(2) Position piston of number 1 cylinder to ignition
TDC.
(3) Remove engine cover. (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(5) Carefully raise locking pawl of top slide rail
and remove front cover at cylinder head (Fig. 7).
(6) Insert a locking pin through 1st camshaft bear-
ing cap into the hole in the inlet camshaft sprocket.
(7) Counter hold the camshaft with an open end
wrench to avoid damage and unbolt driver of inlet
camshaft sprocket.
(8) Remove top guide rail.
INSTALLATION
INSTALLATION - CYLINDER HEAD
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
SERVICE VEHICLES IN WELL VENTILATED AREAS.
RISK OF POISONING FROM INHALING OR SWAL-
LOWING FUEL. RISK OF INJURY FROM SKIN AND
EYE CONTACT WITH FUEL. WEAR PROTECTIVE
CLOTHING.
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents and blow out bolt holes, to
assure that no grease or oil is present during reas-
sembly.
NOTE: If piston or connecting rods have been
replaced, measure piston projection.
NOTE: Check facing cylinder head contact surface.
(1) Position the cylinder head and gasket properly
on engine using the dowel pins as guide.
NOTE: Inspect all cylinder head bolts for defects
and stretching before installation (Refer to 9 -
ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
CYLINDER HEAD BOLT TORQUE SEQUENCE
The M12 cylinder head bolts must be torqued
in 3 stages.
(1) Install M12 cylinder head bolts finger tight.
(2) Torque bolts in numeric order starting with
number 1 to 60 N·m (44 lbs.in.) (Fig. 8).
(3) Install M8 timing chain cover to cylinder head
bolts (1A) (Fig. 8). Tighten to 20N·m (177 lbs.in.).
(4) Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90° (Fig.
8).
(5) Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90° (Fig.
8).
(2) Install turbocharger support bracket. Tighten
bolts to 30N·m (22 lbs.ft.).
(3) Install oil return flow line at turbocharger.
(4) Attach charge air pipe at turbocharger.
(5) Reconnect the precatlytic converter to turbo-
charger. Tighten to 30N·m (22 lbs.ft.).
(6) Install viscous heater.
(7) Reconnect oil dip stick tube. Tighten to 14 N·m
(124 lbs. in.).
(8) Install charge air distribution pipe (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
INSTALLATION).
(9) Install fuel return hose at fuel filter.
(10) Install high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(11) Install fuel return flow line between rail and
high pressure pump.
(12) Install pressure line at high pressure pump.
(13) Install idler gear (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).
(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 timing chain tensioner with new gas-
ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING
Fig. 8 CYLINDER HEAD BOLT TORQUE SEQUENCE
WG ENGINE 9a - 19
CYLINDER HEAD (Continued)
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