Dismantling
1. Unscrew the 8 exhaust manifold mounting nuts, remove the manifold, dispose of the nuts and both gaskets.
2. Disconnect the cooling system hoses from the liquid pump.
V8 engine, ENGINE OVERHAUL, Hoses connecting the distribution pipe to the coolant pump.
3. Remove the left valve timing adjuster.
V8 Engine, ENGINE OVERHAUL, Variable Camshaft Control (VCC).
4. Remove the LRT-12-227 pin from the retainer hole.
5. Turn the crankshaft counterclockwise to the 45° TDC position.
NOTE: While turning the crankshaft, tighten the camshaft timing chain and keep it taut.
6. Remove tools LRT-12-223/6, LRT-12-223/5, LRT-12-223/3 and LRT-12-223/4 from the left cylinder head camshafts.
7. Loosen the bolt securing the chain shoe to the left cylinder head.
Disassembly
1. Loosen the 10 cylinder head mounting bolts in the sequence shown in the figure.
2. Discard the head bolts and remove the 10 bolt washers.
3. With the help of a partner, remove the cylinder head.
4. Discard the cylinder head gasket.
5. Discard the O-ring on the top surface of the cylinder block.
Examination
1. Clean the cylinder head, cylinder block, pins and pin holes. If necessary, remove any remaining sealant with a hardwood scraper. Make sure that no sealant remains in the oil or water passages or in the threaded seats.
CAUTION: Make sure that there is no oil or coolant left in the threaded seats of the cylinder block. Failure to do so may damage the cylinder block when tightening the head bolts.
2. Using a straightedge and feeler gauge, check the deformation of the lower plane of the head in the directions shown in the figure.
TECHNICAL SPECIFICATIONS, Engine - V8.
Assembly
1. Install a new O-ring onto the cylinder block.
2. Apply STC 50550 sealant to the areas shown in the figure.
3. Place the new cylinder head gasket onto the dowel pins in the cylinder block.
4. With the help of a partner, place the head on the block, making sure that it lands on the pins.
5. Replace the head bolt washers and screw in new bolts. Tighten the head bolts to 30 N·m in the sequence shown in the figure. Using an angle torque wrench, tighten the bolts an additional 80° in the same sequence, and then another 80°.
NOTE: Do not attempt to remove the special coating from new bolts.
Assembly
1. Screw in the left camshaft drive chain shoe mounting bolt and tighten it to a torque of 10 Nm.
2. Carefully turn the camshafts until the letters and cylinder numbers located at the rear of the shafts point upward.
3. Loosen the bolt securing the LRT-12-223/4 mandrel to the LRT-12-223/3 mandrel.
4. Install the LRT-12-223/4 and LRT-12-223/3 mandrels onto the rear of the left cylinder head camshafts and tighten the bolt.
5. Install the LRT-12-223/5 and LRT-12-223/6 mandrels onto the left cylinder head and tighten the LRT-12-223/6 using the spark plug threaded seat.
6. Turn the crankshaft clockwise until the TDC marks align.
NOTE: While turning the crankshaft, tighten the camshaft timing chain and keep it taut.
7. Insert pin LRT-12-227 through the hatch and fix the flywheel in the TDC position.
8. Install the left valve timing adjuster.
V8 Engine, ENGINE OVERHAUL, Variable Camshaft Control (VCC).
9. Connect the cooling system hoses to the liquid pump.
V8 engine, ENGINE OVERHAUL, Hoses connecting the distribution pipe to the coolant pump.
10. Wipe the mating surface of the exhaust manifold and install new gaskets.
11. Apply copper powder grease to the exhaust manifold mounting studs, screw on the 8 manifold mounting nuts and tighten them to a torque of 23 Nm.
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