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PRODUKT NIEDOSTĘPNY
Indeks towaru: SILNIK 3,0 CRD
Realizacja zamówienia: 24

WYMIANA LEWEJ USZCZELKI GŁOWICY

CAUTION: Inspect and measure all cylinder head bolt lengths. If out of specification, replace as necessary.

1. Clean and inspect gasket mating surfaces

2. Position correct head gasket on engine block.

3. Place cylinder head on engine block.

CAUTION: If new cylinder head bolts are used, do not lubricate the new cylinder head bolts. They already are coated with an anti scuff treatment.

4. Tighten M8 bolts 9 and 10 to 20 N·m ( 177 in. lbs.).

5. Tighten cylinder head bolts following procedure below.
a. Tighten the M10 bolts 1 through 8 in the sequence shown to 10 Nm (88 in. lbs)
b. Tighten the M10 bolts 1 through 8 in the sequence shown to 60 Nm (531 in. lbs)
c. Tighten the M10 bolts 1 through 8 in the sequence shown an additional 90 degrees
d. Tighten the M10 bolts 1 through 8 in the sequence shown 90 degrees
e. Tighten the M10 bolts 1 through 8 in the sequence shown 90 degrees





NOTE: Followers and tappets assemblies must be installed in same location as removed.

6. Install the followers (2) and tappets (2) into their original positions.

7. Install the glow plugs (1). Tighten glow plugs (1) to 15 N·m (133 in. lbs.).




8. Install the left exhaust camshaft. Tighten the retaining (2) fasteners to 8 N·m (71 in. lbs.).

9. Install the left intake camshaft. Tighten the retaining (1) fasteners to 8 N·m (71 in. lbs.).




NOTE: Care must be taken to assure the proper exhaust camshaft to intake camshaft alignment is maintained. Before mating the drive gear to the camshaft gear a quick check will find the exhaust camshaft drive gear dowel (3) in the 12 O'clock position when viewed through the camshaft seal access hole.

10. Align the camshaft marks (2) so the alignment marks are facing each other.

11. Insert the timing chain, through the cylinder head, and on to the camshaft drive gear.




NOTE: Use the camshaft pins to ensure that the camshaft timing is set correctly. If the pins can not be installed into the camshafts, the camshafts are 180 degrees out of time.




12. Align the balance shaft (2) with the scribe or paint mark.

13. Once the camshaft drive gear is mated with the timing chain, install the camshaft drive gear on to the camshaft and assure the balance shaft is aligned properly.




14. Install the upper two of the three camshaft drive gear bolts. Tighten the bolts to 18 Nm (159 in. lbs.)




15. Install the left lower timing chain guide (1).




16. Install the left upper timing chain guide (4).




17. Install the timing chain tensioner (3).




18. Rotate the engine by the vibration damper bolt enough to gain access to the third camshaft drive gear bolt hole.

19. Install the third camshaft drive gear retaining bolt and tighten the bolt to 18 N·m (13 ft. lbs.).

WARNING:
If the camshaft, balance shaft and or crankshaft alignment marks are not aligned properly immediate damage to the engine will occur. If the camshafts, balance shaft and or crankshaft do not align properly after rotating the engine to the original starting point, STOP and begin the alignment procedure again.

20. Rotate the engine back to TDC by the vibration damper bolt until the crankshaft, camshaft and balance shaft align TDC again.




WARNING:
Check that all the timing chain fits properly on all the timing gears. Failure to do so will result in immediate engine damage.

21. Apply a 1.5mm continuous bead of Mopar Engine Sealant RTV around the diameter of the timing chain cover (1) and Install the cover (1). Tighten the bolts to 8.4 N·m (74 in. lbs.).

22. Raise and support the vehicle.



23. Install the 5 front oil pan to timing cover bolts. Tighten the bolts to 20 N·m (177 in. lbs.).




24. Install # 9102 crankshaft lock (2) into the starter access blank.

25. Lower the vehicle.




26. Install the vibration damper. Tighten the bolts to 210 N·m (154 ft. lbs.) and then an additional 180°.




NOTE: Care must be taken not to get any engine sealer on the camshaft journals.

27. Apply a 1.5 mm continuous bead of Mopar Engine Sealant RTV (1) around the diameter of the left cylinder head cover, and install the cover with new camshaft seals.




28. Tighten the bolts in three stages following the sequence provided. First to 4 N·m (35 in. lbs.), then to 6 N·m (53 in. lbs.), and then to 8.4 N·m (75 in. lbs.).




29. Install the oil filter housing bracket. Tighten the bolts to 14 N·m (123 in. lbs.).

30. Install the high pressure pump. Tighten bolts to 14 N·m (123 in. lbs.).

31. Install the belt idler pulleys (1). Tighten the bolts to 28 N·m (20 ft. lbs.).

32. Install the drive belt tensioner (2). Tighten the bolts to 58 N·m (43 ft. lbs.).

33. Install the drive belt.




CAUTION: The right intake manifold upper thermostat housing bolts should be tightened to 8.4 N·m (74 in. lbs.).

34. Install the intake manifold (4). Tighten bolts to 16 N·m (142 in. lbs.), starting in the middle and tightening in a cross pattern outward until reaching the upper thermostat bolts on the right front manifold.

35. Tighten the upper thermostat bolts on the right cylinder head to 8.4 N·m (74 in.lbs.).




CAUTION: The fuel injector sealing washers MUST be replaced. DO NOT use the old sealing washers or double the sealing washers.

36. Lubricate the fuel injector body (1), install the left fuel injectors (1) and new lower sealing washers.

37. Install the injector retaining claws and tighten the bolts to 7 N·m plus 180 °(62 in. lbs. plus 180°).




38. Properly route and install the fuel return hoses (5) and connect them to the injectors. 




39. Properly route and connect the engine harness.




40. Install the fuel rail (2). Tighten the bolts to 33 N·m (24 ft. lbs.).

CAUTION: Inspect the fuel lines for wear or damage, look closely around the flange area. Replace as necessary. DO NOT over tighten.

41. Install the high pressure fuel lines, including the fuel rail equalizing line. Tighten the line nuts to 27 N·m (177 in. lbs.) and then tighten an additional 60 degrees.




42. Install the fuel filter (2) and connect the harnesses (1) and hoses (3). 




CAUTION: Care must be taken when installing the turbocharger oil housing adaptor (1). The gasket MUST be aligned properly with the oil housing passages or immediate damage to the turbocharger will occur.

43. Install the turbocharger oil housing adaptor (1) with the gasket tabs secured to the adaptor (1) Tighten bolts to 12 N·m (9 ft. lbs.).

44. Install the turbocharger




45. Install the air control valve and resonator.




46. Install the charge air cooler inlet pipe and resonator.




47. Install the cooling fan module.

48. Install the heater hose bracket and secure hoses.

49. Connect the vacuum pump supply hose.

50. Raise and support the vehicle.

51. Remove # crankshaft lock (2).

52. Install the starter blank. 

53. Connect the cooling fan hydraulic lines.

54. Lower the vehicle.

55. Fill the cooling system.

56. Fill power steering system.

57. Connect the negative battery cable.




58. Start engine, allow to warm, turn engine off and inspect for leaks 

59. Purge the air from the power steering system using the scan tool.

60. Install the engine cover brackets and engine cover (1).

 

  

 

 

 

 

 

 

 

WYMIANA PRAWEJ USZCZELKI GŁOWICY

1. Clean and inspect gasket mating surfaces.

2. Position head gasket on engine block. Be sure the coolant passages align (part number should be facing up).

3. Place cylinder head on engine block.

CAUTION: Inspect and measure all cylinder head bolt lengths. If out of specification, replace as necessary 

CAUTION: If new cylinder head bolts are used, do not lubricate the new cylinder head bolts. They already are coated with an anti scuff treatment.

4. Tighten M8 bolts 9 and 10 to 20 Nm (177 in. lbs.).

5. Tighten cylinder head bolts following procedure below.
a. Tighten M10 cylinder head bolts 1 through 8, in the sequence shown to 10 Nm (88 in. lbs.).
b. Tighten M10 cylinder head bolts, 1 through 8, in sequence shown to 60 Nm (44 ft. lbs.).
c. Recheck and tighten M8 bolts 9 and 10 to 20 Nm (177 in. lbs.).
d. And then again, tighten M10 cylinder head bolts, 1 through 8, in sequence an additional 90°.
e. And then again, tighten M10 cylinder head bolts, 1 through 8, in sequence an additional 90°.
f. And then again, tighten M10 cylinder head bolts, 1 through 8, in sequence an additional 90°.



NOTE: Followers and tappets assemblies must be installed in same location as removed.

6. Install the followers (2) and tappets (2) into their original positions.

7. Install the right cylinder head glow plugs (1). Tighten glow plugs to 12 Nm (106 in. lbs.).




8. Install the right exhaust camshaft and retainers. Tighten fasteners to 8 Nm (70 in. lbs.).

9. Install the right intake camshaft and retainers. Tighten fasteners to 8 Nm (70 in. lbs.).

10. Install the camshaft holding tool No. 9555 .




NOTE: Care must be taken to assure the proper exhaust camshaft to intake camshaft alignment is maintained. Before mating the drive gear to the camshaft gear a quick check will find the exhaust camshaft drive gear dowel (3) in the 12 O'clock position when viewed through the camshaft seal access hole.

11. Align the camshaft marks (2) so the alignment marks are facing each other.

12. Insert the timing chain, through the cylinder head, and on to the camshaft drive gear.




WARNING:
If the camshaft, balance shaft or crankshaft alignment marks are not aligned properly, immediate damage to the engine will occur. If the camshafts, balance shaft or crankshaft do not align properly after rotating the engine to the original starting point, Stop and begin the alignment procedure again.

WARNING:
Check that all the timing chain fits properly on all the timing gears. Failure to do so will result in immediate engine damage.

13. Align the balance shaft with the scribe or paint mark.



NOTE: Use the camshaft pins to ensure that the camshaft timing is set correctly. If the pins can not be installed into the camshafts, the camshafts are 180 degrees out of time.

14. Once the camshaft drive gear is mated with the timing chain, install the camshaft drive gear on to the camshaft and assure the balance shaft is aligned properly.




15. Install the upper two right camshaft drive gear bolts. Tighten the bolts to 18 Nm (159 in. lbs.)




16. Install the right lower timing chain guide (2), seat the guide retaining pin at the top, and tighten the guide bolt to 17 Nm (150 in. lbs.).

17. Install the right upper timing chain guide (1), seat the guide pin at the top, and tighten the guide bolt to 17 Nm (150 in. lbs.).




18. Install the timing chain tensioner (3).




19. Rotate the engine by the vibration damper bolt enough to gain access to the third camshaft bolt hole.

20. Install the third camshaft drive gear retaining bolt and tighten the bolt to 17 Nm (150 in. lbs.).

21. Rotate the engine back to TDC by the vibration damper bolt until the crankshaft, camshaft and balance shaft align TDC again.




22. Add a 1.5 mm continuous bead of Mopar Engine Sealant RTV (1) to the timing chain cover and the front portion of the oil pan, then install the timing chain cover. Tighten the bolts to 9 Nm (80 in. lbs.).

23. Raise and support the vehicle.




24. Install the 5 front oil pan (2) to timing cover bolts. Tighten the bolts to 20 Nm (177 in. lbs.).




25. Install the crankshaft lock No. (2).

26. Lower the vehicle.

27. Install the vibration damper. 

28. Remove the camshaft holding tool No.




NOTE: Care must be taken not to get any engine sealer on the camshaft journals.

29. Add a 1.5 mm continuous bead of Mopar Engine Sealant RTV (1) to the cylinder head cover, then install the right cylinder head cover along with a new camshaft seal.




30. Tighten the bolts in three stages following the sequence provided. First to 4 Nm (35 in. lbs.), then to 6 Nm (53 in. lbs.) and then to 9 Nm (80 in. lbs.).




31. Align the pump drive gear (1) with the camshaft drive gear (3) and install the vacuum pump (2) with new gasket. Tighten bolts to 9 Nm (7 ft. lbs.).

32. Connect the vacuum pump supply hose.




CAUTION: The fuel injector sealing washers Must be replaced. Do Not use the old sealing washers or double the sealing washers. Do Not apply injector body lubricant near the injector nozzles.

33. Lubricate the fuel injector body, install the right fuel injectors and new sealing washers.

34. Install the injector retaining claws (3) and tighten the bolts to 7 Nm, plus 180° (62 in. lbs., plus 180°).

35. Properly route and install the fuel return hoses (2) and connect them to the injectors.




36. Install the belt idler pulley (1) under the water pump (7). Tighten the bolts to 28 Nm (20 ft. lbs.).

37. Install the accessory drive belt tensioner (2). Tighten the bolts to 58 Nm (43 ft. lbs.).

38. Install the accessory drive belt.




CAUTION: The right intake manifold upper thermostat housing bolts should be tightened to 8.5 N·m (75 in. lbs.).

39. Install the intake manifold (4). Tighten bolts to 16 Nm (142 in. lbs.), starting in the middle and tightening in a cross pattern outward until reaching the upper thermostat bolts on the right front manifold.

40. Tighten the upper thermostat bolts on the right cylinder head to 8.5 Nm (74 in. lbs.).




41. Install the fuel rail (2). Tighten the bolts to 27 Nm (20 ft. lbs.).

CAUTION: Inspect the fuel lines for wear or damage, look closely around the flange area. Replace as necessary. DO NOT over tighten.

42. Install the high pressure fuel lines (3), including the fuel rail transfer line (1). Tighten the line nuts to 33 Nm (24 ft. lbs.).

43. Install the fuel filter and connect the and hoses using Fuel Line Pliers No. 9539 Hose Clamp pliers.

44. Connect the fuel supply and return hose quick connectors at the left cylinder head cover.




45. Install the oil separator (1) and housing adaptor (2) with new camshaft seal. Tighten the bolts to 11 Nm (97 in. lbs.).

46. Properly route and connect the engine harness.

47. Connect the coolant hose at the thermostat housing.

48. Install the upper radiator hose.

49. Install the exhaust manifold. Tighten the nuts to 25 Nm (222 in. lbs.)