159232-0200 ZEXEL 9 421 610 122 BOSCH PLATE 9421610122 1592320200 5157290260

1. Remove the bolts that hold the cylinder head assembly to the cylinder block.
To prevent damage to the two cylinder head-to-cylinder block dowels, keep the cylinder head assembly level during removal and installation.
2. Fasten a hoist to the cylinder head assembly as shown. Carefully remove the cylinder head assembly from the cylinder block. Remove the cylinder head gasket. The weight of the cylinder head assembly can range from 50 to 75 kg (110 to 165 lb). The following steps are for the installation of the cylinder head assembly.3. Be sure the mating surface of the cylinder head assembly and the cylinder block are thoroughly clean.4. Put a new cylinder head gasket in position on the cylinder block. Be sure the head gasket is dry. Fasten a hoist to the cylinder head assembly, and put it in position on the cylinder block.
3114 Cylinder Head Tightening Sequence
3116 Cylinder Head Tightening Sequence Bolts (1) are large diameter bolts (M20). Bolts (2) are small diameter bolts (M10).5. Apply clean engine oil on the threads of the cylinder head assembly mounting bolts.6. Install the bolts that hold the cylinder head assembly to the cylinder block, and tighten them as follows: a. Tighten the large diameter bolts in the number sequence shown to a torque of 150 15 N m (110 11 lb ft).b. Tighten the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).c. Retorque the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).d. Tighten the small diameter bolts in the number sequence shown to a torque of 55 7 N m (41 5 lb ft).End By:a. install unit fuel injectorsb. install fuel control linkagec. install rocker arm assemblies and push rodsd. install inlet manifolde. install exhaust manifoldf. install fuel filter and fuel filter base