Cylinder Head Replacement - Right Side
Cylinder Head Replacement - Right Side
Special Tools
J-45059 - Angle Meter
For equivalent regional tools, refer to Special Tools Special Tools.
Removal Procedure
1. Remove the engine assembly. Refer to Engine Replacement Removal and Replacement.
2. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement Service and Repair.
3. Remove the intake manifold. Refer to Intake Manifold Replacement - Right Side Intake Manifold Replacement - Right Side.
4. Remove the exhaust pipe. Refer to Exhaust Pipe Removal - Right Side (LGH) 9. Exhaust Pipe Removal - Right Side (LGH)Exhaust Pipe Removal - Right Side (LML) 10. Exhaust Pipe Removal - Right Side (LML).
5. Remove the exhaust manifold.
6. Remove the engine wiring harness nut(s) from the glow plug(s).
7. Remove the engine wiring harness lead(s) from the glow plug(s).
8. Remove the right lower valve rocker arm cover and cover bolts. Refer to Valve Rocker Arm Lower Cover Replacement - Right Side Valve Rocker Arm Lower Cover Replacement - Right Side.
9. Remove and discard the valve rocker arm cover gasket, valve rocker arm cover grommets and valve rocker arm cover bolts if they are serviced with the grommet.
10. Remove the cylinder head bolts in the sequence shown.
11. Discard the large M12 bolts.
12. Remove the cylinder head and discard the cylinder head gasket.
13. Clean the sealing surface of the engine block and the cylinder head.
Caution: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
14. Clean the cylinder head bolt holes in the engine block.
15. For service to the cylinder head, refer to the following:
* Cylinder Head Disassemble
* Cylinder Head Cleaning and Inspection
* Cylinder Head Assemble
Overhaul
Installation Procedure
Caution: The left and right cylinder head gaskets are not interchangeable. Improper placement of the cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.
Note: The stamped letter, R or L, must face up. R is the right bank, L is the left bank.
1. The markings on the gasket are as follows:
* Grade A (1)
* Grade B (2)
* Grade C (3)
* Block over-bored 0.010-0.030 in (0.254-0.762 mm) (4)
* Block over-bored 0.010-0.030 in (0.254-0.762 mm) and deck milled 0.008 in (0.203 mm) (5)
2. Install the right cylinder head gasket of the correct grade. The left and right cylinder head gaskets are not interchangeable. Refer to Cylinder Head Gasket Selection 100. Cylinder Head Gasket Selection.
3. Install the cylinder head.
Caution: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
Caution: Refer to Fastener Caution Fastener Caution.
4. Install NEW M12 cylinder head bolts. Reuse the M8 bolts.
5. Tighten the M12 cylinder head bolts in four steps:
1. 1st step 50 Nm (37 lb ft).
2. 2nd step 80 Nm (59 lb ft).
3. 3rd step tighten 60 degrees using J-45059 - meter.
4. Final step tighten 60 degrees using J-45059 - meter
6. Install the M8 bolts and tighten the M8 cylinder head bolts to 25 Nm (18 lb ft).
7. Install the glow plug(s) to the cylinder head and tighten to 18 Nm (13 lb ft).
8. Install the engine wiring harness lead(s) to the glow plug(s).
9. Install the engine wiring harness nut(s) to the glow plug(s) and tighten to 1.7 Nm (15 lb in).
10. Install the right lower valve rocker arm cover and cover bolts. Refer to Valve Rocker Arm Lower Cover Replacement - Right Side Valve Rocker Arm Lower Cover Replacement - Right Side.
11. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement Service and Repair.
12. Install the exhaust manifold.
13. Install the exhaust pipe.
14. Install the intake manifold. Refer to Intake Manifold Replacement - Right Side Intake Manifold Replacement - Right Side.
15. Install the engine assembly. Refer to Engine Replacement Removal and Replacement.
16. Road test the vehicle for normal operation.