Cylinder Head Replacement

Cylinder Head Replacement


Tools Required
* J 38185 Hose Clamp Pliers
* J 45059 Angle Meter



Removal Procedure





1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair).
2. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement (LAT) ().
3. Remove the intake manifold. Refer to Intake Manifold Replacement (Service and Repair).
4. Reposition the coolant recovery inlet hose clamp (2).
5. Remove the coolant recovery inlet hose (1) from the cylinder head.




6. Reposition the radiator inlet hose clamp using the J 38185.
7. Remove the radiator inlet hose from the cylinder head.
8. Remove the timing chain. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement (Service and Repair).




9. Remove the cylinder head bolts in the sequence shown. Discard the bolts.




10. Remove the cylinder head.
11. Remove the cylinder head gasket.
12. Clean all of the gasket surfaces.
13. Use the following steps when cleaning the cylinder head and cylinder block surfaces:

* Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge either surface.

Important: DO NOT use any other method or technique to clean these gasket surfaces.


* Use a NEW razor blade on the cylinder head and a NEW blade on the cylinder block.

Important: Be careful not to gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the NEW gasket.


* Hold the razor blade as parallel to the gasket surface as possible.

14. Clean the old sealer/lube and any dirt from around the bolt holes.

Important: DO NOT use a tap to clean the cylinder head bolt holes.


15. Clean the bolts holes with a nylon bristle brush.
16. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.



Installation Procedure






Important: DO NOT use any sealing material.


1. Install the cylinder head gasket.
2. Install the cylinder head.
3. Lightly apply clean engine oil to the threads and the bottom side flange of the head bolts and allow the oil to drain before installing.
4. Install NEW cylinder head bolts.

Notice: Refer to Fastener Notice (Fastener Notice).





5. Install and tighten the cylinder head bolts in the sequence shown.

Tighten the bolts to 30 N.m (22 lb ft) plus an additional 155 degrees using the J 45059.





6. Install the NEW front cylinder head bolts.

Tighten the bolts to 35 N.m (26 lb ft).

7. Install the timing chain. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement (Service and Repair).




8. Install the radiator inlet hose to the cylinder head.
9. Position the radiator inlet hose clamp using the J 38185.




10. Install the coolant recovery inlet hose (1) to the cylinder head.
11. Position the coolant recovery inlet hose clamp (2).
12. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (LAT) ().
13. Install the intake manifold. Refer to Intake Manifold Replacement (Service and Repair).
14. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair).