Removal and Replacement

Cylinder Head Replacement (Part 1 Of 3) Engine Model 604 Cylinder Head Shown, Model 606 Similar:

Cylinder Head Replacement (Part 2 Of 3) Engine Model 604 Cylinder Head Shown, Model 606 Similar:

?l�Cylinder Head Replacement (Part 3 Of 3) Engine Model 604 Cylinder Head Shown, Model 606 Similar:

NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.

REMOVAL
1. Disconnect ground cable of the battery
2. Remove engine compartment trim

WARNING:
^ Risk of scalding as a result of hot coolant spraying out
^ Do not open the cap of the expansion reservoir or radiator unless the coolant temperature is below 90° C.
^ Carefully turn cap to the first detent or slowly about 1/2 turn.
^ Wear protective clothing.

3. Drain coolant at crankcase drain
4. Remove poly V-belt.
5. Remove cylinder head cover. Service and Repair
6. Remove resonance intake manifold.
7. Disconnect coolant hoses (12) at cylinder head
8. Inspect condition of hose clips and hoses and replace if necessary
9. Disconnect vacuum pipes (13) at cylinder head, place match mark for assembly alignment.
10. Unbolt exhaust system (6) at exhaust manifold
- Exhaust manifold remains attached to cylinder head
11. Remove chain tensioner (20). [1][2]Procedures
- Replace seal of chain tensioner
12. Remove camshafts (21). [1][2]Procedures
13. Remove camshaft housing (22). Service and Repair
14. Disconnect fuel pipes
- Open fuel filler cap to release residual pressure.
- Disconnect the feed pipes at the body end and connect across with a piece of hose to prevent leakage

WARNING:
^ Risk of explosion as a result of fuel vapors igniting.
^ No fire, naked flame or smoking. Avoid the creation of sparks.
^ Risk of poisoning as a result of inhaling fuel vapors and open handling of fuel.
^ Pour fuels only into the canisters provided for this purpose, and store in such canisters.
^ Risk of injury as a result of fuel splashing into eyes.
^ Wear protective gloves and, if necessary, eye protection when handling fuel.

15. If cylinder head is to be replaced, remove injection nozzles (23), refer to Powertrain Management
16. Disconnect engine wiring harness (29) at cylinder head. [1][2]Procedures
17. Remove oil filter (40). Service and Repair
18. Unbolt fuel filter (70/2) at cylinder head
- Place fuel filter to the side with piping connected
19. Pull out bottom guide rail pin (32), refer to Guide Rail Pin.
20. Remove guide rail (33) in chain housing
21. Unscrew bolts (15) of cylinder head at timing case cover
22. Slacken cylinder head bolts (16, 16a) in stages, take out





- Once engine has cooled down, slacken cylinder head bolts in reverse order of tightening diagram shown above.
23. Inspect cylinder head bolts (16, 16a). Testing and Inspection
24. Bolt on bracket (17) for removing cylinder head
- Bolt on bracket to first and last camshaft bearings (exhaust end) with 7 x 35 mm bolts (19)
25. Remove cylinder head (02)
26. Clean contact surfaces (24) of cylinder block (crankcase), clean threaded holes
- Blow out threaded holes, free of oil and water; inspect contact surfaces
- Inspect contact surface of cylinder block (crankcase) face
- If necessary reface contact surface of cylinder block (crankcase). Service and Repair
27. If cooling and heating system contains oil, remove oil in cooling and heating system.

INSTALLATION
- Install in the reverse order, noting the following:
- Install new cylinder head gaskets (25) onto the crankcase.
- When installing gasket, pay attention to dowel sleeves (26) for locating the cylinder head.

NOTE:
^ If the crankcase has been refaced, it is necessary to install a repair size cylinder head gasket with a thickness of 1.85 mm.
^ Measure piston projection. Testing and Inspection
^ If timing case cover and cylinder head are removed at the same time, the setting of the injection pump will be altered.
^ Test start of delivery and set if necessary.





- Using the illustration, tighten the twelve-point hexagon socket head cylinder head bolts in four stages as follows:
1st stage: 15 Nm
2nd stage: 35 Nm
3rd stage: Turn 90°
4th stage: Wait 10 Min., then tighten an additional 90°

NOTE:
^ Oil thread and head contact surface of cylinder head bolts, insert and tighten in stages
^ It is not necessary to re-tighten the cylinder head bolts after engine has been run

- Tighten cylinder head bolts to timing case cover bolts to: 25 Nm

- Install guide rail so that the two mounting holes for the guide rail pins are facing up (arrow) and the open side of the guide rail is facing in opposite direction of travel
- Coat bottom guide rail pin with Loctite 574 sealant or Omnifit FD 3041 sealant, or equivalent, and knock into the cylinder head as far as the stop.
Ensure that the guide rail (33) is correctly located at the chain housing
- Inspect cooling system for leaks

NOTE: Engine with new cylinder head gasket: do not pressure-test cooling system until engine has reached operating temperature

WARNING:
^ Risk of accident as a result of vehicle starting off when engine running.
^ Secure vehicle to prevent it moving off.
^ Risk of injury as a result of bruises and burns if you insert your hands into engine when it is being started or when it is running.
^ Wear appropriate work clothes when carrying out work on the vehicle.

- Inspect for leaks with engine running
- Read fault memory, erase
Stored faults which may be caused by disconnecting wiring or simulation during removal and installation or test work have to be processed in the fault memories and erased after completing the work, refer to Powertrain Management.