Cylinder Head Assembly: Service and Repair

Cylinder head & components:

Cylinder block & components:

Fig. 2 Intake manifold removal:

Fig. 3 Injection nozzle protective cap set:

Fig. 4 Cylinder head bolt loosening sequence:

Fig. 5 Pre-chamber removal:

1. Disconnect battery ground cable and drain cooling system.
2. Remove camshaft cover, front and rear timing belt covers and belts.
3. Raise and support vehicle.
4. Disconnect exhaust pipe from exhaust manifold.
5. Lower vehicle.
6. Remove air inlet duct from air cleaner and intake manifold. Install cap, Fig. 2, onto intake manifold.
7. Disconnect all electrical connectors and vacuum hoses from temperature sensors.
8. Remove upper and lower coolant hoses and upper radiator hose from thermostat housing.
9. Remove injection lines from injection pump and nozzles. Cap all lines and fittings with cap set No. T84P-9395 or equivalent, Fig. 3.
10. Disconnect glow plug harness from engine harness.
11. Loosen cylinder head bolts in sequence shown in Fig. 4, then remove cylinder head.
12. Remove glow plugs.
13. Using a brass drift and hammer, remove pre-chambers from cylinder head, Fig. 5.
14. Clean pre-chamber cups, pre-chambers, cylinder head and crankcase gasket surfaces.

Fig. 5 Pre-chamber removal:

Fig. 6 Cylinder head gasket installation:

Fig. 7 Cylinder head bolt dimension A:

Fig. 8 Cylinder head bolt tightening steps:

Fig. 9 Cylinder head bolt tightening sequence:

15. Install pre-chambers into cylinder head. Ensure pins are aligned with slots, Fig. 5.
16. Install glow plugs and torque to specification. Note the following:
a. Using compressed air, blow out cylinder head bolt threads in crankcase.
b. Install new cylinder head gasket. Ensure cylinder head oil feed hole is not restricted, Fig. 6.
c. Measure dimension A, Fig. 7, of each cylinder head bolt. If dimension A is more than 4.5 in., replace cylinder head bolt.
d. Rotate camshaft until both intake and exhaust valves for No. 1 cylinder are closed. Rotate crankshaft clockwise until No. 1 piston is halfway up in the cylinder bore toward TDC.
e. Install cylinder head.
f. Before installing cylinder head bolts, paint a white reference mark on each bolt, Fig. 8, then apply a light coat of clean engine oil to bolt threads.
g. Torque cylinder head bolts in sequence shown in Fig. 9 to 22 ft. lbs. Using the painted reference marks, tighten each cylinder head bolt in sequence an additional 90°, Fig. 8. Tighten cylinder head bolts another 90° to complete cylinder head bolt installation.
17. Reverse procedure to install.