Cylinder Head — RH

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
   • Stage 1: Tighten to 20 Nm (177 lb-in).
   • Stage 2: Tighten to 35 Nm (26 lb-ft).
   • Stage 3: Tighten 90 degrees.
   • Stage 4: Tighten 90 degrees.
   • Stage 5: Tighten 45 degrees.

2. Install the cylinder head M6 bolt.
   • Tighten to 10 Nm (89 lb-in).

3. NOTE: The valve tappets must be installed in their original positions.

   NOTE: Coat the valve tappets with clean engine oil prior to installation.

   Install the valve tappets.

4. Install the RH engine lifting eye and the 2 bolts.
   • Tighten to 24 Nm (18 lb-ft).

5. Install the RH secondary timing chain tensioner and the 2 bolts.
   • Tighten to 10 Nm (89 lb-in).

6. Install the RH timing chain guide and bolt.
   • Tighten to 10 Nm (89 lb-in).

7. Install the RH cylinder block drain plug or, if equipped, the block heater.
   • Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
   • Tighten the block heater to 40 Nm (30 lb-ft).

8. If equipped, install the block heater wiring harness onto the engine.
   • Connect the block heater electrical connector and install the heat shield.

9. Install the LH cylinder block drain plug.
   • Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.

10. Install 8 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).

11. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Install a new gasket, RH exhaust manifold and 8 new nuts. Tighten in 2 stages in the sequence shown:
    • Stage 1: Tighten to 15 Nm (133 lb-in).
    • Stage 2: Tighten to 20 Nm (177 lb-in).

12. Install the oil supply tube filter, washer and bolt.
    1. Install a new oil supply tube filter in the oil supply tube block.
    2. Slide the new washer onto the oil supply tube block.
    3. Instal the banjo bolt into the oil supply tube block.

13. Install the RH turbocharger oil supply tube.
    • Tighten the bolt to 40 Nm (30 lb-ft).

14. Install a new gasket, the turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.
    • Tighten to 45 Nm (33 lb-ft).

15. Install the upper turbocharger-to-cylinder block bracket and the 3 bolts and position the bracket as far clockwise as possible and tighten the bolts in the following sequence:
    1. Tighten the lower bolt to 26 Nm (19 lb-ft).
    2. Tighten the upper bolt to 26 Nm (19 lb-ft).
    3. Tighten the turbocharger bolt to 19 Nm (168 lb-in).

16. Using 2 new sealing washers, install the 2 RH turbocharger coolant tubes and banjo bolts.
    • Tighten to 40 Nm (30 lb-ft).

17. Install the coolant tube bracket-to-cylinder head bolt.
    • Tighten to 10 Nm (89 lb-in).

18. If necessary, install the RH cylinder head turbocharger oil supply quick connect fitting.
    • Tighten to 16 Nm (142 lb-in).

19. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

    Install the RH oil supply tube into the quick connect fitting.

20. Install the oil supply tube secondary latch.

21. Install a new gasket and the RH turbocharger oil return tube and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

22. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.

    Connect the turbocharger wastegate regulating valve hose to the RH turbocharger assembly.

23. NOTE: Make sure the heat shield does not contact the wastegate arm.

    Install the 2 upper RH exhaust manifold heat shield and the 5 bolts.
    • Tighten to 12 Nm (106 lb-in).

24. Connect the Cylinder Head Temperature (CHT) sensor electrical connector to the rear of the RH cylinder head.

25. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).

26. Install the RH Camshaft Position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).

27. Connect the RH CMP sensor electrical connector.

28. Install the RH camshafts. For additional information, refer to Camshaft in this section.

29. Install the fuel rails. For additional information, refer to Section 303-04B .