Disassembly and Assembly of Subassemblies

Cylinder Head

Special Tool(s):

Material:

Disassembly

CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components removed for locations.

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

2. Remove the 2 bolts and the exhaust gas recirculation (EGR) valve.
^ Discard the gasket.

3. Remove and discard the cylinder head temperature (CHT) sensor.

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

Remove the spark plugs.

5. NOTE: Use a small screwdriver and grease to remove the valve collets.

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





6. Inspect the components, if necessary.
7. Remove the valves.
8. Using the special tools, remove and discard the valve seals.





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

Assembly

1. NOTE: 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.

Using the special tool, install the valve seals.





3. NOTE: Check the seating of the valve collets.

Using the special tools, install the valve springs.
^ Insert the valve springs and the valve spring retainers.
^ Compress the valve springs and install the valve collets, using grease and a small screwdriver.





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

Install the spark plugs.
^ Tighten to 12 Nm (9 ft. lbs.).

5. Install a new CHT sensor.
^ Tighten to 12 Nm (9 ft. lbs.).

6. Install the EGR valve, using a new gasket.
^ Tighten to 20 Nm (15 ft. lbs.).

7. Using a new gasket, install the coolant outlet and bolts.
^ Tighten to 10 Nm (89 inch lbs.).