Special tool
 | Engine/Differential Mounting Bracket 205-329 (15-105A) |
 | Valve stem seal installation tool 303-037 (21-007A) |
 | Valve Spring Compressor 303-060 (21-024) |
 | Adapter for 303-060 (21-024) 303-060-05 (21-024-05) |
 | Camshaft Seal Installer 303-199A (21-110A) |
 | Valve stem cracker installation tool 303-362 (21-156) |
 | Valve stem seal pliers 303-390 (21-165) |
 | Support stand 303-435 (21-187) |
 | Support bracket for 303-435 303-435-06 (21-031B) |
 | Socket Wrench for Cylinder Head Temperature Sensor 303-680 (21-239) |
| Name | Specification |
| Sealant | WSK-M2G348-A5 |
| Hypoid oil | SQM-2C-9002-AA |
| Motor oil | WSS-M2C912-A1 |
Disassembly
All cars
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions. Failure to follow these instructions may result in personal injury.
WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, it is especially important to maintain absolute cleanliness when working with these components. Always plug any open ports or lines.
CAUTION: Do not disassemble fuel injectors or clean their nozzles, even using ultrasonic cleaning.
1. Using special tools, secure the cylinder head to the support stand.
Vehicles with Exhaust Gas Recirculation (EGR) Cooler
2. Remove the EGR cooler outlet pipe flange bolts.
3. Remove the EGR cooler flange bolts. Discard the gasket as it is no longer needed.
4. Remove the EGR cooler.
Vehicles without EGR cooler
5. Disconnect the EGR pipe from the EGR valve.
6. Remove the EGR pipe.
All cars
7. Remove the exhaust manifold (six bolts and two self-locking nuts). Discard the gasket, bolts and nuts as they are no longer needed.
8. Remove the intake manifold (six bolts and two self-locking nuts). Discard the gasket, bolts and nuts as they are no longer needed.
9. Remove the rear engine lifting eye.
10. Remove the coolant outlet pipe. Discard the pipe as it is no longer needed.
11. Remove the oil pressure switch.
12. Using the special tool, remove the cylinder head temperature (CHT) sensor. Discard the sensor as it is no longer needed.
13. Remove the front engine lifting eye.
14. Remove the glow plug wiring harness.
15. Remove the bolts securing the fuel injector clamps. Discard the bolts as they are no longer needed.
16.
NOTE: Mark the position of the fuel injectors to ensure they are installed in their original position.
Remove the fuel injectors and retaining clips. Discard the fuel injector sealing washers as they are no longer needed.
17. Remove the glow plugs.
18.
CAUTION: Loosen all camshaft bearing cap nuts and bolts one turn - just enough to release the camshaft.
NOTE: Mark the position of the camshaft bearing caps and bolts to ensure they are installed in their original positions.
Remove the camshaft. Discard the camshaft oil seal as it is no longer needed.
19.
NOTE: Mark the positions of the valve lifters and shims to ensure they are installed in their original positions.
Remove the valve lifters and valve adjusting shims.
20.
NOTE: Mark the position of the lower camshaft bearing shells to ensure they are installed in their original position.
Remove the lower camshaft bearing shells.
21.
NOTE: Mark the position of the camshaft bearing cap shells to ensure they are installed in their original positions.
Remove the camshaft bearing cap liners.
22. Remove the brake booster vacuum pump. Discard the O-ring as it is no longer needed.
23. Remove the brake booster vacuum pump drive pusher.
24. Using special tools, remove the valve stem crackers.
25.
NOTE: Mark the position of the valve springs and valve retainers to ensure they are installed in their original positions.
Remove the valve springs with valve retainers.
26. Using a special tool, remove the valve stem seals. Discard the stem seals as they are no longer needed.
27.
NOTE: Mark the valve positions to ensure they are installed in their original positions.
Remove the valves.
Assembly
All cars
1. Apply clean hypoid oil to the valves.
2. Install the process bushings on the valve stems, covering the grooves for the valve crackers (for clarity, the valve is shown removed).
3.
NOTE: Install new valve stem seals.
Using a special tool, install the valve stem seals.
4. Remove the process bushings from the valve stems.
5. Install the valve springs and valve retainers.
6. Using special tools, install the valve stem crackers.
7. Remove the special tools.
8. Apply clean engine oil to the brake booster vacuum pump actuator plunger.
9. Install the brake booster vacuum pump drive pusher.
10.
Note: Install a new O-ring for the vacuum pump of the vacuum booster brake.
Install the brake booster vacuum pump.
11. Install the camshaft bearing cap shells.
12. Apply clean engine oil to the camshaft bearing cap shells.
13. Install the lower camshaft bearing shells.
14. Apply clean engine oil to the lower camshaft bearing shells.
15. Lubricate the valve lifters and adjusting shims with clean engine oil.
16.
NOTE: The writing on the valve adjusting shims faces down.
Install the valve lifters and valve adjusting shims.
17.
NOTE: The larger semicircle should face up.
Install the camshaft into the cylinder head.
18. Apply sealant to bearing cap No.1 in the indicated locations.
19.
NOTE: The arrows on the camshaft bearing caps must point toward the front of the engine.
NOTE: Do not tighten the camshaft bearing caps at this stage.
Install the camshaft bearing caps.
20.
NOTE: Tighten the camshaft bearing cap nuts and bolts, working evenly, one turn at a time.
Tighten the camshaft bearing cap nuts and bolts.
21.
NOTE: Install a new camshaft oil seal.
Using the special tool, install the camshaft oil seal.
22. Install the glow plugs.
23.
NOTE: Install new fuel injector sealing washers.
Install the fuel injector sealing washers.
24. Install the fuel injectors and retaining clips.
25.
NOTE: Install new fuel injector clamp retaining bolts.
Install the fuel injector clamp mounting bolts.
26. Install the glow plug wiring harness.
27. Install the front engine lifting eye.
28.
NOTE: Install a new cylinder head temperature (CHT) sensor.
Using the special tool, install the CHT sensor.
29. Install the oil pressure switch.
30.
NOTE: Install a new coolant outlet hose.
Install the coolant outlet pipe.
31. Install the rear engine lifting eye.
32.
NOTE: Install a new intake manifold gasket and new self-locking nuts and bolts.
Install the intake manifold.
33.
NOTE: Install a new exhaust manifold gasket and new self-locking nuts and bolts.
Install the exhaust manifold.
Vehicles without EGR cooler
34.
NOTE: Do not tighten the upper EGR pipe bolts at this stage.
Install the upper EGR pipe bolts.
35. Install the EGR pipe.
36. Tighten the upper EGR pipe bolts.
Cars with EGR cooler
37. Install the EGR cooler.
38.
NOTE: Install a new EGR cooler flange gasket.
Install the EGR cooler flange bolts.
39. Install the EGR cooler outlet pipe flange bolts.
All cars
40. Disconnect the cylinder head from the support stand. Remove the special tools.
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