Cylinder Head Replacement - Right

This article has been updated with TSB 06-06-01-006B

Cylinder Head Replacement - Right

^ Tools Required
- J 45059 Angle Meter
- J 44639 Fuel Injector Puller
- J 26900-12 Dial Indicator
- J 26900-13 Magnetic Base

Removal Procedure





1. Remove the right wheelhouse inner panel.
2. Remove the turbocharger.
3. Loosen the charged air cooler outlet duct clamp at the charged air cooler.
4. Remove the charged air cooler outlet duct (2).
5. Remove the thermostat housing crossover.
6. Remove the right fuel rail.
7. Remove the right intake manifold.
8. Remove the right exhaust manifold.
9. Remove the valve rocker arm shaft, pushrods, and valve bridges.
10. Remove the glow plugs.





11. Remove the fuel injector return pipe bolts and washers.
12. Remove the fuel injector return pipe.





13. Remove the fuel injector bracket bolts.





14. Install J 44639 to the fuel injector brackets.
15. Pull back on the J 44639 in one steady motion, until the fuel injector breaks free from its seat.
16. Remove the J 44639.





17. Remove the fuel injector with the brackets.
18. Remove the injector locating pins.





19. Remove the cylinder head bolts in the sequence shown and discard.





20. Remove the cylinder head.
21. Remove and discard the cylinder head gasket.
22. Clean the sealing surface of the engine block and the cylinder head.

23. Notice:
Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

Clean the cylinder head bolt holes in the engine block.
24. For service to the cylinder head refer to the following:
^ Refer to Cylinder Head Disassemble.
^ Refer to Cylinder Head Cleaning and Inspection.
^ Refer to Cylinder Head Assemble.

Installation Procedure





1. If the injector sleeve is pulled from the cylinder head when removing the injector, the injector sleeve installation procedure is as follows:

Important:
^ An injector sleeve with scoring or other damage must be replaced.
^ The stamped letter R or L must face up. R is the right bank and L is the left bank.

1.1. Set the new injector sleeve gaskets (1) to the injector sleeve (2).
1.2. Apply sealant (Loctite 272 or equivalent) to the lower sealing area of injector sleeve.






Notice:
The left and right cylinder head gaskets are not interchangeable. Improper placement of the cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.

Important:
The stamped letter R or L, must face up. R is the right bank, L is the left bank.

2. Install the right cylinder head gasket of the correct grade.
3. Install the right cylinder head.





Notice:
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Notice:
This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.


4. Install the NEW cylinder head bolts.
5. Tighten the cylinder head bolts in the following steps using the sequence shown.
1. Tighten the M12 bolts a first pass to 50 Nm (37 ft. lbs.).
2. Tighten the M12 bolts a second pass to 80 Nm (59 ft. lbs.).
3. Tighten the M12 bolts a third pass to 60 degrees, using J 45059.
4. Tighten the M12 bolts a final pass to 60 degrees, using J 45059.
5. Tighten the M8 bolts to 25 Nm (18 ft. lbs.).





6. Install a NEW O-ring onto the fuel injector.
7. Lubricate the O-ring with clean engine oil.
8. Ensure the injector bore is clean and free from carbon.
9. Install a new copper washer into the fuel injector bore in the cylinder head.
10. Install the fuel injector locating pin.
11. If reusing the injectors, clean the injector tip of carbon. Do not clean with a wire brush.
12. Install the fuel injector with fuel injector retainer.
13. Install the fuel injector retainer bolt.
^ Tighten the bolt to 50 Nm (37 ft. lbs.).





14. Install the fuel injector return pipe.
15. Install the fuel injector return pipe to injector bolts and washers.
^ Tighten the bolts to 16 Nm (12 ft. lbs.).
16. Install the fuel injector return pipe to cylinder head bolts and washers.
^ Tighten the bolts to 17 Nm (13 ft. lbs.).
17. Install the valve rocker arm shaft, pushrods, and valve bridges.
18. Install the glow plugs.
19. Install the right exhaust manifold.
20. Install the right fuel rail.
21. Install the right intake manifold.
22. Install the thermostat housing crossover.





23. Install the charged air cooler duct (2).
24. Tighten the charged air cooler outlet duct clamp at the charged air cooler.
^ Tighten the clamp to 6 Nm (53 inch lbs.).
25. Install the turbocharger.
26. Install the right wheelhouse inner panel.
27. Road test the vehicle for normal operation.
28. Inspect for coolant, oil, or exhaust leaks.