Cylinder Head Assembly: Service and Repair

Removal

1. Remove accessory drive belts from engine, then the accessories.
2. Drain radiator coolant, then remove engine drain plugs and drain remaining coolant. Install drain plugs.
3. Remove vibration damper, then the intake and exhaust manifolds and brackets.

Fig. 8 Loosening timing belt tensioner.:

4. Remove timing belt cover, align timing marks, loosen timing belt tensioner bolts 1 and 2, Fig. 8, then remove timing belt. Refer to ``Timing Belt, Replace'' for complete removal and installation procedure.
5. Remove valve cover, then while holding camshaft sprocket with tool Mot. 855 or suitable strap wrench, remove camshaft sprocket retaining bolt and sprocket.

Fig. 9 Cylinder head removal.:

6. Remove all cylinder head bolts except for bolt marked (A), Fig. 9. Do not lift cylinder head from cylinder block. The cylinder head gaskets will stick to the cylinder head, block and liners and destroy the water tight seal at the bottom of the liners.
7. Loosen bolt (A), then using a suitable block of wood placed at point B, Fig. 9, pivot cylinder head on bolt (A), by tapping block of wood with hammer.
8. Remove remaining head bolt and the cylinder head, then install cylinder liner clamps, Mot. 588, on cylinder head to retain cylinder liners. Do not rotate engine until cylinder liners are clamped. If liners are moved, liner seals may break and cause water leaks after assembly.
9. Clean head gasket and block surfaces with suitable gasket remover. Do not use any sharp edged tools for cleaning.
10. Ensure all foreign material is removed from oil passages and remove oil or water from cylinder head bolt holes to allow bolts to be properly tightened.

Installation

1. Install cylinder head locating tool Mot. 720, then remove the cylinder liner clamps.
2. Install cylinder head gasket.

Fig. 10 Cylinder head alignment tool installation.:

3. Use tool Mot. 720 at (A) and the dowel (B) for cylinder head alignment, Fig. 10.
4. Ensure camshaft and crankshaft timing marks are properly aligned, then install cylinder head and hand tighten cylinder head bolts.
5. Tighten cylinder head bolts as follows:

Fig. 5 Cylinder head tightening sequence:

a. Torque to 37 ft.lbs. following sequence shown in Fig. 5.
b. Torque to 59 ft.lbs. following sequence shown in Fig. 5.
c. Loosen head bolts 1/2 turn, then torque to 68 ft.lbs. following sequence shown in Fig. 5.
6. Remove tool Mot. 720.
7. Reverse remaining steps to complete installation, noting the following:
a. Install and tension timing belt as outlined under ``Timing Belt, Replace.''
b. Refill and bleed cooling system as outlined.