Part 2 of 2

Special Tools:

36. Install the access cover.
1. Apply RTV Silicone Sealant F5TZ-19G204-AB or equivalent meeting Navistar specification D15-5012 Type 2, to the access cover.
2. Install the bolts.

37. Install the fuel filter/water separator assembly.
1. Position the fuel filter/water separator assembly.
2. Install the bolts.

38. Position the fuel drain tube and install the bolt.

39. Install the engine oil cooler.
1. Position the two header gaskets and the oil cooler.
2. Install the six bolts.

40. Position the cylinder head gaskets onto the engine block.

41. CAUTION: Do not use too much engine oil on the threads of the cylinder head bolts, or damage to the threads and poor sealing can result. Do not use anti-seize compounds, grease or any other lubricants except engine oil on the cylinder head bolt threads because they will affect the true torque value reading of the bolts.

NOTE: Both the left side and right side cylinder heads are installed in the same way. Only the right side cylinder head is shown.

NOTE: The cylinder head bolts are torque-to-yield and must not be reused.

Install the cylinder head.
1. Position the Cylinder Head Lifting Tool and Heavy Duty Floor Crane onto the cylinder head.
2. Position the cylinder head onto the engine block. Remove the floor crane and the Cylinder Head Lifting Tool.
3. Install the 18 new cylinder head bolts.

42. NOTE: The cylinder head bolts are tightened in four steps.

Tighten the bolts.

43. Further tighten the bolts.

44. Further tighten the bolts.

45. Final tighten the bolts.

46. Install the fuel injector hold down shoulder bolts.

47. Connect the exhaust back pressure tube.

48. Install the fuel line.
1. Position the fuel line clamp onto the right hand cylinder head stud bolt.
2. Install the nut.

49. Install the fuel supply lines onto the cylinder heads.

50. NOTE: All eight fuel injectors are installed the same way. Only one fuel injector is shown.

NOTE: Thoroughly coat the fuel injector O-ring with clean engine oil to aid in installation.

Install the fuel injector.
1. Insert the fuel injector into the cylinder head fuel injector bore.
2. Using the Fuel Injector Installer Tool, seat the fuel injector into the cylinder head fuel injector bore.

51. Install the fuel injector hold down bolts.

52. NOTE: All eight oil deflectors are installed the same way. Only one oil deflector is shown.

Install the oil deflector.
1. Position the oil deflector.
2. Install the bolt.

53. NOTE: All sixteen push rods and rocker arms are installed the same way. Only one push rod and rocker arm is shown.

Install the rocker arms.
1. Apply clean engine oil to the push rod, and insert the push rod onto the engine. Make sure the push rod seats onto the lifter.
2. Position the rocker arm onto the cylinder head.
3. Install the bolts.

54. Install the high pressure oil lines.

55. NOTE: Both the left side and the right side valve cover gaskets are installed the same way. Only the right side gasket is shown.

Install the valve cover gasket.
1. Position the gasket onto the cylinder head.
2. Install the four glow plug electrical leads.
3. Install the four fuel injector electrical connectors.

56. NOTE: Both the left side and the right side valve covers are installed the same way. Only the right side valve cover is shown.

Install the valve cover.
1. Position the valve cover onto the cylinder head.
2. Install the bolts.

57. Install the oil level indicator tube.
1. Position the indicator tube into the oil pan.
2. Position the indicator tube retainer into the stud bolt and install the nut.
58. Install the air inlet duct tube mounting bracket.

59. Install two new O-rings onto the engine.

60. Install the turbocharger pedestal.
1. Position the turbocharger pedestal.
2. Install the bolts.
61. Position the engine harness onto the engine.

62. Connect the electrical connector to the Camshaft Position (CMP) sensor.

63. Position the engine harness and attach the pushpin retainer.

64. Install the glow plug relay and bracket.
1. Position the glow plug bracket and relay onto the two stud bolts.
2. Install the two nuts.

65. Connect the two sensors.
^ Connect the exhaust back pressure sensor.
^ Connect the engine coolant sensor.

66. Connect the engine oil pressure sensor.

67. Connect the engine oil temperature sensor.

68. Connect the injection oil pressure sensor.

69. Connect the fuel heater/water separator electrical connector.

70. Connect the exhaust back pressure solenoid electrical connector.

71. NOTE: Both the left side and the right side nine pin connectors are installed the same way. Only the right side is shown.

Connect the fuel injector/glow plug nine pin connector, engage the retaining clip.

72. Install the exhaust adapter pipes.
1. Position the pipes.
2. Install the four mounting bolts and nuts.

73. Install the generator mounting bracket.
1. Position the generator mounting bracket.
2. Install the mounting bolts.

74. Install the A/C compressor mounting bracket.
1. Position the A/C compressor mounting bracket.
2. Install the mounting bolts.