Cylinder Head Replacement RH
Special Tools:
Removal
All vehicles
1. Disconnect both battery ground cable(s).
Vehicles with air conditioning
2. Discharge the A/C system.
All vehicles
3. Remove the turbocharger compressor manifold.
4. Remove the accessory drive belt.
Vehicles with dual generators
5. Disconnect the lower generator electrical connectors.
6. Remove the engine ground cable.
1. Remove the nut.
2. Remove the starter wire retainer bracket.
3. Remove the engine ground cable.
7. Remove the lower generator mounting bracket retaining bolts and the mounting bracket.
Vehicles with air conditioning
8. Disconnect the A/C compressor electrical connector.
9. Remove the A/C compressor mounting bracket.
1. Remove the bolts.
2. Remove the mounting bracket.
All vehicles
10. Remove the glow plug relay/intake air heater relay and bracket as an assembly.
Vehicles with automatic transmission
11. Remove the bolt and the transmission oil level indicator tube.
All vehicles
12. Remove the valve cover.
13. Remove the rocker arms and push rods.
14. Disconnect the fuel supply line.
15. Disconnect the heater hose.
16. Remove the fuel injectors.
17. Using the special tool, disconnect the high pressure oil hose.
18. Remove the exhaust back pressure tube.
19. Remove the two nuts and bolts from the exhaust manifold and the exhaust adapter pipe.
20. Remove the 18 cylinder head bolts.
21. Install the special tools.
1. Position the special tool on the cylinder head.
2. Install the bolts.
3. Install the special tool.
22. With an assistant, lift the cylinder head and remove it from the vehicle.
23. 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 on 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 valve 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. Install the fuel injectors.
8. Connect the heater hose.
9. Connect the fuel supply line.
10. Install the rocker arms and push rods.
11. Install the valve cover.
Vehicles with automatic transmission
12. Install the transmission oil level indicator tube and bolt.
All vehicles
13. Install the glow plug relay/intake air heater relay and bracket as an assembly.
Vehicles with air conditioning
14. Position the A/C compressor mounting bracket. Install the mounting bracket bolts.
15. Connect the A/C compressor electrical connector.
All vehicles
16. Install the accessory drive belt tensioner assembly.
Vehicles with dual generators
17. Install the lower generator mounting bracket.
18. Connect the lower generator electrical connectors.
19. Install the engine ground cable.
1. Install the engine ground cable.
2. Install the starter wire retaining bracket.
3. Install the nut.
All vehicles
20. Install the drive belt tensioner and the accessory drive belt.
21. Install the turbocharger compressor manifold.
22. Reconnect both battery ground cables.
Vehicles with air conditioning
23. Recharge the A/C system.