Cylinder Head Replacement - Right
Cylinder Head Replacement - Right^ Tools Required
- J 36660-A Torque/Angle Meter
Removal Procedure
1. Disconnect the negative battery cables.
2. Drain the cooling system.
3. Remove the engine cover from the vehicle.
4. Remove the air cleaner from the vehicle.
5. Remove the air intake duct from the turbocharger.
6. Remove the transmission oil level indicator and tube from the upper intake manifold.
7. Remove the heater hoses from the engine.
8. Remove the generator mounting bracket.
9. Remove the thermostat housing crossover from the cylinder heads.
10. Remove the turbocharger from the engine block.
11. Remove the right side lower intake manifold from the cylinder head.
12. Remove the glow plugs from the cylinder head.
13. Remove the fuel injection nozzles from the cylinder head.
14. Remove the front lower cylinder head bolt (5) and drain the coolant from the engine block.
14.1. Insert a cooper tube (3/8 in x 12 in to 18 inch) and a hose into bolt hole (5)
14.2. Siphon coolant from the engine block
15. Remove the valve rocker arms, shafts, and the push rods from the cylinder heads.
16. Remove the exhaust manifold from the cylinder head.
17. Remove the cooper tube used as a siphon from the cylinder head.
18. Remove the remaining cylinder head bolts from the cylinder head in sequence.
19. Remove the cylinder head from the engine block.
20. Remove the cylinder head gasket from the engine block.
Notice: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
21. Clean the cylinder block surface and cylinder head bolt holes.
22. For cleaning and inspection procedures refer to the following:
^ Engine Block Cleaning and Inspection
^ Cylinder Head Disassemble
^ Cylinder Head Cleaning and Inspection
^ Valve Guide Reaming/Valve and Seat Grinding
^ Cylinder Head Assemble
Installation Procedure
Important:
^ Make sure that the block gasket surfaces are clean.
^ The head gasket material is soft. Handle the gasket with care. Make sure the gasket surface is not creased or dented.
^ Do not use a sealer on the head gasket. The head gasket is made with sealant on the gasket surface. Additional sealer may cause leakage or malfunction. In addition, some sealers may attack the initial sealant on the gasket.
1. Install the right cylinder head gasket to the block, over the cylinder head dowel pins.
2. Install the right cylinder head to the block, over the cylinder head gasket and the cylinder head dowel pins.
3. Apply the thread sealant GM P/N 12345382, or equivalent, to the bolt threads and under the bolt heads.
4. Install the cylinder head bolts.
Notice: Refer to Fastener Notice in Service Precautions.
5. Tighten the cylinder head bolts in sequence in four passes.
5.1. Tighten the bolts to 25 Nm (20 ft. lbs.).
5.2. Tighten the bolts to 75 Nm (55 ft. lbs.).
5.3. Retighten the bolts to 75 Nm (55 ft. lbs.).
5.4. Using the J 36660-A, tighten all of the cylinder head bolts in sequence (1-17) an additional 90° - 100° (1/4 plus turn).
6. Install the glow plugs to the cylinder head.
7. Install the fuel injection nozzles to the cylinder head.
8. Install the exhaust manifold to the cylinder head.
9. Install the valve rocker arms, shafts, and the push rods to the cylinder head.
10. Install the generator mounting bracket.
11. Install the heater hoses to the engine.
12. Install the right side lower intake manifold to the cylinder head.
13. Install the turbocharger to the engine block.
14. Install the thermostat housing coolant crossover to the cylinder heads.
15. Install the transmission indicator and tube to the engine block.
16. Install the air intake duct to the turbocharger.
17. Install the air cleaner assembly in the vehicle.
18. Refill the cooling system.
19. Connect the battery negative cables to the batteries.
20. Install the engine cover in the vehicle.