Removal

Cylinder Heads





Special Tool(s)

Removal

Both cylinder heads
1. Remove the engine.





2. Remove the bolts and flexplate.
3. Mount the engine on an engine stand.
4. Remove the rear lifting eye.





5. Remove the special tools.





6. CAUTION: Do not pull on the wiring to remove the glow plug connector or damage may occur.

NOTE: Only one glow plug connector shown.

Remove the glow plug harness.





7. Remove the eight glow plugs.
8. Prior to removing the exhaust manifolds, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specifications.





9. NOTE: RH shown, LH similar.

Remove the bolts and the exhaust manifolds.

LH cylinder head





10. Remove the left cylinder head banjo fitting and fuel line. Discard the sealing washers.





11. Remove the bolts and turbocharger heat shield.
12. Remove the protective covering from the LH cylinder head.

RH cylinder head





13. NOTE: Mark the location of the stud bolts.

Remove the RH valve cover.
^ Remove the stud bolts, bolts and valve cover.
^ Clean and inspect the gaskets. Install a new gasket if necessary.
^ Clean and inspect the sealing surfaces.





14. Remove the RH high pressure oil rail-to-valve cover gasket.

Both cylinder heads





15. Remove the bolts and the high pressure oil rail.





16. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.

Using a 19 mm (0.74 inch) socket, push the fuel injector electrical connector out of the rocker arm carrier.





17. NOTE: If engine oil is found in the engine coolant or engine coolant is found in the combustion chambers, new injector sleeves may need to be installed.

Remove the bolt, the fuel injector hold down and the fuel injector.





18. Remove the crankcase-to-head tube assembly.
^ Remove and discard the O-ring seals.





19. Remove and discard the 20 inner cylinder head bolts.





20. Remove the 16 bolts and the rocker arm assemblies.





21. Remove the bolts and rocker arm carrier.
^ Clean and inspect the gasket. Install new gaskets if necessary.
^ Clean and inspect the sealing surfaces.





22. Mark the 16 valve bridges with a permanent marker and remove.





23. Mark and remove the 16 push rods.





24. Remove the outer cylinder head bolts.





25. Remove the cylinder heads.
1. Install the special tool.
2. Install the bolts.
^ Remove the cylinder head.





26. Remove and discard the cylinder head gasket and dowels.
^ Clean and inspect the gasket sealing surfaces.