1. Remove front console and engine cover.
2. Drain radiator and disconnect batteries.
3. Remove batteries and battery tray.
4. Remove passenger side splash shield.
5. Remove air cleaner, inlet hose, and air horn.
6. Remove surge tank and water valve and hoses.
7. Remove crossover and thermostat housing, inlet tube, and radiator upper hoses as assembly.
8. Remove serpentine belt.
9. Disconnect and remove alternator, brackets, idler pulley, and tensioner.
10. Disconnect or remove:
– Glow plug relay and bracket
– Engine wire harness clips and ground wires
– Passenger side glow plugs and glow plug relay
11. Remove fuel injector line clamps, washers, nuts
12. Remove intake manifold and gaskets. Note attaching stud and bolt locations for installation reference.
13. Disconnect passenger side fuel injector lines at pump and injectors, and remove lines. Cover injectors with duct tape to prevent dirt entry.
14. Remove heat shield and guard. Then remove bolts/nuts attaching crossover pipe to exhaust manifold.
15. Remove rocker arm cover. Tap cover with rubber mallet to loosen. Do not pry on cover to remove.
16. Remove rocker arm shaft bolts and retainers. Remove arm and shaft assemblies individually. Note original position for assembly reference.
17. Remove pushrods. Note position or rods for installation reference as they must be installed in original position.
18. Remove cylinder head bolts. Discard bolts as they are not reusable.
19. Remove cylinder head with aid of helper. Or use chain hoist, portable hoist, or similar device to lift and remove cylinder head.
20. Remove cylinder head gasket. Discard gasket; it is not reusable.
21. Refer to cylinder head cleaning and inspection information if head, valves, valve seats, springs, or seals require service. Check for warpage. If head was only removed to replace blown gasket, proceed to installation procedure.
22. Cover cylinder bores and lifter valleys with shop towels.