8.  Follow Steps 8.a through 8.c in order to install the

Note: Remove the manifolds as one assembly.

tube assembly for the oil feed to the turbocharger.

3.  Remove the exhaust manifold gaskets.

a.  Place a new joint (3) and tube assembly (2) in

position on turbocharger (4).

4.  Remove exhaust manifolds (4) and (6)  from

exhaust manifold (5).

b. Install bolts (1). Tighten the bolts to a torque of

28 N·m (21 lb ft).

5.  If necessary, remove the taperlock studs from the

cylinder head.

c.  Connect tube assembly (2) to the engine oil

filter base.

Installation Procedure

9.  Connect the air hoses to the turbocharger inlet

and the turbocharger outlet.

Table 7

Required Tools

If a new turbocharger was installed, tighten the

V-band clamp for the exhaust housing to 13.5 N·m

(120 lb in). Tighten the  V-band clamp for the

compressor housing to 18 N·m (160 lb in).

Tool

Part Number

Part Description

Qty

A

CV60889

Anti-Seize Compound

1

NOTICE

Keep all parts clean from contaminants.

End By:

a.  Install the exhaust elbow. Refer to Disassembly

and Assembly, “Exhaust Elbow - Remove and

Install”

Contaminants may cause  rapid wear and  shortened

component life.

1.  If necessary, install the taperlock studs to the

cylinder head. Tighten the taperlock studs to  a

torque of 35 N·m (26 lb ft).

i02754773

Exhaust Manifold - Remove

and Install

Removal Procedure

Start By:

a.  Remove the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger - Remove”.

g01380890

Illustration 26

2.  Assemble exhaust manifolds (4), (5) and (6).

3.  Position the exhaust manifold gaskets onto the

taperlock studs.

4.  Install the assembly of the exhaust manifolds to

the cylinder head.

Note: Ensure that the holes in exhaust manifolds are

centralized with the taperlock studs.

g01380890

Illustration 25

5.  Apply Tooling (A) to the threads of the taperlock

studs. Install spacers (1), washers (2) and nuts (3).

1.  Remove nuts (3), washers (2) and spacers (1).

2.  Remove exhaust manifolds (4), (5) and (6).

This document has been printed from SPI². Not for Resale

KENR6906

17

Disassembly and  Assembly Section

Installation Procedures

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01380891

Illustration 27

1.  Thoroughly clean the exhaust elbow and the outlet

of the turbocharger. Inspect the components for

wear or damage. Replace any components that

are worn or damaged.

6.  Tighten the nuts to a torque of 55 N·m (41 lb ft) in

a numerical sequence that is shown in Illustration

27.

End By:

a.  Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Install”.

i02754774

Exhaust Elbow - Remove and

Install

Removal Procedure

g01382827

Illustration 29

NOTICE

Keep all parts clean from contaminants.

2.  Position clamp (1) and install exhaust elbow (3)

to turbocharger (2). Ensure correct orientation of

the clamp.

Contaminants may cause  rapid wear and  shortened

component life.

3.  Tighten clamp (1) to a torque of 14 N·m (10 lb ft).

i02763449

Inlet Manifold - Remove and

Install

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01382827

Illustration 28

1.  Loosen clamp (1).

2.  Remove exhaust elbow (3) and clamp (1) from

turbocharger (2).

This document has been printed from SPI². Not for Resale

18

KENR6906

Disassembly and  Assembly Section

6.  Remove fasteners (8). Note the position of the

brackets that are retained by the fasteners.

7.  Remove inlet manifold (7) from the cylinder head.

8.  Remove gasket (10) (not shown).

9.  If necessary, remove inlet manifold pressure

sensor (3) and remove inlet manifold temperature

sensor (6) from  inlet manifold (7). Refer to

Disassembly and Assembly, “Inlet  Manifold

Pressure Sensor - Remove  and Install” and

Disassembly and Assembly, “Inlet  Manifold

Temperature Sensor - Remove and Install” for

more information.

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

g01383308

Illustration 30

Contaminants may cause  rapid wear and  shortened

component life.

Typical example

1.  Loosen the hose clamps and disconnect air hose

(1) from connection (2).

1.  Ensure that all mating surfaces are clean and free

from debris.

2.  Slide the locking tab into the unlocked position

and disconnect harness assembly (4) from inlet

manifold pressure sensor (3).

3.  Slide the locking tab into the unlocked position

and disconnect harness assembly (4) from inlet

manifold temperature sensor (6).

4.  Loosen clamp (5) and remove connection (2) from

inlet manifold (7).

Note: Make a temporary mark in order to show the

orientation of the connection.

g01384161

Illustration 32

Typical example

2.  Place a new gasket (10) (not shown) in position

on inlet manifold (7).

3.  Position inlet manifold (7) on the cylinder head.

4.  Install fasteners (8). Ensure that the brackets that

are retained by the fasteners are installed in the

correct positions.

5.  Tighten fasteners (8) to a  torque of 55 N·m

(41 lb ft).

g01384161

Illustration 31

Typical example

6.  Install a new O-ring seal (9) to inlet manifold (7).

5.  Remove O-ring seal (9) from inlet manifold (7).

This document has been printed from SPI². Not for Resale

KENR6906

19

Disassembly and  Assembly Section

i02754775

Inlet and  Exhaust Valve

Springs - Remove and Install

Removal Procedure

Table 8

Required Tools

Tool

A

Part Number

CH11148

Part Description

Engine Turning Tool

Qty

1

B

CVT0003

Valve Spring Compressor

1

Start By:

a.  Remove the electronic unit injectors. Refer to

Disassembly and Assembly, “Electronic  Unit

Injector - Remove”.

g01383308

Illustration 33

Typical example

7.  Install connection (2) and clamp  (5) to inlet

manifold (7). Tighten the clamp to  a torque of

14 N·m (10 lb ft).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Note: Ensure correct orientation of the connection.

8.  If necessary, install inlet manifold pressure sensor

(3) and install inlet manifold temperature sensor

(6) to inlet manifold (7). Refer  to Disassembly

and Assembly, “Inlet Manifold Pressure Sensor

- Remove and Install”  and Disassembly and

Assembly, “Inlet Manifold Temperature Sensor -

Remove and Install” for more information.

Note: The following procedure should be adopted in

order to remove the valve springs when the cylinder

head is installed to the engine. Refer to Disassembly

and Assembly, “Inlet and Exhaust Valves - Remove

and Install” for the procedure to remove the  valve

springs from a cylinder head that has been removed

from the engine.

9.  Connect harness assembly (4) to inlet manifold

pressure sensor (3) and slide the locking tab into

the locked position.

1.  Use Tooling (A) to position the appropriate piston

at the top center position before the valve spring

is removed.

10. Connect harness assembly (4) to inlet manifold

temperature sensor (6) and slide the locking tab

into the locked position.

Note: Failure to ensure that the piston is at the top

center position may allow the valve to drop into the

cylinder bore.

11. Connect air hose (1) to connection (2) and tighten

the hose clamps securely.

NOTICE

Do not turn the crankshaft while the valve springs are

removed.

Note: Valve springs must be replaced in pairs for the

inlet valves or the exhaust valves of each cylinder. If

all valve springs require replacement the procedure

can be carried out on two cylinders at the same time.

The procedure can be carried out on the following

pairs of cylinders. 1 with 6, 2 with 5,  and 3 with 4.

Ensure that all of the  valve springs are installed

before changing from one pair of cylinders to another

pair of cylinders.

This document has been printed from SPI². Not for Resale

20

KENR6906

Disassembly and  Assembly Section

8.  Remove spring seats (7) from the valve guides.

g01411612

Illustration 35

9.  If necessary, remove valve stem seals (8).

Installation Procedure

g01380893

Illustration 34

Table 9

Required Tools

Tool

Part Number

Part Description

Qty

Personal injury  can result  from being  struck by

parts propelled by a released spring force.

B

CVT0003

Valve Spring Compressor

1

Make sure to wear all necessary protective equip-

ment.

NOTICE

Keep all parts clean from contaminants.

Follow the  recommended procedure  and use all

recommended tooling to release the spring force.

Contaminants may cause  rapid wear and  shortened

component life.

NOTICE

1.  Inspect the valve springs for damage and for the

correct length. Refer to Specifications, “Cylinder

Head Valves ”.

Plug the  apertures for the  push rods in  the cylinder

head in order to prevent  the entry of loose parts into

the engine.

2.  Lubricate the valve stems with clean engine oil.

2.  Position electronic unit injector clamp (1)  on

Tooling (B). Install Tooling (B) into the electronic

unit injector sleeve.  Tighten the bolt on the

electronic unit injector clamp in order to secure

Tooling (B).

3.  Tighten the nut on Tooling (B) until valve keepers

(3) are loose on valves (2).

4.  Remove valve keepers (3).

5.  Loosen the nut in order to release the pressure

on Tooling (B). Remove electronic unit injector

clamp (1) and Tooling (B) from the electronic unit

injector sleeve.

g01411612

Illustration 36

6.  Remove valve rotators (4).

3.  If necessary, install new valve stem seals (8).

7.  Remove outer valve springs (5) and inner valve

springs (6).

This document has been printed from SPI². Not for Resale