Removal and Installation

Cylinder Head

These cylinder heads can only be used on engines with an intercooler. DO NOT interchange with earlier models.

Removal

1. Drain the coolant. Do not waster reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
2. Drain the engine oil. Dispose of the used oil properly.
3. Disconnect the radiator and heater hoses.
4. Remove the turbocharger.






5. Remove the exhaust manifold.
6. Remove the fuel lines and injector nozzles.






7. Remove the valve covers.
8. Remove the rocker levers and push rods.






9. Remove the fuel/water separator.






10. If the engine is hot, remove the cylinder head bolts in sequence. The removal sequence is not important if the engine is cold. There are 3 sizes of head bolts. Note the position of each bolt for future installation.
11. Remove the cylinder head and gasket from the cylinder block.

Installation

1. The cylinder block and head must be clean and dry.






2. Position the gasket onto the dowels. Make sure the gasket is correctly aligned with the holes in the cylinder block.
3. Carefully put the cylinder head onto the gasket and cylinder block. Make sure the cylinder head is installed onto the dowels in the cylinder block.
4. Install the push rods and rocker levers.
5. Use clean engine oil to lubricate the cylinder head bolt threads and under the bolt heads.
6. The cylinder head bolts are 3 different sizes. Install the bolts in the proper hole. Tighten the bolts as follows:






- Step 1 - Tighten all bolts, in sequence to 90 Nm (66 ft. lbs.), torque. Check the torque. If lower than 90 Nm (66 ft. lbs.), tighten to this torque.
- Step 2 - Tighten all 12 mm bolts, in sequence to 120 Nm (89 ft. lbs.) torque. Check the torque. If lower than 120 Nm (89 ft. lbs.), tighten to this torque.
- Step 3 - Tighten all bolts, in sequence, an additional 90°.
7. Be sure to lubricate the push rod sockets with clean engine oil.
8. Install the rocker lever pedestal bolts and tighten to 24 Nm (18 ft. lbs.) torque.
9. Adjust the valve clearance.
10. Install the valve covers. Tighten the bolts to 24 Nm (18 ft. lbs.) torque.
11. Install the injector nozzles and fuel lines.
12. Install the fuel filter.
13. Install the exhaust manifold.
14. Install the turbocharger.
15. Connect the radiator and heater hoses.
16. Fill the engine with new coolant or the clean drained coolant.
17. Fill the engine with clean lubricating oil.