Cylinder Head - Removal
Cylinder Head
Removal
Both cylinder heads
1. Remove the engine. For additional information, refer to Engine Engine - Removal.
2. Remove the 10 bolts and flexplate.
- Discard the bolts.
3. Mount the engine on an engine stand.
4. NOTICE: Do not pull on the wiring to remove the glow plug connector or damage may occur.
Using the Glow Plug Connector Remover/Installer, remove the glow plug harness.
5. Remove the 8 glow plugs.
6. 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.
7. NOTE: RH shown, LH similar.
Remove the 16 bolts, 16 spacers and the exhaust manifolds.
- Discard the bolts.
LH cylinder head
8. Remove the left cylinder head banjo bolt and fuel tube.
- Discard the sealing washers.
9. Remove the 3 bolts and the turbocharger heat shield.
10. Remove the protective covering from the LH cylinder head.
RH cylinder head
11. NOTE: Mark the location of the stud bolts.
Remove the RH valve cover.
- Remove the 6 stud bolts, 5 bolts and valve cover.
- Clean and inspect the gaskets.
- Clean and inspect the sealing surfaces.
12. Remove the RH high-pressure oil rail-to-valve cover gasket.
Both cylinder heads
13. Disconnect the fuel injector electrical connectors.
14. Remove the crankcase-to-head tube(s).
15. NOTE: LH cylinder head shown, RH cylinder head similar.
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 18 bolts and the high-pressure oil rails.
16. 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 High Pressure Supply Tube Remover, remove the lower crankcase-to-head tube.
17. Inspect the D-ring seals for damage (nicks, cuts and gouges). If damaged, replace the crankcase-to-head tube.
18. NOTICE: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector may occur.
Using the Injector Connector Release Tool, push the fuel injector electrical connectors out of the rocker arm carrier.
19. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
20. NOTICE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
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.
NOTE: The bolt is part of the fuel injector hold-down assembly.
Loosen the bolt and remove the bolt and fuel injector hold-down assembly and the fuel injector.
- Remove and discard the O-ring seals and copper washer.
21. Remove the shop towels.
22. NOTE: LH cylinder head shown, RH cylinder head similar.
Remove and discard the 20 inner cylinder head bolts.
23. Remove the 16 bolts and the rocker arm assemblies.
24. NOTE: LH cylinder head shown, RH cylinder head similar.
Remove the 4 bolts and rocker arm carriers.
- Remove and discard the press-in-place gaskets.
- Clean and inspect the sealing surfaces.
25. Mark the 16 valve bridges with a permanent marker and remove.
26. NOTICE: 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. The push rods are directional and the copper-coated end must be installed in the upward position where it will contact the rocker arm.
Mark the location and remove the 16 push rods.
27. Remove the 10 outer cylinder head bolts.
28. Using the Cylinder Head Lifting Bracket, remove the cylinder heads.
29. Check for cylinder head distortion. For additional information, refer to Cylinder Head Distortion Cylinder Head Distortion.
30. Remove and discard the cylinder head gaskets and dowels.
- Clean and inspect the gasket sealing surfaces.
31. Check the cylinder block distortion. For additional information, refer to Cylinder Block Distortion Cylinder Block Distortion.