Cylinder Head Assembly: Specifications

CYLINDER HEAD SURFACE VARIATION:

In Any 50.8 mm (2.00 inch) Diameter Area: 0.01 mm (0.0004 inch)

CYLINDER HEAD TORQUE/SEQUENCE:

1. The cylinder block and head must be clean and dry.

Cylinder Head/Gasket Alignment:

2. Position the gasket onto the dowels. Make sure the gasket is correctly aligned with the holes in the cylinder block.
3. Carefully put the cylinder head onto the gasket and cylinder block. Make sure the cylinder head is installed onto the dowels in the cylinder block.
4. Install the push rods and rocker levers.
5. Use clean engine oil to lubricate the cylinder head bolt threads and under the bolt heads.
6. The cylinder head bolts are 3 different sizes Install the bolts in the proper hole. Tighten the bolts as follows:

Cylinder Head Tightening Sequence:

^ Step 1-Tighten all bolts, in sequence, to 90 Nm (66 ft. lbs.) torque. Check the torque. If lower than 90 Nm (66 ft. lbs.), tighten to this torque.
^ Step 2-Tighten all long 12 mm bolts (Nos. 4, 5, 12, 13, 20 and 21), in sequence, to 120 Nm (89 ft. lbs.) torque. Check the torque. If lower than 120 Nm (89 ft. lbs.), tighten to this torque.
^ Step 3-Tighten all bolts, in sequence, an additional 90 degrees.

INTAKE MANIFOLD SPECIFICATIONS:

Manifold Cover Bolts 24 Nm (18 ft. lbs.)
Air Inlet Housing Bolts 24 Nm (18 ft. lbs.)
Air Intake Heater Power Supply Nuts 14 Nm (10 ft. lbs.)
Intercooler Outlet Duct Clamps 8 Nm (74 in. lbs.)
High Pressure Fuel Line Nuts 24 Nm (18 ft. lbs.)
EGR Nuts & Bolts 24 Nm (212 in. lbs.)

NOTE: When tightening bolts at EGR valve end of tube, alternate between the upper and lower bolt to allow face of EGR valve to remain square to the mounting flange on the EGR tube.


EXHAUST MANIFOLD TORQUE/SEQUENCE:

Engine Exhaust Manifold Bolt Tightening Sequence:

Exhaust Manifold Bolts 43 Nm (32 ft. lbs.)
Turbocharger Mounting Nuts 32 Nm (24 ft. lbs.)
Turbocharger Inlet & Outlet Clamps 8 Nm (74 in. lbs.)
Turbo Drain Tube Bolts 24 Nm (18 ft. lbs.)
Turbo Drain Tube Fitting Nuts 15 Nm (11 ft. lbs.)
Cab Heater Line Nuts 24 Nm (18 ft. lbs.)
EGR Nuts & Bolts 24 Nm (212 in. lbs.)

NOTE: When tightening bolts at EGR valve end of tube, alternate between the upper and lower bolt to allow face of EGR valve to remain square to tube mounting flange on EGR tube.

CYLINDER HEAD BOLT RE-USABILITY:





The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced.