Cylinder head inspection (page 3 of 9)

17. Align oil level dipstick bracket to coolant outlet elbow, fit bolt and tighten to 25 Nm.
18. Thoroughly clean injectors and injector seats in cylinder head.
19. Fit new sealing washers to injectors and fit injectors to cylinder head.

CAUTION: The injector incorporating the needle lift sensor must be fitted into No.1 cylinder position only. Domed surface of sealing washer must face towards injector.

20. Fit clamp plates to injectors, align injectors and clamp plates to bolt holes in cylinder head.
21. Fit injector clamp plate bolts and tighten to 23 Nm.
22. Using new sealing washers, fit spill return pipe union to injector and tighten banjo bolt to 10 Nm.
23. Remove plugs from injector pipes, injection pump and injector unions.
24. Clean injector pipes, injection pump and injector unions.
25. Fit and align injector pipes to injectors and fuel injection pump.
26. Tighten injector pipes to fuel injection pump unions to 28 Nm.
27. Tighten injector pipes to injector unions to 28 Nm.

CAUTION: To prevent damage to fuel system pipes or components, use 2 spanners when loosening or tightening unions.

28. Connect radiator top hose to coolant outlet elbow and tighten clip.
29. Position engine harness.
30. Secure harness clip to oil level dipstick tube bracket.
31. Connect injector lift sensor multiplug and secure to injection pump bracket.
32. Connect supply lead to No.2 glow plug and tighten terminal nut.
33. Connect multiplug to oil pressure switch.
34. Connect instrument pack temperature gauge sensor connector.
35. Connect multiplug to coolant temperature sensor.
36. Connect main harness to engine harness multiplugs.

37. Position back plate to cylinder head, fit bolts and tighten to 8 Nm.
38. Fit tensioner pulley to gearbox mounting plate locating dowel, fit Allen bolt but do not tighten.
39. Check that timing pin 18G 1523 is fully inserted in hole in flywheel.