Cylinder Head, Right

Removal

1. Disconnect battery ground cables (14301).

2. Remove the radiator (8005). Refer to Section 03-03.

3. Remove the turbocharger assembly. Refer to Section 03-04E.

4. Drain the water fuel separator.

5. Disconnect the fuel supply lines from the rear of both cylinder heads (6049).

   

6. Remove the banjo bolt from the fuel supply line at the fuel pump (9350).

7. Remove the fuel supply line assembly.

8. Remove one generator bolt and position the heater hose aside.

9. Remove the drive belt (8620). Refer to Section 03-05.

10. Disconnect the generator electrical connectors.

11. Remove the generator bracket retaining bolts.

12. Remove the generator bracket (10A313) (with generator (GEN) (10300) attached).

13. Remove the oil level indicator bracket bolts, bracket and oil level dipstick (6750).

14. Remove the oil level indicator tube.

15. Remove the manifold absolute pressure sensor (MAP sensor) (9F479) (MAP) sensor and screws. Position aside.

16. Disconnect the two engine harness electrical connectors from the valve cover gasket (6584).

17. Remove the valve cover bolts and valve cover (6582).

18. Disconnect the electrical connectors from the fuel injector nozzle tip (9E527) and glow plugs.

19. Remove the valve cover gasket.

20. Remove the high pressure oil line to the right cylinder head.

    

21. Remove the exhaust back pressure line.

    

22. Remove the three glow plug relay bracket nuts and the ground wire.

23. Disconnect the heater hose from the right cylinder head.

24. Remove the heater plenum screws, nuts, and clip. Remove the outer half of heater plenum. Refer to Section 12-02.

    

25.  CAUTION: Failure to remove the oil rail drain plugs prior to removing the fuel injectors (9F593) will allow oil to enter the combustion chamber and could result in hydrostatic lock and severe engine damage.

    Remove the oil rail drain plugs.

    

26. Remove the four outboard fuel injector hold-down bolts, retaining screws and four oil deflectors.

    

27.  CAUTION: Make sure to retrieve the fuel injector copper washer, located at the tip of the fuel injector, during removal.

    NOTE: When removing the fuel injectors it is important that all three injector O-rings and the injector tip copper washer are retrieved from the injector bore.

    NOTE: If injector is to be replaced, refer to Section 03-04D for proper injector identification.

    Remove the fuel injectors using Injector Remover T94T-9000-AH1. Position injector remover fulcrum beneath fuel injector hold-down plate and over edge of cylinder head. Install injector remover screw in threaded hole of fuel injector plate as shown. Tighten injector remover screw to lift fuel injector out of fuel injector bore. Discard copper washer. Place fuel injector in Rotunda Injector Protective Sleeve 014-00933 or equivalent and set fuel injector in Rotunda Injector Holding Rack 014-00933 or equivalent.

    

    

28.  CAUTION: Failure to remove oil and fuel from fuel injector bores could result in hydrostatic lock and severe engine damage.

    With fuel injectors removed, vacuum oil and fuel from fuel injector bores using Rotunda Vacuum Pump 014-R1058 or equivalent.

29. Remove the rocker arms (6564) and push rods (6565).

30. Remove the four glow plugs.

31. Raise vehicle.

32. Remove the right turbocharger exhaust inlet pipe retaining nuts and disconnect turbocharger exhaust inlet pipe from exhaust manifold.

33. Lower vehicle.

34. Remove the ground strap bolt at the rear of the cylinder head.

35. Disconnect the fuel return line at the front of the cylinder head.

36. Remove the four inboard fuel injector shoulder bolts.

37. Remove the cylinder head bolts.

38. Install the Rotunda Cylinder Head Lifting Bracket 014-00932 or equivalent.

    

39. Remove the cylinder head and head gasket (6051).

    Cylinder Head Removal

    

40. Clean the cylinder block mating surface.

41. Clean the cylinder head mating surface.

42. Inspect the cylinder head and cylinder block deck. Refer to Cylinder Heads, Inspection and Cylinder Head Flatness in the Cleaning and Inspection portion of this section.

43. To ensure a good seat for the fuel injector O-rings, clean fuel injector bore using Rotunda Injector Sleeve Brush 014-00934 or equivalent. Clean any debris from fuel injector bore.

    

Installation

1. Install head gasket over dowel sleeves and onto the cylinder head surface.

2. Install the cylinder head. Do not damage the gasket.

3. Remove the Rotunda Cylinder Head Lifting Bracket 014-00932-2 or equivalent.

4.  CAUTION: Do not use too much engine oil on the threads or damage to the threads and poor sealing may result. Do not use anti-seize compound, grease or any other lubricants except engine oil on the cylinder head bolt threads because they will affect the true torque value reading of the bolts.

   Lightly lubricate the cylinder head retaining bolt threads and flanges with clean engine oil.

5. Install the cylinder head retaining bolts in sequence to the specified torque. Refer to the following illustration.

   

6. Install the four inboard fuel injector shoulder bolts. Tighten shoulder bolts to 12 Nm (120 lb-in).

7. Connect the fuel return line at the front of the cylinder head.

8. Install the ground strap bolt at the rear of the cylinder head.

9. Connect right turbocharger exhaust inlet pipe to exhaust manifold and loosely install retaining nuts and bolts.

10. Install the fuel injectors with new copper washers. Lubricate the injector O-rings with clean engine oil. Carefully push the injectors square into the bore using hand pressure only to seat the injector O-rings. Position open end of Injector Replacer T94T-9000-AH2 between fuel injector body and fuel injector hold-down plate, while positioning opposite end of tool over edge of cylinder head as shown. Align hole in tool with threaded hole in cylinder head and install bolt from tool kit. Tighten bolt to fully seat fuel injector in bore, then remove bolt and tool.

    

11. Install the four outboard fuel injector hold-down bolts. Tighten the bolts to 13.6 Nm (120 lb-in).

12. Install the four oil deflectors and retaining bolts. Tighten the bolts to 13.6 Nm (120 lb-in).

13.  CAUTION: Failure to follow the next step of this procedure could result in bent valves, causing severe engine damage.

    Rotate engine until the mark on the crankshaft vibration damper (6316) is at 11 o'clock to prevent valve damage when installing rocker arms.

14. Install the push rods, rocker arms and rocker arm bolts (6A527) (copper end up). Tighten the rocker arm bolts to 27 Nm (20 lb-ft).

15. Install the oil rail drain plugs. Tighten oil rail drain plug to 6 Nm (53 lb-in).

16. Install the heater plenum, screws, nuts, and clip.

17. Install the heater hose at the right cylinder head.

18. Install the glow plug relay bracket, nuts (3) and ground wire.

19. Install the exhaust back pressure line.

20. Install the high-pressure oil supply line to the right cylinder head, tighten oil supply fitting to 26 Nm (19 lb-ft).

21. Install the oil level indicator tube.

22. Install the oil level indicator tube bracket, bolts and oil level dipstick.

23. Install MAP sensor and screws.

    

24. Install the valve cover gasket.

25. Connect electrical connectors to the fuel injectors and glow plugs.

26. Install the valve cover and bolts. Tighten bolts to 11 Nm (97 lb-in).

27. Connect the two fuel engine electrical connectors to the valve cover gasket.

28. Install the generator bracket (with generator attached) and retaining bolts. Tighten the generator bracket bolts to 40-55 Nm (30-40 lb-ft).

29. Connect the generator electrical connectors.

30. Install the heater hose clip at the generator and install the generator retaining bolt. Tighten the bolt to 40-55 Nm (30-40 lb-ft).

31. Install the drive belt. Refer to Section 03-05.

    

32. Install the fuel supply lines to the rear of cylinder heads.

33. Install the banjo bolt through the fuel line into the fuel pump. Tighten banjo bolt to 55 Nm (40 lb-ft).

34. Tighten the fuel supply lines to the rear of cylinder heads. Tighten the fittings to standard torque specification listed at the end of this section.

35. Install the turbocharger assembly. Refer to Section 03-04E.

36. Install radiator. Refer to Section 03-03.

37. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

    Connect battery ground cables.