Cylinder Head-RH
Cylinder Head-RH
Special Tool(s):
Special Tool(s)
Material:
Material
Removal
All Vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the engine oil.
3. Remove the intake manifold. Intake Manifold
4. Remove the evaporator core housing. Evaporator Core
5. NOTE: Only one retainer shown.
Disconnect the wiring retainers from the studs.
6. Remove the injection control pressure (ICP) sensor.
7. If equipped, remove the nut and position the transmission fluid and indicator aside.
8. NOTE: Mark the position of the valve cover bolts for the valve cover bolt installation.
Remove the bolts and the valve cover.
- Clean and inspect the valve cover gasket. Install a new gasket if necessary.
9. Remove the high-pressure oil manifold-to-valve cover gasket.
Late Build Vehicle
10. Remove the crankcase-to-head tube.
All Vehicles
11. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
Remove the bolts and the high-pressure oil rail.
Early Build Vehicles
12. NOTE: The rings on the crankcase-to-head tube must be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.
Remove the crankcase-to-head tube.
Late Build Vehicles
13. NOTE: Use a shop towel and brake parts cleaner to remove the oil residue prior to removing.
If the crankcase-to-head tube separated, using the special tool, remove the lower crankcase-to-head tube.
All Vehicles
14. NOTE: LH shown, RH similar.
Inspect the D-ring seals for damage (nicks, cuts and gouges). If damaged, replace the crankcase to-head tube.
15. 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.
16. Prior to removing the fuel injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
17. CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back into service can cause engine damage. A missing snap ring can be ingested into the lube oil system and cause severe engine damage.
CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
NOTE: There is no need to drain the fuel rail.
NOTE: If engine oil is found in the engine coolant or engine coolant is found in the combustion chambers, new fuel injector sleeve may need to be installed.
NOTE: The bolt is part of the fuel injection hold-down assembly.
Loosen the bolt and remove the bolt and fuel injector hold-down assembly and fuel injector.
18. 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.
19. Remove the starter. Starting System
20. Remove the cylinder drain block.
21. NOTE: LH shown, RH similar.
Remove the nuts and bolts from the turbocharger adapter pipe.
22. Remove the turbocharger adapter pipe.
Late Build Vehicles
23. Position the turbocharger adapter pipe to gain access to the adapter pipe joint. Remove the bolts, separate the adapter pipe joint and remove the gasket. Remove the 2 parts of the turbocharger adapter pipe
All Vehicles
24. 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. Position the wiring harness aside.
25. Remove the four glow plugs.
26. Remove and discard the 10 inner cylinder head bolts.
27. Remove the eight bolts and the rocker arm assemblies.
28. Mark the eight valve bridges with a permanent marker and remove.
29. 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 eight push rods.
30. Remove the outer cylinder head bolts.
31. Install the special tool and the lifting crane. With the help of an assistant, remove the cylinder head from the vehicle.
32. Check for cylinder head distortion. Service and Repair
33. Remove and discard the cylinder head gasket and dowels.
- Clean and inspect the gasket sealing surfaces.
34. Check for cylinder block distortion, Service and Repair
Installation
1. CAUTION: Install new O-ring seals on the crankcase-to-head tube. It requires several hours after installation for the O-ring seals to relax back to their original size. If the tube assembly is installed before the O-ring seals have relaxed, damage to the O-ring seals can occur.
2. NOTE: Use care to avoid scratching the blue compound on the cylinder head gasket. Install a new cylinder head gasket with the part number facing up and verify the top five holes and the head gasket push rod holes line up.
Install the dowels and the cylinder head gasket.
3. Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.
4. Install the outer cylinder head bolts finger-tight.
5. NOTE: Coat the end of each valve stem with clean engine oil.
6. 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.
NOTE: Higher mileage engines require push rods to be cleaned so the copper colored end of the push rod can be identified.
Apply clean engine oil to each end of the push rod. Insert them into their respective positions with the copper-colored end up.
Install the eight valve bridges.
7. CAUTION: Rotate the crankshaft until the damper locating dowel notch is in the six o'clock position or engine damage can occur.
NOTE: Apply clean engine oil to the top center of each valve bridge.
Install the rocker arm assemblies and eight bolts.
8. CAUTION: Using too much engine oil on the threads of the cylinder head bolts can 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 can affect the true torque value of the bolts.
NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
Install the 10 inner cylinder head retaining bolts finger-tight.
1 Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
2 Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
3 Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
4 Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees.
5 Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees.
6 Tighten bolts 11 through 15 to 24 Nm (18 lb-ft).
7 Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
10. Install the four glow plugs.
11. NOTE: Clean and apply clean engine oil to the O-ring seals.
Using the special tool, install the glow plug harness.
Early Build Vehicles
12. Position the turbocharger adapter pipe.
Late Build Vehicles
Position the turbocharger adapter pipe to gain access to the adapter pipe joint. Remove the bolts, separate the adapter pipe joint and remove the gasket. Remove the 2 parts of the turbocharger adapter pipe
All Vehicles
13. NOTE: Apply anti-seize lubricants to the bolt threads prior to installing the bolts.
NOTE: Do not tighten until after the turbocharger is installed.
Install the nuts and bolts in the adapter pipe.
14. NOTE: Apply clean engine oil to the O-ring seal prior to installing.
Install the cylinder block drain plug.
15. Install the starter. Starting System
16. CAUTION: If the fuel injector oil inlet D-shaped O-ring seal is damaged, a new fuel injector must be installed.
Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
NOTICE: Failure to tighten the injectors properly can lead to engine failure.
17. CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
Assemble the fuel injector hold-down and bolt on the injector and install the assembly.
18. CAUTION: Be sure the injector wiring is clear of all moving parts or engine damage can occur.
Install the fuel injector electrical connector into the rocker arm carrier.
19. Apply engine oil to the top fuel injector O-ring seals
Early Build Vehicles
20. CAUTION: To prevent engine damage, cheek that the crankcase-to-head tube assembly bottoms out in the branch tube assembly. The oil rail, crankcase-to-head tube and fuel injectors will not function correctly if the tubes are not bottomed out.
Apply clean engine oil on the crankcase-to-head tube O-ring seals and install the tube.
All Vehicles
21. NOTE: Apply clean engine oil on the tubes prior to installing the high-pressure oil rail.
Position the oil rail on the fuel injectors.
- Place the oil rail on top of the carrier so that the four single ball tubes are engaging the injector lead angle.
- Insert three bolts, two on the ends of the straight side of the oil rail and one in the middle of the wavy side of the rail. Install the guide studs six to seven turns.
- Press the oil rail into the fuel injectors. Make sure that the oil rail mounting feet are flat against the mounting surface.
- Loosely install the six bolts.
22. Install the oil rail retaining bolts.
- Remove the three guide bolts.
- Loosely install the three remaining bolts.
- Tighten the bolts in the sequence shown.
23. Install the high-pressure oil manifold-to-valve cover gasket.
24. CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
Position the valve cover gasket. Install the valve cover and 11 bolts.
25. If equipped, position back the transmission fluid indicator and tube. Install the retaining nut.
26. Install the ICP sensor.
27. NOTE: Only one retainer shown.
Connect the wiring retainers to the studs.
28. Install the evaporator core housing. Service and Repair
29. Install the intake manifold. Service and Repair
30. NOTE: Install a new oil filter.
Fill the crankcase with clean engine oil.