Cylinder Head LH

Cylinder Head LH

Removal

CAUTION: If the fuel supply manifold is used as a leverage device, damage can 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. Remove the upper heater water hose.
1 Squeeze the heater hose clamp.
2 Remove the heater water hose.





14. Position the lower heater water hose aside.
1 Remove the bolt.
2 Squeeze the hose clamp.
3 Detach the heater water hose and position it aside.





15. Remove the thermostat housing.
1 Remove the bolts.
2 Release the bypass hose clamp.





16. Remove the oil level indicator tube.
17. Remove the exhaust manifolds.





18. Remove the LH hydraulic chain tensioner.





19. Remove the bolt.





20. Remove the bolt.





21. CAUTION: To avoid breaking the cassette, remove the camshaft sprocket from the chain and cassette to gain clearance to remove the cylinder 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.





22. Remove the 12 mm bolts (8), and 8 mm bolts (2) in the sequence shown. 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.

LH:

2. NOTE: Cylinder head bolts are torque-to-yield. New bolts must be installed.

Install the 12 mm bolts and tighten in the sequence shown.





3. Install the 8 mm bolts.





4. Tighten the 12 mm bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts 80°.
^ Stage 2: Tighten the bolts an additional 80°.





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 the thermostat housing into the 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 water temperature indicator sender unit and the Engine Coolant Temperature (ECT) sensor electrical connectors.





14. Install the electrical harness retainer.





15. Connect the Crankshaft Position (CKP) sensor electrical connector.





16. Install the accessory bracket.





17. Install the routing clip and bolt.





18. Install the generator mounting bracket.





19. Connect the generator wiring.
20. Install the drive belt tensioner.
21. Install the accessory drive belt.
22. Install the fan shroud.
23. Install the roller followers.
24. Install the intake manifold.