Cylinder Head Replacement - Left Side

Cylinder Head Replacement - Left Side

Special Tools

J-45059 - Angle Meter

For equivalent regional tools, refer to Special Tools Special Tools.

Removal Procedure

1. Remove the engine assembly. Refer to Engine Replacement Removal and Replacement.

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

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

4. Remove the exhaust pipe. Refer to Exhaust Pipe Removal - Left Side Exhaust Pipe Removal - Left Side.

5. Remove the exhaust manifold. Refer to Exhaust Manifold Removal - Left Side Exhaust Manifold Removal - Left Side.




6. Remove the engine wiring harness nut(s) from the glow plug(s).

7. Remove the engine wiring harness lead(s) from the glow plug(s).




8. Remove the left lower valve rocker arm cover and cover bolts. Refer to Valve Rocker Arm Lower Cover Replacement - Left Side Valve Rocker Arm Lower Cover Replacement - Left Side.

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

10. Remove and discard the valve rocker arm cover gasket, valve rocker arm cover grommets and valve rocker arm cover bolts if they are serviced with the grommet.




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

12. Discard the large M12 bolts.




13. Remove the cylinder head and discard the cylinder head gasket.

14. 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.

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

16. 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

* 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.

Note: The stamped letter, R or L, must face up. R is the right bank, L is the left bank.

1. The markings on the gasket are as follows:

* Grade A (1)

* Grade B (2)

* Grade C (3)

* Block over-bored 0.010-0.030 in (0.254-0.762 mm) (4)

* Block over-bored 0.010-0.030 in (0.254-0.762 mm) and deck milled 0.008 in (0.203 mm) (5)

2. Install the left cylinder head gasket of the correct grade. The left and right cylinder head gaskets are not interchangeable. Refer to Cylinder Head Gasket Selection Cylinder Head Gasket Selection.




3. Install the cylinder head.





Caution: Refer to Fastener Caution Fastener Caution.

4. Install NEW M12 cylinder head bolts.

5. Tighten the M12 cylinder head bolts in four steps:

1. 1st step 50 Nm (37 lb ft).

2. 2nd step 80 Nm (59 lb ft).

3. 3rd step tighten 60 degrees using J-45059 - meter.

4. Final step tighten 60 degrees using J-45059 - meter

6. Reuse the M8 bolts. Install the M8 bolts and tighten the M8 cylinder head bolts to 25 Nm (18 lb ft).




7. Install the glow plug(s) to the cylinder head and tighten to 18 Nm (13 lb ft).

8. Install the engine wiring harness lead(s) to the glow plug(s).

9. Install the engine wiring harness nut(s) to the glow plug(s) and tighten to 1.7 Nm (15 lb in).

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




11. Install the left lower valve rocker arm cover and cover bolts. Refer to Valve Rocker Arm Lower Cover Replacement - Left Side Valve Rocker Arm Lower Cover Replacement - Left Side.

12. Install the exhaust manifold. Refer to Exhaust Manifold Installation - Left Side Exhaust Manifold Installation - Left Side.

13. Install the exhaust pipe. Refer to Valve Rocker Arm Lower Cover Replacement - Left Side Valve Rocker Arm Lower Cover Replacement - Left Side.

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

15. Install the engine assembly. Refer to Engine Replacement Removal and Replacement.

16. Road test the vehicle for normal operation.