Right Cylinder Head

RIGHT





CAUTION: Inspect and measure all cylinder head bolt lengths. If out of specification, replace as necessary Cylinder Head Bolt Inspection.

1. Clean and inspect gasket mating surfaces.
2. Position head gasket on engine block. Be sure the coolant passages align (part number should be facing up).
3. Place cylinder head on engine block.

CAUTION: Inspect and measure all cylinder head bolt lengths. If out of specification, replace as necessary Cylinder Head Bolt Inspection. Do Not lubricate new cylinder head bolts. They already are coated with an anti scuff treatment.

4. Tighten cylinder head bolts following procedure below.
- Tighten M12 cylinder head bolts 1 through 8, in the sequence shown to 60 Nm (44 ft. lbs.).
- Tighten bolts 9 and 10 to 20 Nm ( 177 in. lbs.).
- Tighten 12 mm cylinder head bolts, 1 through 8, in sequence shown, an additional 90 degrees.
- Recheck and tighten M8 bolts 9 and 10 to 20 Nm ( 177 in. lbs.).
- And then again, tighten M12 cylinder head bolts, 1 through 8, in sequence an additional 90 degrees.





NOTE: Followers and tappets assemblies must be installed in same location as removed.

5. Install the followers (2) and tappets (2) into their original positions.
6. Install the glow plugs (1). Tighten glow plugs to 12.5 Nm (100 in. lbs.).




7. Install the right exhaust camshaft. Tighten the retaining fasteners to 8 Nm (71 in. lbs.).
8. Install the right intake camshaft. Tighten the retaining fasteners to 8 Nm (71 in. lbs.).




NOTE: Care must be taken to assure the proper exhaust camshaft to intake camshaft alignment.

9. Align the camshaft marks so the alignment marks are facing each other.
10. Insert the timing chain, through the cylinder head, and on to the camshaft drive gear.




11. Align the balance shaft with the scribe or paint mark.
12. Once the camshaft drive gear is mated with the timing chain, install the camshaft drive gear on to the camshaft and assure the balance shaft is aligned properly.




13. Install the upper two of the three camshaft drive gear bolts.




14. Install the right lower timing chain guide (2), seat the guide pin at the top, and tighten the guide bolt to 12 Nm (9 ft. lbs.).
15. Install the right upper timing chain guide (1), seat the guide pin at the top, and tighten the guide bolt to 12 Nm (9 ft. lbs.).




16. Install the timing chain tensioner (3).




17. Rotate the engine by the vibration damper bolt enough to gain access to the third camshaft bolt hole.
18. Install the third camshaft drive gear retaining bolt and tighten the bolt to 18 Nm (13 ft. lbs.).

WARNING: If the camshaft, balance shaft and or crankshaft alignment marks are not aligned properly, immediate damage to the engine will occur. If the camshafts, balance shaft and or crankshaft do not align properly after rotating the engine to the original starting point, STOP and begin the alignment procedure again.

19. Rotate the engine back to TDC by the vibration damper bolt until the crankshaft, camshaft and balance shaft align TDC again.
20. Tighten the two remaining camshaft drive gear bolts to 18 Nm (13 ft. lbs.).

WARNING: Check that all the timing chain fits properly on all the timing gears. Failure to do so will result in immediate engine damage.





21. Add a 1.5 mm continuous bead of Mopar Engine Sealant RTV (1) to the timing chain cover and the front portion of the oil pan, then install the timing chain cover. Tighten the bolts to 8.5 Nm (74 in. lbs.).
22. Raise and support the vehicle.




23. Install the 5 front oil pan (2) to timing cover bolts. Tighten the bolts to 20 Nm (177 in. lbs.).




24. Install special tool # 9102 crankshaft lock (2).
25. Lower the vehicle.
26. Install the vibration damper. Tighten the bolts to 200 Nm (148 ft. lbs.). and then an additional 90°.




NOTE: Care must be taken not to get any engine sealer on the camshaft journals.

27. Add a 1.5 mm continuous bead of Mopar Engine Sealant RTV (1) to the cylinder head cover, then install the right cylinder head cover along with a new camshaft seal.




28. Tighten the bolts in three stages following the sequence provided. First to 4 Nm (35 in. lbs.), then to 6 Nm (53 in. lbs.) and then to 8.5 Nm (75 in. lbs.).




29. Install the oil separator (1) and housing adaptor (2) with new camshaft seal. Tighten the bolts to 11 Nm (97 in. lbs.).




30. Align the pump drive gear (1) with the camshaft drive gear (3) and install the vacuum pump (2) with new gasket. Tighten bolts to 9 Nm (7 ft. lbs.).




31. Install the belt idler pulleys (1) Tighten the bolts to 58 Nm (43 ft. lbs.).
32. Install the accessory drive belt tensioner (2). Tighten the bolts to 58 Nm (43 ft. lbs.).
33. Install the accessory drive belt.




CAUTION: The right intake manifold upper thermostat housing bolts should be tightened to 8.5 Nm (74 in. lbs.).

34. Install the intake manifold (4). Tighten bolts to 16 Nm (142 in. lbs.), starting in the middle and tightening in a cross pattern outward until reaching the upper thermostat bolts on the right front manifold.
35. Tighten the upper thermostat bolts on the right cylinder head to 8.5 Nm (74 in.lbs.).




CAUTION: The fuel injector sealing washers MUST be replaced. DO NOT use the old sealing washers or double the sealing washers. DO NOT apply injector body lubricant near the injector nozzles.

36. Lubricate the fuel injector body, install the right fuel injectors and new sealing washers.

CAUTION: The fuel injector retaining claw bolts are torque to yield and must always be replaced.

37. Install the injector retaining claws (3) and tighten the bolts to 7 Nm, plus 180° (62 in. lbs., plus 180°).
38. Properly route and install the fuel return hoses (2) and connect them to the injectors.
39. Properly route and connect the engine harness (1).




40. Install the fuel rail (2). Tighten the bolts to 27 Nm (20 ft. lbs.).

CAUTION: Inspect the fuel lines for wear or damage, look closely around the flange area. Replace as necessary. DO NOT over tighten.

41. Install the high pressure fuel lines (3), including the fuel rail transfer line (1). Tighten the line nuts to 33 Nm (24 ft. lbs.).
42. Install the fuel filter and connect the harnesses and hoses using Fuel Line Pliers 9539 Hose Clamp pliers.




CAUTION: Care must be taken when installing the turbocharger oil housing adaptor. The gasket MUST be aligned properly with the oil housing passages or immediate damage to the turbocharger will occur.

43. Install the turbocharger oil housing adaptor with the gasket tabs secured to the adaptor. Tighten bolts to 12 Nm (9 ft. lbs.).
44. Install the turbocharger Turbocharger - Installation.




45. Install the charge air inlet pipe (1) and resonator (3).




46. Install the air control valve and resonator (4).




47. Install the cooling fan module.
48. Connect the vacuum pump supply hose.
49. Raise and support the vehicle.
50. Remove special tool #9102 crankshaft lock (2).
51. Install the starter blank.
52. Connect the cooling fan hydraulic lines.
53. Lower the vehicle.
54. Fill the cooling system.
55. Fill power steering system.
56. Install the strut tower support (2).
57. Connect the negative battery cable.
58. Start engine, allow to warm, turn engine off and inspect for leaks.
59. Purge the air from the power steering system using the scan tool.




60. Install the engine cover brackets and engine cover (3).