• Glow Plug
• Throttle Body Gasket

EN-52074 Glow Plug Bore Reamer

Equivalent regional tools:Special Tools

1. Oil Filler Cap»Remove



2. Intake Manifold Cover Bolt(1)»Remove
3. Intake Manifold Cover(2)»Remove
4. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.



5. Charge Air Cooler Outlet Air Hose Clamp (1)»Loosen until disengaged[2x]
6. Charge Air Cooler Outlet Air Hose(2)»Remove



7. Disconnect the throttle body electrical connector.
8. Throttle Body Bolt(1)»Remove[3x]
9. Throttle Body(2)»Remove
10. Throttle Body Gasket(3)»Remove and DISCARD



11. Air Cleaner Outlet Duct Clamp(1)»Loosen[2x]
12. Air Cleaner Outlet Front Duct(2)»Remove



13. Disconnect the wiring harness connector (1).
14. Clean around the glow plug.




Caution: Ensure each glow plug is fully intact when removed from the cylinder head. A broken tip could remain within the combustion chamber, which may not be obvious during removal. Damage to the engine may result if a broken glow plug tip remains within the engine.

Note:

• Glow plugs must be DISCARDED whenever removed, and replaced with NEW.
• If the cylinder head is removed, the accompanying glow plug must be DISCARDED and replaced with NEW.
• Do not use power tools to install the glow plug.
• Cylinder head removal may be required to retrieve a broken tip.

15. Remove and DISCARD the glow plug (1) from the cylinder head.
16. Inspect each glow plug tip and ensure the glow plug is not broken. If a broken tip is suspected, inspect the combustion chamber for the glow plug tip.

1. Inspect the charge air cooler outlet air hose (2):
1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces.
2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found.
3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing.




Caution: The glow plug bore MUST be cleaned prior to glow plug installation. If the glow plug bore is not cleaned of carbon buildup prior to glow plug installation, it may cause severe damage to the glow plug. If the glow plug is damaged, the glow plug bore and combustion chamber must be cleaned of all debris, and the glow plug must be replaced.

2. Using the EN-52074 Glow Plug Bore Reamer (1), clean the glow plug bore. Hole must be free of lubricant and grease.

Note:

• Avoid canting of the glow plug during the insertion process into cylinder head bore.
• Handle with extreme care, do not allow glow plugs to touch each other. Any impact to glow plug requires replacement with NEW.
• Do not use power tools to install the glow plug.

1. Install the NEW glow plug (1) by hand a minimum of 3 turns into the cylinder head thread.

Caution: Refer to Component Fastener Tightening Caution.

2. Glow Plug(1)»Tighten—Fastener Specifications



3. Connect the wiring harness connector (1).



4. Air Cleaner Outlet Front Duct(2)»Install

Caution: Refer to Fastener Caution .

5. Air Cleaner Outlet Duct Clamp(1)»Tighten[2x]—Fastener Specifications



6. Throttle Body Gasket(3)»Install NEW
7. Throttle Body(2)»Install
8. Throttle Body Bolt(1)»Install and tighten[3x]—Fastener Specifications
9. Connect the throttle body electrical connector.



10. Charge Air Cooler Outlet Air Hose(2)»Install
11. Charge Air Cooler Outlet Air Hose Clamp (1)»Tighten[2x]—Fastener Specifications
12. Oil Filler Cap»Remove



13. Intake Manifold Cover(2)»Install
14. Intake Manifold Cover Bolt(1)»Install and tighten—Fastener Specifications
15. Oil Filler Cap»Install