Installation

Cylinder Heads





Special Tool(s)





Material

Installation

Both cylinder heads

1. NOTE: Use care to avoid scratching the blue compound on the cylinder head gasket. Install a new cylinder head gasket with the part number facing upward and verify the top five holes and the head gasket push rod holes line up.

Install new dowels and the cylinder head gasket.





2. Using the special tools, install the cylinder head on the engine.
1. Install the lifting bracket.
2. Install the bolts.
^ Install the cylinder head.





3. Install the outer cylinder head bolts finger-tight.





4. NOTE: Higher mileage engines require push rods to be cleaned so the copper colored end of the push rod can be identified.

Apply clean engine oil to each end of the push rod. Insert them into their respective positions with the copper colored end up.





5. NOTE: Coat the end of each valve stem with clean engine oil.

Install the 16 valve bridges.





6. Install the rocker arm carrier.
^ Install the press-in-place gasket.
^ Install the rocker arm carrier and bolts.





7. CAUTION: Rotate the crankshaft until the damper locating dowel notch is in the six o'clock position or engine damage can occur.

NOTE: Apply clean engine oil to the top center of each valve bridge.

Install the rocker arm assemblies and 16 bolts.





8. CAUTION: Using too much engine oil on the threads of the cylinder head bolts can cause damage to the threads and poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads can affect the true torque value of the bolts.

NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.

Install the 20 inner cylinder head retaining bolts finger-tight.





9. Tighten the head bolts in this sequence.
1. Tighten bolts 1 through 10 to 88 Nm (65 ft. lbs.).
2. Tighten bolts 1, 3, 5, 7 and 9 to 115 Nm (85 ft. lbs.).
3. Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
4. Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees.
5. Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees.
6. Tighten bolts 11 through 15 to 24 Nm (18 ft. lbs.).
7. Tighten bolts 11 through 15 to 31 Nm (23 ft. lbs.).





10. NOTE: Install new O-ring seals and apply clean engine oil.

Install a crankcase-to-head tube assembly.





11. CAUTION: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.

NOTE: Lubricate the fuel injector and O-ring seals liberally with clean engine oil.

Install new O-ring seals and a copper washer on the fuel injector.





12. Install the fuel injector, the fuel injector hold-down and bolt.





13. CAUTION: Be sure the injector wiring is clear of all moving parts or engine damage can occur.

Install the fuel injector electrical connector into the rocker carrier.





14. NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high pressure oil rail.

Position the high pressure oil rail on the injectors.
^ Place the high pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle.
^ Insert three guide bolts, two on the ends of the straight side of the high pressure oil rail and one in the middle of the wavy side of the high pressure rail. Install the guide studs six to seven turns.
^ Press the high pressure oil rail into the fuel injectors.
^ Inspect that the high pressure oil rail mounting feet are flat against the mounting surface.
^ Loosely install the six bolts.





15. Install the remaining bolts and tighten.
^ Remove the three guide bolts.
^ Loosely install the three remaining bolts.
^ Tighten the nine bolts in the sequence shown.

RH cylinder head





16. Install the RH high pressure oil rail-to-valve cover gasket.





17. CAUTION: To prevent engine damage, do not use air powered tools when installing the valve cover.

Install the RH valve cover.





18. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, therefore allowing alignment of the remaining bolts.

NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.

Install the right exhaust manifold and the bolts.

LH cylinder head
19. Cover the LH cylinder head with an appropriate covering.





20. Install the turbocharger heat shield and bolts.





21. NOTE: Install new sealing washers. Install the left cylinder head fuel line.





22. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, therefore allowing alignment of the remaining bolts.

NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.

Install the left exhaust manifold and the bolts.

Both cylinder heads





23. Install the eight glow plugs.





24. NOTE: Clean and inspect the glow plug connector O-ring seals and install new as necessary.

NOTE: Apply clean engine oil to the O-ring seals.

Install the glow plug harness.





25. Install the special tools.





26. Install the special tool.
27. Install the lifting crane and remove the engine from the engine stand.





28. Install the flexplate and the bolts.
^ Tighten the bolts in this sequence.
^ Tighten all bolts to 5 Nm (44 inch lbs.).
^ Tighten all bolts to 94 Nm (69 ft. lbs.) in the sequence shown.
29. Install the engine.