Cylinder Head
REMOVAL - CYLINDER HEAD1. Disconnect negative battery cable.
2. Position piston of cylinder #1 to ignition TDC.
3. Raise and support vehicle.
4. Install retaining lock # 8932 for crankshaft/ starter ring gear.
WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN APPROVED CONTAINER ONLY. WEAR PROTECTIVE GLOVES, CLOTHING AND EYE WEAR.
5. Drain cooling system at radiator and crankcase.
6. Lower vehicle.
7. Remove engine cover.
8. Remove camshafts.
9. Remove tappets (Fig. 13).
10. Remove the camshaft housing at the cylinder head (Fig. 13).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK OF INJURY FROM SKIN AND EYE CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING WHEN HANDLING FUEL.
11. Remove the high pressure fuel pump intermediate gear (Fig. 13).
12. Disconnect the engine side of the engine harness and set aside.
13. Disconnect the charge air pipe at the cylinder head and set aside with the engine harness connected.
14. Disconnect the turbocharger oil supply line at the cylinder head and turbocharger (Fig. 13).
15. Disconnect the turbocharger at the exhaust manifold (Fig. 13).
16. Unbolt the transmission dipstick tube from the cylinder head (Fig. 13).
17. Disconnect the upper radiator hose and by pass hose at the thermostat housing (Fig. 13).
NOTE: Capture any fuel spillage when disconnecting fuel lines.
18. Disconnect the fuel line at the rear of the fuel rail (Fig. 13).
19. Remove upper timing case to cylinder head bolts (Fig. 14).
NOTE: Loosen cylinder head bolts in the reverse order of the tightening sequence.
20. Remove cylinder head bolts and inspect.
21. Remove cylinder head (Fig. 14).
NOTE: Carefully clean all mating surfaces and bolt thread holes. Assure that no oil or grease is present during reassembly.
22. Clean all mating surfaces and blow out bolt thread holes
INSTALLATION - CYLINDER HEAD
WARNING: Refer to Fuel System Warning.
NOTE: Thoroughly clean all mating surfaces with appropriate solvents and blow out bolt holes, to assure that no grease or oil is present during reassembly.
NOTE: If piston or connecting rods have been replaced, measure piston protrusion.
NOTE: Check facing cylinder head contact surface.
1. Position the cylinder head and gasket properly on engine using the dowel pins as guide (Fig. 14).
NOTE: Inspect all cylinder head bolts for defects and stretching before installation.
CYLINDER HEAD BOLT TORQUE SEQUENCE
The M12 cylinder head bolts must be torqued in 3 stages.
1. Install M12 cylinder head bolts finger tight (Fig. 14).
2. Torque bolts in numeric order starting with number 1 to 60 Nm (44 inch lbs.) (Fig. 16).
3. Install M8 timing chain cover to cylinder head bolts. Tighten to 20 Nm (177 inch lbs.).
4. Tighten M12 cylinder head bolts in numeric order starting with number 1 an additional 90° (Fig. 16).
5. Tighten M12 cylinder head bolts in numeric order starting with number 1 an additional 90° again (3 stages). (Fig. 16).
2. Install fuel return flow line between rail and high pressure pump (Fig. 13).
3. Connect the coolant hoses to the thermostat housing (Fig. 13).
4. Connect the coolant pipe at the cylinder head (Fig. 13).
5. Reconnect transmission oil dip stick tube. Tighten to 14 Nm (124 inch lbs.) (Fig. 13).
6. Reconnect the turbocharger to the exhaust manifold. Tighten to 30 Nm (22 ft. lbs.) (Fig. 13).
7. Install oil return flow line with new seals at turbocharger. Tighten bolt of supply line to turbocharger to 18Nm (160 inch lbs.) and bolt of supply line to cylinder head to 9 Nm (80 inch lbs.) (Fig. 13)
8. Install charge air distribution pipe.
9. Install and properly route the engine wiring harness, making appropriate connections.
10. Install high pressure fuel pump intermediate gear (Fig. 13).
11. Install high pressure pump.
12. Install the camshaft housing to cylinder head (Fig. 13).
13. Install the tappets (Fig. 13).
14. Install camshafts.
15. Install top guide rail.
16. Install front cover at cylinder head.
17. Install cylinder head cover.
18. Install fuel high pressure pipes and injectors.
19. Install timing chain tensioner with new gasket. Tighten to 80 Nm (59 ft. lbs.).
20. Remove retaining lock for crankshaft/starter ring gear.
21. Install air intake tube at turbocharger.
22. Install engine cover.
NOTE: DO NOT pressure test cooling system until engine has reached operating temperature.
23. Refill cooling system with proper coolant mixture to proper level.
24. Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.
25. Start engine and inspect for leaks. Care must be taken to observe the fuel system warning