Cylinder Head Replacement - Left Side

Cylinder Head Replacement - Left Side

Special Tools

J 45059 - Angle Meter

Removal Procedure




1. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LGH) Thermostat Housing Crossover Replacement.

2. Remove the intake manifold. Refer to Intake Manifold Replacement - Left Side Intake Manifold Replacement - Left Side.

3. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (V6) Exhaust Manifold Replacement - Left Side (V6)Exhaust Manifold Replacement - Left Side (V8) Exhaust Manifold Replacement - Left Side (V8)Exhaust Manifold Replacement - Left Side (Diesel) Exhaust Manifold Replacement - Left Side (Diesel).

4. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement Service and Repair.

5. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 2 Glow Plug Replacement - Bank 2.

6. Remove the cylinder head bolts in the sequence shown.

7. Discard the large M12 bolts.




8. Remove the cylinder head.

9. Remove and discard the cylinder head gasket.

10. Clean the sealing surface of the engine block and the cylinder head.

Caution:
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.

11. Clean the cylinder head bolt holes in the engine block.

12. For service to the cylinder head refer to the following:

* Cylinder Head Disassemble Cylinder Head Disassemble

* Cylinder Head Cleaning and Inspection Cylinder Head Cleaning and Inspection

1. Place clean rags in the cylinder bores and push rod openings in order to keep out debris.

2. Use the J-28410 or equivalent to carefully clean the gasket sealing surface of large sealing or corrosion matter. When scraping, take care not to scratch or gouge the metal surfaces. Do not push the debris into oil, coolant, and combustion openings or bolt holes.

3. Inspect the gasket sealing surfaces for corrosion, especially in the areas that were in contact with the crimped tabs of the first generation head gasket. If corrosion is present, continue with the rest of the steps in this procedure for proper cleaning. If the sealing surface is sufficiently clean and smooth, then torque to specification.

4. For surfaces that have corrosion or pitting, wrap a piece of flat steel (4"x 2" or larger) with 600 grit wet grade sand paper. Using Moisture Displacing Lubricant, P/N 88862629 (in Canada, use 89020803) or equivalent, wet sand the block surface to remove any remaining gasket material or corrosion. Do not use any paper coarser than 600 grit.

Note: Do not use any power type sanding devices. Do not use a wire brush or wheel to clean gasket surfaces. Do not use chemical cleaning agents on gasket surfaces.

5. Take care to keep the sanding block parallel to the block surface and evenly sand the sealing surface. Some areas of corrosion will still show a stain. Do not attempt to wet sand these areas down to a shiny metal surface.

6. Change the sanding paper when it becomes clogged. Carefully and frequently wipe the surface, using a clean cloth each time, to prevent sanding debris from building up and contaminating the oil and coolant cavities.

7. Clean the bolt threads and holes and remove the rags from the bore cavities and pushrod openings.

8. Repeat the above cleaning procedure on the cylinder head gasket surface.

9. Clean the engine block and cylinder head gasket surfaces with Brake Parts Cleaner, P/N 88862650 (in Canada, use 88901247) or equivalent, to remove any traces of oil or debris.

* Cylinder Head Assemble Cylinder Head Assemble

Installation Procedure





Caution:
The left and right cylinder head gaskets are not interchangeable. Improper placement of the cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.

1. Install the cylinder head gasket of the correct grade. Refer to Cylinder Head Gasket Selection Specifications Cylinder Head Gasket Selection Specifications.

2. Install the cylinder head.




3. Install NEW M12 cylinder head bolts.

4. Reuse the M8 cylinder head bolts.

Caution: Refer to Fastener Caution Fastener Caution.

5. Tighten the cylinder head bolts in the following steps using the sequence shown.

1. Tighten the M12 bolts a first pass to 50 Nm (37 lb ft).

2. Tighten the M12 bolts a second pass to 80 Nm (59 lb ft).

3. Tighten the M12 bolts a third pass to 60 degrees, using J 45059 - angle meter.

4. Tighten the M12 bolts a final pass to 60 degrees, using J 45059 - angle meter.

5. Tighten the M8 bolts to 25 Nm (18 lb ft).

6. Install the glow plugs. Refer to Glow Plug Replacement - Bank 2 Glow Plug Replacement - Bank 2.

7. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement Service and Repair.

8. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (V6) Exhaust Manifold Replacement - Left Side (V6)Exhaust Manifold Replacement - Left Side (V8) Exhaust Manifold Replacement - Left Side (V8)Exhaust Manifold Replacement - Left Side (Diesel) Exhaust Manifold Replacement - Left Side (Diesel).

9. Install the intake manifold. Refer to Intake Manifold Replacement - Left Side Intake Manifold Replacement - Left Side.

10. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LGH) Thermostat Housing Crossover Replacement.

11. Road test the vehicle for normal operation.

12. Inspect for coolant, oil, or exhaust leaks.