Usage:
Start By:
a. remove rocker shaft assemblies
b. remove turbocharger
1. Remove the valve cover bases from the cylinder head.
2. Remove sensor (7)
NOTE: Sensor (7) may be located differently on later engines) from cylinder head (8). If necessary, remove the O-ring seal from sensor (7).
3. Remove bolt and locknut (5).
4. Disconnect connector (6).
5. Remove bolt (4) and sensor (3), if so equipped. If necessary, remove the O-ring seal from sensor (3).
6. Remove three bolts (2) and water lines group (1).
7. Remove bolt (9) from timing advance housing.
8. Remove bolt (10) and support (11).
9. Remove bolt and support (12). Remove the remaining ten bolts and the supports along the intake side of the cylinder head.
10. Disconnect hose clamp (13) from the exhaust manifold.
11. Attach tooling (A).
12. Remove twenty bolts (14) and the cylinder head. The weight of the cylinder head is approximately 172 kg (380 lb).
| NOTICE |
|---|
Do not put the cylinder head down on a flat surface. Direct injection nozzles extend out from the bottom surface of the cylinder head and will be damaged by the weight of the head. |
Install Cylinder Head
1. Thoroughly clean the bottom surface of the cylinder head. Install a new head gasket and water seals. Do not use any adhesives.
NOTE: A new spacer plate gasket must be used when the cylinder head is installed. See "Remove and Install Spacer Plate" in the Disassembly and Assembly section.
2. Attach tooling (D).
3. Install the cylinder head to the block. The weight of the cylinder head is approximately 172 kg (380 lb).
4. Put clean engine oil on the threads of all the cylinder head bolts. Install twenty bolts (14). Do not tighten at this time.
5. Use the tightening sequence below to tighten the bolts that hold the cylinder head in position.
a. Tighten bolts 1 through 20 in sequence to 280 ± 27 N·m (210 ± 20 lb ft).
b. Tighten bolts 1 through 20 in sequence to 440 ± 20 N·m (320 ± 15 lb ft).
c. Repeat Step 5b.
6. Install support (12).
7. Connect hose clamp (13) to exhaust manifold.
8. Install bolt (10) and support (11). Install the remaining ten bolts and the supports along the intake side of the cylinder head. Torque all twelve bolts (10) to 43 ± 7 N·m (32 ± 5 lb ft).
9. Install bolt (9) to timing advance housing.
10. Put the gasket in position. Install three bolts (2) and water lines group (1).
11. If removed, install the O-ring seal to sensor (3). Install bolt (4) and sensor (3).
12. Connect connector (6).
13. Install bolt and locknut (5).
14. If removed, install the O-ring seal to sensor (7). Install sensor (7) to cylinder head (8).
15. Install the two valve cover bases. Use the tightening sequence above, and tighten the bolts to a torque of 14 ± 4 Nm (10 ± 3 lb ft).
16. Fill the cooling system with coolant to the correct level.
End By:
a. install turbocharger
b. install rocker shaft assemblies