Cylinder Head Assembly: Service and Repair

Fig. 9 Precombustion Chamber Inspection:

Fig. 10 Cylinder Head Tightening Sequence:

Fig. 6 Manifold Assemblies:

Fig. 7 Intake Manifold Tightening Assembly:

1. On E-Series models, remove engine cover.
2. On all models, disconnect battery ground cables, then drain cooling system.
3. Remove fan shroud halves, then the fan and clutch assembly. The fan retaining nut has lefthand threads.
4. Disconnect fuel supply line heater and alternator electrical connectors from alternator.
5. Remove alternator and vacuum pump.
6. On F-Series models, disconnect and plug fuel lines from fuel filter.
7. On all models, remove alternator and vacuum pump mounting bracket, and on F-Series models, the fuel filter and bracket as an assembly.
8. Remove heater hose from cylinder head.
9. Remove injector pump.
10. Remove intake manifold.
11. Raise and support vehicle.
12. Disconnect exhaust pipe from exhaust manifold.
13. Remove transmission filler tube attaching bolt, then lower vehicle and remove engine oil dipstick and tube.
14. Remove valve cover, rocker arms and pushrods.
15. Remove injection nozzles and glow plugs.
16. Remove cylinder head attaching bolts.
17. On E-Series models, install suitable bar through rings on lifting eyes, then lift cylinder head from engine.
18. On F-Series models, attach hoist to lifting eyes and lift cylinder head from engine. Clean the precombustion chambers and inspect for cracks or burns. Some cracking and burning is acceptable, Fig. 9. When installed, the precombustion chambers may seat from .003 inch above to .001 inch below the cylinder head.
19. On all models, reverse procedure to install. Tighten cylinder head attaching bolts in sequence to specifications as shown in Fig. 10. Tighten intake manifold attaching bolts in sequence, Figs. 6 and 7, to specifications.