Cylinder Head Assembly: Service and Repair

Removal
1. Remove the left-hand camshafts. For additional information, refer to Camshaft.





2. Disconnect the engine coolant temperature (ECT) and fuel temperature sensor (FTS) electrical





3. Disconnect the electrical connector.





4. Detach the fuel charging wiring harness.





5. NOTE: Fuel may still be present in the fuel injection supply manifold.

Detach the fuel injection supply manifold, lower intake manifold and place to one side.
- Remove and discard the lower intake manifold O-ring seals.





6. Remove the fuel injection supply manifold and lower intake manifold.
- Disconnect the electrical connector.





7. Remove the oil level indicator tube.
- Remove and discard the oil level indicator tube O-ring seal.





8. Remove the water pump outlet pipe.
- Remove and discard the water pump outlet pipe O-ring seals.





9. Remove the coolant bypass tube.
^ Remove and discard the coolant bypass tube O-ring seals.





10. Remove the exhaust manifold.
^ Remove and discard the exhaust manifold gasket.





11. NOTE: Remove the bolts in the indicated sequence.
Remove the cylinder head.
- Remove and discard the cylinder head gasket.
12. Clean and inspect the cylinder head and cylinder block.

Installation

1. NOTE: The head gaskets must be installed over the cylinder block dowels.

Install a new cylinder head gasket.





2. CAUTION: Use care when installing the cylinder head. Damage to the cylinder block, cylinder head or the cylinder head gasket may result.

NOTE: Make sure the cylinder head is installed in its original position.

NOTE: Tighten the bolts in the indicated sequence in six stages.

Position the cylinder head and install new cylinder head bolts and washers.
- Stage 1: Tighten to 30 Nm.
- Stage 2: Tighten 90° degrees.
- Stage 3: Loosen 360 degrees (one full turn) in reverse order.
- Stage 4: Tighten to 30 Nm.
- Stage 5: Tighten 90 degrees.
- Stage 6: Tighten 90 degrees.





3. Install the exhaust manifold.
- Install the new exhaust manifold gasket.
- Complete the tightening sequence.
- Tighten to 20 Nm.





4. Install the coolant bypass tube.
- Install the new coolant bypass tube O-ring seals.
- Tighten to 10 Nm.





5. Install the water pump outlet pipe.
- Install the new water pump outlet pipe O-ring seals.
- Tighten to 10 Nm.





6. Install the oil level indicator tube.
- Install a new O-ring seal.
- Tighten to 10 Nm.





7. Attach the fuel injection supply manifold and lower intake manifold.
- Connect the electrical connector.





8. Install the fuel injection supply manifold, lower intake manifold.
- Install new lower intake manifold O-ring seals.
- Tighten to 10 Nm.





9. Attach the fuel charging wiring harness.





10. Connect the electrical connector.





11. Connect the engine coolant temperature (ECT) and fuel temperature sensor (FTS) electrical connectors.
12. Install the left-hand camshafts. For additional information, refer to Camshafts.