Overhaul

Cylinder Head









Cylinder Head (View 1 of 2)









Cylinder Head (View 2 of 2)









Disassembly

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

NOTE: If the components are to be reinstalled, mark the location of the components removed, they must be installed in the same location.

1. Remove the 2 bolts and the fuel rail and injectors as an assembly.

2. Remove the 4 fuel injector clips and the 4 fuel injectors.





3. Remove and discard the 8 fuel injector O-ring seals.





4. Remove the 5 bolts and the intake manifold.

5. Remove the 2 bolts and the LH engine lift eye.

6. Remove the 3 bolts, stud bolt and the coolant outlet.
- Discard the gasket.

7. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug.

NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.

Remove the 4 spark plugs.

8. NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets.

Using the Valve Spring Compressors, compress the valve spring and remove the valve spring collets, the valve spring retainers and the valve springs.





9. Inspect the valve springs. For additional information, refer to Engine System - General Information Valves, Guides, Seats, and Springs.

10. NOTE: Note the location of the valves if they are to be reused

Remove the valves.

11. Inspect the valves. For additional information, refer to Engine System - General Information Valves, Guides, Seats, and Springs. Install new parts, as necessary.

12. NOTE: Use a valve stem seal pliers (such as Snap-on(R) YA-8230 or equivalent).

Using valve stem seal pliers, remove and discard the valve seals.

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.

Install the valves.

2. Install the valve stem seal installation sleeve.





3. NOTE: Lubricate the valve stem, guides and valve stem seals with clean engine oil prior to installation.

Using valve stem seal pliers, install the valve seals.

4. NOTE: Check the seating of the valve collet.

Using the Valve Spring Compressors, install the valve spring.

- Insert the valve spring and the valve spring retainer.

- Compress the valve spring and install the valve collet using some multi-purpose grease and a small screwdriver.





5. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug.

Install the 4 spark plugs.

- Tighten to 15 Nm (133 lb-in).

6. Using a new gasket, install the coolant outlet, 3 bolts and the stud bolt.
- Tighten to 19 Nm (168 lb-in).

7. Install the LH engine lift eye and the 2 bolts.
- Tighten to 19 Nm (168 lb-in).

8. Inspect and install new intake manifold gaskets if necessary.





9. Install the intake manifold and the 5 bolts.
- Tighten to 18 Nm (159 lb-in).

10. NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.

Install the new O-ring seals onto the fuel injectors and lubricate them with clean engine oil.





11. Install the 4 fuel injectors and the 4 fuel injector clips into the fuel rail.





12. Install the fuel rail and fuel injectors as an assembly and install the 2 bolts.
- Tighten to 11 Nm (97 lb-in).