Removal and Replacement

Cylinder Head





LH cylinder head









RH cylinder head









Removal

NOTICE: The cylinder heads must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

Both cylinder heads

1. Remove the cooling fan. For additional information, refer to Engine Cooling - Diesel Engine Cooling Fan.

2. NOTE: Engine shown removed for clarity.

Remove the 4 nuts and position the cooling fan stator forward.





3. Remove the accessory drive belt. For additional information, refer to Accessory Drive Service and Repair.

4. Remove the LH exhaust manifold or RH exhaust manifold. For additional information, refer to Exhaust Manifold - LH Exhaust Manifold - LH or Exhaust Manifold - RH Exhaust Manifold - RH.

5. Remove the LH rocker arms or RH rocker arms. For additional information, refer to Rocker Arm Removal and Replacement.

6. Remove the coolant crossover manifold assembly. For additional information, refer to Engine Cooling - Diesel Engine Service and Repair.

Left cylinder head

7. Disconnect the Charge Air Cooler (CAC) temperature sensor and wire retainer.





8. Loosen the clamp and remove the CAC tube.





9. Disconnect the power steering tube from the retainer.





10. NOTE: The third bolt is located behind the power steering tube.

Remove the 3 bolts and position the power steering pump aside.





11. Disconnect the lower engine wire harness retainer from the power steering bracket.





12. NOTE: Boot positioned back for clarity.

Disconnect the generator electrical connector, remove the nut and disconnect the B+ terminal.





13. If equipped, disconnect the turbocharger wastegate control vacuum and electrical connector.





14. NOTE: Engine shown removed for clarity.

Remove the 4 bolts and the power steering bracket.





15. Remove the bolt and position the ground strap aside. Disconnect the wire retainer.





16. NOTICE: The M12 cylinder head bolts must be discarded and new bolts installed. They are torque-to- yield design and cannot be reused.

Remove the 23 head bolts.

- Discard the 18 M12 cylinder head bolts.

17. NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

With the help of an assistant, remove the LH cylinder head.

Right cylinder head with dual generator

18. Remove the generator. For additional information, refer to Charging System Service and Repair.

Right cylinder head

19. Remove the bolt and accessory drive belt tensioner.





20. NOTE: The quick connect coupling illustrated is to show the spring clip in the released location only. The quick connect coupling on the hose may differ.

Disconnect the coolant hoses from the secondary coolant pump.

- Pull the coolant pump hose spring clip up until the end of the clip is in the detent on the quick connect coupling. Disconnect the coolant hose from the secondary coolant pump.





21. Remove the 4 bolts and the secondary coolant pump.





22. Disconnect the fuel volume control valve electrical connector and position the engine wiring harness aside.





23. NOTICE: The M12 cylinder head bolts must be discarded and new bolts installed. They are torque-to-yield design and cannot be reused.

Remove the 22 head bolts.

- Discard the 18 M12 cylinder head bolts.

24. NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

With the help of an assistant, remove the RH cylinder head.

Both cylinder heads

25. Remove and discard the cylinder head gasket(s).

26. Remove and discard the cylinder head dowels.

27. Check the cylinder head distortion. For additional information, refer to Cylinder Head Distortion Cylinder Head Distortion.

28. Check the cylinder block distortion. For additional information, refer to Cylinder Block Distortion Cylinder Block Distortion.

Installation

Both cylinder heads

1. Install the new cylinder head dowels.

2. Install the cylinder head gasket(s).

Right cylinder head

3. With the help of an assistant, install the RH cylinder head.

4. NOTICE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads may affect the true torque value of the bolts.

NOTE: Lightly lubricate the new 12 mm cylinder head bolt threads and flanges with clean engine oil.

Install the 22 cylinder head bolts.

- Tighten finger-tight.

5. Tighten the cylinder head bolts in 8 stages, in the sequence shown.
- Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).

- Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).

- Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).

- Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).

- Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.

- Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.

- Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.

- Stage 8: Tighten bolts 19 through 22 to 30 Nm (22 lb-ft).





6. Position back the engine wiring harness and connect the fuel volume control valve electrical connector.





7. Install the secondary coolant pump and 4 bolts.
- Tighten to 25 Nm (18 lb-ft).





8. NOTE: The quick connect coupling illustrated is to show the spring clip in the released location only. The quick connect coupling on the hose may differ.

Connect the coolant hoses to the secondary coolant pump.

- Make sure the spring clip is in place and the coolant hose quick connect coupling is secure.





9. Install the accessory drive belt tensioner and bolt.
- Tighten to 48 Nm (35 lb-ft).





Right cylinder head with dual generator

10. Install the generator. For additional information, refer to Charging System Service and Repair.

Left cylinder head

11. With the help of an assistant, install the LH cylinder head.

12. NOTICE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads may affect the true torque value of the bolts.

NOTE: Lightly lubricate the new M12 cylinder head bolt threads and flanges with clean engine oil.

Install the 23 cylinder head bolts.

- Tighten finger-tight.

13. Tighten the cylinder head bolts in 8 stages, in the sequence shown.
- Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).

- Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).

- Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).

- Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).

- Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.

- Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.

- Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.

- Stage 8: Tighten bolts 19 through 23 to 30 Nm (22 lb-ft).





14. Position back the ground strap and install the bolt. Connect the wire retainer.
- Tighten to 10 Nm (98 lb-in).





15. NOTE: Engine shown removed for clarity.

Install the power steering bracket and 4 bolts.

- Tighten to 24 Nm (18 lb-ft).





16. If equipped, connect the turbocharger wastegate control vacuum and electrical connector.





17. NOTE: Boot positioned back for clarity.

Connect the generator electrical connector, the generator B+ terminal and install the nut.

- Tighten to 17 Nm (150 lb-in).





18. Connect the lower engine wire harness retainer to the power steering bracket.





19. NOTE: The third bolt is located behind the power steering tube.

Position back the power steering pump and install the 3 bolts.

- Tighten to 24 Nm (18 lb-ft).





20. Position the power steering tube into the retainer.





21. Install the CAC tube and the clamp.
- Tighten to 9 Nm (80 lb-in).





22. Connect the CAC temperature sensor and wire retainer.





Both cylinder heads

23. Install the coolant crossover manifold assembly. For additional information, refer to Engine Cooling - Diesel Engine Service and Repair.

24. Install the LH rocker arms or RH rocker arms. For additional information, refer to Rocker Arm Removal and Replacement.

25. Install the LH exhaust manifold or RH exhaust manifold. For additional information, refer to Exhaust Manifold - LH Exhaust Manifold - LH or Exhaust Manifold - RH Exhaust Manifold - RH.

26. Install the accessory drive belt. For additional information, refer to Accessory Drive Service and Repair.

27. NOTE: Engine shown removed for clarity.

Position the cooling fan stator and install the 4 nuts.

- Tighten to 17 Nm (150 lb-in).





28. Install the cooling fan. For additional information, refer to Engine Cooling - Diesel Engine Cooling Fan