Cylinder Head Removal

Cylinder Head Assembly Drawing 1. Cylinder head cover
2. Cover gasket
3. Camshaft bearing cap
4. Compensating shim
5. Valve lifter
6. Valve keepers
7. Valve spring retainer
8. Valve spring
9. Valve stem oil seal
10. Valve spring seat
11. Valve guide
12. Camshaft
13. Cylinder head bolt
14. Cylinder head
15. Sealing sleeve
16. Cylinder head connection fitting
17. Cylinder head gasket
18. Exhaust manifold
19. Manifold gasket
20. Camshaft seal flange
21. Camshaft timing gear
22. Upper timing belt cover
23. Timing belt idler pulley
24. Return spring
25. Compensating shim
26. Valve seat
27. Valve
28. Fuel return line
29. Injector
30. Injector seat
31. Seal
32. Center timing belt cover
33. Rubber cap
34. Current bus bar
35. Glow plug
36. Manifold gasket
37. Intake manifold

Cylinder Head Bolt Tightening Sequence

The following describes the removal and installation of the cylinder head without removing the engine.

PROCEDURE
1. Disconnect the battery.
2. Drain the coolant.
3. Remove the injector lines, injectors and fuel supply line.
4. Disconnect the power wire from the intake manifold. Remove the 4 rubber caps from the glow plugs, remove the 4 nuts, remove the current bus bar and unscrew the four glow plugs. Glow plug mounting is shown on the right side of the Cylinder Head Assembly Drawing.
5. Remove the timing belt as described in the previous chapter. Also remove the camshaft timing gear.
6. Disconnect the throttle cable mechanism.
7. Remove the coolant drain pipe and heater pipe. This also releases the engine lifting bracket. There is a gasket under the pipe flange. Disconnect the hose at one end.
8. Remove the center timing belt cover (32) from the front of the engine, see Cylinder Head Assembly Drawing.
9. Remove the six cylinder head cover nuts and sealing washers and remove the cover with the gasket.
10. Remove the front engine lifting bracket.
11. Loosen the eighteen cylinder head bolts evenly in the sequence shown in Cylinder Head Bolt Tightening Sequence.
12. Lift the cylinder head off the dowel pins and place it on a workbench. If the cylinder head is stuck, separate it from the cylinder block using a screwdriver inserted between the cylinder head and the cylinder block projection. Take care not to damage the cylinder head. Remove all traces of the old gasket. Do not allow pieces of the old gasket to fall into the cylinder block.