Cylinder Head Assembly: Service and Repair

Cylinder Head LH

Removal
1 Remove the cover and disconnect the battery ground cable. For additional information, refer to Specifications [1][2]Battery
2
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.
3 Remove the fuel injection supply manifold. For additional information, refer to Fuel Injection Supply Manifold Service and Repair




4
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
Remove the LH charge air cooler adaptor assembly.
- Remove the 5 bolts.
- Discard the gasket.
5 Remove the timing drive components. For additional information, refer to Timing Drive Components Service and Repair
6 Remove the special tool from the LH cylinder head.
7
CAUTION: Evenly and progressively, release the camshaft bearing caps.
NOTE:
Remove the camshaft bearing caps. Note: their position, orientation and markings. Each is marked with its position (number) and an orientation (arrow).
Remove the camshaft bearing caps.
- Remove the 20 bolts.




8 Remove the camshafts.




9
NOTE:
Note the fitted position.
NOTE:
Make sure the shim remains with the tappet.
Remove the 16 tappets.





10 Remove the CMP sensor.
- Remove the Torx bolt.
- Remove and discard the O-ring seal.





11 Release the LH catalytic converter.
- Remove and discard the 2 nuts.





12
CAUTION: The bolts can only be used twice, mark the bolts with a center punch. If two punch marks are visible, discard the bolts.
CAUTION: Vehicles fitted with Polydrive cylinder head bolts, the cylinder head bolts must be removed using a 10 mm Polydrive socket or a 10 mm Allen key. Failure to follow this instruction may result in damage to the component.
NOTE:
Remove the bolts in the indicated sequence.
Remove the 12 cylinder head bolts.

13
CAUTION: The cylinder head must not be placed mating face down. Failure to follow this instruction may result in damage to the vehicle.
With assistance remove the cylinder head.





14 Remove and discard the cylinder head gasket.
- Clean the cylinder head locating dowels.
- Clean and inspect the cylinder head and cylinder block.





15
NOTE:
Do not disassemble further if the component is removed for access only.
Remove the LH heat shield.
- Remove the 4 screws.





16
NOTE:
Do not disassemble further if the component is removed for access only.
Remove the exhaust manifold.
- Remove and discard the 8 bolts.
- Remove the 8 spacers.





17 Remove and discard the exhaust manifold gasket.
- Remove the bolt.

Installation
1 Clean the component mating faces.




2 Check cylinder head face for distortion, across the center and from corner to corner.
3 For cylinder head face distortion data, refer to specifications. For additional information, refer to Specifications [1][2]Mechanical Specifications




4
NOTE:
For cylinder head with distortion above the maximum allowance, the cylinder head material must be measured.
Measure the cylinder head material.
- Check measurement from the centre of the exhaust dowel to the cylinder head face as shown.
- If the measurement is less than 51.88 mm the cylinder head requires replacement.
5 Install the exhaust manifold gasket.
- Clean the component mating faces.
- Tighten the bolt to 50 Nm (37 lb.ft).




6 Install the exhaust manifold.
- Clean the component mating faces.
- Install the spacers.
- Evenly and progressively, tighten the new bolts in the sequence shown, to 24 Nm (18 lb.ft).
7 Install the heat shield.
- Tighten the screws.
8
CAUTION: The head gasket must be installed over the cylinder block dowels.
Install a new cylinder head gasket.
9 With assistance install the cylinder head.





10
NOTE:
Tighten the bolts 1 to 10 in the sequence shown.
Install the cylinder head bolts.
- Lubricate the new cylinder head bolt threads with clean engine oil.
- Tighten the bolts 1 to 10 to 20 Nm (15 lb.ft).
- Tighten the bolts 1 to 10 to 35 Nm (26 lb.ft).
- Tighten the bolts 1 to 10, a further 90 degrees.
- Tighten the bolts 1 to 10, a further 90 degrees.
- Tighten the M8 bolts 11 and 12, to 25 Nm (18 lb.ft).

11 Attach the catalytic converter.
- Tighten the nuts to 40 Nm (30 lb.ft).

12 Install the CMP sensor.
- Clean the components.
- Install a new O-ring seal.
- Tighten the Torx bolt to 7 Nm (5 lb.ft).

13 Install the tappets.
- Clean the components.
- Lubricate the components with clean engine oil.

14 Install the camshafts.
- Clean the component mating faces.
- Lubricate the journals and camshaft lobes with clean engine oil.





15 Install the camshaft bearing caps.
- Clean the component mating faces.
- Evenly and progressively tighten the bolts in the sequence shown to 10 Nm (7 lb.ft).





16
NOTE:
RH illustration shown, LH is similar.
Install the special tool to the LH cylinder head.
- Install the 3 bolts.

17
NOTE:
Do not install the LH valve cover until valve clearance adjustment has been completed.
Install the timing drive components. For additional information, refer to Timing Drive Components Service and Repair

18 Install the charge air cooler adaptor assembly.
- Clean the component mating faces.
- Install a new gasket.
- Tighten the bolts to 25 Nm (18 lb.ft).

19 Install the fuel injection supply manifold. For additional information, refer to Fuel Injection Supply Manifold Service and Repair

20 Rotate the engine clockwise to position the camshaft lobe away from the valve tappet.





21
CAUTION: Camshaft lobes must be 180 degrees away from each valve tappet or valve clearance will be incorrect.
Using the feeler gauge set, measure the clearance between the camshaft and the valve shim.

22 Repeat the above procedure for the remaining 15 shims.





23 Install the special tool 303-540, to the cylinder head.
- Tighten the 2 bolts to 10 Nm (7 lb.ft).





24
CAUTION: Do not rotate the crankshaft while the special tool 303-540/02 is attached to 303-540.
Attach the special tool 303-540/02 to 303-540.
- Secure with the 2 wing nuts.





25 Position the special tool to the tappet as shown.





26 Using the special tool, compress the valve spring.





27
CAUTION: Do not use a magnet to remove shims. Failure to follow these instructions may result in damage to the vehicle.
NOTE:
Use the following formula to calculate the required shim thickness. Original shim thickness + measured shim clearance - desired clearance = required shim thickness.
Remove, clean and measure the shim.
- Surround the immediate working area with a cloth, to retain any loose shims displaced by the compressed air.
- Use the special tool 303-590, aimed at the edge of the shim, to lift it from the tappet. Note the position of each one.

28
CAUTION: Shims must be fitted with the size markings facing the tappet, not the camshaft.
CAUTION: Do not use a magnet to install shims. Failure to follow these instructions may result in damage to the vehicle.
Install the new shim.
- Clean the components.
- Lubricate the shim with clean engine oil.
- Release and remove the special tools as required.





29 Using the feeler gauge set, measure the clearance between the camshaft and the valve shim.

30 Repeat the above procedure for the remaining valves.

31 Connect the battery ground cable and install the cover. For additional information, refer to Specifications [1][2]Battery