1. DISCHARGE FUEL SYSTEM PRESSURE

27020 2.REMOVE GENERATOR ASSEMBLY

17111 3.REMOVE INTAKE MANIFOLD

17141 4.REMOVE EXHAUST MANIFOLD

5.DISCONNECT WIRE HARNESS

a.

Disconnect the 4 fuel injector assembly connectors.

b.

Disengage the 2 clamps to disconnect the engine wire from the 2 wire harness clamp brackets.

c.

Remove the 2 bolts and disconnect the wire harness.

d.

Disconnect the engine coolant temperature sensor connector.

e.

Disconnect the camshaft position sensor connector.

6.SET NO. 1 CYLINDER TO TDC/COMPRESSION

15100 7.REMOVE OIL PUMP ASSEMBLY

23901 8.DISCONNECT FUEL TUBE SUB-ASSEMBLY

23807 9.REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

23807V 10.REMOVE NO. 1 DELIVERY PIPE SPACER

23291 11.REMOVE INJECTOR VIBRATION INSULATOR

23250 12.REMOVE FUEL INJECTOR ASSEMBLY

44774 13.DISCONNECT UNION TO CONNECTOR TUBE HOSE

16571C 14.DISCONNECT NO. 1 RADIATOR HOSE

44774E 15.DISCONNECT VACUUM BRAKE HOSE

a.

Slide the clip and disconnect the vacuum brake hose from the No. 1 hose to hose tube.

87245 16.DISCONNECT INLET HEATER WATER HOSE

a.

Slide the clip and disconnect inlet heater water hose from the cylinder head sub-assembly.

87246 17.DISCONNECT OUTLET HEATER WATER HOSE

a.

Slide the clip and disconnect the outlet heater water hose from the No. 1 water by-pass pipe.

16268 18.REMOVE NO. 1 WATER BY-PASS PIPE

a.

Remove the 2 bolts, 2 nuts and the No. 1 water by-pass pipe.

b.

Remove the gasket from the cylinder block sub-assembly.

44763A 19.REMOVE NO. 1 HOSE TO HOSE TUBE

a.

Remove the 2 bolts and No. 1 hose to hose tube.

13540 20.REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

13559 21.REMOVE CHAIN TENSIONER SLIPPER

13561 22.REMOVE NO. 1 CHAIN VIBRATION DAMPER

13506 23.REMOVE CHAIN SUB-ASSEMBLY

13512 24.REMOVE NO. 2 CAMSHAFT

13511 25.REMOVE CAMSHAFT

11101 26.REMOVE CYLINDER HEAD SUB-ASSEMBLY

0.625,1.854 0.781,2.052 0.156,0.198 10 false 1 1.146,1.792 1.302,1.99 0.156,0.198 10 false 5 1.646,1.823 1.948,2.021 0.302,0.198 10 false 10 2.208,1.75 2.365,1.948 0.156,0.198 10 false 8 2.594,1.781 2.75,1.979 0.156,0.198 10 false 4 2.74,0.125 2.896,0.323 0.156,0.198 10 false 2 2.219,0.208 2.427,0.406 0.208,0.198 10 false 6 1.688,0.167 1.896,0.365 0.208,0.198 10 false 9 1.156,0.198 1.365,0.396 0.208,0.198 10 false 7 0.635,0.094 0.844,0.292 0.208,0.198 10 false 3

a.

Using an 8 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head set bolts and 10 plate washers in several steps in the order shown in the illustration.

NOTICE:

·

Removing the cylinder head set bolts in the wrong order may cause warpage or cracking of the cylinder head sub-assembly.

·

Do not drop the plate washers into the cylinder head sub-assembly.

b.

Using a screwdriver, remove the cylinder head sub-assembly by prying between the cylinder head sub-assembly and cylinder block sub-assembly.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly and cylinder block sub-assembly.

HINT:

Tape the screwdriver tip before use.

11115 27.REMOVE CYLINDER HEAD GASKET

a.

Remove the cylinder head gasket from the cylinder block sub-assembly.