Cylinder Head LH
Cylinder Head - LH
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the engine oil.
3. Remove the intake manifold.
4. Remove the LH cylinder block drain plug.
5. Remove the fuel injector control module mounting bracket.
6. Disconnect the glow plug connector and position aside.
7. Remove the nut and position the oil level indicator and tube aside.
8. NOTE: Mark the position of the valve cover bolts for valve cover bolt installation.
Remove the eleven bolts and the valve cover. Remove the valve cover gasket.
9. Disconnect the high-pressure oil rail supply line at the high-pressure oil rail.
10. Remove the bolts and the high-pressure oil rail.
11. Disconnect and remove the high-pressure oil supply line.
12. NOTICE: Do not attempt to put battery voltage to the fuel injector or damage to the fuel injector will occur.
Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
13. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
14. NOTICE: To prevent engine damage, do not use air tools to remove the fuel injectors. The clip that extracts the injector can dislodge and fall into the oil drain hole.
NOTICE: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system causing severe engine damage.
NOTE: There is no need to drain the fuel rail.
NOTE: if engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve.
Remove the bolt, filel injector hold-down and fuel injector.
15. NOTE: if a snap ring or a piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.
Remove the shop towels.
16. NOTE: LH shown, RH similar.
Remove the nuts and bolts from the turbocharger adapter pipe.
17. Remove the turbocharger adapter pipe.
18. NOTE: Remove and discard the 0-ring.
Remove the oil level indicator and tube.
19. Remove the bolts and turbocharger heat shield.
20. Remove the glow plug buss bar.
21. Remove the four glow plugs.
22. Disconnect the exhaust back pressure tube at the exhaust manifold.
23. Remove the retaining nuts. Remove the exhaust back pressure sensor and tube assembly.
24. Remove the retaining nut from the fuel tube bracket and position the fuel tubes aside.
25. Remove the bolt and the idler pulley.
26. Disconnect the heater hose from the front cover and position aside.
27. Remove the fan shroud mounting stud.
28. NOTE: Remove and discard the sealing washers. Remove the banjo bolt and the fuel tube.
29. Remove and discard the crankcase-to-head tube assembly.
30. NOTICE: Make sure the insulation blanket is not damaged (torn, cracked or fabric separated from the metallic skin) when removing the lower rear cylinder head bolt. If the insulation blanket is damaged, the entire blanket must be replaced.
NOTE: It may be necessary to slightly compress or deform the insulation blanket to gain tool clearance to remove the lower rear cylinder head bolt.
NOTE: The back two cylinder head bolts cannot be removed from the head in vehicle. Raise these bolts and secure them in position so they will clear the cylinder block deck as the head is removed.
Remove and discard the inner cylinder head bolts.
31. Remove the eight bolts and the rocker arm assemblies.
32. Mark the eight valve bridges with a permanent marker and remove.
33. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
Mark and remove the eight push rods.
34. Remove the outer cylinder head bolts.
35. Install the special tool and the lifting crane. With the help of an assistant, remove the cylinder from the vehicle.
36. Check for cylinder head distortion.
37. Remove the cylinder head gasket and dowels.
Clean and inspect the gasket sealing surfaces.
