Dodge Sprinter 2006 Manual page 1597

VA
(2) H a n d st a r t clea n h ea d bolt s a n d t igh t en per
t h e followin g pr ocedu r e:
• In st a ll M12 cylin der h ea d bolt s fin ger t igh t (F ig.
15).
• Tigh t en bolt s in n u m er ic or der st a r t in g wit h
n u m ber 1 t o 15 N·m (133 lbs.in .) (F ig. 17).
• Tigh t en bolt s in n u m er ic or der st a r t in g wit h
n u m ber 1 t o 60 N·m (44 lbs.ft .) (F ig. 17).
• In st a ll M8 t im in g ch a in cover t o cylin der h ea d
bolt s. Tigh t en t o 20N·m (177 lbs.in .).
• Tigh t en M12 cylin der h ea d bolt s in n u m er ic
or der st a r t in g wit h n u m ber 1 a n a ddit ion a l 90° (F ig.
17).
• Tigh t en M12 cylin der h ea d bolt s in n u m er ic
or der st a r t in g wit h n u m ber 1 a n a ddit ion a l 90° a ga in
(4 st a ges). (F ig. 17).
Fig. 17 CYLINDER HEAD BOLT TORQUE
SEQUENCE
(3) In st a ll fu el r et u r n flow lin e bet ween r a il a n d
h igh pr essu r e pu m p (F ig. 14).
(4) Con n ect t h e coola n t h oses t o t h e t h er m ost a t
h ou sin g (F ig. 14).
(5) Con n ect t h e coola n t pipe a t t h e cylin der h ea d
(F ig. 14).
(6) Recon n ect t r a n sm ission oil level in dica t or t u be.
Tigh t en t o 14 N·m (124 lbs. in .) (F ig. 14).
(7) Recon n ect t h e t u r boch a r ger t o t h e exh a u st
m a n ifold. Tigh t en t o 30N·m (22 lbs.ft .) (F ig. 14).
(8) In st a ll oil r et u r n flow lin e wit h n ew sea ls a t
t u r boch a r ger. Tigh t en bolt of su pply lin e t o t u r bo-
ch a r ger t o 18N·m (160 lbs. in .) a n d bolt of su pply lin e
t o cylin der h ea d t o 9N·m (80 lbs. in .) (F ig. 14)
(9) In st a ll ch a r ge a ir dist r ibu t ion pipe (Refer t o 11
- E XH AUST SYSTE M/TURBOCH ARGE R SYSTE M -
INSTALLATION).
(10) In st a ll a n d pr oper ly r ou t e t h e en gin e wir in g
h a r n ess, m a kin g a ppr opr ia t e con n ect ion s.
(11) In st a ll h igh pr essu r e fu el pu m p in t er m edia t e
gea r (F ig. 14).
(12) In st a ll h igh pr essu r e pu m p (Refer t o 14 -
F UE L SYSTE M/F UE L DE LIVE RY/F UE L INJ E C-
TION P UMP - INSTALLATION).
(13) In st a ll t h e ca m sh a ft h ou sin g wit h t a ppet s t o
cylin der h ea d (F ig. 14).
(14) In st a ll ca m sh a ft s (Refer t o 9 - E NGINE /CYL-
INDE R H E AD/CAMSH AF T(S) - INSTALLATION).
(15) In st a ll t op gu ide r a il (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING
SP ROCKE TS - INSTALLATION).
(16) In st a ll fr on t cover a t cylin der h ea d (Refer t o 9
- E NGINE /CYLINDE R H E AD - INSTALLATION).
(17) In st a ll cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R
COVE R(S) - INSTALLATION).
(18) In st a ll fu el h igh pr essu r e pipes a n d in ject or s
(Refer t o 14 - F UE L SYSTE M/F UE L INJ E CTION/
F UE L INJ E CTOR - INSTALLATION).
(19) In st a ll t im in g ch a in t en sion er wit h n ew ga s-
ket . (Refer t o 9 - E NGINE /VALVE TIMING/TIMING
BE LT/CH AIN AND SP ROCKE TS - INSTALLATION)
Tigh t en t o 80N·m (59 lbs.ft .).
(20) Rem ove r et a in in g lock for cr a n ksh a ft /st a r t er
r in g gea r.
(21) In st a ll a ir in t a ke t u be a t t u r boch a r ger (Refer
t o 11 - E XH AUST SYSTE M/TURBOCH ARGE R SYS-
TE M - INSTALLATION).
(22) In st a ll t h e fa st en er s
exh a u st pipe t o t h e su ppor t br a cket a t t h e r ea d of
t h e en gin e.
(23) In st a ll t h e u pper su ppor t br a cket fa st en er.
(24) In st a ll t h e lower t u r bo su ppor t br a cket bolt .
(25) In st a ll en gin e cover (Refer t o 9 - E NGINE -
INSTALLATION).
NOTE: DO NOT pressure test cooling system until
engine has reached operating temperature.
(26) Refill coolin g syst em wit h pr oper coola n t m ix-
t u r e t o pr oper level (Refer t o 7 - COOLING/E NGINE /
COOLANT - STANDARD P ROCE DURE ).
(27) Con n ect n ega t ive ba t t er y ca ble.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(28) St a r t en gin e a n d in spect for lea ks. Ca r e m u st
be t a ken t o obser ve t h e fu el syst em wa r n in g (Refer t o
14 - F UE L SYSTE M - WARNING)
ENGINE 9 - 27
BE LT/CH AIN
H E AD/CYLINDE R
r et a in in g t h e
AND
H E AD
fr on t