1D
Valves and Cylinder Head Assembly Removal and Installation
Reference: Valves and Cylinder Head Components:K9K
Removal
1) Remove engine assembly from vehicle referring to Engine Assembly Removal and Installation:K9K .
2) Remove exhaust manifold referring to Exhaust Manifold Removal and Installation:K9K .
3) Remove camshaft from cylinder head referring to Camshaft and Tappet Removal and Installation:K9K .
4) Remove EGR body and intake pipe No.1 and No.2 referring to EGR Valve and Intake Pipe Removal and Installation:K9K .
5) Remove thermostat assembly referring to Thermostat Assembly Removal and Installation:K9K .
6) Remove injection pump referring to Injection Pump Removal and Installation:K9K .
7) Remove common rail referring to Common Rail (High Pressure Fuel Injection Rail) Removal and Installation:K9K .
8) Remove fuel injector referring to Fuel Injector Removal and Installation:K9K .
9) Remove generator and generator upper bracket referring to Generator Removal and Installation:K9K .
10) Remove grow plugs referring to Glow Plug Removal and Installation:K9K .
11) Loosen cylinder head bolts in numerical order as indicated in the figure, and remove them.
12) Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary.
Installation
1) Clean mating surface of cylinder head and cylinder block.
Remove oil, old gasket and dust from mating surface.
2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block.
4) Tighten new cylinder head bolts gradually as follows.
NOTE:
Do not oil cylinder head bolt.
a) Tighten all bolts to 25 N·m (2.5 kgf-m, 18.0 lbf-ft) according to numerical order in the figure.
b) Retighten all bolts 255° according to numerical order in the figure.
Tightening torque
Cylinder head bolt ( a ): Tighten 25 N·m (2.5 kgf-m, 18.0 lbf-ft) and 255° by the specified procedure
5) Install grow plugs referring to Glow Plug Removal and Installation:K9K .
6) Install generator and generator upper bracket referring to Generator Removal and Installation:K9K .
7) Install fuel injector referring to Fuel Injector Removal and Installation:K9K .
8) Install common rail referring to Common Rail (High Pressure Fuel Injection Rail) Removal and Installation:K9K .
9) Install injection pump referring to Injection Pump Removal and Installation:K9K .
10) Install thermostat referring to Thermostat Assembly Removal and Installation:K9K .
11) Install EGR body and intake pipe referring to EGR Valve and Intake Pipe Removal and Installation:K9K .
12) Install tappet and camshaft to cylinder head referring to Camshaft and Tappet Removal and Installation:K9K .
13) Install exhaust manifold referring to Exhaust Manifold Removal and Installation:K9K .
14) Install engine assembly to vehicle referring to Engine Assembly Removal and Installation:K9K .