Cylinder Head Assembly: Service and Repair
Cylinder Head LHService Repair No - 12.29.04
Removal
1. Disconnect the battery ground cable.
2. Raise and support the vehicle.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
3. Remove the fuel rail.
4. Remove the LH bank camshafts.
5. Disconnect the LH catalytic converter from the exhaust manifold.
^ Remove and discard the 2 nuts.
6. Disconnect the RH catalytic converter from the exhaust manifold.
^ Remove and discard the 2 nuts.
7. Remove the camshaft position (CMP) sensor.
^ Remove the screw.
^ Disconnect the electrical connector.
8. Remove the 12 cylinder head bolts.
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.
9. With assistance remove the cylinder head.
^ Clean the component mating faces.
10. Remove and discard the cylinder head gasket.
^ Clean the cylinder head locating dowels.
^ Clean and inspect the cylinder head and cylinder block.
11. 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 gasket/heat shield bolt.
^ Discard the gasket/heat shield.
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.
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 center 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.
^ Clean the component mating faces.
^ Install the gasket/heat shield and tighten the bolt to 10 Nm (7 ft. lbs.).
^ Install, and lightly tighten the bolts.
^ Evenly and progressively, tighten the bolts in the sequence shown to 20 Nm (15 ft. lbs.).
6. Install a new cylinder head gasket.
CAUTION: The head gasket must be installed over the cylinder block dowels.
7. With assistance install the cylinder head.
8. 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 to 20 Nm (15 ft. lbs.).
^ Tighten the bolts to 35 Nm (26 ft. lbs.).
^ 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 ft. lbs.).
9. Install the CMP sensor.
^ Tighten the screw to 7 Nm. (5 ft. lbs.).
^ Connect the electrical connector.
10. Position the RH catalytic converter to the exhaust manifold.
^ Clean the components.
^ Tighten the new nuts to 20 Nm (15 ft. lbs.).
11. Position the LH catalytic converter to the exhaust manifold.
^ Clean the components.
^ Tighten the new nuts to 20 Nm (15 ft. lbs.).
12. Install the LH bank camshafts.
13. Install the fuel rail.
14. Connect the battery ground cable.