Installation Procedure
Required Tools     | |||
Tool     | Part Number     | Part Description     | Qty     |
A     | 9U-6238     | Guide Bolt     | 2     |
B     | 8T-3052     | Degree Wheel     | 1     |
C     | 5P-3975     | Rubber Lubricant     | -     |
NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Thoroughly clean the top of the cylinder block and the bottom of the cylinder head. Ensure that there is no debris in the cylinder bores.
- Install the cylinder head gasket on dowels (6) on top of the cylinder block.
Note: Do Not use any sealant or compound on the cylinder head gasket.
Illustration 1 | g01001065 |
- Install Tooling (A) in the cylinder block.
- Use a suitable lifting device to install the cylinder head. The weight of the cylinder head is approximately 57 kg (126 lb).
Note: Ensure that the cylinder head is positioned on dowels (6) .
- Remove Tooling (A) .
- Clean the threads of the cylinder head bolts. Inspect the cylinder head bolts.
Note: Do Not use bolts if there is any visual reduction in the diameter of the Threads (Y) that has not been engaged with the cylinder block. Use a straight edge to check the bolts.
Illustration 2 | g00951563 |
- Lubricate the threads and the shoulder of the cylinder head bolts with clean engine oil before installation.
- Install bolts (5) on cylinder head (1) .
Note: The short bolts are installed in holes that are marked 1, 2, 3, 4, 5, 6, and 9.
Note: The long bolts are installed in holes that are marked 7, 8, and 10.
Illustration 3 | g03742524 |
- Tighten the cylinder head bolts in numerical order to a torque of 50 N·m (37 lb ft).
- Tighten the cylinder head bolts in numerical order to a torque of 100 N·m (74 lb ft).
- Use Tooling (B) to achieve the correct final torque.
Note: If Tooling (B) is not used, place an index mark on each bolt.
Illustration 4 | g00951562 |
- Tighten the cylinder head bolts in numerical order.
- Turn the short bolts (2, 5, 6, 7, 8, 9, and 10) for an additional 225 degrees.
- Turn the long bolts (1, 3, and 4) for an additional 270 degrees.
- Install new O-ring seals on bypass tube (4) . Apply Tooling (C) to the O-ring seals. Install the bypass tube in cylinder head (1) . Install bolts (3) .
Illustration 5 | g01001037 |
- Connect the harness assembly to coolant temperature sensor (2) .
- Connect the harness assembly to the bus bar for the glow plugs.
- Install the upper radiator hose to the water temperature regulator housing.
- Fill the cooling system with coolant. Fill the lubrication system with engine oil.
Note: Refer to Operation and Maintenance Manual, "Refill Capacities" for the cooling system capacity and the lubrication system capacity of the engine.
End By:
- Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
- Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".
- Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".