LEMON Manuals: Even more car manuals for everyone
Home >> Jeep >> 2005 >> Wrangler Rubicon, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 502 (2.8L Diesel Engine (Service Information)) >> Cylinder Head Cover >> Removal >> Removal - Cylinder Head Cover

Removal - Cylinder Head Cover

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: CYLINDER HEAD COVER/INTAKE MANIFOLD ASSEMBLY
GC0026153Courtesy of DAIMLERCHRYSLER CORP.
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS (LONG)
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
3 - CYLINDER HEAD
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS (SHORT)
CAUTION: Before removing the cylinder head cover/intake manifold the witness mark on the crankshaft hub must rotated to the 3 O'clock position or, 90° ATDC to assure proper alignment of the camshafts and the crankshaft. Failure to do so could result in valve and/or piston damage during reassembly (Refer to ENGINE/VALVE TIMING - STANDARD PROCEDURE) .
  1. Disconnect negative battery cable.
  2. Remove engine cover and bracket. Refer to ENGINE COVER .
  3. Remove the air cleaner housing (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL) .
  4. Drain cooling system. Refer to STANDARD PROCEDURE .
  5. Evacuate the air conditioning.
  6. Disconnect the coolant recovery hose at the radiator.
  7. Remove the charge air inlet hose at the coolant module.
  8. Remove the upper radiator hose at the radiator.
  9. Separate the A/C hoses from the cooling fan shroud.
  10. Remove cooling fan and fan drive viscous drive assembly, along with the fan shroud. Refer to RADIATOR - FAN - VISCOUS .
  11. Remove accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) .
  12. Remove cooling fan support (Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL) .
  13. Disconnect the EGR cooler pipe behind the inner timing cover.
  14. Remove generator (Refer to ELECTRICAL/CHARGING/GENERATOR - REMOVAL) , and generator rear support bracket.
  15. Remove the accessory drive belt Idler pulleys L.H. Thread. 
  16. Remove the drive belt tensioner.
  17. Remove the power steering pump pulley.
  18. Remove the vibration damper.
    CAUTION: Before removing the cylinder head cover/intake manifold the witness mark on the crankshaft hub must rotated to the 3 O'clock position or, 90° after TDC to assure proper alignment of the camshafts and the crankshaft. Failure to do so could result in valve and/or piston damage during reassembly.
  19. Rotate the crankshaft hub to 90° after TDC (3 O'clock position).
  20. Remove heater hose pipe fasteners.
    NOTE: It may be necessary to rotate the camshaft gear bolt slightly to gain proper camshaft alignment pin seating against the intake manifold. Alignment pins must seat flush against the intake manifold.
  21. Install the intake camshaft locking pin VM.1052 and exhaust camshaft locking pin VM.1053 (Refer to ENGINE/VALVE TIMING - STANDARD PROCEDURE) .
  22. Remove outer timing belt cover (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - REMOVAL) .
  23. Remove timing belt (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) .
    Fig 2: VM.1085 CAMSHAFT LOCKING TOOL
    GC0026125Courtesy of DAIMLERCHRYSLER CORP.
  24. Install special tool VM.1085 and remove camshaft gears. See Fig 2.
  25. Remove timing belt idler pulleys L.H. Thread. 
  26. Remove inner timing belt cover (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - REMOVAL) .
  27. Disconnect coolant temperature sensor, camshaft position sensor, boost pressure/intake air temperature sensor, fuel injectors, fuel temperature sensor, fuel rail solenoid, and EGR air flow electrical connectors.
  28. Disconnect the main engine harness connectors at the right inner fender well and position the harness over the left side of the engine and aside.
    Fig 3: EGR AIR CONTROL VALVE
    GC0026154Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL LEVEL INDICATOR
    2 - RETURN FUEL JUNCTION BLOCK
    3 - RETURN FUEL FROM HIGH PRESSURE PUMP
    4 - EGR VALVE
    5 - EGR TUBE FROM EGR COOLER
    6 - EGR AIR CONTROL VALVE
    7 - BRAKE BOOSTER VACUUM TUBE
    8 - FUEL RAIL
  29. Disconnect the brake booster vacuum pipe from the EGR air control valve. See Fig 3.
  30. Separate the main engine harness from the bracket on the EGR air control valve.
  31. Remove the EGR tube from the underside of the EGR air control valve. See Fig 3.
  32. Separate the block heater wiring harness from the oil level indicator tube.
  33. Remove the oil level indicator tube from the EGR air control valve. See Fig 3.
  34. Remove fuel injectors (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL) .
  35. Remove fuel rail (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL RAIL - REMOVAL) .
  36. Disconnect oil separator outlet hose at separator.
  37. Remove the oil separator from the intake manifold/cylinder head cover.
  38. Disconnect the return fuel junction block from the intake manifold/cylinder head cover.
  39. Remove cylinder head cover/intake manifold retaining bolts. See Fig 1.
  40. Lift cylinder head cover/intake manifold from cylinder head. See Fig 1.
    NOTE: When removing rocker arm and lifter assemblies, Always keep lifters in an upright position and in the order that they were removed from the cylinder head.
  41. Remove rocker arm and lifter assemblies from cylinder head.
  42. Remove cylinder head cover/intake manifold gasket from cylinder head.
scientia non olet · About LEMON Manuals