Cylinder Head Assembly: Service and Repair

Removal

CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.

1. Remove the lower intake manifold.
2. Remove the valve covers.
3. Remove the roller followers.
4. Remove the fan shroud.
5. Remove the accessory drive belt.





6. Disconnect the generator electrical connectors.





7. Remove the generator mounting bracket.





8. Remove the bolts and position the accessory bracket aside.





9. Disconnect the crankshaft position (CKP) sensor electrical connector.





10. Remove the electrical harness retainer.





11. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.





12. Disconnect the EGR tube nut.





13. Position the EGR valve bracket aside.





14. Remove the upper heater water hose.
1 Squeeze the heater hose clamp.
2 Remove the heater water hose.





15. Remove the lower heater water hose and position aside.
1 Remove the bolt.
2 Squeeze the hose clamp.
3 Remove the heater water hose and position aside.





16. Disconnect the water bypass hose and position aside.





17. Remove the thermostat housing.





18. Remove the crankcase vent separator spring steel clip and remove the separator.





19. Remove the oil level indicator tube.
20. Remove the exhaust manifolds.





21. Remove the LH hydraulic chain tensioner.





22. Remove the bolt.





23. Remove the bolt.





24. CAUTION: To avoid breaking the cassette, remove the camshaft sprocket from the chain and cassette to gain clearance to remove cylinder the head.

Note: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.

Install a rubber band on the LH cassette to hold the chain and camshaft sprocket in place.





25. Remove the eight 12 mm bolts and two 8 mm bolts in the sequence shown and remove the LH cylinder head.
- Discard the head gasket.
26. Remove the RH hydraulic chain tensioner.





27. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

Using the special tool, remove bolt and the camshaft sprocket.





28. Remove the bolt.





29. CAUTION: To avoid breaking the cassette, remove the camshaft sprocket from the chain and cassette to gain clearance to remove cylinder the head.

Note: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.

Remove the RH camshaft sprocket from the cassette.





30. Remove the two 8 mm bolts and the eight 12 mm bolts in the sequence shown, and remove the RH cylinder head.
- Discard the head gasket.

Installation





1. Note: The LH is shown, the RH is similar.

Position the cylinder head gasket and the cylinder head.





2. Note: The LH is shown, the RH is similar.

Install the eight 12 mm bolts and tighten to 35 Nm (26 ft. lbs.) in the sequence shown.





3. Note: The LH is shown, the RH is similar.

Install the two 8 mm bolts.





4. Note: The LH is shown, the RH is similar.

Tighten the eight 12 mm bolts in the sequence shown in two stages.
- Stage 1: Tighten 90 degrees.
- Stage 2: Tighten an additional 90 degrees.





5. Install the RH rear camshaft sprocket in the cassette.





6. Note: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Install the RH rear camshaft bolt.





7. Install the bolt.





8. Note: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Install the LH front camshaft bolt.





9. Install the LH bolt.
10. Carry out camshaft timing.
11. Install the exhaust manifolds.





12. Install the oil level indicator tube.





13. Install the crankcase vent separator and the spring steel clip.





14. Install the thermostat housing.





15. Connect the water bypass hose.





16. Install the lower heater water hose.
1 Position the heater water hose.
2 Squeeze the heater hose clamp and position.
3 Install the bolt.





17. Install the upper heater water hose.
1 Position the heater water hose.
2 Squeeze the hose clamp and position.





18. Install the EGR bracket.





19. Connect the EGR tube nut.





20. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.





21. Install the electrical harness retainer.





22. Connect the crankshaft position (CKP) sensor electrical connector.





23. Install the accessory bracket.





24. Install the generator mounting bracket.





25. Connect the generator electrical connectors.
26. Install the accessory drive belt.
27. Install the fan shroud.
28. Install the roller followers.
29. Install the valve covers.
30. Install the lower intake manifold.