Tools Required

1. Disconnect the battery negative cables. Refer to Battery Negative Cable Disconnection and Connection .
2. Drain the engine coolant and the engine block. Refer to Cooling System Draining and Filling .
3. Remove the air cleaner layer. Refer to Air Cleaner Replacement .
4. Remove the cooling layer. Refer to Cooling Layer Removal .
5. Remove the turbocharger. Refer to Turbocharger Replacement .
6. Remove the turbocharger charged air cooler outlet duct.

6.1.	Remove the clamp and hose from the charged air cooler.

6.2.	Remove the charged air cooler outlet duct.

7. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement .
8. Remove the right fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 .
9. Remove the right intake manifold. Refer to Intake Manifold Replacement - Right Side .
10. Remove the upper right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Upper Right Side .
11. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side t.
12. Remove the lower right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Lower Left Side .
13. Remove the valve rocker arm shaft assembly, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
14. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 1 .



15. Remove the fuel injector return pipe eye bolts and washers.
16. Remove the fuel injector return pipe assembly.



17. Remove the fuel injector bracket bolts.
18. Using the J 44639 , remove the fuel injectors with the fuel injector brackets.
19. Remove the injector bracket pins.



20. Remove the cylinder head bolts in the proper sequence and discard.



21. Remove the cylinder head assembly.
22. Remove and discard the cylinder head gasket.
23. Clean the sealing surface of the engine block and the cylinder head.

Notice: 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.

24. Clean the cylinder head bolt holes in the engine block.

1. The cylinder head gasket thickness is determined by the piston head projection from the cylinder block deck surface. There are cylinder head gaskets available in 3 different thicknesses. Follow the procedure below and use the chart to determine what gasket to use for each bank of cylinders.
2. Be sure the piston and cylinder deck are free of carbon, gasket material, or other objects that may give you an erroneous measurement.



3. Use the J 26900-13 and the J 26900-12 to measure the piston projection across 2 different points on each piston.

3.1.	Zero a dial indicator to the cylinder deck surface.

3.2.	Place the dial indicator pointer on the piston top. Be sure the pointer is directly above the piston pin centerline to prevent inaccurate readings from piston rocking.

3.3.	Rotate the engine to roll the piston through Top Dead Center while noting the maximum reading on the dial indicator.

3.4.	Repeat the procedure at the second measuring point on the piston.

4. Calculate the average value of piston projection for each cylinder.
5. Obtain the maximum piston projection value for that bank of cylinders.
6. Determine the gasket grade by the maximum piston projection value using the chart.
7. If the difference between the highest measured piston head projection and the lowest measured piston projection, within one bank of cylinders, exceeds 0.1 mm (0.0039 in), then following items need to be checked.

•	Crankshaft bearing clearance

•	Connecting rod bearing clearance

•	Connecting rod to piston pin clearance

•	Piston to piston pin clearance

8. If any of the above clearances are beyond specifications, then refer to the appropriate section for repair. If all of the above clearances are within the service limits but the piston projection variation is over 0.1 mm (0.0039 in), then replace the connecting rod and piston assembly.

1. If the injector sleeve is pulled from the cylinder head when removing the injector, the injector sleeve installation procedure is as follows:

Important: An injector sleeve with scoring or other damage must be replaced.

1.1.	Set the new injector sleeve gaskets (1) to the injector sleeve (2).

1.2.	Apply sealant, LOCTITE 272 or equivalent, to the lower sealing area of injector sleeve.





Notice: 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.

2. Install the right cylinder head gasket of the correct grade selected.

Confirm the discerning mark "R" for RH and "L" for LH of the cylinder head gasket.

3. Install the right cylinder head assembly.

Notice: Refer to Fastener Notice in the Preface section.





Notice: 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.

4. Install the NEW cylinder head bolts.
5. Tighten the cylinder head bolts in the following steps using the proper sequence.

Tighten

1. Tighten the M12 bolts to 50 N·m (37 lb ft).
2. Tighten the M12 bolts to 80 N·m (59 lb ft).
3. Using the J 45059 tighten the M12 bolts 60 degrees.
4. Using the J 45059 tighten the M12 bolts 60 degrees.
5. Tighten the M8 bolts to 25 N·m (18 lb ft).



6. Install a new O-ring onto the fuel injector.
7. Lubricate the O-ring with clean engine oil.
8. Ensure the injector bore is clean and free from carbon.
9. Install a new copper washer into the fuel injector bore in the cylinder head.
10. Install the fuel injector bracket pin.
11. If reusing the injectors, clean the injector tip of carbon. Do not clean with a wire brush.
12. Install the fuel injector with fuel injector bracket.
13. Install the fuel injector bracket bolt.

Tighten
Tighten the fuel injector bracket bolt to 50 N·m (37 lb in).




14. Install the fuel injector return pipe assembly.
15. Install the fuel injector return pipe to injector eye bolts and washers.

Tighten
Tighten the fuel injector return pipe to injector eye bolts to 15 N·m (133 lb in).

16. Install the fuel return pipe to cylinder head eye bolts and washers.

Tighten
Tighten the fuel injector return pipe to cylinder head eye bolts to 15 N·m (133 lb in).

17. Install the valve rocker arm shaft assembly, pushrods and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
18. Install the glow plugs. Refer to Glow Plug Replacement - Bank 2 .
19. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
20. Install the lower right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Upper Right Side .
21. Install the upper right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Upper Left Side .
22. Install the right fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 .
23. Install the right intake manifold. Refer to Intake Manifold Replacement - Right Side .
24. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement .
25. Install the turbocharger charged air cooler duct.
26. Install the turbocharger. Refer to Turbocharger Replacement .
27. Install the cooling layer. Refer to Cooling Layer Installation .
28. Install the air cleaner layer. Refer to Air Cleaner Replacement .
29. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
30. Fill the cooling system. Refer to Cooling System Draining and Filling .
31. Road test the vehicle for normal operation.
32. Inspect for coolant, oil or exhaust leaks.