Cylinder Head – Remove and Install


Removal Procedure

If necessary, remove the secondary fuel filter and the fuel filter base.
If necessary, remove the fuel priming pump and the primary fuel filter.
Remove:
- the exhaust manifold.
- the fuel manifold
- the electronic control module and the mounting bracket.
- the electronic unit injectors.
- the valve mechanism cover base.
- the glow plugs. Drain the coolant from the cooling system into a suitable container for storage or for disposal.


Disconnect the upper radiator hose (not shown) from the water temperature regulator housing (1) on the cylinder head.


Remove the air inlet hose (not shown) from the inlet connection (3) on the inlet manifold (2). Follow Steps to disconnect the harness assembly (4) from the coolant temperature sensor (5). Slide the locking tab (not shown) into the unlocked position.
Disconnect the harness assembly (4) from the coolant temperature sensor (5).
Follow Steps to disconnect the harness assembly (4) from the boost pressure sensor (6).
Slide the locking tab (not shown) into the unlocked position. Disconnect the harness assembly (4) from the boost pressure sensor (6). Follow Steps to disconnect the harness assembly (4) from inlet air temperature sensor (7).
Slide the locking tab (not shown) into the unlocked position. Disconnect the harness assembly (4) from the inlet air temperature sensor (7).
Remove all cable ties that secure the harness assembly (4) to the cylinder head or to the inlet manifold. The harness assembly should be positioned in order to avoid causing an obstruction during the removal of the cylinder head.


Loosen the tube clips for the tube assembly (8). Remove the tube assembly (8) for the fuel return from the cylinder head and from the transfer pump (not shown). Plug the port in the transfer pump with a new plug. Cap the tube assembly with new caps.
If the diesel engine has a wastegate solenoid, loosen the tube clips for the tube assembly (9). Remove the tube assembly (9) from the wastegate solenoid (not shown) and from the cylinder head. Plug the port in the wastegate solenoid with a new plug. Cap the tube assembly with new caps.


Remove the two setscrews (10). Remove the bypass tube (11) from the cylinder head. Remove the O-ring seals (12) and (13) from the bypass tube (11). Discard the O-ring seals.


Sequence for tightening the setscrews for the cylinder head

Gradually loosen the setscrews (14) in the reverse numerical order to the tightening sequence. Refer to the illustration. Follow the correct sequence in order to help prevent distortion of the cylinder head. Remove the setscrews (14) from the cylinder head (15).


Attach a suitable lifting device (16) to the cylinder head (15). Support the weight of the cylinder head. The weight of the cylinder head is approximately 66 kg (145.5 lb). A spreader bar must be used in order to distribute the weight of the cylinder head during the lifting operation.
Use the suitable lifting device (16) to carefully lift the cylinder head (15) off the cylinder block. Do not use a lever to separate the cylinder head from the cylinder block. Take care not to damage the machined surfaces of the cylinder head during the removal procedure.


Remove the cylinder head gasket (17). Discard the cylinder head gasket.
Note the position of the dowels (18) in the cylinder block.
If necessary, remove the water temperature regulator (1) from the cylinder head (15). If necessary, remove the inlet manifold (2) from the cylinder head (15).

Installation Procedure

Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Do not damage the mating surfaces of the cylinder head of the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the mating surface of the cylinder head for distortion.  If the mating surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
If necessary, install the inlet manifold to the cylinder head.


Inspect the dowels (18) for damage. If necessary, replace the dowels in the cylinder block. Install Tooling to the cylinder block. Align the cylinder head gasket (17) with the dowels (18). Install the cylinder head gasket (17) onto the cylinder block.


Use a suitable lifting device (16) to lift the cylinder head (15). The weight of the cylinder head is approximately 66 kg (145.5 lb). A spreader bar must be used in order to distribute the weight of the cylinder head during the lifting operation.
Use Tooling to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block. Ensure that the cylinder head is correctly positioned on the dowels (18). Remove Tooling.


Clean the setscrews (14). Follow Steps for the procedure to inspect the setscrews. Check the length of the setscrews. Some diesel engines have all setscrews of the same length. Some engines have two longer setscrews.
Use a straight edge to check the threads of the setscrews. Refer to Illustration. Replace any setscrews that show visual reduction in the diameter of the thread over length (Y). Lubricate the threads and the shoulder of the setscrews (14) with clean engine oil.


Sequence for tightening the setscrews for the cylinder head

Install the setscrews (14) to the cylinder head (16). If the engine has two longer setscrews, install the longer setscrews in holes (X).
Tighten the setscrews to a torque of 50 N·m (37 lb ft) in the numerical sequence. Tighten the setscrews to a torque of 100 N·m (74 lb ft) in the numerical sequence. Refer to Illustration. Turn the setscrews through an additional 225 degrees in the numerical sequence. Refer to Illustration. Use Tooling to achieve the correct final torque.


Use Tooling in order to lubricate the O-ring seals. Install two new O-ring seals (12) and (13) to the bypass tube (11). Install the bypass tube in the cylinder head. Install the setscrews (10). Tighten the setscrews to a torque of 22 N·m (16 lb ft).


Remove the plugs and caps from the ports and tube assemblies.
Install the tube assembly (8) for the fuel return to the cylinder head and to the transfer pump. Secure the tube clips for the tube assembly (8).
If the diesel engine has a wastegate solenoid, install the tube assembly (9) for the wastegate solenoid to the cylinder head. Secure the tube clips for the tube assembly (9).


Follow Steps to connect the harness assembly (4) to the inlet air temperature sensor (7). Connect the harness assembly (4) to the inlet air temperature sensor (7). Slide the locking tab (not shown) into the locked position.
Follow Steps to connect the harness assembly (4) to the boost pressure sensor (6). Connect the harness assembly (4) to the boost pressure sensor (6). Slide the locking tab (not shown) into the locked position. Follow Steps to connect the harness assembly (4) to the coolant temperature sensor (5).
Connect the harness assembly (4) to the coolant temperature sensor (5).
Slide the locking tab (not shown) into the locked position.
Use new cable ties in order to secure the harness assembly to the cylinder head and to the inlet manifold. Ensure that the harness assembly is not strained. Ensure that the harness assembly is clear of other engine components. Install the inlet hose (not shown) to the inlet connection (3) on the inlet manifold (2).


If necessary, install the water temperature regulator housing (1) to the cylinder head. Connect the upper radiator hose (not shown) to the water temperature regulator housing (1) on the cylinder head. Fill the cooling system with coolant. If necessary, fill the engine oil pan to the correct level that is indicated on the engine oil level gauge. Install:
- the glow plugs.
- the valve mechanism cover base.
- the electronic unit injectors.
- the electronic control module and the mounting bracket.
- the fuel manifold.
- the exhaust manifold.
- If necessary, install the fuel filter base and the secondary fuel filter
- If necessary, install the fuel priming pump and the primary fuel filter.