Cylinder Head, Removing and Installing Overview

Cylinder Head, Removing and Installing Overview
Compression checking, Refer to Compression Test, Testing and Inspection

Note:
^ When installing an exchange cylinder head (complete with installed camshafts): Oil the contact surfaces between the lifters and the cam lobes before installing the valve cover.
^ Do NOT remove the plastic packing pieces which protect the open valves until immediately before installing the cylinder head.
^ If the cylinder head is replaced:
- - Replace the entire engine coolant.

1. Toothed belt guard, upper section
2. Toothed belt
^ Mark direction of engine rotation before removing
^ Check for wear
^ Do not kink
^ Removing and installing, Refer to Timing Belt, Service and Repair
3. 20 Nm (15 ft. lbs.)
4. 20 Nm (15 ft. lbs.)
5. 45 Nm (33 ft. lbs.)
6. Camshaft sprocket
^ Drive off of camshaft taper using hammer and drift through toothed belt guard openings
7. Tensioning roller (semi- automatic, toothed belt)
^ Checking, Refer to Timing Belt, Testing and Inspection
8. Idler roller
9. Toothed belt guard, rear
10. 10 Nm (7 ft. lbs.)
11. Lifting eye
12. Cylinder head bolt
^ Replace
^ Note sequence when loosening and tightening, Refer to Cylinder Head, Service and Repair
13. Oil deflector
14. Valve cover
^ With vulcanized seal
^ Replace complete if damaged or leaking

CAUTION: The valve cover seal is an integral part of the valve cover. Replace the valve cover only if it is damaged or leaking.

15. Seal
^ Replace if damaged
16. Cap
^ Replace seal if damaged
17. Breather pipe
18. Retaining clip
19. Pressure regulating valve
^ For Positive Crankcase Ventilation valve
20. Gasket
^ Replace if damaged
21. 5 Nm (44 inch lbs.)
22. Fuel injector lines
^ 25 Nm (18 ft. lbs.)
^ Remove using 3035 offset tubing wrench
^ Always remove fuel line cluster as an assembly
^ Do not bend, kink or alter shape
23. Exhauster
^ For brake booster
24. Gasket
^ Always replace
25. Fuel injector
26. Glow plug
^ 15 Nm (11 ft. lbs.)
27. Cylinder head gasket
^ Replace
^ Note marking go to Fig. 2
^ If replaced; also replace entire engine coolant





Fig. 1 Cylinder head distortion, checking
Max permissible distortion: 0 1 mm

Note: Reworking Diesel cylinder heads is not permissible.





Fig. 2 Cylinder head gasket, identification
^ Part No. see arrow -1-
^ Production control code see arrow -2- (ignore)
^ Holes see arrow -3-

Note: Different thicknesses of cylinder head gasket are installed depending on the piston projection dimension. When replacing the cylinder head gasket, install a new gasket with the same identification.