Disassembly and Assembly of Sub-Assemblies

Cylinder Head





Special Tool(s)





Material

Disassembly





1. NOTE: One lifting eye is shown, the other is similar.

Remove the bolts and the two lifting eyes.





2. Remove and discard the Cylinder Head Temperature (CHT) sensor.





3. Remove the bolts and the Exhaust Gas Recirculation (EGR) valve.





4. Remove the EGR tube.





5. Remove the spark plugs.





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

Remove the 16 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 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 motor oil.

Install the valves.





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

Lubricate the valve and guides with clean engine oil and, using the special tool, install the valve stem 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.
- Remove the special tools.





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

Install the 16 tappets.





6. Install a new CHT sensor.





7. Install the spark plugs.





8. Install the EGR tube.





9. Install the EGR valve, gasket and bolts.





10. NOTE: One lifting eye is shown, the other is similar

Install the lifting eyes and bolts.