Tools Required

1. Remove the right wheelhouse inner panel. Refer to Wheelhouse Panel Replacement .
2. Remove the turbocharger. Refer to Turbocharger Replacement .
3. Loosen the charged air cooler outlet duct clamp at the charged air cooler.
4. Remove the charged air cooler outlet duct (2).
5. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement .
6. Remove the right fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 .
7. Remove the right intake manifold. Refer to Intake Manifold Replacement - Right Side .
8. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
9. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
10. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 1 .



11. Remove the fuel injector return pipe bolts and washers.
12. Remove the fuel injector return pipe.



13. Remove the fuel injector bracket bolts.



14. Install J 44639 to the fuel injector brackets.
15. Pull back on the J 44639 in one steady motion, until the fuel injector breaks free from its seat.
16. Remove the J 44639 .



17. Remove the fuel injector with the brackets.
18. Remove the injector locating pins.



19. Remove the cylinder head bolts in the sequence shown and discard.



20. Remove the cylinder head.
21. Remove and discard the cylinder head gasket.
22. Clean the sealing surface of the engine block and the cylinder head.

Notice: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

23. Clean the cylinder head bolt holes in the engine block.
24. For service to the cylinder head refer to the following:

•	Refer to Cylinder Head Disassemble .

•	Refer to Cylinder Head Cleaning and Inspection .

•	Refer to Cylinder Head Assemble .

1. If the injector sleeve is pulled from the cylinder head when removing the injector, the injector sleeve installation procedure is as follows:

Important:     •  An injector sleeve with scoring or other damage must be replaced.    •  The stamped letter R or L must face up. R is the right bank and L is the left bank.

1.1.	Set the new injector sleeve gaskets (1) to the injector sleeve (2).

1.2.	Apply sealant LOCTITE 272,or equivalent to the lower sealing area of injector sleeve.





Notice: The left and right cylinder head gaskets are not interchangeable. Improper placement of the cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.

Important: The stamped letter R or L, must face up. R is the right bank, L is the left bank.

2. Install the right cylinder head gasket of the correct grade. Refer to Cylinder Head Gasket Selection Specifications .
3. Install the right cylinder head.

Notice: Refer to Fastener Notice in the Preface section.





Notice: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.

4. Install the NEW cylinder head bolts.
5. Tighten the cylinder head bolts in the following steps using the sequence shown.

Tighten

1. Tighten the M12 bolts a first pass to 50 N·m (37 lb ft).
2. Tighten the M12 bolts a second pass to 80 N·m (59 lb ft).
3. Tighten the M12 bolts a third pass to 60 degrees, using J 45059 .
4. Tighten the M12 bolts a final pass to 60 degrees, using J 45059 .
5. Tighten the M8 bolts to 25 N·m (18 lb ft).



6. Install a NEW O-ring onto the fuel injector.
7. Lubricate the O-ring with clean engine oil.
8. Ensure the injector bore is clean and free from carbon.
9. Install a new copper washer into the fuel injector bore in the cylinder head.
10. Install the fuel injector locating pin.
11. If reusing the injectors, clean the injector tip of carbon. Do not clean with a wire brush.
12. Install the fuel injector with fuel injector retainer.
13. Install the fuel injector retainer bolt.

Tighten
Tighten the bolt to 50 N·m (37 lb ft).




14. Install the fuel injector return pipe.
15. Install the fuel injector return pipe to injector bolts and washers.

Tighten
Tighten the bolts to 16 N·m (12 lb ft).

16. Install the fuel injector return pipe to cylinder head bolts and washers.

Tighten
Tighten the bolts to 17 N·m (13 lb ft).

17. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
18. Install the glow plugs. Refer to Glow Plug Replacement - Bank 2 .
19. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
20. Install the right fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 .
21. Install the right intake manifold. Refer to Intake Manifold Replacement - Right Side .
22. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement .



23. Install the charged air cooler duct (2).
24. Tighten the charged air cooler outlet duct clamp at the charged air cooler.

Tighten
Tighten the clamp to 6 N·m (53 lb in).

25. Install the turbocharger. Refer to Turbocharger Replacement .
26. Install the right wheelhouse inner panel. Refer to Wheelhouse Panel Replacement .
27. Road test the vehicle for normal operation.
28. Inspect for coolant, oil, or exhaust leaks.