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Cylinder Head Replacement

Cylinder Head Replacement



Special Tools

• EN-38188 Cylinder Head Broken Bolt Extractor Kit

• EN-45059 Angle Meter


For equivalent regional tools, refer to Special Tools (LDK, LHU) .

Removal Procedure


1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

2. Drain the cooling system. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .

3. Remove the camshaft position actuator solenoid valve - intake. Refer to Camshaft Position Actuator Solenoid Valve Replacement (Exhaust) Camshaft Position Actuator Solenoid Valve Replacement (Intake) .

4. Remove the camshaft position actuator solenoid valve - exhaust. Refer to Camshaft Position Actuator Solenoid Valve Replacement (Exhaust) Camshaft Position Actuator Solenoid Valve Replacement (Intake) .

5. Remove the intake manifold. Refer to Intake Manifold Replacement .

6. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement (Diesel) Exhaust Manifold Replacement (LHU/A20NFT) .

7. Remove the timing chain guide - upper. Refer to Timing Chain Guide Replacement - Upper .

8. Remove the hydraulic valve lash adjuster - exhaust. Refer to Hydraulic Valve Lash Adjuster Replacement - Exhaust .

9. Remove the hydraulic valve lash adjuster - intake. Refer to Hydraulic Valve Lash Adjuster Replacement - Intake .

10. Remove the cylinder head to the block fastener in sequence.


11. Remove the cylinder head (1) and the cylinder head gasket (2) from the block.


12. Clean all of the gasket surfaces.

• Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surfaces.

•
Note

Do not use any other method or technique to clean these gasket surfaces.


Use a new blade for each cylinder head and cylinder block.

•
Note

Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket.


Hold the razor blade (1) as parallel to the gasket surfaces (2) as possible.


13.
Note

Do not use a tap to clean the cylinder head fastener holes.


Clean the fastener holes with a nylon bristle brush.

14.
Warning

Wear safety glasses when using compressed air in order to prevent eye injury.


When cleaning the cylinder head bolt holes, use a suitable solvent in spray form. Use a compressed-air cleaning pistol with an extra long nozzle to reach the bottom of the holes.

15. Remove any broken long cylinder head fastener using the EN-38188 cylinder head broken bolt extractor kit.


Installation Procedure


1.
Note

Do not use any sealing material.


Install the cylinder head gasket (1) to the cylinder block (2). On right ones sit pay attention from the cylinder head lock pin (3).


2. Ensure the number 1 cylinder is at top dead center (TDC).

Setting up the crankshaft balancer mark (1) to the oil pump housing mark (2).


3. Refer to Fastener Caution .

Note

Always use NEW cylinder head fastener.


Install the cylinder head.


4. Install NEW cylinder head fastener.

• Tighten the fasteners in sequence to 30 Nm (22 lb ft) .

• Tighten the fastener in additional 155 degrees in sequence using the EN-45059 angle meter.

5. Install the front cylinder head fastener (1) and tighten to 35 Nm (26 lb ft) .


6. Install the hydraulic valve lash adjuster - intake. Refer to Hydraulic Valve Lash Adjuster Replacement - Intake .

7. Install the hydraulic valve lash adjuster - exhaust. Refer to Hydraulic Valve Lash Adjuster Replacement - Exhaust .

8. Install the timing chain guide - upper. Refer to Timing Chain Guide Replacement - Upper .

9. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (Diesel) Exhaust Manifold Replacement (LHU/A20NFT) .

10. Install the intake manifold. Refer to Intake Manifold Replacement .

11. Install the camshaft position actuator solenoid valve - exhaust. Refer to Camshaft Position Actuator Solenoid Valve Replacement (Exhaust) Camshaft Position Actuator Solenoid Valve Replacement (Intake) .

12. Install the camshaft position actuator solenoid valve - intake. Refer to Camshaft Position Actuator Solenoid Valve Replacement (Exhaust) Camshaft Position Actuator Solenoid Valve Replacement (Intake) .

13. Fill the cooling system. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .

14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .