Removal
Preparatory Step:
• Drain the coolant.
• Remove all water and heater hoses.
Remove the turbocharger and exhaust manifold. Refer to Procedures (7-05) and (7-06).
Remove the injectors and fuel lines.
10 mm
Remove the intake manifold cover and intake heater (if equipped).
Note the manifold cover orientation for proper direction during installation.
3/8 Inch Square Drive
Remove the drive belt.
13 mm
Remove the belt tensioner.
5 mm Allen
Remove the belt tensioner bracket.
10 mm
Remove the fan hub assembly.
NOTE: Omit this step if the fan bracket is not attached to the cylinder head.
10 mm
Loosen the alternator link, mounting bolt and water inlet connection capscrews.
Remove the alternator bracket mounting capscrews and pivot the alternator away from the engine.
10 mm
Remove the thermostat housing assembly.
18 mm
Remove the cylinder head capscrews in the sequence shown.
Remove the cylinder head and gasket from the cylinder block.
Cylinder Head Weight:
4 Cylinder – 36 Kg [80 lb]
6 Cylinder-5 1 .3 Kg [114 lb]
NOTE: Inspect the coolant passages. A large build up of rust and lime will require removal of the cylinder block for cleaning in a hot tank.
Straight Edge and Feeler Gauge
Use a straight edge and feeler gauge to measure the overall flatness of the cylinder block. The overall flatness, end to
end and side to side, must not exceed 0.075 mm [0.003 in].
Visually inspect the combustion deck for any localized dips or imperfections. If present, the cylinder block head
deck must be ground.
Refer to the Alternate Repair Manual for regrind/milling procedures and limits.
