Disassembly of the cylinder head K4M

Dismantling the K4M Engine Cylinder Head

After removing the cylinder head, we dismantle it and carry out fault assessment.

Removal of the cylinder head was covered in the article — “Removing the cylinder head from the engine”.

Securing the heat shield to the exhaust manifold
Fig. 1. Securing the heat shield to the exhaust manifold

We remove the lower heat shield of the exhaust manifold (Figure 1).

Unscrewing the lambda sensor
Fig. 2. Unscrewing the lambda sensor

We pass a 22 mm ring spanner over the lambda sensor wire and unscrew it.

Removing the upper heat shield
Fig. 3. Removing the upper heat shield

We unscrew the upper heat shield fastening and remove it (Fig. 3 shows the shield with the cylinder head fitted).

Removing the exhaust manifold
Fig. 4. Removing the exhaust manifold

We remove the exhaust manifold (Figure 4).

Tightening sequence of the thermostat retaining bolts
Fig. 5. Tightening sequence of the thermostat retaining bolts: А — air bleed union

We unscrew the thermostat housing from the cylinder head and remove it (Figure 5).

Tightening sequence of the lower intake pipe bolts
Fig. 6. Tightening sequence of the lower intake pipe bolts

We remove the injector body backing plate (see Fig. 6).

Removing the valves with the Mot1502 tool
Fig. 7. Removing the valves with the Mot1502 tool

We compress the valve springs with the Mot1502 tool. The valve spring retainer must enter the recess (1) of the pressure bush (3) of the Mot1502 tool (see Fig. 7). For correct compression of the valve springs, the plunger (2) of the tool must be centred on the valve stem.

Remove the collets, valve spring retainers, valve springs, valves and oil-deflector caps using the Mot1335 pliers.

Removing the exhaust valve tappet

Fitting the tappet removal tool
Fig. 8. Fitting the tappet removal tool: 1 — guide pin; 2 — receiving hole in the head; 3 — tool pin; 4 — screw
  1. We bring the pin (3) of the Mot1669 tool to the stop (В) at the end of the guide slot by unscrewing the screw (4) (see Fig. 8).
  2. Fit the Mot1669 tool onto the cylinder head, correctly inserting the guide pin (1) into the hole (2) of the cylinder head cover (see Fig. 8).
Removing the tappet
Fig. 9. Removing the tappet
  1. We secure the Mot1669 tool to the cylinder head cover with three bolts (see 3, Fig. 9).
  2. Screw in the screw (1) until the pin (2) comes to the stop at point (А) at the end of the guide slot.
Tappet retaining bolt
Fig. 10. Tappet retaining bolt
  1. We unscrew the tappet retaining bolt (see the arrow, Fig. 10).
  2. Unscrew the screw (1) until the pin (2) comes to the stop at point (В) at the end of the guide slot (see Fig. 9).
  3. We remove the Mot1669 tool from the cylinder head cover.
  4. We remove the tappet and the spring.

Fitting the exhaust valve tappet

Fitting the tappet
Fig. 11. Fitting the tappet
  1. Fit the spring and the tappet, aligning the tappet slot (1) with the hole (2) in the cylinder head cover (see Fig. 11).
  2. Bring the pin (3) of the Mot1669 tool to the stop at the end of the guide slot by unscrewing the screw (4) (see Fig. 8).
  3. Fit the Mot1669 tool onto the cylinder head, correctly inserting the centring pin (1) into the hole (2) of the cylinder head cover (see Fig. 8).
  4. Secure the Mot1669 tool to the cylinder head cover with three bolts (see 3, Fig. 9).
  5. Screw in the screw (1) until the pin (2) comes to the stop at point (А) at the end of the guide slot.
Fitting the tappet (1.6 L engine)
Fig. 12. Fitting the tappet (1.6 L engine)
  1. Screw the hex socket bolt in the head of the Mot1669 tool into the cylinder head cover to lock the tappet (see the arrow, Fig. 12).
  2. Unscrew the screw (1) until the pin (2) comes to the stop at point (В) at the end of the guide slot (see Fig. 9).
  3. Remove the Mot1669 tool from the cylinder head cover.

Assembly of the cylinder head is carried out in the reverse order, after fault assessment and repair of the cylinder head.