Removal
1. Remove the camshaft and tappets.
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 mounting bolts in the reverse order to that shown in the figure Cylinder head bolt tightening sequence. Remove the bolts together with the washers.
7. Separate the cylinder head from the cylinder block using two metal rods with the ends bent at 90° and installed in the hole for the head mounting bolts.
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 the condition of the mating surfaces of the cylinder head and cylinder block for scratches, nicks and other damage. If the defects are shallow, remove them by grinding, otherwise the part must be replaced.
3. Select a gasket of the required thickness. Use only new cylinder head bolts.
Installation
1. Thoroughly clean 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 onto the cylinder block.
3. Install the cylinder head onto the cylinder block.
4. Lubricate the threaded portion and the back of the cylinder head bolt heads with Molykote Rapid Plus or any high-quality material.
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5. Gently insert each bolt into its hole and tighten by hand.
6. Gradually and in the indicated sequence (see figure Cylinder head bolt tightening sequence) tighten the cylinder head mounting bolts to the required torque.
7. Using the special template, re-tighten the bolts to the required angle.
8. The remaining installation steps are performed in the reverse order of removal.
9. After installing the engine on the vehicle, start the engine and warm it up until the cooling fan turns on at least twice. Turn off the engine and let it cool for 3.5 hours. Then remove the cylinder head cover, relieve residual pressure in the cooling system by removing the expansion tank cap, and tighten the cylinder head mounting bolts as follows.
10. Gradually and in the sequence shown in the figure Cylinder head bolt tightening sequence, loosen each mounting bolt one at a time, tighten each bolt to the required torque and turn it to the required angle.
11. Install the cylinder head cover and the coolant expansion tank cap.