Removing
1. Remove the camshaft and pushrods.
2. Remove the intake and exhaust manifolds.
3. Remove the high pressure fuel pump pulley.
4. Remove the bolts and remove the engine mount from the front of the engine.
5. Remove the remaining electrical wiring, hoses and their support elements associated with the cylinder head.
6. Gradually and sequentially unscrew the cylinder head bolts in the reverse order shown in fig. Cylinder head bolt tightening sequence. Remove bolts with washers.
7. Separate the cylinder head from the cylinder block using two metal rods with ends bent at 90°and installed in the head bolt hole.
8. Remove the cylinder head from the block and remove the gasket.
Preparing for installation
1. Clean the mating surfaces of the cylinder head and cylinder block.
2. Check up a condition of interfaced surfaces of a head of the block of cylinders and the block of cylinders on presence of scratches, scratches and other damages. If the defects are shallow, remove them by grinding, otherwise a replacement part is necessary.
3. Choose the gasket of the required thickness. Bolts of fastening of a head of the block of cylinders use only new.
Installation
1. Thoroughly wipe the mating surfaces of the cylinder head and cylinder block. Check that the two guide pins are in their sockets in the cylinder block.
2. Install a new cylinder head gasket to the cylinder block.
3. Install the cylinder head to the cylinder block.
4. Lubricate the threaded part and the reverse side of the heads of the cylinder head bolts with Molykote Rapid Plus or any high quality material.
5. Slowly place each bolt into its hole and hand-tighten.
6. Gradually and in the specified sequence (see fig. Cylinder head bolt tightening sequence) tighten bolts of fastening of a head of the block of cylinders the demanded moment.
7. Using the special template, retighten the bolts to the required angle.
8. The remaining installation steps are performed in the reverse order of removal.
9. After installing the engine in the vehicle, start the engine and warm it up until the cooling fan turns on at least two times. Turn off the engine and cool it down for 3.5 hours. Then remove the cylinder head cover, release the residual pressure in the cooling system by removing the expansion tank cap, and tighten the cylinder head bolts as follows.
10. Gradually and in the sequence shown in Fig. Cylinder head bolt tightening sequence, loosen each mounting bolt one at a time, tighten each bolt to the required torque and tighten to the required angle.
11. Install the cylinder head cover and coolant expansion tank cap.