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Cylinder Head Assembly: Service and Repair





Cylinder Head Replacement

Removal Procedure

Special Tools

* EN 38188 - Cylinder Head Broken Bolt Extractor Kit

* EN 45059 - Angle Meter

For equivalent regional tools, refer to Special Tools Special Tools.

1. Drain the coolant system. Refer to Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill).

2. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

3. Remove the camshaft cover. Refer to Camshaft Cover Replacement (LCV) Camshaft Cover ReplacementCamshaft Cover Replacement (LTG) Camshaft Cover Replacement.

4. Remove the intake manifold. Refer to Intake Manifold Replacement (LCV) Intake Manifold ReplacementIntake Manifold Replacement (LTG) Intake Manifold Replacement.

5. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement (LUK) Exhaust Manifold ReplacementExhaust Manifold Replacement (LCV) Exhaust Manifold ReplacementExhaust Manifold Replacement (LTG) Exhaust Manifold Replacement.

6. Remove the engine front cover. Refer to Engine Front Cover Replacement (LCV) Service and RepairEngine Front Cover Replacement (LTG) Service and Repair.

7. Remove the camshaft position actuator and camshaft - Intake. Refer to Camshaft Position Actuator and Camshaft Replacement - Intake Camshaft Position Actuator and Camshaft Replacement - Intake.




8. Remove the cylinder head to the block bolts in sequence.
Discard the bolts.





Caution:
In order to prevent damage to the valves and injectors during cylinder head removal, set the cylinder head on blocks.

9. Remove the cylinder head (2).

10. Remove the cylinder head gasket (3).

11. Clean all of the gasket surfaces.

12. Use the following procedures when cleaning the cylinder head and cylinder block surfaces:

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

Note: Do not use any other method or technique to clean these gasket surfaces.

Note: 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.

Note: Do not use a tap to clean the cylinder head bolt holes.

13. Clean the old sealer/lube and dirt from the bolt holes.

14. Clean the bolt holes with a nylon bristle brush.

Warning

Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals.

15. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.

16. Remove any broken long cylinder head bolts using the EN 38188 - kit.

17. For cylinder head disassemble. Refer to Cylinder Head Disassemble Cylinder Head Disassemble.

18. For cylinder head cleaning and inspection. Refer to Cylinder Head Cleaning and Inspection Cylinder Head Cleaning and Inspection

Installation Procedure

1. For cylinder head assemble. Refer to Cylinder Head Assemble Cylinder Head Assemble.





Note: Do not use any sealing material.

2. Install the cylinder head gasket (3) to the block.

3. Install the cylinder head (2). Ensure the number 1 cylinder is at top dead center (TDC). The key on the crankshaft should be on top in the 12 o'clock position.





Caution: Refer to Fastener Caution Fastener Caution.

Note: Always use NEW cylinder head bolts.

4. Install the cylinder head bolts.

1. Tighten the bolts in sequence to 30 Nm (22 lb ft).

2. Tighten the bolts an additional 190 degrees in sequence using the EN 45059 - meter.

5. Install the camshaft position actuator and camshaft - Intake. Refer to Camshaft Position Actuator and Camshaft Replacement - Intake Camshaft Position Actuator and Camshaft Replacement - Intake.

6. Install the engine front cover. Refer to Engine Front Cover Replacement (LCV) Service and RepairEngine Front Cover Replacement (LTG) Service and Repair.

7. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (LUK) Exhaust Manifold ReplacementExhaust Manifold Replacement (LCV) Exhaust Manifold ReplacementExhaust Manifold Replacement (LTG) Exhaust Manifold Replacement.

8. Install the intake manifold. Refer to Intake Manifold Replacement (LCV) Intake Manifold ReplacementIntake Manifold Replacement (LTG) Intake Manifold Replacement.

9. Install the camshaft cover. Refer to Camshaft Cover Replacement (LCV) Camshaft Cover ReplacementCamshaft Cover Replacement (LTG) Camshaft Cover Replacement.

10. Refill the engine with NEW oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

11. Refill the coolant system. Refer to Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill).

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