Cylinder Head Replacement With CTF

1. Tilt the cab. Refer to Cab Tilting in General Information.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the air inlet pipes.
5. Remove the exhaust gas recirculation (EGR) pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls - 7.8L.
6. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 7.8L.
7. Remove the turbocharger assembly. Refer to Turbocharger Replacement in Engine Controls - 7.8L.
8. Remove the intake manifold assembly. Refer to Intake Manifold Replacement .
9. Remove the exhaust manifold assembly. Refer to Exhaust Manifold Replacement in Engine Exhaust.
10. Remove the heat shield and bracket.
11. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
12. Remove the valve rocker arm shaft assembly.
13. Remove the camshaft assembly. Refer to Camshaft Replacement .
14. Remove the fuel injector nozzles.
15. Remove the coolant line from the air compressor to the cylinder head.
16. Remove the glow plugs. Refer to Glow Plug Replacement in Engine Controls - 7.8L.
17. Remove the air compressor line bracket from the rear of the cylinder head.



18. Remove the cylinder head bolts from the cylinder head in the numerical order shown in the illustration.
19. Remove the cylinder head and the gasket from the engine.
20. Inspect the threaded parts for wear or damage.
21. Clean carbon deposits from the combustion chambers.
22. Clean all traces of the old cylinder head gasket from the cylinder head and the engine block.
23. Clean the cylinder head bolt threads using a wire brush.
24. Clean metal chips and dirt from the threads in the cylinder block.

Important: Use a straight edge to check the flatness of the cylinder head. If the cylinder head has more than 0.2 mm (0.0078 in) gap between the straight edge and the surface of the cylinder head, replace the cylinder head.

25. Inspect the cylinder head for cracks or damage.

Important: Apply sealant to the rear corners of the cylinder block before installing the cylinder head gasket with the part number facing up.

1. Install the cylinder head and gasket to the block.



2. Apply molybdenum grease to the large head bolts (M14 bolts).
3. Apply clean engine oil to the small head bolts (M10 bolts).
4. Install the cylinder head bolts to the cylinder head.

Notice: Refer to Fastener Notice in the Preface section.

5. Tighten the cylinder head bolts in the following sequence:

5.1.	First pass for bolts 1-26:

Tighten
Tighten bolts 1-26 to 98 N·m (72 lb ft).

5.2.	Second pass for bolts 1-26:

Tighten
Tighten bolts 1-26 to 147 N·m (108 lb ft).

5.3.	Turn bolts 1-26 an additional 30 to 60 degrees.

6. Tighten the remaining cylinder head bolts in the following sequence:

Tighten
For bolts 27 and 28 tighten to 38 N·m (28 lb ft).

7. Install the camshaft assembly. Refer to Camshaft Replacement .
8. Install the rocker arm shaft assembly.
9. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
10. Install the coolant line from the air compressor to the cylinder head.
11. Install the air compressor lines and the bracket to the rear of the cylinder head.
12. Install the glow plugs. Refer to Glow Plug Replacement in Engine Controls - 7.8L.
13. Install the fuel injector nozzles.
14. Install the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Exhaust.
15. Install the intake manifold. Refer to Intake Manifold Replacement .
16. Install the turbocharger assembly. Refer to Turbocharger Replacement in Engine Controls - 7.8L.
17. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 7.8L.
18. Install the EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls - 7.8L.
19. Install the air inlet pipes.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
21. Lower the cab.

Cylinder Head Replacement Without CTF

1. Tilt the cab. Refer to Cab Tilting in General Information.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the air inlet pipes.
5. Remove the turbocharger assembly. Refer to Turbocharger Replacement in Engine Controls - 7.8L.
6. Remove the intake manifold assembly. Refer to Intake Manifold Replacement .
7. Remove the exhaust manifold assembly. Refer to Exhaust Manifold Replacement in Engine Exhaust.
8. Remove the heat shield and bracket.
9. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
10. Remove the valve rocker arm shaft assembly.
11. Remove the camshaft assembly. Refer to Camshaft Replacement .
12. Remove the fuel injector nozzles.
13. Remove the coolant line from the air compressor to the cylinder head.
14. Remove the glow plugs. Refer to Glow Plug Replacement in Engine Controls - 7.8L.
15. Remove the air compressor line bracket from the rear of the cylinder head.



16. Remove the cylinder head bolts from the cylinder head in the numerical order shown in the illustration.
17. Remove the cylinder head and the gasket from the engine.
18. Inspect the threaded parts for wear or damage.
19. Clean carbon deposits from the combustion chambers.
20. Clean all traces of the old cylinder head gasket from the cylinder head and the engine block.
21. Clean the cylinder head bolt threads using a wire brush.
22. Clean metal chips and dirt from the threads in the cylinder block.

Important: Use a straight edge to check the flatness of the cylinder head. If the cylinder head has more than 0.2 mm (0.0078 in) gap between the straight edge and the surface of the cylinder head, replace the cylinder head.

23. Inspect the cylinder head for cracks or damage.

Important: Apply sealant to the rear corners of the cylinder block before installing the cylinder head gasket with the part number facing up.

1. Install the cylinder head and gasket to the block.



2. Apply molybdenum grease to the large head bolts (M14 bolts).
3. Apply clean engine oil to the small head bolts (M10 bolts).
4. Install the cylinder head bolts to the cylinder head.

Notice: Refer to Fastener Notice in the Preface section.

5. Tighten the cylinder head bolts in the following sequence:

5.1.	First pass for bolts 1-26:

Tighten
Tighten bolts 1-26 to 98 N·m (72 lb ft).

5.2.	Second pass for bolts 1-26:

Tighten
Tighten bolts 1-26 to 147 N·m (108 lb ft).

5.3.	Turn bolts 1-26 an additional 30 to 60 degrees.

6. Tighten the remaining cylinder head bolts in the following sequence:

Tighten
For bolts 27 and 28 tighten to 39 N·m (28 lb ft).

7. Install the camshaft assembly. Refer to Camshaft Replacement .
8. Install the rocker arm shaft assembly.
9. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
10. Install the coolant line from the air compressor to the cylinder head.
11. Install the air compressor lines and the bracket to the rear of the cylinder head.
12. Install the glow plugs. Refer to Glow Plug Replacement in Engine Controls - 7.8L.
13. Install the fuel injector nozzles.
14. Install the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Exhaust.
15. Install the intake manifold. Refer to Intake Manifold Replacement .
16. Install the turbocharger assembly. Refer to Turbocharger Replacement in Engine Controls - 7.8L.
17. Install the air inlet pipes.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
19. Lower the cab.