Cylinder Head - Installation
Cylinder Head
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 5 holes and the head gasket push rod holes line up.
Install new dowels and the cylinder head gaskets.
2. Using the Cylinder Head Lifting Bracket, install the cylinder heads on the engine.
3. Install the 10 outer cylinder head bolts finger-tight.
4. NOTICE: 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. The push rods are directional and the copper-coated end must be installed in the upward position where it will contact the rocker arm.
Apply clean engine oil to each end of the push rods and insert them into their respective positions.
5. NOTE: Coat the end of each valve stem with clean engine oil.
Install the 16 valve bridges.
6. NOTE: LH cylinder head shown, RH cylinder head similar.
Install the new press-in-place gaskets, the rocker arm carriers and 4 bolts.
- Tighten to 62 Nm (46 lb-ft).
7. NOTICE: Rotate the crankshaft until the damper locating dowel notch is in the 6 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 the 16 bolts.
- Tighten to 31 Nm (23 lb-ft).
8. NOTICE: 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.
NOTE: LH cylinder head shown, RH cylinder head similar.
Install the 20 new inner cylinder head retaining bolts finger-tight.
9. Tighten the head bolts in sequence in 7 stages:
- Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
- Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
- Stage 3: Tighten bolts 1 through 10 an additional 90 degrees.
- Stage 4: Tighten bolts 1 through 10, a second time, 90 degrees.
- Stage 5: Tighten bolts 1 through 10, a third time, 90 degrees.
- Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 lb-ft).
- Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
10. NOTE: 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 injectors.
11. NOTICE: Failure to tighten the injector correctly can lead to engine failure.
NOTICE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
Assemble the fuel injector hold down and bolt on the fuel injector and install the assembly.
- Tighten to 35 Nm (26 lb-ft).
12. NOTICE: 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.
13. Apply clean engine oil to the top fuel injector O-ring seals.
14. NOTICE: Using the bolts to push the high pressure oil rail into the fuel injectors can damage the fuel injectors and high pressure oil rail.
NOTE: LH cylinder head shown, RH cylinder head similar.
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 4 single ball tubes are engaging the fuel injector lead angle.
- Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
- Manually 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 6 bolts.
15. NOTE: LH cylinder head shown, RH cylinder head similar.
Remove the 3 guide bolts, install the 3 remaining high-pressure oil rail bolts and tighten the 9 high-pressure oil rail bolts in the sequence shown.
- Tighten to 13 Nm (115 lb-in).
16. Apply clean engine oil to the D-ring seals and reassemble the crankcase-to-head tube if necessary. Install the crankcase-to-head tube(s).
- Tighten to 82 Nm (60 lb-ft).
17. Connect the fuel injector electrical connectors.
RH cylinder head
18. Install the high-pressure oil rail-to-valve cover gasket.
19. NOTICE: To prevent engine damage, do not use air-powered tools when installing the valve cover.
Position the RH valve cover gasket, RH valve cover, 6 stud bolts and 5 bolts.
- Tighten to 9 Nm (80 lb-in).
20. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.
NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
Install the RH exhaust manifold, 8 spacers and the 8 new bolts.Tighten the 8 new bolts in the sequence shown.
- Tighten to 38 Nm (28 lb-ft).
LH cylinder head
21. Cover the LH cylinder head with an appropriate covering.
22. Position the turbocharger heat shield and install the 3 bolts.
1. Tighten to 49 Nm (36 lb-ft).
2. Tighten to 11 Nm (97 lb-in).
23. NOTE: Install new sealing washers.
Install the LH cylinder head fuel tube.
- For Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).
- For copper sealing washers, tighten to 38 Nm (28 lb-ft).
24. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.
NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
Install the LH exhaust manifold, 8 spacers and the 8 new bolts. Tighten the 8 new bolts in the sequence shown.
- Tighten to 38 Nm (28 lb-ft).
Both cylinder heads
25. Install the 8 glow plugs.
- Tighten to 19 Nm (168 lb-in).
26. NOTE: Clean and apply clean engine oil to the O-ring seals.
Using the Glow Plug Connector Remover/Installer, install the glow plug harness.
27. Install the Adapter for 303-D043.
28. Install the Adapter for 303-D043.
29. Remove the engine from the engine stand.
30. Install the flexplate and 10 new bolts. Tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 94 Nm (69 lb-ft).
31. Install the engine. For additional information, refer to Engine Engine - Installation.