Cylinder Head Assembly: Service and Repair

Fig. 2 Diagnostic connector:

1. Disconnect battery ground cable and drain cooling system.
2. Disconnect heater hose, then remove accessory drive belts.
3. Remove valve cover, then disconnect diagnostic connectors, Fig. 2.
4. Disconnect coolant temperature switch and glow plug electrical connectors.
5. Disconnect breather hose and bracket.
6. Remove oil dipstick tube to intake manifold attaching clamp and position tube aside.
7. Disconnect boost pressure switch electrical connector.
8. Disconnect radiator hose from cylinder head, then the idle boost coolant hose.
9. Remove vacuum pump from cylinder head.
10. Disconnect No. 1 injector nozzle to injection pump leak hose.
11. Using tool T84P-9395-B or equivalent, disconnect injection lines from nozzles and injection pump. Cap nozzles and lines to prevent dirt entry.
12. Disconnect turbocharger oil lines.

Fig. 3 TDC aligning pin installed:

13. Rotate crankshaft pulley until No. 1 cylinder is at TDC, compression stroke, then install TDC aligning pin, tool No. T84P-6400-A or equivalent between cylinder block flange and flywheel, Fig. 3.
14. Loosen camshaft drive sprocket retaining bolt, then camshaft drive belt tensioning roller nut and bolt. Remove drive belt.

Fig. 4 Cylinder head bolt removal & installation:

15. Loosen cylinder head attaching bolts following sequence shown in Fig. 4, then remove cylinder head.
16. Clean cylinder head and crankcase sealing surfaces using suitable spray solvent. Do not score or scratch sealing surfaces, since leakage may occur due to high compression pressures.
17. Check cylinder head for warpage. If warpage exceeds .006 inch, replace cylinder head.

Fig. 5 Cylinder head gasket selection chart:

18. Select cylinder head gasket thickness as follows:
a. Mount dial indicator D82L-4201-A and height gauge D84P-6100-A so that indicator pointer is on top of No. 1 position.
b. Rotate crankshaft until piston is at TDC.
c. Zero indicator on crankcase, then move indicator pointer to front of piston. Record measurement. Move pointer to rear of piston and again record measurement. Average the two measurements.
d. Repeat steps a through c for remaining pistons.
e. Using measurement of highest piston, select the correct cylinder head gasket using chart shown, Fig. 5.
19. Clean carbon and oil deposits from head bolts. Keep oil and/or antifreeze from entering cylinder head bolt holes, since damage to crankcase may result. If either enters bolt holes, blow out using compressed air.
20. Position head gasket onto crankcase, then install cylinder head.

Fig. 4 Cylinder head bolt removal & installation:

21. Install and torque cylinder head bolts in sequence shown, Fig. 4.
22. Reverse steps 1 through 13 to complete installation, noting the following:
a. Torque turbocharger oil lines to 14---17 ft. lbs.
b. Torque injection line fittings to nozzles and pump to 14---18 ft. lbs.
c. Torque vacuum pump-to-cylinder head attaching bolts to 6---7 ft. lbs.
d. After installation is complete, start and run engine for 15 minutes, checking for any fuel, coolant or oil leaks. Repair as necessary.
e. After running engine for 25 minutes, stop engine and remove valve cover. Using a suitable breaker bar, tighten cylinder head bolts an additional quarter turn (90 degrees). Adjust valves to specifications, then install valve cover.