Cylinder Head Assembly: Service and Repair

CYLINDER HEAD

Removal
1. Drain the engine coolant.
2. Relieve the fuel system pressure.
3. Remove the valve tappets.
4. Remove the generator.

5. Disconnect the vacuum hose.

6. Disconnect the vacuum hose.

7. Disconnect the knock sensor (KS) electrical connector.

8. Disconnect the cylinder head temperature (CHT) sensor electrical connector.

9. Detach the fuel charging wiring harness.

10. Remove the bolt from the accelerator cable support bracket.

11. Remove the bolt from the generator mounting bracket.

12. Disconnect the wiring harness retainer from the intake manifold.

13. Disconnect the ignition coil and the radio interference suppressor electrical connectors.

14. Remove the bolt from the power steering pressure hose support bracket.

15. Position the thermostat housing aside.
^ Disconnect the electrical harness retainer.
^ Remove the bolts.

16. Remove the bolt and the oil level indicator.

17. Using the special tool, disconnect the fuel lines.
18. Remove the power steering bracket retainers and position aside.

19. Raise the vehicle.

20. Install the engine mount lower bracket.
21. Lower the vehicle.

22. Install the studs.

23. Install the engine mount upper bracket.

24. Remove the special tool.

Caution:
^ The bolts are torque-to-yield and new bolts must be installed or engine damage may occur.

25. Remove the cylinder head bolts in the sequence shown and remove the cylinder head.
^ Discard the gasket.
^ Discard the bolts.

Installation

Caution:
^ The cylinder head sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge the aluminum sealing surfaces.

1. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for flatness.

2. Install a new head gasket on the cylinder block.

Caution:
^ The bolts are torque-to-yield and new bolts must be installed or engine damage may occur.

3. Install the cylinder head and tighten the bolts in three stages using the sequence shown.
^ Stage 1: Tighten the bolts to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten the bolts to 40 Nm (30 ft. lbs.).
^ Stage 3: Tighten the bolts an additional 90 degrees.

4. Install the special tool.

5. Remove the engine mount upper bracket.

6. Remove the studs.
7. Raise and support the vehicle.

8. Remove the engine mount lower bracket.
9. Drain engine oil and replace the oil filter. Fill the crankcase with SAE 5W-20 Motor Oil.
10. Lower the vehicle.