Left Cylinder Head

LEFT





1. Disconnect negative battery cable.
2. Remove engine cover (3) and brackets.




3. Remove the strut tower support (2).
4. Remove the air cleaner outlet tube (1).
5. Remove the charge air inlet tube (4).
6. Drain cooling system.
7. Disconnect the vacuum hose at the vacuum pump and set aside.
8. Remove upper radiator hose.
9. Disconnect the coolant reservoir hose at thermostat housing and set aside.




10. Disconnect the fuel supply and return hose quick connects at the left cylinder head cover.
11. Loosen the high pressure fuel pipes at the fuel rail (2) and disconnect the high pressure fuel pipes at the left injectors.
12. Disconnect the high pressure fuel line at the high pressure pump.
13. Disconnect the fuel rail solenoid (3) wiring harness connector and remove the left fuel rail (2) along with the fuel rail transfer pipe (1).
14. Remove the low pressure fuel supply and return pipe bundle (4) fasteners.




15. Disconnect the right fuel rail pressure sensor and remove the fuel rail.
16. Disconnect the camshaft position sensor (CMP) (6), the right fuel injector wiring harness connectors, the right return fuel hoses from the injectors.
17. Remove the return fuel bundle fasteners (5).
18. Disconnect the water in fuel sensor (3) (if equipped) and the turbocharger servo motor (2) harness connectors.
19. Remove the fuel filter (4) bracket fasteners.
20. Disconnect the fuel return hose bundle (5), engine ground strap, at the right front of the intake manifold.




NOTE: Fuel filter assembly, hoses and lines may seep fuel. Capture any fuel spillage and store in appropriately marked containers.

21. Remove the fuel filter (2), hose (1) and pipe (3) assemblies and position aside.




22. Remove the turbochargerTurbocharger - Removal.

NOTE: Observe the way the engine oil supply and return ports in the turbocharger adaptor housing align to the engine block for oil flow through the turbocharger. Failure to do so will result in immediate turbocharger failure.

23. Remove turbocharger oil housing adaptor (1).
24. Disconnect the swirl valve actuator (3), glow plugs, EGR pressure sensor and coolant temperature sensor (4) wiring harness connector.
25. Remove the main engine wiring harness (2) fasteners and position the harness aside.




26. Disconnect the EGR coolant pipe (1) from the rear of the EGR housing.
27. Remove the EGR valve.

NOTE: The intake manifold is of the split design meaning that there are two halves. Whenever the intake manifold is removed, inspect the shared coolant passage (3) in the front of the intake manifold for leaks, repair as necessary.

28. Remove the intake manifold.




29. Remove the accessory drive belt.
30. Remove the two idler pulleys (1).
31. Remove the belt tensioner (2).




32. Rotate the engine by the vibration damper bolt, to TDC.
33. Raise and support the vehicle.
34. Remove right side starter blank.
35. Disconnect the hydraulic cooling fan lines and capture the fluid in a approved and clearly marked container.




36. Remove the front oil pan retaining bolts (2).
37. Lower the vehicle.




38. Remove the left rear heater hose retainer.
39. Remove the left fuel injectors (1).
40. Disconnect the vacuum supply hose.
41. Remove the oil filter housing bracket.

CAUTION: The timing cover is sealed with Mopar(R) sealant that may be difficult when separating components. If the component are difficult to separate heat the sealed edges or area with a heat gun. DO NOT use any heat source that works with flame.

42. Remove the left cylinder head cover.




43. Observe the left camshaft gear alignment marks (2) on the rear of the camshaft gears (1,3). If they are together, continue with the next step. If the left camshaft alignment marks (2) are separated, rotate the engine by the vibration damper another 360 degrees, until camshaft marks (2) align together and the vibration damper reaches TDC.




44. Raise and support the vehicle.
45. Install special tool #9102 crankshaft lock into the starter access blank.
46. Lower the vehicle.




47. Remove the cooling fan module.
48. Remove the vibration damper.

CAUTION: The timing cover is sealed with Mopar(R) sealant that may be difficult when separating components. If the component are difficult to separate heat the sealed edges or area with a heat gun. DO NOT use any heat source that works with flame.

49. Remove front timing chain cover.




50. Paint mark or scribe the balance shaft (2) position to the engine block (1) and timing chain.
51. Paint mark or scribe the timing chain to crankshaft gear and camshaft drive gear relation.
52. Raise and support the vehicle.
53. Remove special tool #9102 crankshaft locking tool.
54. Lower the vehicle.




55. Remove the high pressure fuel pump (4)Removal
56. Rotate the engine and remove the left camshaft drive gear (3) lower bolt.

NOTE: The left exhaust camshaft drive gear (3) dowel pin should align at approximately the 12 O'clock position when viewing through the camshaft seal access hole.

57. Rotate the engine back to TDC and check the alignment marks at the balance shaft, camshaft gear and crankshaft gear.




58. Remove the timing chain tensioner (3).




59. Remove the remaining left camshaft drive gear (3) retaining bolts.
60. Separate the left camshaft drive gear (3) and chain from camshaft.




NOTE: Followers and tappets assemblies must be installed in same location as removed.

61. Remove the left camshaft retainers (1 and 2) and camshafts.
62. Remove the left camshaft drive gear.




63. Make a roll pin tool by using a tube, nut, bolt and washer. Place the nut on the bolt and the bolt through the tube. Thread the bolt into the roll pin and turn the nut to remove the roll pin (as illustrated).




64. Remove the left lower timing chain guide fastener (2) and guide (1).

NOTE: Do Not store the cylinder head on the sealing surface. The glow plugs protrude into the cylinder surface area and may be damaged.

65. Remove the left cylinder head glow plugs.
66. Remove cylinder head and gasket from engine block.