Removal
- Tools Required- J 39083 Glow Plug Connector Tool, or equivalent
1. Remove the intake manifold.
2. Disconnect the fuel injection lines. Refer to Powertrain Management.
3. Remove the valve rocker arm covers.
4. Drain the cooling system.
5. Raise the vehicle.
6. Support the vehicle with safety stands.
7. Remove the exhaust pipe from the exhaust manifold. Refer to Exhaust System.
8. Lower the vehicle.
9. Remove the components as follows for the left cylinder head:
- The air conditioning compressor and the bracket. Refer to Heating and Air Conditioning.
- The power steering pump with the bracket. Refer to Steering and Suspension.
- The glow plug relay
- The oil level indicator tube
- The upper radiator hose
- The wiring harness
10. Remove the following components for the right cylinder head:
- The ground strap
- The generator and the rear bracket
- The vacuum pump and the bracket
- The turbocharger assembly. Refer to Turbocharger.
- The wire harness at the clips and move aside
11. Disconnect the wire from the coolant sensor at the cylinder head.
12. Remove the glow plug wires. Use the J39083 in order to disconnect the glow plug connectors from the glow plugs on the right hand cylinder head. The connector cannot be reached with the hand. Do not pull on the mow pluck harness wire.
NOTE: The valve rocker arm assemblies and the pushrods must be marked for proper assembly.
13. Remove the valve rocker arm assemblies and the pushrods.
14. Remove the water pump bypass and the heater hoses.
15. Remove the coolant crossover pipe/thermostat housing assembly.
16. Remove the exhaust manifold. Refer to Exhaust System.
17. Remove the cylinder head bolts. The rear bolt in the left cylinder head may have to remain in the head during removal.
18. Remove the cylinder head.
19. Clean the following parts:
- The carbon deposits from the combustion chambers
- Clean all traces of the old head gasket from the cylinder head and block. The use of a motorized wire brush is not recommended.
- The cylinder head bolt threads using a wire brush
- The metal chips and dirt from the threads in the block
20. Inspect the following components:
- The cylinder head for cracks between the intake and exhaust ports. Use the magnaflux or dye method if available.
- The sealing surfaces of the block and cylinder head for nicks, heavy scratches or other damage
- The block for missing or damaged dowel pins or dowel pins in the wrong location
21. Measure the following items:
- The cylinder head warpage.
- The pre-chamber installed depth.