Cylinder Head-LH
Cylinder Head-LH
Removal
CAUTION: If the fuel supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
1. Remove the intake manifold.
2. Remove the roller followers.
3. Remove the fan shroud.
4. Remove the accessory drive belt.
5. Disconnect the generator wiring.
6. Remove drivebelt tensioner.
7. Remove the generator mounting bracket
8. Remove the bolt and the wiring harness routing clip.
9. Remove the bolts and position the accessory bracket aside.
10. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
11. Remove the electrical harness retainer.
12. Disconnect the water temperature indicator sender unit and the Engine Coolant Temperature (ECT) sensor electrical connectors.
13. Disconnect the EGR tube nut.
14. Remove the upper heater water hose.
1 Squeeze the heater hose clamp.
2 Remove the heater water hose.
15. Remove the lower heater water hose and position aside.
1 Remove the bolt.
2 Squeeze the hose clamp.
3 Remove the heater water hose and position aside.
16. Remove the thermostat housing.
1 Remove the bolts.
2 Release the bypass hose clamp.
17. Remove the oil level indicator tube.
18. Remove the exhaust manifolds.
19. Remove the LH hydraulic chain tensioner.
20. Remove the bolt.
21. Remove the bolt.
22. CAUTION: To avoid breaking the cassette, remove the camshaft sprocket from the chain and cassette to gain clearance to remove cylinder the head.
NOTE: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.
Remove the LH camshaft sprocket from the cassette.
23. Remove the eight 12 mm bolts and two 8 mm bolts in the sequence shown and remove the LH cylinder head.
^ Discard the head gasket.
^ Discard the cylinder head bolts.
Installation
1. Position the cylinder head gasket and the cylinder head.
NOTE: LH shown, RH similar.
Install the cylinder head and tighten the bolts in the sequence shown.
2. NOTE: New cylinder head bolts must be installed. They are torque to yield design and cannot be reused.
3. NOTE: LH shown, RH similar.
Install the cylinder head and tighten the new bolts in the sequence shown in two stages.
^ Stage 1: Tighten to 12 Nm (9 lb-ft).
^ Stage 2: Tighten to 25 Nm (18 lb-ft).
4. Install the two 8 mm bilts
NOTE: LH shown, RH similar.
Tighten the bolts in the sequence shown in two stages.
^ Stage 1: Rotate 90 degrees.
^ Stage 2: Rotate an additional 90 degrees.
5. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install the LH front camshaft bolt.
6. Install the LH bolt.
7. Carry out camshaft timing.
8. Install the exhaust manifolds.
9. Install the oil level indicator tube.
10. Install the thermostat housing.
1 Install thermostat housing into bypass hose.
2 Install the bolts.
3 Position the bypass hose clamp.
11. Install the lower heater water hose.
1 Position the heater water hose.
2 Squeeze the heater hose clamp and position.
3 Install the bolt.
12. Install the upper heater water hose.
1 Position the heater water hose.
2 Squeeze the hose clamp and position.
13. Connect the EGR tube nut.
14. Connect the water temperature indicator sender unit and the Engine Coolant Temperature (ECT) sensor electrical connectors.
15. Install the electrical harness retainer.
16. Connect the Crankshaft Position (CKP) sensor electrical connector.
17. Install the accessory bracket.
18. Install the routing clip and bolt.
19. Install the generator mounting bracket.
20. Connect the generator wiring.
21. Install drive belt tensioner.
22. Install the accessory drive belt.
23. Install the fan shroud.
24. Install the roller followers.
25. Install the intake manifold.