Cylinder Head Replacement - Left or Front

REMOVAL PROCEDURE





1. Remove the intake manifold.
2. Remove the water outlet housing.
3. Adjust the water crossover pipe for access.
4. Remove the engine mount strut bracket.
5. Remove the left (front) exhaust manifold.
6. Remove the camshaft covers.
7. Install the J 42038 on the camshafts.
8. Remove the primary camshaft drive chain.
9. Remove the left (front) cylinder head camshafts.

Important: Place the valve train parts in a rack in order to make sure that they are installed in the same location from which they were removed.

10. Remove the valve rocker arms.

Important: Place the valve train parts in a rack in order to ensure that they are installed in the same location from which they were removed.

11. Remove the lifters.
12. Remove the M6 external drive bolts (1 & 3) from the front portion of the cylinder head. Note the location of the longer M6 bolt (1).
13. Remove and discard the M11 internal drive cylinder head bolts (2). DO NOT reuse the cylinder head bolts.
14. Remove the cylinder head. Make sure that no dowel guide pins are stuck in the cylinder head.





15. Remove the cylinder head gasket. Make sure all of the gasket material is removed.
16. Place the cylinder head on a flat, clean surface with the combustion chambers face-up in order to prevent damage to the deck face.
17. To disassemble the cylinder head.
18. To clean and inspect the cylinder head.
19. To inspect the valve springs.
20. To grind the seats and valves.
21. To assemble the cylinder head.


INSTALLATION PROCEDURE

^ Tools Required
- J 36660 Electronic Torque Angle Meter





1. Make sure all the cylinder head locating pins are securely mounted in the cylinder block deck face.
2. Install a new cylinder head gasket using the deck face locating pins for retention.





3. Align the cylinder head with the deck face locating pins.
4. Place the cylinder head in position on the deck face.

Important: DO NOT reuse the old M11 cylinder head bolts.

5. Install new M11 cylinder head bolts (2).
6. Install the M6 bolts at the front of the cylinder head. Install the longer M6 bolt (1) in the outboard location as shown. Install the two shorter M6 bolts (3) in the locations shown.





Notice: Refer to Fastener Notice in Service Precautions.

7. Tighten the M 11 bolts.
a. Tighten the M11 cylinder head bolts a first pass in sequence to 40 Nm (30 lb ft).
b. Tighten the M11 cylinder head bolts a second pass in sequence an additional 100 degrees using the J 36660.
c. Tighten the M11 cylinder head bolts a final pass in sequence an additional 100 degrees (200 degrees total) using the J 36660.
8. Tighten the long M6 bolt (1).
^ Tighten the long M6 cylinder head bolt to 12 Nm (106 lb in.).
9. Tighten the two shorter M6 bolts (3).
^ Tighten the two shorter M6 cylinder head bolts to 12 Nm (106 lb in.).
10. Install the lifters.
11. Install the rocker arms.
12. Install the left (front) cylinder head camshafts.
13. Install the primary camshaft drive chain.
14. Remove the J 42038 from the camshafts.
15. Install the camshaft covers.
16. Install the water crossover pipe.
17. Install the left (front) exhaust manifold.
18. Install the engine mount strut bracket.
19. Install the water outlet housing.
20. Install the intake manifold.