Cylinder Head Replacement RH

Special Tools:

Removal
All vehicles
1. Disconnect both battery ground cables.
2. Remove the engine cover.
3. Remove the parking lamps and the headlamp assemblies.
4. Remove the radiator.

Vehicles with air conditioning
5. Remove the A/C condenser.

All vehicles
6. Remove the radiator grille, radiator grille opening panel and the upper radiator support.
7. Remove the turbocharger compressor manifold.
8. Remove the accessory drive belt.

Vehicles with dual generators





9. Disconnect the lower generator quick connector.





10. Remove the engine ground cable.
1. Remove the nut.
2. Remove the starter wire retaining bracket.
3. Remove the engine ground cable.





11. Remove the lower generator mounting bracket retaining bolts and the mounting bracket.





12. Remove the upper generator mounting bracket retaining bolts and the mounting bracket.

All vehicles





13. Disconnect the generator electrical connectors.
14. Remove the accessory drive belt tensioner assembly.





15. Remove the generator bracket retaining bolts and the generator mounting bracket.
16. Remove the glow plug relay/intake air heater relay and bracket as an assembly.





17. Remove the bolt, and the transmission oil level indicator tube.
18. Remove the valve cover.
19. Remove the rocker arms and push rods.





20. Disconnect the fuel supply line.





21. Disconnect the heater hose.
22. Remove the fuel injectors.





23. Remove the inboard fuel injector hold-down bolts.





24. Using the special tool, disconnect the high pressure line.





25. Disconnect the exhaust back pressure tube.





26. Remove the two nuts and bolts from the exhaust manifold and the exhaust adapter pipe.





27. Remove the 18 cylinder head bolts.





28. Install special tools.
1. Position the special tool on the cylinder head.
2. Install the bolts.
3. Install the special tool.





29. With an assistant, lift the cylinder head and remove it from the vehicle.
30. Clean and inspect the cylinder head mating surface.

Installation
All vehicles
1. Install the cylinder head gasket.





2. Using the special tools, with an assistant lift the cylinder head and position it onto the cylinder block. Remove the special tools.

3. CAUTION: Do not use too much engine oil on the threads of the cylinder head bolts, or damage to the threads and poor sealing can result. Do not use anti-seize compounds, grease or any other lubricants except engine oil on the cylinder head bolt threads because they will affect the true torque value reading of the bolts.





Lightly lubricate the cylinder head retaining bolt threads and flanges with clean engine oil and install the cylinder head retaining bolts.
^ Tighten the bolts in the sequences shown in three stages.
^ Stage 1: Using the first sequence, tighten the bolts to 88 Nm (65 ft. lbs.).
^ Stage 2: Using the first sequence, tighten the bolts to 115 Nm (85 ft. lbs.).
^ Stage 3: Using the second sequence, tighten the bolts to 129 Nm (95 ft. lbs.).





4. Install the two nuts and bolts in the exhaust manifold and the exhaust adapter pipe.





5. Install the exhaust back pressure tube.





6. Connect the high pressure oil hose. Pull on the high pressure oil hose to make sure the fitting is correctly connected.

7. Note: Make sure the bolt holes are free of contaminants prior to bolt installation.





Install the four inboard fuel injector hold-down bolts.
8. Install the fuel injectors.





9. Connect the heater hose.





10. Connect the fuel supply line.
11. Install the rocker arms and push rods.
12. Install the valve cover.





13. Install the transmission oil level indicator tube and bolt.
14. Install the glow plug relay/intake air heater relay and bracket as an assembly.





15. Position the generator mounting bracket and install the generator mounting bracket bolts.
16. Install the accessory drive belt tensioner assembly.





17. Connect the generator electrical connectors.

Vehicles with dual generators





18. Position the upper generator mounting bracket and install the retaining bolts.





19. Position the lower generator mounting bracket and install the retaining bolts.





20. Install the engine ground cable.
1. Install the engine ground cable.
2. Install the starter wire retaining bracket.
3. Install the nut.





21. Connect the lower generator quick connector.

All vehicles
22. Install the drive belt tensioner and the accessory drive belt.
23. Install the turbocharger compressor manifold.
24. Install the radiator grille, radiator grille opening panel and the upper radiator support.

Vehicles with air conditioning
25. Install the A/C condenser.

All vehicles
26. Install the radiator.
27. Install the parking lamps and the headlamp assemblies.
28. Install the engine cover.
29. Reconnect both battery ground cables.