Installation

Cylinder Heads

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Special Tools






Material

Installation

Both cylinder heads





1. CAUTION: Install new D-ring seals on the crankcase-to-head tube. It requires several hours after installation for the D-ring seals to relax back to their original size. If the tube assembly is installed before the D-ring seals have relaxed, damage to the D-ring seals can occur.

Inspect the D-ring seals for damage (nicks, cuts and gouges). If damaged, replace the crankcase-to head tube.

NOTE: Early build cylinder heads, head gasket, cylinder block, rocker arm carrier and injectors and injector hold-down clamps are not interchangeable with late build engines, It is necessary to identify the head style prior to working on the cylinder heads. Early build heads are equipped with injector hol-down clamps with a square end T40 Torx bolt. Late build heads have injector hold-down clamps with a tapered end and a T45 Torx bolt.





Determin if the cylinder heads are early build (left frame of illustration) or late build (right frame of illustration).

2. NOTE: Use care to avoid scratching the blue compound on the cylinder head gasket . Install a new cylinder head gasket with the part number facing upward and verify the top 5 holes and the head gasket push rod holes line up.

Install new dowels and the cylinder head gasket.





3. Using the special tools, install the cylinder head on the engine.
1 Install the lifting bracket.
2 Install the bolts.
^ Install the cylinder head.





4. Install the outer cylinder head bolts finger-tight.

5. CAUTION: 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: On early build vehicles, higher mileage engines require push rods to be cleaned so the copper-colored end of the push rod can be identified and installed with the copper-colored end up. Push rods on late build vehicles and service push rods do not have a copper-colored end and can be installed with either end up.





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

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





Install the 16 valve bridges.





7. NOTE: Early build engines will have 8 rocker arm carrier-to-cylinder head bolts. Late build will have 2 rocker arm carrier-to-cylinder head bolts.

NOTE: Early build shown, late build similar.

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

Install the press-in-place gasket, the rocker arm carrier and the rocker arm carrier and bolts.
^ Tighten to 31 Nm (23 ft. lbs.).





8. CAUTION: Rotate the crankshaft until the damper locating dowel notch is in the 6 o'clock position or engine damage can occur.

NOTE: Apply clean engine oil to the top center of each valve bridge.

Install the rocker arm assemblies and the 16 bolts.
^ Tighten to 31 Nm (23 ft. lbs.).





9. CAUTION: Using too much engine oil on the threads of the cylinder head bolts can 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 can affect the true torque value of the bolts.

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

NOTE: Install the 20 new inner cylinder head retaining bolts finger-tight.





10. Tighten the head bolts in sequence in 7 stages:
^ Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 ft. lbs.).
^ Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 ft. lbs.).
^ Stage 3: Tighten bolts 1 through 10 an additional 90 degrees.
^ Stage 4: Tighten bolts 1 through 10, a second time, 90 degrees.
^ Stage 5: Tighten bolts 1 through 10, a third time, 90 degrees.
^ Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 ft. lbs.).
^ Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 ft. lbs.).

11. CAUTION: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.

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





Install new O-ring seals and a copper washer on the fuel injector.

12. CAUTION: Failure to tighten the injector properly can lead to engine failure.

CAUTION To prevent engine damage, do not use air tools when removing and installing the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall off.





Install the fuel injector, the fuel injector hold-down and bolt.
^ Tighten to 33 Nm (24 ft. lbs.).





13. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.

Install the fuel injector electrical connector into the rocker carrier.





14. Apply clean engine oil to the top fuel injector O-ring seals.

15. NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high-pressure oil rail.

Position the high-pressure oil rail on the injectors.
^ Place the high-pressure oil rail on top of the carrier so that the 4 single ball tubes are engaging the fuel injector lead angle.





^ Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
^ Press the high-pressure oil rail into the fuel injectors.
^ Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface.
^ Loosely install the 6 bolts.





16. Remove the 3 guide bolts, install the remaining bolts and tighten the 9 bolts in the sequence shown.
^ Tighten to 13 Nm (10 ft. lbs.).





17. Apply clean engine oil and reassemble the crankcase-to-head tube. Install the crankcase-to-head tube.
^ Tighten to 82 Nm (60 ft. lbs.).





18. Connect the fuel injector electrical connector.

RH cylinder head





19. Install the high-pressure oil rail-to-valve cover gasket.

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





Position the RH valve cover gasket, RH valve cover and install the fasteners.
^ Tighten to 9 Nm (80 inch lbs.).


21. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.

NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.

NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.





Install the RH exhaust manifold and the bolts.
^ Tighten to 38 Nm (28 ft. lbs.).

LH cylinder head
22. Cover the LH cylinder head with an appropriate covering.





23. Position the turbocharger heat shield and install the 3 bolts.
1 Tighten to 49 Nm (36 ft. lbs.).
2 Tighten to 11 Nm (8 ft. lbs.).

24. NOTE: Install new sealing washers.





Install the LH cylinder head fuel line.
^ Tighten to 38 Nm (28 ft. lbs.).

25. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.

NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.

NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.





Install the LH exhaust manifold and the bolts.
^ Tighten to 38 Nm (28 ft. lbs.).

Both cylinder heads





26. install the 8 glow plugs.
^ Tighten to 19 Nm (14 ft. lbs.).

27. NOTE: Clean and apply clean engine oil to the O-ring seals.




Using the special tool, install the glow plug harness.





28. Install the special tools.





29. Install the special tool.
30. Install the lifting crane and remove the engine from the engine stand.





31. Install the flexplate and tighten the new bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 94 Nm (69 ft. lbs.).

32. Install the engine.