Diesel Data: Automotive Repair

Cylinder Head Assembly: Specifications

CYLINDER HEAD SUB-ASSEMBLY





Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.

Torque 70 Nm (714 kgf-cm, 52 ft-lbf)





Mark the front side of the cylinder head bolt with paint.
Retighten the cylinder head bolts 90° in the sequence shown in the illustration.
Check that the paint mark is now at a 90° angle to the front.

CYLINDER HEAD SET BOLT

Standard bolt length 141.3 to 142.7 mm (5.563 to 5.618 in.)

Maximum bolt length 144.2 mm (5.677 in.)

SURFACE VARIATION

Cylinder head

Maximum warpage
Cylinder block side 0.08 mm (0.0031 in.)
Intake manifold side 0.08 mm (0.0031 in.)
Exhaust manifold side 0.08 mm (0.0031 in.)

INTAKE MANIFOLD





Install the intake manifold with the 5 bolts and 2 nuts.
Torque 30 Nm (305 kgf-cm, 22 ft-lbf)

CAMSHAFT BEARING





Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
No. 1 Bearing cap
Torque 30 Nm (301 kgf-cm, 22ft-lbf)
No. 3 Bearing cap
Torque 9.0 Nm (92 kgf-cm, 80in-lbf)

NO. 2 CAMSHAFT BEARING





Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
No. 2 Bearing cap
Torque 30 Nm (301 kgf-cm, 22ft-lbf)
No. 3 Bearing cap
Torque 9.0 Nm (92 kgf-cm, 80in-lbf)

EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

Except for PZEV:




Tighten the 5 nuts in the sequence shown in the illustration.
Torque 37 Nm (378 kgf-cm, 27ft-lbf)

For PZEV:




Tighten the 5 nuts in the sequence shown in the illustration.
Torque 37 Nm (378 kgf-cm, 27ft-lbf)

CAMSHAFT TIMING GEAR/SPROCKET

Torque 54 Nm (551 kgf-cm, 40 ft-lbf)