Cylinder Head Cover(s)

CYLINDER HEAD COVER(S)

REMOVAL
1. Disconnect negative battery cable.
2. Disconnect the air inlet and set aside.
3. Detach hose from oil separator.
4. Disconnect the camshaft position sensor.
5. Disconnect fuel injector and glow plug harness and set aside.
6. Remove fuel high pressure pipes and injectors.
7. Disconnect the out let line.





8. Remove cylinder head cover retaining bolts and remove cover (Fig. 21).

INSTALLATION

NOTE: Do Not tighten the cylinder head cover first. The fuel injectors are aligned by way of the cylinder head cover.

1. Fit cylinder head cover with new gasket and install bolts (Fig. 21).
2. Insert all fuel injectors and tensioning claws. Insert new bolts and tighten in the following order: 3, 4, 5, 2, 1.
3. Tighten cylinder head cover bolts to 9 Nm (80 inch lbs.).
4. Install and properly route fuel injector and glow plug wiring harness, making appropriate connections.
5. Connect the camshaft position sensor.
6. Connect the return flow line.
7. Attach oil separator hose.
8. Install the fuel injector lines.
9. Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

10. Start engine and inspect for leaks. Care must be take to observe the fuel system warning.