Inspection

^ Drain the coolant and oil
^ Disconnect the radiator and heater hoses
^ Remove the turbocharger and sir crossover
^ Remove the exhaust manifold
^ Remove the fuel lines and injector nozzles
^ Remove the valve covers
^ Remove the rocker levers and push rod
^ Remove the fuel filter





If engine is hot, remove the cylinder head capscrews in the sequence shown. The removal sequence is not important if the engine is cold.





Remove the cylinder head and gasket from the cylinder block.

NOTE: Inspect the coolant passages. A large build up of rust and lime will require removal of the cylinder block for cleaning in a hot tank.





Inspect the cylinder bores for damage or excessive wear. Rotate the crankshaft so the piston is at BDC to inspect the bores.

Measure the cylinder bores.

Limit:
^ Maximum Diameter: 102.116 mm [4.0203 inch]
^ Out-of-Roundness: 0.038 mm [.0015 inch]
^ Taper: 0.076 mm [0.003 inch]

Refer to the limits for the oversize cylinder bores.

NOTE: Do not proceed with in-chassis repair if the bores are damaged or worn beyond the above limits.





Check the top surface for damage caused by the cylinder head gasket leaking between cylinders.

Check the top surface for flatness between each cylinder.

Top surface flatness (Maximum overall variation)

0.075 mm [0.003 inch] (Maximum variation within any 50.00 mm [2.0 inch] diameter area) 0.01 mm [0.0004 inch].

NOTE: Do not proceed with the in-chassis overhaul if the cylinder head surface is damaged or not flat.