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(2) Hand start clean head bolts and tighten per the following procedure: • Install M12 cylinder head bolts finger tight (Fig. 15). • Tighten bolts in numeric order starting with number 1 to 15 N·m (133 lbs.in.) (Fig. 17). • Tighten bolts in numeric order starting with number 1 to 60 N·m (44 lbs.ft.) (Fig. 17). • Install M8 timing chain cover to cylinder head bolts. Tighten to 20N·m (177 lbs.in.). • Tighten M12 cylinder head bolts in numeric order starting with number 1 an additional 90° (Fig. • Tighten M12 cylinder head bolts in numeric order starting with number 1 an additional 90° again (3) Install fuel return flow line between rail and high pressure pump (Fig. 14). (4) Connect the coolant hoses to the thermostat housing (Fig. 14). (5) Connect the coolant pipe at the cylinder head (Fig. 14). (6) Reconnect transmission oil level indicator tube. Tighten to 14 N·m (124 lbs. in.) (Fig. 14). (7) Reconnect the turbocharger to the exhaust manifold. Tighten to 30N·m (22 lbs.ft.) (Fig. 14). (8) Install oil return flow line with new seals at turbocharger. Tighten bolt of supply line to turbo- (9) Install charge air distribution pipe (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM - (10) Install and properly route the engine wiring harness, making appropriate connections. (11) Install high pressure fuel pump intermediate gear (Fig. 14). (12) Install high pressure pump (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC- (13) Install the camshaft housing with tappets to cylinder head (Fig. 14). (14) Install camshafts (Refer to 9 - ENGINE/CYL- INDER HEAD/CAMSHAFT(S) - INSTALLATION). (15) Install top guide rail (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION). (16) Install front cover at cylinder head (Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLATION). (17) Install cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). (18) Install fuel high pressure pipes and injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ (19) Install timing chain tensioner with new gas- ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING (20) Remove retaining lock for crankshaft/starter ring gear. (21) Install air intake tube at turbocharger (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYS- (22) Install the fasteners retaining the front exhaust pipe to the support bracket at the read of (23) Install the upper support bracket fastener. INSTALLATION). NOTE: DO NOT pressure test cooling system until (26) Refill cooling system with proper coolant mix- ture to proper level (Refer to 7 - COOLING/ENGINE/ (27) Connect negative battery cable. WARNING: USE EXTREME CAUTION WHEN THE (28) Start engine and inspect for leaks. Care must be taken to observe the fuel system warning (Refer to Fig. 17 CYLINDER HEAD BOLT TORQUE SEQUENCE VA ENGINE 9 - 27 |