Cylinder Head Assembly: Service and Repair

Cylinder Head

Removal

1. Disconnect the battery ground cable.
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. Disconnect the EGR tube and the ground strap.





7. Disconnect the Engine Coolant Temperature (ECT) sensor and the Exhaust Gas Recirculation (EGR) valve electrical connectors.





8. Disconnect the EGR coolant hose.





9. Disconnect the coolant bypass hose.





10. Remove the bolts and the cylinder head.
11. Remove the head gasket.
12. Clean and inspect the cylinder head and engine block.

Installation

1. Install the head gasket.





2. Install the cylinder head and lubricate the cylinder head bolts with clean engine oil. Install the cylinder head bolts and 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 degrees.
^ Stage 5: Turn the bolts an additional 90 degrees.





3. Connect the coolant bypass hose.





4. Connect the EGR coolant hose.





5. Connect the ECI sensor and the EGR valve electrical connectors.





6. Connect the EGR tube and the ground strap.





7. Install the fuel injector supply manifold spacers.
8. Install the fuel injector supply manifold.
9. Install the exhaust manifold.
10. Install the camshafts.
11. Connect the battery ground cable.