Cylinder Head Assembly: Service and Repair

Cylinder Head

Removal
1. Disconnect the battery ground cable.

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage can occur. Service and Repair

2. Remove the camshafts.
3. Remove the exhaust manifold.
4. Remove the fuel injector supply manifold.





5. Remove the fuel injector supply manifold spacers.





6. Remove the Positive Crankcase Ventilation (PCV) hose clips.





7. Disconnect the EGR tube and the ground strap.





8. Disconnect the engine coolant temperature sender unit and the Exhaust Gas Recirculation (EGR) valve electrical connectors.





9. Disconnect the EGR coolant hose and remove it from the hose bracket.





10. Disconnect the coolant bypass hose.





11. Remove the bolts and the cylinder head.
^ Discard the bolts.





12. Remove and discard the head gasket.
13. Inspect the cylinder head mating surfaces.

Installation

1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean the cylinder head gasket surfaces with metal surface cleaner.





2. Apply silicone gasket and sealant to the locations shown.





3. Install a new head gasket.





4. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

NOTE: Lubricate the cylinder head bolts with clean engine oil.

Install the cylinder head and new bolts. Tighten the bolts in the sequence shown in five stages.
^ Stage 1: Tighten the bolts to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten the bolts to 15 Nm (11 ft. lbs.).
^ Stage 3: Tighten the bolts to 45 Nm (33 ft. lbs.).
^ Stage 4: Turn the bolts 90°.
^ Stage 5: Turn the bolts an additional 90°.





5. Connect the coolant bypass hose.





6. Connect the EGR coolant hose.





7. Connect the engine coolant temperature sender unit and the EGR valve electrical connectors.





8. Connect the EGR tube and the ground strap.





9. Install the PCV hose clips.





10. Install the fuel injector supply manifold spacers.
11. Install the fuel injector supply manifold.
12. Install the exhaust manifold.
13. Install the camshafts.
14. Connect the battery ground cable,