Cylinder Head Assembly: Service and Repair

Cylinder Head

Service Repair No - 12.29.04

Removal

1. Remove the cover and disconnect the battery ground cable.

2. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

3. Remove the fuel rail.
4. Remove the generator.
5. Remove both exhaust manifolds.
6. Remove the camshafts.
7. Release the fuel pipe.





8. Release the engine wiring harness clips.





9. Remove the spark plugs.





10. CAUTION: Mark the components to aid installation.

CAUTION: Extreme cleanliness must be exercised when handling these components.

Remove the 12 two-stage hydraulic lash adjusters.





11. CAUTION: Mark the components to aid installation.

CAUTION: Extreme cleanliness must be exercised when handling these components.

Remove the 12 tappets.





12.





13. Remove and discard the 14 cylinder head bolts.





14. NOTE: This step requires the aid of another technician.

Remove the cylinder head.
15. Remove and discard the cylinder head gasket.





16. NOTE: Make sure that these components are installed to the noted removal position.

Remove the dowels.

Check that the cylinder block water jacket restrictors are installed.





Installation

1. Install the dowels.
2. Clean and inspect the cylinder head and cylinder block.
3. Check cylinder head face for distortion, across the center and from corner to corner.





4. CAUTION: The head gasket must be installed over the cylinder block dowels.

Install a new cylinder head gasket.

5. CAUTION: Make sure that the component is correctly located on the locating dowels.

NOTE: This step requires the aid of another technician.

Install the cylinder head.

6. CAUTION: Make sure that new cylinder head bolts are installed.

CAUTION: Take extra care not to damage the mating faces.

NOTE: The cylinder head tightening process is carried out once to 45 Nm, then the bolts are loosened and the final torque and angle applied.

NOTE: The cylinder head tightening process is carried out once to 45 Nm, then the bolts are loosened and the final torque and angle applied.

Tighten the cylinder head bolts in the sequence shown.
Torque:
45 Nm

Check the cylinder head bolt torque in the sequence shown.
Torque:
45 Nm

Tighten the cylinder head bolts in the sequence shown.
Torque:
90°

Tighten the cylinder head bolts in the sequence shown.
Torque:
180°





7. CAUTION: Make sure that the choke valves (1), (2) are in place.





8. CAUTION: Extreme cleanliness must be exercised when handling these components.

CAUTION: Make sure that these components are installed to the noted removal position.

Install the tappets.

9. CAUTION: Extreme cleanliness must be exercised when handling these components.

CAUTION: Make sure that these components are installed to the noted removal position.

Install the lash adjusters.

10. Install the engine wiring harness clips.

Torque:
6 Nm

11. Install the spark plugs.

Torque:
28 Nm

12. Secure the fuel line.

Torque:
10 Nm

13. Install the camshafts.
14. Install the generator.
15. Install the fuel rail.
16. Install both exhaust manifolds.
17. Connect the battery ground cable and install the cover.