Cylinder Head Replacement - Left
Cylinder Head Replacement - Left Side
Tools Required
- J 45059 Angle Meter
Removal Procedure
1. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement Service and Repair.
2. Remove the intake manifold. Refer to Intake Manifold Replacement - Left Side Service and Repair.
3. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side Service and Repair.
4. Remove the bolt and ground straps from the rear of the cylinder head.
5. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement Service and Repair.
6. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 2 Service and Repair.
7. Remove the cylinder head bolts in the sequence shown.
8. Discard the large M12 bolts.
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket.
11. Clean the sealing surface of the engine block and the cylinder head.
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.
12. Clean the cylinder head bolt holes in the engine block.
13. For service to the cylinder head refer to the following:
- Refer to Cylinder Head Disassemble Overhaul.
- Refer to Cylinder Head Cleaning and Inspection Overhaul.
- Refer to Cylinder Head Assemble Overhaul.
Installation Procedure
Notice: 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 Mechanical Specifications.
2. Install the cylinder head.
Notice: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
3. Install NEW M12 cylinder head bolts.
4. Reuse the M8 cylinder head bolts.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
5. Tighten the cylinder head bolts in the following steps using the sequence shown.
Tighten
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.
4. Tighten the M12 bolts a final pass to 60 degrees, using J 45059.
5. Tighten the M8 bolts to 25 Nm (18 lb ft).
6. Position the ground straps to the rear of the cylinder head, and install the bolt.
Tighten
Tighten the bolt to 34 Nm (25 lb ft).
7. Install the glow plugs. Refer to Glow Plug Replacement - Bank 2 Service and Repair.
8. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement Service and Repair.
9. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side Service and Repair.
10. Install the intake manifold. Refer to Intake Manifold Replacement - Left Side Service and Repair.
11. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement Service and Repair.
12. Road test the vehicle for normal operation.
13. Inspect for coolant, oil, or exhaust leaks.