45
Group 21 Short block
4.
Dip them completely (even bolt heads) in rust pre-
ventative 116 1346 and let them run off on a net.
The bolts should have stopped dripping when they
are installed (otherwise oil cold may well up and
be regarded as leakage).
IMPORTANT!
The bolts are phosphated and
must not be cleaned with a steel wire brush. If
the cylinder head is painted, the contact surfac-
es for the cylinder head bolts must be free from
paint. The clamping force in the joint could oth-
erwise be very poor.
5.
Check that the dowels (guides) are fitted to the
block.
6.
Tighten the cylinder head bolts in three steps as
follows. Refer to tightening diagram.
1st tightening
30 Nm
2nd tightening
70 Nm
Final tightening:
100 ± 2.5 Nm
7.
Install the copper injector washers.
Install the injectors. Tightening torque refer to
“Technical data”.
8.
Install the pushrods, valve caps and rocker arm
mechanism with gasket. Tightening torque, please
refer to the “Technical Data” chapter.
9.
Install the oil pressure pipe between the block and
rocker arm mechanism together with the oil pres-
sure sensor. Install the oil pressure valve.
Tightening torque, please refer to the “Technical
Data” chapter.
Turn the crankshaft round a couple of rotations.
10. Adjust the valve clearances. Tightening torque,
please refer to the “Technical Data” chapter.
11. Install the valve cover.
12. Install the injection pump hollow bolt and banjo
union with new copper washers.
13. Install new copper gaskets and install the return
fuel line. Tighten the nuts and connect the return
pipe.
14. Install the delivery pipes, tightening torque refer to
“Technical data”.
15. Install the glow plugs and power rail.
16. Install the circulation pump, tightening torque refer
to “Technical data”.
17. Clean the sealing ring seat in the cylinder block
and the contact surface of the plate. Install the
rear crankshaft seal.
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Summary of Contents for D2-55
Page 1: ...Workshop manual Group 20 23 26 30 A 2 0 D2 55 D2 75 ...
Page 2: ......
Page 103: ... References to Service Bulletins Group No Date Refers to ...
Page 104: ... Notes ...
Page 105: ... Notes ...
Page 106: ... Notes ...
Page 108: ...7742969 English 08 2006 ...