IMPACT 3.

0 Tuesday, 10 November 2015

Chassis ID Path
21/Repair/T, ENG-VE11/Cylinder head, pressure test (first). Cylinder head removed

Model Identity
132423051

Publish date ID/Operation No.

Saturday, 30 November 2013 21171-4

21171-4 Cylinder head, pressure test (first)

Cylinder head removed

Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.

CAUTION
Risk of material damage.
Risk of impurities being introduced into the fuel system.

▶ Ensure conditions of maximum cleanliness when carrying out any work on the fuel system.

Special tools

88890148 9990105 9990106 9990107 9996239

9996662

1 Remove the screws and sleeves.

2 Remove the exhaust manifold.

3 Remove the gaskets.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

4 Disassemble the exhaust manifold.

5 Check that the parts are free of cracks and other damage.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

6 Remove the screws.

7 Remove the inlet manifold.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

8 Clean the mating surfaces.

9 Install the tools.

Required material

SEALING_WASHER 9990105

SEALING_WASHER 9990106

CONNECTING_WASHER 9990107

PRESSURE GAUGE 9996662

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

A SEALING_WASHER 9990105

B SEALING_WASHER 9990106

C CONNECTING_WASHER 9990107

D PRESSURE GAUGE 9996662

10 Install the lifting chains (A).

Required material

LIFTING CHAIN 9996239 2 pcs

Note
Install soft washers to protect the sealing surfaces.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

11 Pressurise the cylinder head using the valve (2).

Tech data

Pressure, test 100 kPa

12 Close the valve (1).

13 Check that the pressure does not drop.

Tech data

Cylinder head, pressure testing, time 2 min

14 Open the valve (1).

15 Lower the pressure using valve (2).

Tech data

Pressure, test ≈ 0 kPa

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

16 Fill the container with water.

Tech data

Water container, temperature 70 ℃

17 Place the cylinder head in the water bath.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

18 Pressurise the cylinder head using the valve (2).

Tech data

Pressure, test 50 kPa

19 Close the valve (1).

20 Check for leakage.

Tech data

Cylinder head, pressure testing, time 1 min

21 Open the valve (1).

22 Increase the pressure using valve (2).

Tech data

Pressure, test 150 kPa

23 Close the valve (1).

24 Check that the pressure does not drop.

Tech data
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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

Cylinder head, pressure testing, time 2 min

25 Open the valve (1).

26 Lower the pressure using valve (2).

Tech data

Pressure, test ≈ 0 kPa

27 Remove the cylinder head from the bath.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

28 Remove the pressure gauge.

29 Remove the tools.

CAUTION
Risk of personal injury.
Loose particles can spatter up and injure the eyes. Work with compressed air can cause hearing
impairment.

▶ Always wear safety goggles and hearing protection when working with compressed air.

30 Dry the cylinder head using compressed air.

Note
Clean the fuel channels thoroughly.

31 Remove the gaskets.

32 Clean the mating surfaces.

33 Install the gaskets.

Note
Use new parts.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

34 Apply assembly compound.

Note
Use a recommended assembly compound.

35 Assemble the exhaust manifold.

36 Apply a thin layer of assembly compound.

Note
Use only recommended assembly paste.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

37 Check the gasket.

38 Install the inlet manifold.

39 Install the screws.

40 Torque tighten the screws.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

Tightening torque

Inlet manifold, screw 1. Tightening sequence: 1-12

10 ±4 Nm

2. Tightening sequence: 1-12

24 ±4 Nm

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 10 November 2015

Required material

TORQUE WRENCH 88890148

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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