Cylinder Head

Cylinder Head





Cylinder Head and Associated Parts

Disassembly

NOTE:
^ During disassembly, be sure that the valve train components are kept together and identified so that they can be reinstalled in their original locations.
^ Before removing the cylinder head from the engine and before disassembling the valve mechanism, perform a compression test and note the results.

1. Remove cylinder head assembly.
2. Remove high pressure fuel pump.
3. Remove tappet (11).





4. Use the J-8062 valve spring compressor and J-42898 valve spring compressor adapter to remove the split collar (12), valve spring with upper seat (13) and valve (14).
5. Remove spark plug (1).

CAUTION: Do not remove the sparkplugs when the head end plugs are hot. Clean dirt and debris from sparkplug recess areas before removal.

Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the bare metal. Do not use surface conditioning disc on any gasket sealing surface.

Inspection and Repair
1. Inspect cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, determine the cause.
- Insufficient torque on head bolts
- Improper installation
- Loose or warped cylinder head
- Missing dowel pins
- Warped case surface
2. Inspect cylinder head for cracks, especially between valve seats and in the exhaust ports.
3. Inspect cylinder head deck for corrosion, sand particles in head and porosity.

CAUTION:
^ Do not attempt to weld the cylinder head. Replace it.
^ Do not reuse cylinder head bolts.





4. Inspect cylinder head deck, common chamber and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are "out of flat" with "round" by more than specification, the surface should be ground to within specifications. Replace the head if it requires machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 inch) or less
Warpage limit: 0.1 mm (0.0039 inch)
Maximum Repairable limit: 0.2 mm (0.0079 inch)
Head height
Standard height: 133.2 mm (5.2441 inch)
Warpage limit: 0.1 mm (0.0039 inch)
Maximum Repairable limit: 133.0 mm (5.2362 inch)

Reassembly
1. Install cylinder head assembly.
2. Install Spark plug and tighten all the spark plugs to specified torque.
Torque: 18 Nm (13.3 ft. lbs.)