Disassembly and Assembly of Sub-Assemblies

Cylinder Head

Special Tool(s):

Material:

Disassembly





1. Remove the rear lifting eye and the front bracket.
2. Remove the cylinder head temperature (CHT) sensor.





3. Disconnect the coolant hose and remove the 4 bolts and the coolant outlet pipe.
^ Discard the gasket.
4. Remove the 2 bolts and the exhaust gas recirculation (EGR) valve.
^ Discard the EGR valve gasket.
5. Remove and discard the 4 spark plugs.

6. CAUTION: Note location of the tappets prior to removal.

Remove the 16 valve tappets.





7. Using the special tools, compress the valve spring and remove the valve spring retainer keys, the valve spring retainers, and the valve springs.
^ Remove the special tools.
8. Inspect the valve spring, valve spring retainer and valve spring retainer key. Install new parts as necessary.

9. CAUTION: Note the location of the valves if they are to be reused.

NOTE: Mark each valve if the original valves are to be used.

Remove the valves.





10. Using the special tools, remove and discard the valve stem seals.
11. Inspect the valves. Install new parts as necessary.

Assembly

1. NOTE: If installing the original valves, make sure the valves are installed in the same position from which they were removed. Coat the valve stems with clean engine oil prior to installation.

Install the valves.





2. NOTE: Use the protector provided with the replacement kit to prevent damage to the valve seals.

Lubricate the valve stems and guides with clean engine oil and, using the special tool, install the valve seals onto the cylinder head valve guides.
3. Place the valve spring in position over the valve and install the valve spring retainer.





4. Using the special tools, compress the valve spring and install the valve spring retainer keys.

5. NOTE: Be sure to install the tappets in the same location as they were removed from.

Install the 16 valve tappets.
6. Install a new CHT sensor.
^ Tighten to 12 Nm (9 ft. lbs.).
7. Install 4 new spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.).
8. Using a new gasket, install the EGR valve and the 2 bolts.
^ Tighten to 27 Nm (20 ft. lbs.).





9. Using a new gasket, install the coolant outlet pipe, the 4 bolts and connect the coolant hose.
^ Tighten to 10 Nm (89 inch lbs.).





10. Install the rear lifting eye and front lifting eye bracket.
^ Tighten to 45 Nm (33 ft. lbs.).