Camshaft and Camshaft Gears - Remove and Install

Camshaft - Remove and Install

Removal Procedure

Remove the rockershaft and pushrods. Remove the front housing. The engine should be mounted on a suitable stand and placed in the inverted position.

Remove the thrust washer (1) from the cylinder block. Do not remove the dowel (2) from the cylinder block unless the dowel is damaged. The thrust washer can have one or two slots (X).

Do not damage the lobes or the bearings when the camshaft is removed or installed. Carefully remove the camshaft (3) from the cylinder block. If necessary, remove the key (4) from the camshaft (3).

Installation Procedure

Clean the camshaft and the thrust washer. Inspect the camshaft and the thrust washer for wear and for damage. Replace any worn components or any damaged components. Clean the camshaft bearing in the cylinder block. Inspect the camshaft bearing for wear and for damage. If necessary, replace the camshaft bearing. Inspect the lifters for wear and for damage. Replace any worn lifters or any damaged lifters. If necessary, install a new key (4) into the camshaft (3). Lubricate the bearing surfaces of the camshaft (3) and lubricate the lobes of the camshaft with clean engine oil.

Carefully install the camshaft (3) into the cylinder block.

Lubricate the thrust washer with clean engine oil. Align the slot (X) in the thrust washer (1) with the dowel (2) in the cylinder block. Install the thrust washer (1) into the recess in the cylinder block. The thrust washer can have one or two slots (X). Install the front housing. Install the rockershaft and pushrods.

Camshaft Gear

Removal Procedure

Remove the valve mechanism cover. Remove the front cover.

Use Tooling in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke.

Install Tooling through the hole (X) in the camshaft gear (1) into the front housing. Use Tooling in order to lock the camshaft in the correct position.

Remove the plug (4) from the cylinder block. Install Tooling into the hole (Y) in the cylinder block. Use Tooling in order to lock the crankshaft in the correct position.

Loosen the nuts (6) on all rocker arms (7). Unscrew the adjusters (5) on all rocker arms (7) until all valves are fully closed. Failure to ensure that all adjusters are fully unscrewed can result in contact between the valves

and pistons.

Alignment of timing marks

Mark the gears (1) and (8) in order to show alignment.

Remove Tooling. Remove the setscrew (3) and the washer (2) from camshaft gear (1). Remove the camshaft gear (1) from the camshaft. If the camshaft gear is a tight fit on the nose of the camshaft, use a prybar in order to remove the camshaft gear. If necessary, remove the key (not shown) from the nose of the camshaft.

Installation Procedure

Ensure that number one piston is at top dead center on the compression stroke.

Ensure that Tooling is installed in hole (Y) in the cylinder block. Use Tooling in order to lock the crankshaft in the correct position. Ensure that the camshaft gear and the key are clean and free from wear or damage. If necessary, install the key into the nose of the camshaft. Ensure that the key is squarely seated.

Align the keyway in the camshaft gear (1) with the key in the camshaft. Install camshaft gear onto the camshaft. Ensure that the timing marks on gears (1) and (8) are in alignment and that the mesh of the gears is correct. Refer to Illustration.

Install Tooling through the hole (X) in the camshaft gear into the front housing. Install the washer (2) and the setscrew (3) to the camshaft gear (1).

Remove Tooling. Install the plug (4) into hole (Y) in the cylinder block. Refer to Illustration. Tighten the setscrew (3) to a torque of 95 N�m (70 lb ft).

Checking backlash

Ensure that the backlash for the gears (1) and (8) is within specified values.

Ensure that the end play for the camshaft gear (1) is within specified values.

Lubricate the teeth of the gears with clean engine oil. Adjust the valve lash.

Install the front cover. Install the valve mechanism cover.

Lifter Group

Removal Procedure

Remove the engine oil pump. Remove the camshaft. If the crankshaft is installed, use Tooling to rotate the crankshaft in order to gain access to the appropriate lifters (1).

Use Tooling in order to remove the lifters (1). Place a temporary identification mark on each lifter in order to identify the correct location. Repeat Steps to remove the remaining lifters.

Installation Procedure

Clean the lifters. Follow Steps to inspect the lifters. Replace any worn lifters or damaged lifters. Inspect the seat of the pushrod in the lifter for visual wear or damage. Inspect the shank of the lifter for wear or damage. Inspect the face of the lifter that runs on the camshaft for visual wear or damage.

If the crankshaft is installed, use Tooling to rotate the crankshaft to access to the cylinder block in order to install the appropriate lifters (1). Lubricate the lifters (1) with clean engine oil. Use Tooling to install the lifters (1) to the cylinder block. Ensure that used lifters are installed in the correct location. The lifters should be free to rotate. Repeat Steps to install the remaining lifters. Install the camshaft. Install the engine oil pump.

Camshaft Bearings

Removal Procedure

Remove the engine oil pump. Remove the camshaft.

Inspect the camshaft bearing (1). If the camshaft bearing (1) is worn or damaged use Tooling in order to remove the camshaft bearing from the cylinder block. Remove the camshaft bearing from the front of the cylinder block.

Installation Procedure

Clean the bearing housing in the cylinder block. Ensure that the oil hole in the bearing housing is free from debris.

Lubricate the bearing housing in the cylinder block with clean engine oil.

Accurately align the large oil hole (X) in camshaft bearing (1) with the oil hole in the cylinder block. The groove (Y) in the camshaft bearing must be to the top of the cylinder block. Use Tooling in order to install the camshaft bearing (1) into the cylinder block. Install the camshaft bearing so that the front edge of the bearing is flush with the face of the recess in the cylinder block. Ensure that the oil holes are correctly aligned. If the oil is not correctly aligned, the camshaft bearing should be removed. Install the camshaft. 

Brake servo and master cylinder

Description

- The brake servo is located between the brake pedal and the master cylinder. It is fitted at the rear of the master cylinder and uses pressure from the 17 bar circuit to power assist the master cylinder piston.

Identifying ports and ports on master cylinders 

A : Control of the trailer braking arrangement

B : Supply of brake master cylinders from tank

C : To main brake

D : Pressure balancing valve

E : Trailer brake pressure chamber

F : Trailer brake valve

Identifying ports and channels on the Brake servo 

A : 17 bar supply

E : To housing return

T : Piston chamber (10)

1 . Functioning of the brake servo 

Rest position

- Piston (10) is pushed to the right by the action of spring (16).

- 17 bar pressure enters port A until it reaches groove (2) where it is stopped by spool (6). The chamber T is linked to the return E via hole (9), the central channel (5) and open port (1).

Operating position

- When pressing the brake pedal, a force is applied to spool (6) via piston (7) and rod (8). The spool (6) is pushed to the left and closes the link to the tank via supply port (1). Hole (3) is placed in communication with groove (2). The oil under pressure arrives in the supply slot at the rear of the piston (10) via channel (5) and hole (9) and enters in front of the piston until an equilibrium is obtained between the resistance of the master cylinder, via thrust-rod (17) and the force applied to piston (10).

- Pressure acting on the face of the piston (7) produces a reaction force due to the effort of the push rod (8). This equilibrium gives a waiting position for which the slightest change in force at the pedal turns into an increase or decrease in pressure until the equilibrium is newly restored. The machine's amplification factor is the ratio of surfaces of pistons (7) (10) 1/4-4.

Maximum braking position

- In this position, the groove (2) and hole (3) are entirely in communication. The spool (6) is thrust up against the pad (11), and total possible pressure (17 bar) is applied to the rear of the piston (10), and maximum assistance force is obtained. The amplifier thus reaches saturation and an increase in force on the master cylinder is not possible except by pressing the pedal harder.

Servicing

- The brake servo does not require servicing. Any defective assemblies should be completely replaced.

Functioning of the master cylinders with trailer braking

Unlatched pedals 

Tractor braking and balancing

- The force applied on a pedal and transmitted by rod (17), via the brake servo, moves piston (4) along the bore of the active cylinder. Valve (1) closes the supply port, the balancing valve (3) then opens and oil under pressure is directed towards ports C and D. Through port D, the pressure closes valve (3) on the passive master cylinder.

Trailer braking

- The action on piston (4) also produces a movement of piston (6) and the closing of valve F. The oil contained in chamber E is directed to chamber E� of the passive master cylinder and towards port B� via the intermediary of the open valve F�. The valve F and piston (6) assembly rapidly abuts against the bottom of the active master cylinder.

- In this position, only the tractor brake is activated, the trailer is not braked.

Latched pedals 

Braking and pressure balancing

- The force applied to both pedals and transmitted by rods (17) through the intermediary of the servo, moves pistons (4) along the bores of the two master cylinders. The beginning of the travel of each piston, while displacing a certain volume of oil, closes the two F valves. The simultaneous movement of pistons (4) opens the balancing valves (3) and stops them from closing again. A balancing of pressures is carried out in the two master cylinders by way of the communicating pipe screwed into port D. The oil under pressure is also directed to tractor braking port C.

Trailer braking

- The continued action of pistons (4) (6) closes valves F and F�. Chambers E and E� which are pressurised, supply the trailer braking valve via ports A and A�.

- In the case of an incident involving the tractor�s braking circuit, the trailer will remain braked even though the tractor is not.

- In the case of a failure of the trailer braking valve or its channels, the tractor will remain braked.

In versions without trailer braking, the master cylinder does not have port A, valve F or piston (6).

Adjusting the servo brake rod 

Measure the position of master cylinder piston (4) in relation to the flange, dimension A. When measuring this dimension do not compress spring (5).

Smear the threads of the push rod nut with Loctite 542.

Place the push rod in position in the brake assistance servo.

Measure the position of the end of the push rod (17) in relation to the flange of the servo brake, dimension B. When measuring the dimension take care not to compress spring (16) on piston (10).

Correct the length of the push rod so as to obtain a clearance of J = 0.5 � 0.25 mm between push rod (17) and piston (4) on the assembly of the master cylinder and brake servo. Proceed in the same manner for the second servo brake.

Adjusting the brake pedals 

If disassembled, smear the pins (5) (6) with molybdenum bisulphide grease.

Smear the threads of yoke (1) with Loctite 542 and screw it onto rod (8).

Fit the return spring (3).

Adjust yoke (1) by turning rod (8) so as to obtain the dimension Y between support (4) and the centre of pin (6) in the yoke.

Y = 113 � 0.5 mm without brake servo

Y = 139 � 0.5 mm with servo brake

Proceed in the same way with the second yoke. Press each pedal ensuring that it goes through its full travel. Check that the pedals return freely to their initial position. Check that the pedal latch functions normally without any hard points.

Tractor engine fuel system � Test and inspect

Fuel System - Inspect

A problem with the components that transport fuel to the tractor engine can cause low fuel pressure. This can decrease engine performance. Check the fuel level in the fuel tank. Ensure that the vent in the fuel cap is not filled with dirt. Check all fuel lines for fuel leakage. The fuel lines must be free from restrictions and faulty bends. Verify that the fuel return line is not collapsed.

Install new fuel filters. Cut the old filter open with a suitable filter cutter. Inspect the filter for excess contamination. Determine the source of the contamination. Make the necessary repairs. Operate the hand priming pump (if equipped). If excessive resistance is felt, check that there is fuel in the fuel return line to the tank.

Air in Fuel - Test

This procedure checks for air in the tractor engine fuel system. This procedure also assists in finding the source of the air. Examine the fuel system for leaks. Check the fuel level in the fuel tank. Air can enter the fuel system on the suction side between the fuel transfer pump and the fuel tank.

Install a suitable fuel flow tube with a visual sight gauge in the fuel return to tank line. When possible, install the fuel flow tube in a straight section of the fuel line that is at least 304.8 mm (12 inches) long. Do not install the fuel flow tube near the following devices that create turbulence:

� Elbows

� Relief valves

� Check valves

Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no fuel that is present in the fuel flow tube, prime the fuel system.  If the tractor engine starts, check for air in the fuel at varying engine speeds. When possible, operate the engine under the conditions which have been suspect.

(1) A steady stream of small bubbles with a diameter of approximately 1.60 mm (0.063 inch) is an acceptable amount of air in the fuel.

(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) are also acceptable if there is two seconds to three seconds intervals between bubbles.

(3) Excessive air bubbles in the fuel are not acceptable.

If excessive air is seen in the fuel flow tube in the fuel return line, install a second fuel flow tube at the inlet to the fuel transfer pump. If a second fuel flow tube is not available, move the fuel flow tube from the fuel return line and install the fuel flow tube at the inlet to the fuel transfer pump. Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If the diesel engine starts, check for air in the fuel at varying engine speeds.

If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system after the fuel transfer pump. If excessive air is seen at the inlet to the fuel transfer pump, air is entering through the suction

side of the fuel system. To avoid damage, do not use more than 55 kPa (8 psi) to pressurize the fuel tank.

Pressurize the fuel tank to 35 kPa (5 psi). Do not use more than 55 kPa (8 psi) in order to avoid damage to the fuel tank. Check for leaks in the fuel lines between the fuel tank and the fuel transfer pump. Repair any leaks that are found.

If the source of the air is not found, disconnect the supply line from the fuel tank and connect an external fuel supply to the inlet of the fuel transfer pump. If this corrects the problem, repair the fuel tank or the stand pipe in the fuel tank.

Finding Top Center Position for No.1 Piston

Remove the front cover. Use Tooling in order to rotate the crankshaft until the hole (X) in the camshaft gear (1) aligns with the hole in the front housing.

Install Tooling through the hole (X) in the camshaft gear (1) into the front housing. Use Tooling in order to lock the camshaft in the correct position.

Remove the plug (4) from the cylinder block. Install Tooling into the hole (Y) in the cylinder block. Use Tooling in order to lock the crankshaft in the correct position.

Fuel Injection Timing - Check

� Removal of the fuel injection pump

� The bolts that hold the fuel injection pump to the front housing are loosened.

Set the number one piston at the top center piston on the compression stroke.

Carefully remove the fuel injection pump from the front housing..

To check the fuel injection pump timing

Position Tooling onto the shaft (8) of the fuel injection pump. Align the lever of Tooling with the key slot (7). Engage the lever into the key slot.

Insert the locking pin of Tooling into the hole (6) in fuel injection pump. If the locking pin can be inserted into the hole, the fuel injection pump timing is correct. If the locking pin cannot be inserted into the hole, the fuel injection pump timing is not correct. If the fuel injection pump timing has been lost follow Steps in order to reset the fuel injection pump timing.

If necessary, loosen the locking screw (4) on the fuel injection pump. Slide the spacer (5) into position (X). Tighten the locking screw (4) to a torque of 9 N�m (80 lb in). This will prevent the locking screw from tightening against the shaft (8). The fuel injection pump is now unlocked. Position Tooling onto the shaft (8) of the fuel injection pump. Align the lever of Tooling with the key slot (7) in the fuel injection pump. Engage the lever into the key slot.

Use the lever of Tooling to rotate the shaft (8) until the pin of Tooling can be engaged into the hole (6). Engage the pin of Tooling into the hole.

Loosen the locking screw (4) in the fuel injection pump. Slide the spacer (5) into position (Y). Tighten the locking screw (4) against the shaft of the fuel injection pump to a torque of 9 N�m (80 lb in). The fuel injection pump is now locked. Remove Tooling. Reinstall the fuel injection pump to the front housing.  

Diesel Engine Fuel System - Prime

Do not crank the tractor engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. If air enters the fuel system, the air must be purged from the fuel system before the tractor engine can be started. Air can enter the fuel system when the following events occur:

� The fuel tank is empty or the fuel tank has been partially drained.

� The low pressure fuel lines are disconnected.

� A leak exists in the low pressure fuel system.

� The fuel filter has been replaced.

Hand Fuel Priming Pump

Use the following procedures in order to remove air from the fuel system:

Ensure that the fuel system is in working order. Restore the fuel supply.

Operate the fuel priming pump (1). Count the number of operations of the fuel priming pump. After 100 depressions of the fuel priming pump stop.

The tractor engine fuel system should now be primed and the engine should now be able to start. Do not loosen the high pressure fuel line in order to purge air from the fuel system. This procedure is not required. Operate the diesel engine starter and crank the engine. After the engine has started, operate the engine at low idle for a minimum of five minutes, immediately after air has been removed from the fuel system.  Operating the engine for this period of time will help ensure that the fuel system is free of air. After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments.

Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard.

Electric Fuel Priming Pump

Ensure that the fuel system is in working order. Restore the fuel supply.

The electric fuel priming pump will operate for 90 seconds. If necessary the electric fuel priming pump can be stopped during the 90 seconds of operation, by operation of the switch.

Turn the keyswitch to the �RUN� position. Operate the switch for the electric priming pump. After 90 seconds of the electric fuel priming pump operation the fuel system will be primed and the electric fuel priming pump will turn off.

The diesel engine should now be able to start. Do not loosen the high pressure fuel line in order to purge air from the fuel system. This procedure is not required.

Operate the engine starter and crank the engine. After the engine has started, operate the engine at low idle for a minimum of five minutes, immediately after air has been removed from the fuel system.

Operating the tractor engine for this period of time will help ensure that the fuel system is free of air. After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. 

Rocker Shaft and Pushrod � Remove and Install

Rocker Shaft

Disassembly Procedure

Remove:

- the rocker shaft assembly.  Make an identification mark on each rocker arm assembly in order to show the location. The components must be reinstalled in the original location. Do not interchange components.

- the pedestals (1) from the rocker shaft (5). It is not necessary to remove the locators (2) from the pedestals.

- the rocker arm assembly (4) for the exhaust valve from rocker shaft (5).

- rocker arm assembly (3) for the inlet valve from rocker shaft (5). Begin at the rear of the rocker shaft assembly. The rocker arm assembly for the inlet valve is longer than the rocker arm assembly for the exhaust valve.

- the spring (6) from the rocker shaft (5). Repeat Steps to remove the remaining rocker arms from the rocker shaft (5).

- If necessary, remove retaining clip (7) and remove spring (8) from the front end of the rocker shaft (5).

- If necessary, remove the nuts (10) and the adjusters (9) from the rocker arms. Make a temporary identification mark on each adjuster in order to show the location.

Assembly Procedure

Ensure that all components are clean and free from wear or damage.  If necessary, replace any components that are worn or damaged.

If necessary, install the nuts (10) and the adjusters (9) to the rocker arm assemblies (3) and (4). If the original adjusters are reused, ensure that the adjusters are installed in the original positions.

Install:

- the retaining clip (7) and the spring (8) to the front end of the rocker shaft (5). Lubricate the bores of the rocker arm assemblies (3) and (4) and the rocker shaft (5) with clean engine oil.

- the rocker arm assembly (3) for number 1 inlet valve to the rocker shaft.

- the rocker arm assembly (4) for number 1 exhaust valve to the rocker shaft (5). The rocker arm assembly for the inlet valve is longer than the rocker arm assembly for the exhaust valve. Used components should be installed in the original location. If necessary, ensure that the locator (2) is correctly seated in the pedestal (1). Ensure that the counterbores for the holes in the rocker shaft (5) are upward. Align the locator (2) with the hole to the front of the rocker shaft (5).

- the pedestal to the rocker shaft.

- the spring (6) to the rocker shaft (5). Repeat Steps to assemble the remaining components to the rocker shaft (5).

- the rocker shaft assembly.

Rocker Shaft and Pushrod

Installation Procedure

Clean the valve bridges. Inspect the valve bridges for wear or damage. Replace any valve bridges that are worn or damaged.

Lubricate the valve bridges (4) with clean engine oil. Install the valve bridges to the cylinder head. Install used valve bridges in the original location and in the original orientation. Ensure that the valve bridges are correctly seated on the valves. New valve bridges may be installed in either orientation.

Clean the pushrods. Inspect the pushrods for wear or damage. Replace any pushrods that are worn or damaged.

Apply clean engine lubricating oil to both ends of the pushrods (3). Install the pushrods to the engine with the cup upward. Ensure that the pushrods (3) are installed in the original location and that the ball end of each

pushrod is correctly seated in the valve lifters.

Ensure that the rocker shaft assembly is clean and free from wear or damage. Install the 12 torx screws (1) in the rocker shaft.

Position the rocker shaft assembly (2) onto the cylinder head. The retaining clip (6) should face the front of the engine. Ensure that the adjustment screws (5) are properly seated in the ends of pushrods (3).

Gradually tighten the torx screws (1). To avoid distortion of the rocker shaft assembly (2), tighten the torx screws in the center first. Work toward the outside of the rocker shaft assembly. Tighten the torx screws (1) to a torque of 35 N�m (26 lb ft).

Use Tooling in order to check the valve lash. If necessary, adjust the valve lash.

Install the valve mechanism cover.

Cylinder Head � Remove and Install

Removal Procedure

If necessary, remove the secondary fuel filter and the fuel filter base.

If necessary, remove the fuel priming pump and the primary fuel filter.

Remove:

- the exhaust manifold.

- the fuel manifold

- the electronic control module and the mounting bracket.

- the electronic unit injectors.

- the valve mechanism cover base.

- the glow plugs. Drain the coolant from the cooling system into a suitable container for storage or for disposal.

Disconnect the upper radiator hose (not shown) from the water temperature regulator housing (1) on the cylinder head.

Remove the air inlet hose (not shown) from the inlet connection (3) on the inlet manifold (2). Follow Steps to disconnect the harness assembly (4) from the coolant temperature sensor (5). Slide the locking tab (not shown) into the unlocked position.

Disconnect the harness assembly (4) from the coolant temperature sensor (5).

Follow Steps to disconnect the harness assembly (4) from the boost pressure sensor (6).

Slide the locking tab (not shown) into the unlocked position. Disconnect the harness assembly (4) from the boost pressure sensor (6). Follow Steps to disconnect the harness assembly (4) from inlet air temperature sensor (7).

Slide the locking tab (not shown) into the unlocked position. Disconnect the harness assembly (4) from the inlet air temperature sensor (7).

Remove all cable ties that secure the harness assembly (4) to the cylinder head or to the inlet manifold. The harness assembly should be positioned in order to avoid causing an obstruction during the removal of the cylinder head.

Loosen the tube clips for the tube assembly (8). Remove the tube assembly (8) for the fuel return from the cylinder head and from the transfer pump (not shown). Plug the port in the transfer pump with a new plug. Cap the tube assembly with new caps.

If the diesel engine has a wastegate solenoid, loosen the tube clips for the tube assembly (9). Remove the tube assembly (9) from the wastegate solenoid (not shown) and from the cylinder head. Plug the port in the wastegate solenoid with a new plug. Cap the tube assembly with new caps.

Remove the two setscrews (10). Remove the bypass tube (11) from the cylinder head. Remove the O-ring seals (12) and (13) from the bypass tube (11). Discard the O-ring seals.

Sequence for tightening the setscrews for the cylinder head

Gradually loosen the setscrews (14) in the reverse numerical order to the tightening sequence. Refer to the illustration. Follow the correct sequence in order to help prevent distortion of the cylinder head. Remove the setscrews (14) from the cylinder head (15).

Attach a suitable lifting device (16) to the cylinder head (15). Support the weight of the cylinder head. The weight of the cylinder head is approximately 66 kg (145.5 lb). A spreader bar must be used in order to distribute the weight of the cylinder head during the lifting operation.

Use the suitable lifting device (16) to carefully lift the cylinder head (15) off the cylinder block. Do not use a lever to separate the cylinder head from the cylinder block. Take care not to damage the machined surfaces of the cylinder head during the removal procedure.

Remove the cylinder head gasket (17). Discard the cylinder head gasket.

Note the position of the dowels (18) in the cylinder block.

If necessary, remove the water temperature regulator (1) from the cylinder head (15). If necessary, remove the inlet manifold (2) from the cylinder head (15).

Installation Procedure

Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Do not damage the mating surfaces of the cylinder head of the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.

Inspect the mating surface of the cylinder head for distortion.  If the mating surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.

If necessary, install the inlet manifold to the cylinder head.

Inspect the dowels (18) for damage. If necessary, replace the dowels in the cylinder block. Install Tooling to the cylinder block. Align the cylinder head gasket (17) with the dowels (18). Install the cylinder head gasket (17) onto the cylinder block.

Use a suitable lifting device (16) to lift the cylinder head (15). The weight of the cylinder head is approximately 66 kg (145.5 lb). A spreader bar must be used in order to distribute the weight of the cylinder head during the lifting operation.

Use Tooling to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block. Ensure that the cylinder head is correctly positioned on the dowels (18). Remove Tooling.

Clean the setscrews (14). Follow Steps for the procedure to inspect the setscrews. Check the length of the setscrews. Some diesel engines have all setscrews of the same length. Some engines have two longer setscrews.

Use a straight edge to check the threads of the setscrews. Refer to Illustration. Replace any setscrews that show visual reduction in the diameter of the thread over length (Y). Lubricate the threads and the shoulder of the setscrews (14) with clean engine oil.

Sequence for tightening the setscrews for the cylinder head

Install the setscrews (14) to the cylinder head (16). If the engine has two longer setscrews, install the longer setscrews in holes (X).

Tighten the setscrews to a torque of 50 N�m (37 lb ft) in the numerical sequence. Tighten the setscrews to a torque of 100 N�m (74 lb ft) in the numerical sequence. Refer to Illustration. Turn the setscrews through an additional 225 degrees in the numerical sequence. Refer to Illustration. Use Tooling to achieve the correct final torque.

Use Tooling in order to lubricate the O-ring seals. Install two new O-ring seals (12) and (13) to the bypass tube (11). Install the bypass tube in the cylinder head. Install the setscrews (10). Tighten the setscrews to a torque of 22 N�m (16 lb ft).

Remove the plugs and caps from the ports and tube assemblies.

Install the tube assembly (8) for the fuel return to the cylinder head and to the transfer pump. Secure the tube clips for the tube assembly (8).

If the diesel engine has a wastegate solenoid, install the tube assembly (9) for the wastegate solenoid to the cylinder head. Secure the tube clips for the tube assembly (9).

Follow Steps to connect the harness assembly (4) to the inlet air temperature sensor (7). Connect the harness assembly (4) to the inlet air temperature sensor (7). Slide the locking tab (not shown) into the locked position.

Follow Steps to connect the harness assembly (4) to the boost pressure sensor (6). Connect the harness assembly (4) to the boost pressure sensor (6). Slide the locking tab (not shown) into the locked position. Follow Steps to connect the harness assembly (4) to the coolant temperature sensor (5).

Connect the harness assembly (4) to the coolant temperature sensor (5).

Slide the locking tab (not shown) into the locked position.

Use new cable ties in order to secure the harness assembly to the cylinder head and to the inlet manifold. Ensure that the harness assembly is not strained. Ensure that the harness assembly is clear of other engine components. Install the inlet hose (not shown) to the inlet connection (3) on the inlet manifold (2).

If necessary, install the water temperature regulator housing (1) to the cylinder head. Connect the upper radiator hose (not shown) to the water temperature regulator housing (1) on the cylinder head. Fill the cooling system with coolant. If necessary, fill the engine oil pan to the correct level that is indicated on the engine oil level gauge. Install:

- the glow plugs.

- the valve mechanism cover base.

- the electronic unit injectors.

- the electronic control module and the mounting bracket.

- the fuel manifold.

- the exhaust manifold.

- If necessary, install the fuel filter base and the secondary fuel filter

- If necessary, install the fuel priming pump and the primary fuel filter.