Cylinder Head

Cylinder Head

Special Tool(s):

Material:

LH Exhaust Manifold:

RH Exhaust Manifold:

LH Cylinder Head:

RH Cylinder Head:

Disassembly

LH cylinder head
1. Remove the nuts and separate the EGR cooler clamps. Remove the horizontal EGR cooler.
2. Remove the bolts, EGR cooler bracket, exhaust manifold and exhaust manifold gasket.
^ Discard the bolts and exhaust manifold gasket.
^ Remove and discard the EGR cooler clamps.

RH cylinder head
3. Remove the lifting bracket from the cylinder head.
4. Remove the front end accessory drive studs.





5. Remove the 3 bolts, nut and heat shield.
6. Remove the 3 spacers.
7. Remove the stud bolts, bolts, exhaust manifold and exhaust manifold gasket.
^ Discard the stud bolts, bolts and exhaust manifold gasket.

Both cylinder heads
8. Install the valve spring compressor.





9. Remove the valve stem keys.
10. Remove the valve spring compressor.
11. Remove the valve spring retainer.
12. Remove the valve spring.

13. NOTE: It may be necessary to file the tip of the valve to aid in removal of the valve from the cylinder head.

Remove the valve.
14. Remove the valve seal assembly.
15. Clean and inspect the valves, valve guides and valve seats. If they are serviceable, resurface to specifications.

Assembly

Both cylinder heads

1. NOTE: Lubricate the valve stem seal with clean engine oil prior to installing.

NOTE: The valve stem seal will not seat completely by hand. The valve spring compressor will seat the valve stem seal when installing the retaining keys.

Install the valve seal assembly.
2. Install the valve.
3. Install the valve spring.
4. Install the valve spring retainer.
5. Install the valve spring compressor.
6. Install the valve stem keys.

7. CAUTION: Verify that the valve spring retaining keys are correctly seated after removal of the valve spring compressor or engine damage may occur.

Remove the valve spring compressor.





RH cylinder head

8. NOTE: Do not use anti-seize on the exhaust manifold fasteners.

Position a new exhaust manifold gasket and the exhaust manifold. Install the new bolts and new stud bolts. Tighten the fasteners in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
^ Using the same torque, repeat the tightening sequence on all exhaust manifold fasteners.





9. Install the spacers.
^ Tighten to 19 Nm (168 lb-inch).
10. Install the heat shield, bolts and nut.
^ Tighten to 19 Nm (168 lb-inch).
11. Install the front end accessory drive studs.
^ Tighten to 9 Nm (80 lb-inch).





LH cylinder head

12. NOTE: Do not use anti-seize on the exhaust manifold fasteners.

NOTE: The new EGR cooler clamps must be installed on the EGR cooler bracket prior to installing the bracket.

Position a new exhaust manifold gasket and the exhaust manifold. Install the EGR cooler bracket and new bolts. Tighten the bolts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
^ Using the same torque, repeat the tightening sequence on all exhaust manifold bolts.





13. NOTE: Do not tighten the clamps at this time.

Position the EGR cooler locating pin into the slot in the EGR cooler bracket and loosely install the 2 new clamp nuts.

Both cylinder heads
14. Install the special tool on the cylinder head.