Cylinder Head - Installation

  1. Fit a new cylinder head gasket ensuring that the head to crankcase location dowels are correctly in place.
    2. Cylinder head gasket cart_2

    1. Cylinder head gasket

  2. Ensure that the cylinder head face is completely clean.
  3. Carefully lower the cylinder head over the camshaft drive chain and locate the head onto the dowels.
    4. caution
    Using the correct procedure to fit and tighten the cylinder head bolts will ensure the long term reliability of the cylinder head gasket. Clean each bolt, paying particular attention to the threads. If any of the threads are damaged, replace the bolt(s). Lubricate the threads of the bolts with engine oil, and then wipe clean with a lint-free cloth leaving minimal oil on the threads (that is, almost dry to touch).Tighten the bolts using the three-stage procedure given below. Failure to observe these important items may lead to engine damage through a damaged head gasket.
    note
    New cylinder head bolts and washers must be fitted.
  4. Lubricate the threads on the bolts and the top surface of the hardened washer with clean engine oil.
  5. Fit new bolts and washers to the cylinder head as noted for removal and tighten until finger tight.
  6. The cylinder head bolts are tightened in four stages, in the sequence shown below. This is to ensure that the cylinder head gasket seals correctly to the head and crankcase.
    7. note
    For stages one, two and four of the cylinder head tightening operation, a torque wrench of known, accurate calibration must be used.For stage three of the cylinder head tightening operation, the bolts must be turned through a set number of degrees to reach the final setting. To accurately gauge the turn, T3880105 - Torque Angle Gauge must be used.

Stage 1

  • Tighten the cylinder head bolts to 15 Nm, in the sequence shown below.

Cylinder Head Tightening Sequence Cylinder head tighten

Cylinder Head Tightening Sequence

Stage 2

  • Tighten the cylinder head bolts to 20 Nm, in the sequence shown above.

Stage 3

Fit the service tool T3880105 between the Torx socket and the drive handle and locate the Torx drive to the bolt. Pick an increment point on the torque turn gauge which aligns with a suitable reference point on the head.

  • Tighten the cylinder head bolts through 120° of bolt rotation as measured using the service tool T3880105, in the sequence shown above.

Stage 4

  • Tighten the cylinder head bolts to 40 Nm, in the sequence shown above.

  1. Fit the screws securing the side of the cylinder head to the crankcase and tighten to 10 Nm.
    2. Cylinder head outside two screws cdra_1

    Cylinder head to upper crankcase screws

  2. Install the camshaft drive chain tensioner blades.
  3. Clean and lubricate the tappet buckets with a 50/50 solution of engine oil and molybdenum disulphide grease and refit the buckets and shims in the same locations from which they were removed.

Perform the following operations

Perform the following operations: