamps do not protrude over bores.

Refit
1. Clean cylinder head face.





2. Remove bolts securing cylinder liner clamps LRT-12-144 to cylinder block and remove clamps.
3. Clean cylinder block face, dowels and dowel holes.
4. Clean cylinder head bolts and wipe dry.
5. Lightly lubricate threads and beneath heads of cylinder head bolts with clean engine oil.
6. Ensure locating dowels are in cylinder block.
7. Fit new cylinder head gasket onto cylinder block with the word 'TOP' uppermost.
8. With assistance, fit cylinder head and carefully position RH inlet to LH inlet manifold and cylinder head to dowels.
9. Carefully enter new cylinder head bolts, DO NOT DROP. Screw bolts into place by hand.





10. Tighten cylinder head bolts progressively in the sequence illustrated to: Stage 1-25 Nm (18 ft. lbs.). Stage 2-25 Nm (18 ft. lbs.). Stage 3-25 Nm (18 ft. lbs.). Stage 4-Using an angle torque gauge, tighten bolts in the same sequence to 180°.
11. Clean mating surfaces of camshaft cover and carrier.
12. Clean inside of camshaft cover. If necessary, wash oil separator gauze and blow dry.
13. Fit new gasket and position camshaft cover to carrier.

CAUTION: When fitting camshaft cover gasket, ensure arrows on gasket point towards inlet manifold.





14. Fit bolts and tighten in sequence illustrated to 9 Nm (7 ft. lbs.).
15. Remove and discard lower 'O' rings from injectors.
16. Clean injectors and injector locations in fuel rail.
17. Lubricate new 'O' rings with castor oil and fit to injectors.
18. Position fuel rail assembly and secure injectors to inlet manifolds.
19. Position injector protection cover to RH fuel rail and secure injector harness to protection cover with clips.
20. Fit bolts securing fuel rail to inlet manifolds and tighten to 9 Nm (7 ft. lbs.).
21. Connect coolant bleed hose to inlet manifold and secure with clip.
22. Connect breather hoses to RH camshaft cover and inlet manifold.
23. Position ignition coils to LH inlet manifold.
24. Position earth lead, fit nuts and bolts securing ignition coils to LH inlet manifold and tighten to 9 Nm (7 ft. lbs.).
25. Position plug top coils to spark plugs and RH camshaft cover, fit and tighten bolts to 9 Nm (7 ft. lbs.).
26. Position earth lead to RH camshaft cover, fit bolt and tighten to 9 Nm (7 ft. lbs.).
27. Connect multiplugs to plug top coils and secure with locking clips.
28. Clean camshaft timing belt cover backplate bolts and apply Loctite 242 to the first 3 threads.
29. Fit camshaft timing belt.
30. Position backplate, fit and tighten bolts to 9 Nm (7 ft. lbs.).
31. Clean exhaust manifold and mating face on cylinder head.
32. Fit new exhaust manifold gasket, position exhaust manifold, fit nuts and tighten to 45 Nm (33 ft. lbs.).
33. Connect RH H02S multiplug, secure multiplug in coolant rail bracket.