Usage:
Start By:
a. remove exhaust manifold
b. remove rocker shaft assembly and push rods
1. Drain the coolant from cooling system into a suitable container for storage or disposal.
2. Loosen clamps (3) and remove hose (1).
3. Loosen clamps (4) and disconnect hose (2).
4. Remove two bolts (5) that hold the water pump to the cylinder head.
5. Unplug connector (6). Disconnect connector (7).
6. Remove bolts (11) and plate (9).
7. Remove the four bolts, the washers, the cover, and the gasket from the rear opening on the cylinder head. Install Tool (A) and fasten a hoist.
8. Remove twenty bolts (10) and seven bolts (8). Remove the cylinder head. The weight of the cylinder head assembly is approximately 177 kg (390 lbs).
| NOTICE |
|---|
Do not set the cylinder head on a flat surface because of possible damage to the fuel injection nozzle tips. |
NOTE: The following steps are for the installation of the cylinder head.
NOTE: When the cylinder head is removed, a new spacer plate gasket must be installed. See the topic "Remove & Install Spacer Plate".
9. Make sure the surfaces that make contact between the cylinder head and cylinder block are clean and dry. Install a new gasket on the cylinder block.
10. Install Tool (A) on the cylinder head and fasten a hoist. Put the cylinder head in position on the engine.
11. Remove Tool (A).
12. Loosen the adjusting screws (13) on the rocker arms for valve clearance. This will prevent a bent valve or push rod during installation of the rocker shaft assembly.
13. Install the push rods.
NOTE: The O-ring seal in the rear support must be installed new each time the bolt is removed from the rear support bracket.
14. Put rocker shaft assembly (14) in position on the cylinder head.
| NOTICE |
|---|
Make sure the dowels on each end of the rocker shaft assembly are in alignment with the holes in the cylinder head. |
15. Put 5P-0960 Molylube on all head bolts and washer faces. Install the rocker shaft bolts, bolts (8), and bolts (10) with the washers.
16. Tighten the bolts as follows:
a. Tighten bolts 1 through 26 in number sequence to a torque of 150 N·m (110 lb ft).
b. Tighten bolts 1 through 26 again in number sequence to a torque of 250 ± 17 N·m (185 ± 13 lb ft).
c. Tighten bolts A through G in letter sequence (hand tighten only) to a torque of 43 ± 7 N·m (32 ± 5 lb ft).
17. Make adjustments until the inlet valve clearance is 0.38 mm (.015 in) and the exhaust valve. Clearance is 0.64 mm (.025 in). See the topic "Valve Clearance Setting" in Testing & Adjusting. Tighten the locknuts for adjusting screw (13) to a torque of 29 ± 7 N·m (21 ± 5 lb ft).
18. Put the gasket and cover (12) in position on the cylinder head. Install the four bolts and washers.
19. Put plate (9) in position and install bolts (11) and the washers.
20. Install the gasket and two bolts (5) that hold the water pump to the cylinder head.
21. Connect connector (6) and connector (7).
22. Put hose (2) in position and tighten clamps (4).
23. Put hose (1) in position and tighten clamps (3).
24. Fill the cooling system with coolant to the proper level.
End By:
a. install rocker shaft assembly and push rods
b. install exhaust manifold