Disassembly and Assembly of Sub-Assemblies

Cylinder Head

Special Tool(s):

Material:

Disassembly





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

Remove the bolts and the 2 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 the 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.
8. Inspect the valve spring, valve spring retainer and valve spring retainer key.





9. CAUTION: Note the 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 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 protector provided with the replacement kit to prevent damage to the valve seals.

Lubricate the valve stems and guides with clean engine oil and, using the special tool, install the valve 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.





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.
^ Tighten to 12 Nm (9 ft. lbs.).





7. Install the spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.).





8. Install the EGR tube.
^ Tighten to 55 Nm (41 ft. lbs.).





9. Install the EGR valve, gasket and 2 bolts.
^ Tighten to 27 Nm (20 ft. lbs.).





10. NOTE: One lifting eye shown, other lifting eye similar. Install the 2 lifting eyes and the bolts.
^ Tighten to 45 Nm (33 ft. lbs.).