Cylinder Head - Installation

INSTALLATION





WARNING: THE OUTSIDE EDGE OF THE HEAD GASKET IS VERY SHARP. WHEN HANDLING THE NEW HEAD GASKET, USE CARE NOT TO INJURE YOURSELF.

1. Install a new gasket with the part number side up, and locate the gasket over the dowel sleeves.
2. Using an engine lifting crane, lower the cylinder head onto the engine.
3. Lightly lubricate head bolts under bolt head and on threads, with engine oil and install. Using the sequence shown , tighten bolts in the following steps:
a. Torque bolts to 70 Nm (52 ft. lbs.).
b. Back off 360 degrees in sequence.
c. Torque bolts to 105 Nm (77 ft. lbs.).
d. Re-check all bolts to 105 Nm (77 ft. lbs.).
e. Tighten all bolts an additional 1/4 turn (90°).




4. Install push rods into their original locations. Verify that they are seated in the tappets.
5. Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
6. Install rocker housing and bolts. Tighten to 24 Nm (18 lb. ft.).
7. Install fuel injector.




8. Lubricate valve stem tips and install the crossheads in their original locations.
9. Lubricate the rocker arms (1) and pedestals (2) and install them in their original locations. Install the bolts and torque them to 36 Nm (27 ft. lbs.).
10. Verify that the valve lash settings are maintained.
11. Install cylinder head cover gasket onto rocker housing.
12. Install injector harness nuts. Tighten to 1.25 Nm (11 in. lbs.).
13. Connect injector harness connectors at cylinder head cover gasket.
14. Install wire harness P-clip to cylinder head behind filter housing 24 Nm (18 ft. lbs.).
15. Connect the IAT/MAP sensor connector.
16. Install the fuel filter housing assembly and hand tighten mounting bolts, Do not torque at this time.
17. Connect WIF sensor, and fuel heater.

CAUTION: Failure to follow procedure will result in fuel leaks and/or fuel system failure.

18. Install the fuel rail and high pressure fuel lines as follows:
a. Hand tighten fuel rail bolts.
b. Hand tighten fuel drain line to pressure limiting valve. Hand tighten banjo bolt at fuel filter housing.
c. Hand tighten fuel rail-to-cylinder head high pressure fuel lines.
d. Install fuel line brace bolts-to-intake manifold finger tight for fuel lines #2 thru #5.
e. Install fuel line brace nut to rear lift bracket stud, finger tight, for fuel line #6.
f. Hand tighten fuel pump to fuel rail line.
g. Torque fuel line nuts at cylinder head to 30 Nm ( 22 ft. lbs.).
h. Torque fuel line nuts at fuel rail to 30 Nm (22 ft. lbs.)
i. Using a back up wrench, torque fuel pump to fuel rail line to 37 Nm (27 ft. lbs.). At injection pump.
j. Torque fuel pump to fuel rail line to 37 Nm (27 ft. lbs.) at fuel rail.
k. Torque fuel drain banjo bolt at pressure limiting valve and front of fuel filter housing to 24 Nm (18 ft. lbs.).
l. Torque fuel line brace bolts to 24 Nm (18 ft. lbs.).
m. Torque fuel line brace nut to 24 Nm (18 ft. lbs.).
n. Torque rail bolts to 24 Nm (18 ft. lbs.).
o. Connect fuel pressure sensor.
p. Torque fuel filter mounting bolts to 24 Nm (18 ft. lbs.).
19. Reposition number 6 fuel line shield and torque to 43 Nm (32 ft. lbs.).
20. Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary. Torque banjo bolts to 24 Nm (18 ft. lbs.).
21. Connect fuel return line at back of cylinder head hand tight.
22. Connect fuel return line at filter housing hand tight.
23. Torque banjo connections at cylinder head and fuel filter housing to 24 Nm (18 ft. lbs.)
24. Install bracket to rear of filter housing. Torque to 24 Nm (18 ft. lbs.).
25. Using new gaskets, install the intake grid heater and air inlet housing. Torque bolts to 24 Nm (18 ft. lbs.).
26. Install wire harness P-clip and push on clip to air inlet housing.
27. Connect engine oil level indicator tube at fuel filter housing and at air inlet housing.
28. Install the charge air cooler-to-air inlet housing duct assembly. Torque all clamps to 11 Nm (100 in. lbs.).
29. Connect intake grid heater wires.
30. Secure engine harness to front of cylinder head with bolt at four locations.
31. Connect engine coolant temperature sensor connector.
32. Connect radiator upper hose to thermostat housing.
33. Rotate generator into position. Install upper bolt and torque upper and lower bolts.
34. Install wire harness push-on clip below bracket.
35. Install wire harness P-clip to top of bracket.
36. Install fan support and torque to 32 Nm (24 ft. lbs.).
37. Install cooling fan/drive.
38. Install accessory drive belt.
39. Install exhaust manifold/turbocharger assembly, using new gaskets. Start all bolts/spacers by hand. Starting from the center bolts out, Torque bolts to 43 Nm (32 ft. lbs.), then retorque from the center out again.
40. Install exhaust manifold heat shield to exhaust manifold studs. Install retaining nuts. Torque to 24 Nm (18 ft. lbs.).
41. Install exhaust bolt retention straps across cylinders 5 & 6.
42. Using a new gasket, connect the turbocharger oil drain tube. Torque to 24 Nm (18 ft. lbs.).
43. Perform the turbocharger pre-lube procedure.
44. Connect the turbocharger oil supply line. Torque to 24 Nm (18 ft. lbs.).
45. Install air cleaner housing and duct.
46. Connect air inlet temperature/pressure sensor.
47. Raise vehicle on hoist.

NOTE: Do not reuse the clamp for the exhaust pipe to turbocharger elbow connection.

48. Install the exhaust pipe to turbocharger elbow using a new clamp. Torque bolts to 11 Nm (100 in. lbs.).
49. Lower vehicle.
50. Fill engine coolant.
51. Start engine and check for leaks.