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. Drain the engine coolant. Remove the drive belt. Remove the power steering (P/S) pump (A), and the P/S hose clamp (B). Do not disconnect the P/S hoses from the pump. Remove fuel feed hose. |

Remove the fuel return hose (A) and brake booster vacuum hose (B). |

Remove the expansion tank. |

Remove the upper radiator hose. |

Remove the heater hoses. Remove the intake manifold. Remove the exhaust manifold. Remove the exhaust gas recirculation (EGR) valve. Remove the fuel pump. Remove the engine wire harness connectors and wire harness clamps from the cylinder head. Four injector connectors Four glow plug connectors Engine coolant temperature (ECT) sensor connector Camshaft position (CMP) sensor connectors Turbocharger boost control solenoid connector Remove the cam chain. |

Remove the camshaft holder bolts. To prevent damaging the camshafts, unscrew the bolts two turns at a time, in crisscross pattern. |

Remove the upper camshaft holders and camshafts. |

Remove four bolts securing the lower camshaft holder, then remove the lower camshaft holder. |

Remove the rocker arm/hydraulic tappet assemblies. |

Remove the two 6 mm bolts (A), then remove the cylinder head bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. Remove the cylinder head. NOTE: Do not place the cylinder head, facing lower the block surface with the glow plugs and valves. |