For 1990-2009 cars only
Removal Procedure
- Tilt the cab. Refer to Cab Tilting .
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Drain the cooling system. Refer to Cooling System Draining and Filling .
- Remove the air inlet pipes.
- Remove the exhaust gas recirculation (EGR) pipe. Refer to Exhaust Gas Recirculation Pipe Replacement.
- Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .
- Remove the turbocharger assembly. Refer to Turbocharger Replacement.
- Remove the intake manifold assembly. Refer to Intake Manifold Replacement .
- Remove the exhaust manifold assembly. Refer to Exhaust Manifold Replacement .
- Remove the heat shield and bracket.
- Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
- Remove the valve rocker arm shaft assembly.
- Remove the camshaft assembly. Refer to Camshaft Replacement .
- Remove the fuel injector nozzles.
- Remove the coolant line from the air compressor to the cylinder head.
- Remove the glow plugs. Refer to Glow Plug Replacement .
- Remove the air compressor line bracket from the rear of the cylinder head.
- Remove the cylinder head bolts from the cylinder head in the numerical order shown in the illustration.
- Remove the cylinder head and the gasket from the engine.
- Inspect the threaded parts for wear or damage.
- Clean carbon deposits from the combustion chambers.
- Clean all traces of the old cylinder head gasket from the cylinder head and the engine block.
- Clean the cylinder head bolt threads using a wire brush.
- Clean metal chips and dirt from the threads in the cylinder block.
- Inspect the cylinder head for cracks or damage.
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.
Installation Procedure
- Install the cylinder head and gasket to the block.
- Apply molybdenum grease to the large head bolts (M14 bolts).
- Apply clean engine oil to the small head bolts (M10 bolts).
- Install the cylinder head bolts to the cylinder head.
- Tighten the cylinder head bolts in the following sequence:
- Tighten the remaining cylinder head bolts in the following sequence:
- Install the camshaft assembly. Refer to Camshaft Replacement .
- Install the rocker arm shaft assembly.
- Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
- Install the coolant line from the air compressor to the cylinder head.
- Install the air compressor lines and the bracket to the rear of the cylinder head.
- Install the glow plugs. Refer to Glow Plug Replacement.
- Install the fuel injector nozzles.
- Install the exhaust manifold. Refer to Exhaust Manifold Replacement .
- Install the intake manifold. Refer to Intake Manifold Replacement .
- Install the turbocharger assembly. Refer to Turbocharger Replacement .
- Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement.
- Install the EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement.
- Install the air inlet pipes.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Lower the cab.
Important: Apply sealant to the rear corners of the cylinder block before installing the cylinder head gasket with the part number facing up.
Notice: Refer to Fastener Notice in the Preface section.
| 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. |
Tighten
For bolts 27 and 28 tighten to 38 N·m (28 lb ft).
