Disassembly and Assembly of Subassemblies

Cylinder Head

Special Tool(s):

Material:

Disassembly

NOTE: If the components are to be reinstalled, mark the location of the components removed, they must be installed in the same location.





1. Remove the 4 bolts and the coolant outlet.
^ Discard the gasket.

2. Remove the 2 bolts and the EGR valve.
^ Discard the gasket.

3. Remove the cylinder head temperature (CHT) sensor.
4. Remove the EGR tube.

5. CAUTION: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug.

NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.

Remove the spark plugs.

6. NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets.

Using the special tools, compress the valve spring and remove the valve spring collets, the valve spring retainers and the valve springs.





7. Inspect the valve spring, valve spring retainer and valve spring retainer key.

8. CAUTION: Note the location of the valves if they are to be reused.

NOTE: Mark each valve if the original valves are to be used.

Remove the valves.





9. Using the special tools, remove and discard the valve seals.





10. Inspect the valves. Install new parts, as necessary.

Assembly

1. NOTE: If installing the original valves, make sure the valves are installed in the same position from which they were removed. Coat the valve stems with clean engine oil.

Install the valves.





2. NOTE: Use the protector provided with the replacement kit to prevent damage to the valve seals.

Lubricate the valve stems and guides with clean engine oil and, using the special tool, install the valve seals onto the cylinder head valve guides.





3. Place the valve spring in position over the valve and install the valve spring retainer.

4. NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets.

Using the special tools, compress the valve spring and install the valve collets.





5. CAUTION: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug.

Install the spark plugs.
^ Tighten to 12 Nm (9 lb-ft).
6. Install the EGR tube.
^ Tighten to 55 Nm (41 lb-ft).
7. Install the CHT sensor.
^ Tighten to 12 Nm (9 lb-ft).
8. Using a new gasket, install the EGR valve, and the 2 bolts.
^ Tighten to 20 Nm (15 lb-ft).
9. Using a new gasket, install the coolant outlet and the 4 bolts.
^ Tighten to 10 Nm (89 lb-in).