TORQUE
TORQUE
|DESCRIPTION |N·m |In. Lbs. |Ft. Lbs. |
|CONNECTING ROD-BOLTS |
|Step 1 |30 |— |22 |
|Step 2 |60 |— |44 |
|Step 3 |Rotate 60° |
|CRANKSHAFT MAIN CAP-BOLTS |
|Step 1 |50 |— |37 |
|Step 2 |80 |— |59 |
|Step 3 |Rotate 90° |
|CYLINDER HEAD BOLTS |
|Step 1 |70 |— |52 |
|Step 2 |Back off 360° |
|Step 3 |105 |— |77 |
|Step 4 Verify |105 |— |77 |
|Step 5 |Rotate All Bolts 1/4 Turn (90°) |
|Cylinder Head Cover Bolts |24 |— |18 |
|Breather Cover Bolts |24 |— |18 |
|HPC Nut |50 |— |37 |
|Flexplate to Engine |137 |— |101 |
|Flywheel to Engine (NV 5600) |137 |— |101 |
|Flywheel/Crankshaft Adapter |137 |— |101 |
|G56 Dual Mass Flywheel |137 |— |101 |
|Fuel Delivery Lines-Banjo |24 |— |18 |
|Fuel Drain Line-Banjo |24 |— |18 |
|Fuel Line - Rail to Cylinder Head |30 |— |22 |
|Fuel Line - Pump to Fuel Rail |37 |— |27 |
|Injector Fuel Line Brace |24 |— |18 |
|#6 Fuel Line Brace Nut at Lift Bracket Stud |24 |— |18 |
|Fuel Rail Holddown Bolt |24 |— |18 |
|Oil Pan - Bolts |28 |— |21 |
|Oil Pan - Drain Plug |50 |— |37 |
|Oil Pressure Regulator - Plug |80 |— |59 |
|Oil Pressure Switch |18 |— |13 |
|OIL PUMP BOLTS |
|Step 1 |8 |— |6 |
|Step 2 |24 |— |18 |
|Oil Suction Tube (Flange) - Bolts |24 |— |18 |
|Oil Suction Tube (Brace) - Bolt |43 |— |32 |
|Rocker Arm/Pedestal - Bolts |36 |— |27 |
|1. |Inspect fuel injector: |
| |a. |
| |Look for burrs on injector inlet. |
| | |
| | |
| |b. |
| |Check nozzle holes for hole erosion or plugging. |
| | |
| | |
| |c. |
| |Inspect end of nozzle for burrs or rough machine marks. |
| | |
| | |
| |d. |
| |Look for cracks at nozzle end. |
| | |
| | |
| |e. |
| |If any of these conditions occur, replace injector. |
| | |
|2. |Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air. |
|[pic] |
|3. |The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a certain thickness . |
| |A new shim (1) with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim|
| |(1) . Shim Thickness: 1.5 mm (.060”) |
|4. |Install new shim (1) (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer|
| |in place during installation. |
|5. |Install new o-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore. |
|6. |Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel |
| |injector mounting flange to engage O-ring and seat injector. |
|7. |Tightening Sequence: |
| |a. |
| |Install fuel injector holdown clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a |
| |preliminary tightening of these bolts to 5 N·m (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is|
| |seated and centered. |
| | |
| | |
| |b. |
| |After tightening, relieve bolt torque, but leave both bolts threaded in place. |
| | |
| | |
| |c. |
| |Install high-pressure connector and retaining nut. Do a preliminary tightening to 15 N·m (11 ft. lbs.) torque. |
| | |
| | |
| |d. |
| |Alternately tighten injector holdown bolts to 10 N·m (89 in. lbs.) torque. |
| | |
| | |
| |e. |
| |Do a final tightening of the high-pressure connector and retaining nut. Tighten to 50 N·m (37 ft. lbs.) torque. |
| | |
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