Cylinder Head Removal
NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
  • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 38 °C (100 °F) before loosening the cylinder head bolts.
  • Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.
  1. Remove the engine cover.
  1. Remove the fuel hose.
  1. Remove the fuel return hose (A) and brake booster vacuum hose (B).
  1. Remove the heater hose.
  1. Remove the engine wire harness connectors and wire harness clamps from the cylinder head.
    • Four fuel injector connectors
    • Four glow plug connectors
    • Engine coolant temperature (ECT) sensor 1 connector
    • Camshaft position (CMP) sensor connector
    • Turbocharger boost control solenoid connector
    • Exhaust gas recirculation (EGR) control solenoid connector
  1. Remove the EGR pipe.
  1. Remove the camshaft holder bolts. To prevent damaging the camshafts, unscrew the bolts, in sequence, two turns at a time.
  1. Remove the upper camshaft holders and camshafts.
  1. Remove four bolts securing the lower camshaft holder, then remove the lower camshaft holder.
  1. Remove the rocker arm/hydraulic tappet assemblies.
  1. Remove the two 6 mm bolts (A), then remove the cylinder head bolts. To prevent warpage, unscrew the bolts, in sequence, 1/3 of a turn at a time; repeat the sequence until all bolts are loosened.
  1. Remove the cylinder head.
    NOTE: Do not place the cylinder head, facing lower the engine block surface with the glow plugs and valves.