Cylinder Head - Installation - Body On

Cylinder Head - Body On









Installation

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body was not removed, refer to Cylinder Head - Body Off Cylinder Head - Installation - Body Off.

Both cylinder heads

1. Install the 4 new cylinder head dowels.





2. NOTE: Install a new cylinder head gasket with the part number facing up. Verify the top 5 bolt holes and the head gasket push rod holes line up.

NOTE: Use care to avoid scratching the blue compound on the cylinder head gaskets.

Place the 2 new cylinder head gaskets over the dowel sleeves and onto the crankcase.





3. Using the Heavy Duty Floor Crane and the Cylinder Head Lifting Bracket, install the cylinder heads.





4. Install the 10 outer bolts for the cylinder heads.
- Tighten finger-tight.





5. NOTICE: Using too much engine oil on the threads of the cylinder head bolts may 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 may affect the true torque value of the bolts.

NOTE: Left cylinder head shown, right cylinder head similar.

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

Install the 20 cylinder head retaining bolts for the cylinder heads.

- Tighten finger-tight.





6. NOTE: If bolt chatter occurs during Stage 4 or 5, loosen the bolt and repeat Stage 3.

Tighten the cylinder head bolts in 7 stages in the sequence shown:

- Stage 1: Tighten bolts 1 through 10 to 95 Nm (70 lb-ft).

- Stage 2: Loosen bolts 1 through 10.

- Stage 3: Tighten bolts 1 through 10 to 156 Nm (115 lb-ft).

- Stage 4: Tighten bolts in sequence, 1 through 10, an additional 90 degrees.

- Stage 5: Tighten bolts in sequence, 1 through 10, a second time, an additional 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).





7. NOTE: Lubricate the seals with clean engine oil prior to installation.

If necessary, install a new seals for the high-pressure fuel rail.





8. Install the new press-in-place gaskets, the valve cover bases and the 22 bolts.
- Tighten to 13 Nm (115 lb-in).





9. 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.

NOTE: Install the copper ends of the push rods facing upward.

Apply clean engine oil to each end of the push rods and insert them into their respective positions.





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

Install the 16 valve bridges.





11. Position the 2 rocker arm spacer bars.





12. NOTE: Apply clean engine oil to the top center of each valve bridge and rocker arm ball socket.

Install the rocker arm assemblies and the 16 bolts in the following sequence.

1. Position the crankshaft with the No. 1 and the No. 4 cylinders at approximately Top Dead Center (TDC) by observing the damper dowel pin and clocking it to the 10:30 position (as viewed from the front of the engine).

2. Determine which cylinder is actually in the firing position by observing the push rods for No. 3 intake and No. 8 intake valves.

3. If the No. 3 intake push rod shows cam lift, this is the No. 1 firing position. Tighten only fulcrum plates No. 1, 2, 7 and 8 per Substeps 4 through 6. If the No. 8 intake push rod shows cam lift, this is the No. 4 firing position. Tighten only fulcrum plates No. 3, 4, 5 and 6 per Substeps 4 through 6.

4. Partially run down both M10 bolts until they contact the fulcrum plate.

5. Fully run down and tighten the inboard (upper) bolt.
- Tighten to 61 Nm (45 lb-ft).

6. Fully run down and tighten the outboard (lower) bolt.
- Tighten to 61 Nm (45 lb-ft).

7. Rotate the crankshaft one revolution to position it at the alternate cylinder TDC (dowel again at 10:30 position).

8. Identify the remaining group of fulcrum plates per Substep 3 and tighten per Substeps 4 through 6.

9. Verify that the pivot foot is centered on the valve bridge.





13. NOTE: The bead on the soft steel washer must be installed facing out.

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

Install a new O-ring seal and a soft steel washer on the fuel injector.





14. NOTICE: Failure to tighten the fuel injector correctly can lead to engine failure.

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

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

- Tighten to 2 Nm (18 lb-in).





15. NOTE: RH shown, LH similar.

Install the high-pressure fuel rails and 4 bolts.

- Tighten hand-tight.





16. NOTE: Use a back-up wrench on the fuel injector fittings.

NOTE: Use a crowfoot wrench to aid in tightening the fuel injector supply tube.

Install the new fuel injector supply tubes in the following sequence.

1. Remove the protective caps from the high-pressure fuel rails and fuel injectors one at a time prior to assembly of each tube.

2. Position the 8 fuel injector supply tubes (one at a time) between the high-pressure fuel rail and fuel injectors, and fully hand start and seat the tube nuts onto the mating high-pressure fuel rail and fuel injector connectors. Snug the fuel injector supply tube nuts using the inside-out step sequence (2 inside tubes first, then 2 outside tubes).
- Calculate the correct torque wrench setting for the following torque.

- Tighten to 2 Nm (18 lb-in).

3. Tighten the fuel injector hold-down clamp bolts.
- Tighten to 38 Nm (28 lb-ft).

4. Tighten the high-pressure fuel rail bolts.
- Tighten to 31 Nm (23 lb-ft).

5. NOTE: Pre-tighten the 8 fuel injector tube nuts at the fuel injectors first, then the 8 nuts at the high-pressure fuel rails.

Pre-tighten the fuel injector tube nuts at the fuel injectors and at the high-pressure fuel rails.
- Calculate the correct torque wrench setting for the following torque.

- Tighten to 12 Nm (106 lb-in).

6. NOTE: Place a visible mark with a permanent marker on the high-pressure fuel rail and fuel injector threaded connection. Turning the tube nuts one flat of the nut is equal to 60 degrees.

Complete the tightening of the fuel injector tube nuts at the fuel injectors and at the high-pressure fuel rails.
- Tighten the tube nuts 60 degrees.





17. NOTE: The terminals in the fuel charging harness plug are not serviced, install a new the fuel charging harness if damaged.

NOTE: Inspect the O-ring seals for damage or swelling prior to installing, install a new if necessary.

Install the 2 fuel charging harness electrical connectors into the valve cover bases.





18. NOTE: RH side shown, LH side similar.

Position the fuel charging harness on the high-pressure fuel rail and connect the 8 fuel injector electrical connectors. Connect the Fuel Rail Pressure (FRP) sensor electrical connector.





19. Install the 8 glow plugs.
- Tighten to 14 Nm (124 lb-in).





20. NOTICE: To prevent engine damage, do not use air-powered tools when installing the valve cover.

NOTE: Alternate tightening the bolts to tighten evenly.

NOTE: RH shown, LH similar.

Install new press-in-place gaskets. Install the valve covers, 6 bolts and 4 stud bolts.

- Tighten to 9 Nm (80 lb-in).





RH cylinder head

21. Position the crankcase vent oil separator tube. Install the 2 bolts and nut.
- Tighten the nut to 13 Nm (115 lb-in).

- Tighten the bolts to 25 Nm (18 lb-ft).





22. Connect the crankcase vent oil separator tube at the crankcase.





23. NOTE: Only one glow plug connector shown.

Install the glow plug harnesses and connect the retainers.

- Make sure the seals are securely seated in the valve covers.





Left cylinder head

24. Position the LH valve cover bracket and install the 3 retaining nuts.
- Tighten to 9 Nm (80 lb-in).





25. NOTE: Install a new O-ring seal on the oil indicator and tube. Apply clean engine oil to the O-ring seal.

Install the oil indicator and tube. Install the bolt.

- Tighten to 13 Nm (115 lb-in).





26. Install the retaining nut for the oil level indicator and tube.
- Tighten to 31 Nm (23 lb-ft).





27. Position the fuel supply and return tubes and install the bolt.
- Tighten to 31 Nm (23 lb-ft).





28. NOTE: Install a new O-ring seal on the tube and a new clamp on the hose.

NOTE: Hand start both bolts prior to tightening the bolts.

Install the EGR cooler tube and install the 2 bolts.

- Tighten to 13 Nm (115 lb-in).





29. NOTICE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.

Tighten the clamp for the EGR cooler hose.

- Tighten to 4 Nm (35 lb-in).





30. Install the bolt for the fuel supply and return tube retainer.
- Tighten to 31 Nm (23 lb-ft).





31. NOTE: Install a new O-ring seal.

Install the LH heater return tube and 2 bolts.

- Tighten to 13 Nm (115 lb-in).





32. NOTE: Only one glow plug connector shown.

Install the glow plug harnesses and connect the retainers.

- Make sure the seals are securely seated in the valve covers.





Both cylinder heads

33. Position the engine wiring harness on the engine. Connect the glow plug harness electrical connector and retainer on the RH valve cover.





34. Connect the Crankshaft Position (CKP) sensor and retainer.





35. Connect the pushpin retainers to the oil drain back tube brackets.





36. Position the harness in the retaining clip and the pushpin retainer.





37. Connect the Camshaft Position (CMP) sensor electrical connector and pushpin retainer.





38. Connect the glow plug harness electrical connector and pushpin retainers at the LH valve cover bracket.





39. NOTE: LH shown, RH similar.

NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.

Install the 2 cylinder block coolant drain plugs.

- Tighten to 20 Nm (177 lb-in).





40. Using the Heavy Duty Floor Crane, remove the engine from the Car/Truck Engine Stand.

41. NOTICE: The engine mount bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.

NOTICE: The engine mount bracket bolts must not be tightened more than 90 degrees after initial torque or damage to the bolts may occur.

NOTICE: Clean the engine mount mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine mount bracket or engine mount damage.

NOTE: Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

Install the RH engine mount bracket and 4 new bolts. Tighten in 2 stages:
- Stage 1: Tighten to 30 Nm (22 lb-ft).

- Stage 2: Tighten a minimum of an additional 60 degrees.





42. NOTICE: Only use hand tools when installing the center bolt or damage to the center bolt may occur.

Install the RH engine mount and new center bolt.

- Tighten to 350 Nm (258 lb-ft).





43. Install the starter and 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





44. Install the engine. Carry out the Engine - Body On Engine - Installation - Body On.