Cylinder Head and Valve Train Dissasembly and Assembly

Cylinder Head and Valve Train Components Disassembly and Assembly

Tools Required:
MKM-571-B Gauge
KM-340-0 Cutter Set
KM-340-7 Guide Drift
KM-340-13 Cutters
KM-340-26 Cutters
KM-348 Valve Spring Compressor
KM-653 Adapter
KM-805 Valve Guide Reamer

Disassembly
1. Remove the cylinder head with the intake manifold and the exhaust manifold attached.
2. Remove the exhaust manifold heat shield bolts.
3. Remove the exhaust manifold heat shield.
4. Remove the exhaust manifold retaining nuts in the sequence shown.
5. Remove the exhaust manifold.
6. Remove the exhaust manifold gasket.





7. Remove the exhaust manifold studs.
8. Remove the thermostat housing mounting bolts.
9. Remove the thermostat housing assembly.
10. Remove the fuel rail assembly.





11. Remove the coolant bypass housing mounting bolts and the housing.
12. Remove the intake manifold retaining nuts and retaining bolt in the sequence shown.
13. Remove the intake manifold.





14. Remove the intake manifold gasket.
15. Remove the Direct Ignition System (DIS) coil and the Exhaust Gas Recirculation (EGR) mounting bracket bolts.
16. Remove the DIS ignition coil and the EGR mounting bracket and ignition wires.
17. Remove the intake manifold studs.





18. Remove the spark plugs.





19. Remove the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.
20. Remove the intake camshaft caps. Maintain the correct positions for installation.
21. Remove the intake camshaft.
22. Remove the intake valve tappet adjusters.
23. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
24. Remove the exhaust camshaft.





25. Remove the exhaust valve tappet adjusters.
26. Compress the valve springs with the valve spring compressor KM-348 and the adapter KM-653.
27. Remove the valve retainers.
28. Remove the valve spring compressor KM-348 and the adapter KM-653.
29. Remove the valve spring caps.





30. Remove the valve springs. Maintain the original position of the valve springs for installation.
31. Remove the valves. Maintain the original position of the valves for installation.





32. Remove the valve stem seals.

Assembly
1. Coat the valve stems with engine oil.
2. Insert the valves in the cylinder head in their original positions.
3. Insert the valve spring seats.
4. Push the accompanying assembly sleeve onto the valve stem.
5. Insert the new valve stem seat.
6. Carefully drive the valve stem seal onto the stop with light taps.
7. Install the valve springs in their original positions.





8. Install the valve spring caps.
9. Compress the valve springs with the valve spring compressor KM-348 and adapter KM-653.
10. Install the valve keys.





11. Remove the valve spring compressor KM-348 and adapter KM-653.
12. Lubricate the valve tappet adjusters with engine oil.





13. Install the valve tappet adjusters.
14. Install the intake camshaft.
15. Install the intake camshaft bearing caps in their original positions.
16. Install the exhaust camshaft.
17. Install the exhaust camshaft bearing caps in their original positions.
18. Install the camshaft bearing cap bolts.





19. Tighten the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.
Tighten: Tighten the camshaft bearing cap bolts to 8 Nm (71 inch lbs.).
20. Install the spark plugs.
Tighten: Tighten the spark plugs to 20 Nm (15 ft. lbs.).
21. Install the DIS coil and EGR mounting bracket.





22. Install the DIS coil and EGR mounting bracket bolts.
Tighten: Tighten the direct ignition system coil and exhaust gas recirculation mounting bracket bolts to 25 Nm (18 ft. lbs.).
23. Install the intake manifold studs.
24. Install the intake manifold gasket.
25. Install the intake manifold.





26. Install the intake manifold retaining nuts and retaining bolt in the sequence shown.
Tighten: Tighten the intake manifold retaining nuts and retaining bolt to 22 Nm (16 ft. lbs.).
27. Install the fuel rail assembly.
28. Install the thermostat housing assembly.
29. Install the thermostat housing mounting bolts.
Tighten: Tighten the thermostat housing mounting bolts to 15 Nm (11 ft. lbs.).





30. Install the coolant bypass housing and mounting bolts.
Tighten: Tighten the coolant bypass housing bolts to 15 Nm (11 ft. lbs.).
31. Install the exhaust manifold studs.
32. Install the exhaust manifold gasket.
33. Install the exhaust manifold.
34. Install the exhaust manifold retaining nuts in the sequence shown.
Tighten: Tighten the exhaust manifold retaining nuts to 22 Nm (16 ft. lbs.).
35. Install the exhaust manifold heat shield.
36. Install the exhaust manifold heat shield bolts.
Tighten: Tighten the exhaust manifold heat shield bolts to 8 Nm (71 inch lbs.).





37. Install the cylinder head with the intake manifold and the exhaust manifold attached.