3.3 Cylinder head
3.3.1 Removing cylinder head
Procedure
1.
Disconnect current from the main switch.
2.
Clean the engine externally and drain the coolant. Disconnect the coolant hoses from the cylinder
head and the thermostat housing.
3.
Remove the suction hoses between the turbocharger and the air filter and between the turbocharger
and the inlet manifold.
4.
Disconnect the turbocharger pressure and return oil pipes.
5.
Remove the valve cover.
6.
Disconnect the wires from the intake air heater and injectors.
7.
Remove the injector leak-off fuel pipe and the high-pressure pipes. Remove the injectors. Fit
blanking-off caps on all open connections.
WARNING:
Do not make any work at the common rail high pressure fuel system when the
engine is running. Wait at least 30 seconds after stopping the engine .The first high
pressure component has to be loosened slowly, so that the pressure inside the fuel
system can adjust to ambient pressure. If the jet of high pressure fuel contacts your
skin, fuel penetrates the skin causing severe injuries. Get medical help immediately!
8.
Remove the inlet and exhaust manifolds and the thermostat housing.
NOTE: It is possible to remove the cylinder head even though these parts are attached to the head.
9.
Remove the rocker arm mechanism and the push rods.
10.
Loosen all the cylinder head bolts first by a 1/4 turn, then loosen them fully and remove. Remove the
cylinder head.
3.3.2 Removing valves
Procedure
1.
Ensure that the valves to be re-used are marked, so that they can be re-fitted in their original
locations.
2.
Compress the valve springs with standard valve spring press.
3.
Remove the valve cotters, spring guide and spring.
4.
Remove the valve stem seals and remove the valves.
3.3.3 Checking cylinder head
Procedure
1.
Remove the soot from the exhaust ports, clean the sealing surfaces and wash the cylinder head.
3. Maintenance
4th Generation Engines 3-15
8370 79492
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