Removal

2005

Cylinder Heads





Special Tool(s)

Material:

Material

Removal

Both cylinder heads
1. Remove the engine.





2. Remove the bolts and flexplate.
^ Discard the bolts.
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.

Using the special tool, 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 specification.





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. NOTE: Do not remove the oil rail end plugs or acoustic wave alternator port fitting. Service parts are not available to support the components.

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 the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
17. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.





18. CAUTION: To prevent engine damage, do not use air tools when removing and installing the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall off.

CAUTION: 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: 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.

19. NOTE: If a snap ring or 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.





20. NOTE: The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.

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





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





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





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





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





25. CAUTION: 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 the location and remove the 16 push rods.





26. Remove the outer cylinder head bolts.





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





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