Diesel Data: Automotive Repair

Removal and Installation






REMOVAL
1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect negative battery cable.
3. Remove air cleaner duct and air cleaner, disconnect all vacuum lines, electrical wiring and fuel line from fuel rail and throttle body.
4. Remove throttle linkage.
5. Remove accessory drive belts.
6. Remove power brake vacuum hose from intake manifold.
7. Raise vehicle and remove exhaust pipe from manifold.
8. Remove power steering pump assembly and set aside.
9. Disconnect coil pack wiring connector and remove coil pack from engine.
10. Remove cam sensor and fuel injectors wiring connectors.
11. Remove timing belt and camshaft sprocket.
12. Remove cylinder head cover.
13. Remove camshaft and cam follower assemblies.
14. Remove cylinder head bolts.

NOTE: Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the aluminum head sealing surface.

INSTALLATION
1. Before installing the bolts the threads should be oiled with engine oil. The 4 short bolts 110 mm (4.330 inch) are to be installed in positions 7, 8, 9, and 10.
2. Tighten the cylinder head bolts in this sequence shown. Follow the four step procedure listed below.
- First Bolts 1 thru 6 to 34 Nm (25 ft. lbs.) and Bolts 7 thru 10 to 28 Nm (20 ft. lbs.).
- Second Bolts 1 thru 6 to 68 Nm (50 ft. lbs.) and Bolts 7 thru 10 to 28 Nm (20 ft. lbs.).
- Third Bolts 1 thru 6 to 68 Nm (50 ft. lbs.) and Bolts 7 thru 10 to 28 Nm (20 ft. lbs.).
- Fourth Turn an additional 1/4 Turn, Do not use a torque wrench for this step.
3. Reverse removal procedure, for rest of installation.