Installation

Installation






Special Tool(s)






Material


One-piece head tube






1. CAUTION: Install new D-ring seals on the crankcase-to-head tube. It requires several hours after installation for the D-ring seals to relax back to their original size. If the tube assembly is installed before the D-ring seals have relaxed, damage to the D-ring seals can occur.

Install new D-ring seals on each end of the crankcase to head tube assemblies.

Two-piece head tube






2. CAUTION: Install new D-ring seals on the crankcase-to-head tube. It requires several hours after installation for the D-ring seals to relax back to their original size. If the tube assembly is installed before the D-rings have relaxed, damage to the D-ring seals can occur.

Install new D-ring seals on the crankcase-to-head tube.

All vehicles

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

Install the dowels and the cylinder head gasket.






4. NOTE: Position the fuel lines in place before the cylinder head is installed.

NOTE: The back two cylinder head bolts cannot be installed into the head in vehicle. Lightly lubricate the threads of two new cylinder head bolts with clean engine oil. Position these bolts in the head and secure them in position so they will clear the cylinder block deck as the head is installed.

Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.






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






6. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.

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

NOTE: If a push rod has been replaced, it may not have a copper-colored end and can be installed with either end up.

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






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

Install the eight valve bridges.






8. 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 eight bolts.






9. 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.

CAUTION: Make sure the insulation blanket is not damaged (torn, cracked or fabric separated from the metallic skin) when installing the lower rear cylinder head bolt. If the insulation blanket is damaged, the entire blanket must be replaced.

NOTE: It may be necessary to slightly compress or deform the insulation blanket to gain tool clearance to install the lower rear cylinder head bolt.

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

Install the 10 new cylinder head retaining bolts finger-tight.






10. Tighten the head bolts in the following sequence.

1. Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
2. Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
3. Tighten bolts in sequence 1 through 10, clockwise 90°.
4. Tighten bolts in sequence 1 through 10, a second time, clockwise 90°.
5. Tighten bolts in sequence 1 through 10, a third time, clockwise 90°.
6. Tighten bolts 11 through 15 an to 24 Nm (18 lb-ft).
7. Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).






11. NOTE: Install new sealing washers.

Install the fuel line and the banjo bolts.
For Viton sealing washers, tighten to 25 N.m (18 lb-ft).
For copper sealing washers, tighten to 38 N,m (28 lb-ft.






12. Install the fan shroud mounting stud.






13. Position back and connect the heater hose.






14. Install the idler pulley and bolt.






15. Position the exhaust backpressure bracket assembly and install the retaining nuts.






16. Tighten the exhaust backpressure tube fitting at the exhaust manifold.






17. Position the fuel lines and install the fuel line bracket retaining bolt.

18. NOTE: Install a new O-ring and apply clean engine oil.





Install the oil level indicator and tube.






19. Install the turbocharger heat shield and bolts.






20. Position the turbocharger adapter pipe.






21. NOTE: Apply anti-seize lubricants to the bolt threads prior to installing the bolts.

NOTE: Do not tighten until after the turbocharger is installed.

Install the nuts and bolts in the adapter pipe.






22. Install the four glow plugs.






23. 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-rings liberally with clean engine oil.

Install new O-rings and copper washer on the fuel injector.






24. CAUTION: Failure to tighten the injector properly can lead to engine failure.

CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.

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






25. CAUTION: Make 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.






26. Apply engine oil to the top fuel injector O-rings.

Early build






27. NOTE: Install a new lower O-ring.

Install a new crankcase to head tube assembly.






28. Install the high-pressure oil rail and bolts.

- Install the high-pressure oil rail.
- Install the bolts finger tight.






29. Tighten the bolts in the sequence shown.






30. Install the high-pressure oil line.






31. NOTE: Clean and inspect the O-rings and install new as necessary.

NOTE: Apply clean engine oil to the O-rings before installing.

Install the glow plug buss bar.

One-piece head tube






32. CAUTION: To prevent engine damage, check that the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function correctly if the tube is not bottomed out.

NOTE: Install new O-rings.

Apply clean engine oil and install the crankcase-to-head tube assembly.

Late build






33. NOTE: Apply clean engine oil to the top fuel injector D-ring before installing the high pressure oil rail.

Position the oil rail on the fuel injectors.

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






34. Install the oil rail retaining bolts.

- Remove the three guide bolts.
- Loosely install the three remaining bolts.
- Tighten the bolts in the sequence shown.

Two-piece head tube






35. NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installation.

If equipped with an updated crankcase-to-head tube, install the crankcase-to-head tube assembly.

Late build






36. NOTE: Clean and apply clean engine oil to the O-rings prior to installing.

Using the special tool, install the glow plug harness.

All vehicles






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

NOTE: Late build shown, early build similar.

NOTE: Clean and inspect the valve cover gasket. Install a new gasket if necessary.

Position the valve cover gasket. Install the valve cover and 11 bolts.






38. Position back the oil level indicator and install the nut.






39. NOTE: Late build shown, early build similar.

Connect the glow plug connector.






40. NOTE: Late build shown, early build similar.

Install the fuel injector control module mounting bracket.

41. NOTE: Install a new oil filter.

Fill the crankcase with clean engine oil.






42. NOTE: Lightly lubricate the O-ring with clean engine oil before installing.

Install the cylinder block drain plug.

43. Install the intake manifold.