Installation

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°.
7. Be sure to lubricate the push rod sockets with clean engine oil. Be sure push rod is seated properly in the tappet.
8. Install the rocker lever pedestal bolts and tighten to 24 Nm (18 ft. lbs.) torque.
9. Adjust the valve clearance.
10. Install the valve covers. Tighten the bolts to 24 Nm (18 ft. lbs.) torque.
11. Install the injector nozzles and fuel lines.
12. Install the remote fuel filter/water separator head. Install the fuel filter/water separator.
13. Install the exhaust manifold.
14. Install the EGR tube and start fasteners by hand.
15. Tighten all bolts/nuts to 24 Nm (212 inch lbs.) torque. 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.
16. Install the turbocharger.
17. Connect the radiator and heater hoses.
18. Fill the engine with new coolant or the clean drained coolant.
19. Fill the engine with clean lubricating oil.