Removal
Cylinder Head
Special Tool(s) (Part 1):
Special Tool(s) (Part 2):
Material:
Removal
Both cylinder heads
1. Remove the engine.
2. Remove the bolts and flexplate.
^ Discard the bolts.
3. Mount the engine on an engine stand.
4. Remove the rear lifting eye.
5. Remove the special tools.
6. CAUTION: Do not pull on the wiring to remove the glow plug connector or damage may occur.
Using the special tool, remove the glow plug harness.
7. Remove the 8 glow plugs.
8. Prior to removing the exhaust manifolds, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specification.
9. NOTE: RH shown, LH similar.
Remove the 16 bolts, 16 spacers and the exhaust manifolds.
LH cylinder head
10. Remove the left cylinder head banjo fitting and fuel line.
^ Discard the sealing washers.
11. Remove the bolts and the turbocharger heat shield.
12. Remove the protective covering from the LH cylinder head.
RH cylinder head
13. NOTE: Mark the location of the stud bolts.
Remove the RH valve cover.
^ Remove the stud bolts, bolts and valve cover.
^ Clean and inspect the gaskets.
^ Clean and inspect the sealing surfaces.
14. Remove the RH high-pressure oil rail-to-valve cover gasket.
Both cylinder heads
15. Disconnect the fuel injector electrical connector.
16. Remove the crankcase-to-head tube.
17. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
Remove the bolts and the high-pressure oil rail.
18. NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
If the crankcase-to-head tube separated, using the special tool, remove the lower crankcase-to-head tube.
19. Inspect the D-ring seals for damage (nicks, cuts and gouges). If damages, replace the crankcase-to-head tube.
NOTE: Early build cylinder heads, head gasket, cylinder block, rocker arm carrier and injectors and injector hold-down clamps are not interchangeable with late build engines, It is necessary to identify the head style prior to working on the cylinder heads. Early build heads are equipped with injector hol-down clamps with a square end T40 Torx bolt. Late build heads have injector hold-down clamps with a tapered end and a T45 Torx bolt.
Determin if the cylinder heads are early build (left frame of illustration) or late build (right frame of illustration).
20. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
21. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
22. CAUTION: To prevent engine damage, do not use air tools when removing and installing the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall off.
CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system, causing severe engine damage.
NOTE: There is no need to drain the fuel rail.
NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve. For additional information, refer to Fuel Delivery and Air Induction.
Remove the bolt, the fuel injector hold down and the fuel injector.
23. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.
Remove the shop towels.
24. NOTE: Left cylinder head shown, right cylinder head similar.
Remove and discard the 20 inner cylinder head bolts.
25. Remove the 16 bolts and the rocker arm assemblies.
26. NOTE: Left cylinder head shown, right cylinder head similar.
Remove the bolts and rocker arm carrier.
^ Clean and inspect the gasket. Install new gaskets if necessary.
^ Clean and inspect the sealing surfaces.
27. Mark the 16 valve bridges with a permanent marker and remove.
28. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
Mark the location and remove the 16 push rods.
29. Remove the outer cylinder head bolts.
30. Remove the cylinder heads.
1 Install the special tool.
2 Install the bolts.
^ Remove the cylinder head.
31. Remove and discard the cylinder head gasket and dowels.
^ Clean and inspect the gasket sealing surfaces.
32. Check for cylinder head and cyclinder block distortion. Service and Repair