Right Cylinder Head

RIGHT





1. Disconnect negative battery cable.
2. Remove engine cover (3) and brackets.




3. Remove the strut tower support (2).
4. Drain cooling system.




5. Remove the turbocharger Turbocharger - Removal.

NOTE: Observe the way the engine oil supply and return ports in the turbocharger adaptor align to the engine block for oil flow through the turbocharger. Failure to do so will result in immediate turbocharger failure.

6. Remove turbocharger oil housing adaptor (1).




7. Remove the intake manifold.




8. Remove the accessory drive belt.
9. Remove the two idler pulleys (1).
10. Remove the belt tensioner (2).




11. Rotate the engine by the vibration damper bolt, to TDC.
12. Raise and support the vehicle.
13. Remove right side starter blank.
14. Disconnect the hydraulic cooling fan lines and capture the fluid in a approved and clearly marked container.




15. Remove the front oil pan retaining bolts.
16. Lower the vehicle.




17. Remove the breather/oil separator (1) assembly from the right cylinder head cover.
18. Remove the right fuel injectors (6).
19. Remove the fuel rail (3).
20. Disconnect the vacuum supply hose from the vacuum pump (4).
21. Remove the vacuum pump (4).

CAUTION: Exercise caution when servicing the cylinder head covers. If a cylinder head cover is damaged, the cylinder head must also be replaced. Do not rotate the engine without special cam holding tools #9555 if cylinder head covers are removed.

NOTE: If the cylinder head cover is difficult to remove, DO NOT PRY or damage the cover. Use a heat gun to warm the sealing surface until the cover can be removed.

22. Remove the right cylinder head cover.




23. Observe the right camshaft gear alignment marks (2). If they are together, continue with the next step. If the right camshaft alignment marks are separated, rotate the engine by the vibration damper until camshaft marks align together and the vibration damper reaches TDC.




24. Raise and support the vehicle.
25. Install special tool #9102 crankshaft lock (2).




26. Lower the vehicle.
27. Remove the cooling fan module.
28. Remove the vibration damper (1) using special tool # 9944 (2).




29. Remove front timing chain cover (1).




30. Paint mark or scribe the balance shaft (2) position to the engine block and timing chain.
31. Paint mark or scribe the timing chain to crankshaft gear and camshaft drive gear relation.




32. Raise and support the vehicle.
33. Remove special tool #9102 crankshaft locking tool (2).
34. Lower the vehicle.




35. Rotate the engine and remove the right camshaft drive gear (1) lower bolt.
36. Rotate the engine back to TDC and check the alignment marks at the balance shaft, camshaft gear and crankshaft gear.




37. Remove the timing chain tensioner (3).




38. Remove the remaining right camshaft drive gear (1) retaining bolts.
39. Separate the right camshaft drive gear (1) and chain from camshaft.
40. Remove the right camshaft drive gear (1).




41. Remove the right camshafts retainers (1,2) and camshafts.




42. Remove the right upper timing chain upper guide (3).




43. Remove the right lower timing chain guide (1).

NOTE: Followers and tappets assemblies must be installed in same location as removed.

NOTE: Do Not store the cylinder head on the sealing surface. The glow plugs protrude into the cylinder surface area and may be damaged.

44. Remove the right cylinder head glow plugs.
45. Remove cylinder head and gasket from engine block.