Cylinder Head — LH

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

5. Install the upper LH primary timing chain guide and the bolt.
   • Tighten to 10 Nm (89 lb-in).

6. 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).

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

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

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

10. 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, LH exhaust manifold and turbocharger assembly and 8 new nuts. Tighten the nuts 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).

11. Install the upper turbocharger bracket-to-cylinder block and the 2 bolts.
    • Do not tighten the bolts at this time.

12. Install the lower turbocharger-to-cylinder block bracket and the 2 bolts.
    • Do not tighten the bolts at this time.

NOTICE: The next 4 steps must be performed in order or damage to the turbocharger may occur.

13. Tighten the upper turbocharger bracket-to-turbocharger bolt.
    • Tighten to 19 Nm (168 lb-in).

14. Tighten the upper turbocharger bracket-to-cylinder block bolt.
    • Tighten to 25 Nm (18 lb-ft).

15. Tighten the lower turbocharger bracket-to-turbocharger bolt.
    • Tighten to 19 Nm (168 lb-in).

16. Tighten the lower turbocharger bracket-to-cylinder block bolt.
    • Tighten to 11 Nm (97 lb-in).

17. 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. Install the banjo bolt into the oil supply tube block.

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

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

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

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

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

22. Install the LH oil supply tube secondary latch.

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

24. 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 LH turbocharger assembly.

25. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).

26. Install the stud, generator and the nut and bolt.
    • Tighten the stud to 8 Nm (71 lb-in).
    • Tighten the nut and bolt to 47 Nm (35 lb-ft).

27. Connect the generator electrical connector.

28. Connect the generator B+ cable and install the nut.
    • Tighten to 17 Nm (150 lb-in).

29. Install the LH coolant tube bracket-to-cylinder head nut.
    • Tighten to 10 Nm (89 lb-in).

30. Attach the pin-type wire harness retainer to the rear of LH cylinder head.

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

32. Connect the LH CMP sensor electrical connector.

33. Install the LH camshafts. For additional information, refer to Camshaft in this section.

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