battery MERCEDES-BENZ SPRINTER 2006 Service Manual

AIR CLEANER ELEMENT
REMOVAL
(1) Remove heat shield.
(2) Disconnect air flow sensor from housing (Fig.
10).
(3) Unclip the air cleaner housing lid (Fig. 10).
(4) Remove air cleaner element (Fig. 10).
INSTALLATION
(1) Position and seat the air cleaner element into
the lower housing (Fig. 10).
(2) Install the housing cover and snap retainers
into place (Fig. 10).
(3) Install air flow sensor into housing cover and
connect. (Fig. 10).
(4) Connect the air cleaner restriction sensor (Fig.
10)..
(5) Install heat shield.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the heat shield.
(3) Remove the air flow sensor (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/MANIFOLD AIR
FLOW (MAF) SENSOR - REMOVAL).
(4) Disconnect the air intake pressure sensor,
unclip the top of the air cleaner housing and remove
(Fig. 11).
(5) Take out air cleaner element (Fig. 11).
(6) Detach bottom part of the air cleaner housing
at the body (Fig. 11).
(7) Take air intake hose out of inner fender and
out of the rubber bushing in the wheel housing liner,
then detach it at the bottom part of the air cleaner
housing (Fig. 11).
#9543 ADAPTOR
#9544 VIBRATION DAMPER PULLER
Fig. 10 AIR CLEANER ELEMENT
1 - AIR CLEANER HOUSING COVER
2 - AIR FLOW SENSOR
3 - AIR CLEANER ELEMENT
4 - AIR CLEANER HOUSING
VAENGINE 9 - 21

(8) Remove bottom portion of the air cleaner hous-
ing out of the rubber bushings in the inner fender
and remove (Fig. 11).
INSTALLATION
NOTE: Ensure that the seal between the inner
fender well and the air intake hose is correctly
installed.
(1) Seat and retain bottom portion of the air
cleaner housing into the bushings on the inner
fender (Fig. 11).
(2) Install the air intake hose to the air cleaner
housing the align and install it in the inner fender
and wheel housing liner (Fig. 11).
(3) Install air cleaner element (Fig. 11).
(4) Install and clip air cleaner top to air cleaner
body and connect the air intake pressure sensor (Fig.
11).
(5) Install air flow sensor (Fig. 11).
(6) Install heat shield.
(7) Connect negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cylinder head is made of high temperature
resistant aluminum alloy and features optimized spi-ral swirl intake ducts and a separate camshaft hous-
ing made of die cast aluminum. The combustion
chamber features four valves per cylinder, central
injectors and glow plugs arranged slant wise. The
intake and exhaust valves have solid valve stems and
conical valve springs. The cylinder head is not ser-
viceable and must be replaced should a repair
become necessary.
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER HEAD
BOLT INSPECTION
(1) Measure cylinder head bolts between points
shown (Fig. 12).
Cylinder Head
BoltsThread Diame-
ter12 M
Length When
New102 mm
Maximum
Length104 mm
(2) If the cylinder head bolt length is greater than
the maximum allowable measurement, replace the
cylinder head bolts.
STANDARD PROCEDURE - MEASURE CYLIN-
DER HEAD SURFACE
NOTE: DO NOT machine the cylinder head surface.
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Remove valves.
(4) Inspect cylinder head contact surface for flat-
ness, porous and damage.
(5) Using a straight edge, measure cylinder head
and cylinder block flatness.
(6) Measure cylinder head height at point (1) indi-
cated and retain reading (Fig. 13).
Fig. 11 AIR CLEANER HOUSING
1 - AIR FLOW SENSOR
2 - GASKET
3 - AIR INTAKE HOSE
4 - AIR CLEANER HOUSING
5 - AIR CLEANER ELEMENT
6 - AIR INTAKE PRESSURE SENSOR
7 - AIR CLEANER HOUSING COVER
Fig. 12 Measuring Cylinder Head Bolts
9 - 22 ENGINEVA

NOTE: The camshaft housing Must Not be
machined. Basic bore of the camshaft bearings will
be altered.
(7) Measure cylinder head height (1) at point indi-
cated, record stock removal (Fig. 13) CYLINDER
HEAD SPECIFICATIONS.
(8) Measure valve setback at points (2) indicated
(Fig. 13) CYLINDER HEAD SPECIFICATIONS.
NOTE: If measurement is less than dimension ª2º
no further correct valve clearance compensation is
possible; replace the cylinder head.
CYLINDER HEAD SPECIFICATIONS
Description Specification
Height of Cylinder Head
(1), With Out Camshaft
Housing126.85mm to 127.15mm
Valve Set Back (2) With
New Valves and New
Valve Seat RingsExhaust Valve: 1.0mm -
1.4mm
Intake Valve: 1.1mm -
1.5mm
REMOVAL
REMOVAL - CYLINDER HEAD
(1) Disconnect negative battery cable.
(2) Position piston of cylinder #1 to ignition TDC.(3) Raise and support vehicle.
(4) Install retaining lock # 8932 for crankshaft/
starter ring gear.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING COOLANT. DO NOT OPEN COOL-
ING SYSTEM UNLESS TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN CAP SLOWLY TO RELEASE
PRESSURE. STORE COOLANT IN APPROVED CON-
TAINER ONLY. WEAR PROTECTIVE GLOVES,
CLOTHING AND EYE WEAR.
(5) Drain cooling system at radiator and crankcase
(Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
DARD PROCEDURE).
(6) Loosen the lower turbo support bracket bolt.
(7) Remove the upper support bracket bolt.
(8) Loosen the fasteners retaining the exhaust pipe
to the support bracket at the rear of the engine.
(9) Lower vehicle.
(10) Remove engine cover. (Refer to 9 - ENGINE
COVER- REMOVAL).
(11) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
Fig. 13 Cylinder Head Measurments
1 - CYLINDER HEAD HEIGHT
2 - VALVE SETBACK
VAENGINE 9 - 23

(23) Remove upper timing case to cylinder head
bolts (Fig. 15).
NOTE: Loosen cylinder head bolts in the reverse
order of the tightening sequence.
(24) Remove cylinder head bolts and inspect (Refer
to 9 - ENGINE/CYLINDER HEAD - STANDARD
PROCEDURE).
(25) Remove cylinder head (Fig. 15).
NOTE: Carefully clean all mating surfaces and bolt
thread holes. Assure that no oil or grease is present
during reassembly.
(26) Clean all mating surfaces and blow out bolt
thread holes.
REMOVAL - CYLINDER HEAD FRONT COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - REMOVAL).WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
SERVICE VEHICLE IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. RISK OF POISON-
ING FROM INHALING AND SWALLOWING FUEL.
RISK OF INJURY FROM SKIN AND EYE CONTACT
WITH FUEL. POUR FUELS ONLY INTO SUITABLE
AND APPROPRIATELY MARKED CONTAINERS.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL.
(5) Remove vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
REMOVAL).
(6) Remove bolts attaching front cover.
NOTE: Lower portion of front cover is sealed with
RTV sealant. Carefully tug at front cover until it
loosens from cylinder head.
(7) Raise locking pawl of top guide rail and remove
cylinder head front cover (Fig. 16).
NOTE: Dowel pins are use as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
Fig. 15 CYLINDER HEAD
1 - CYLINDER HEAD BOLT
2 - CYLINDER HEAD
3 - DOWEL4 - GASKET
5 - BOLT TO TIMING COVER
VAENGINE 9 - 25

REMOVAL - CYLINDER HEAD GUIDE RAIL
(1) Disconnect negative battery cable.
CAUTION: Rotate engine at crankshaft only. DO
NOT rotate the engine with the bolt of the camshaft
sprocket. DO NOT rotate the engine back.
NOTE: Markings on the camshaft and camshaft
bearing cap must be aligned.
(2) Position piston of number 1 cylinder to ignition
TDC.
(3) Remove engine cover. (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(5) Carefully raise locking pawl of top slide rail
and remove front cover at cylinder head (Fig. 16).
(6) Insert a locking pin through 1st camshaft bear-
ing cap into the hole in the inlet camshaft sprocket.
(7) Counter hold the camshaft with an open end
wrench to avoid damage and unbolt driver of inlet
camshaft sprocket.
(8) Remove top guide rail.
INSTALLATION
INSTALLATION - CYLINDER HEAD
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents and blow out bolt holes, to
assure that no grease or oil is present during reas-
sembly. If piston or connecting rods have been
replaced, measure piston protrusion. Inspect all cyl-
inder head bolts for defects and stretching before
installation (Refer to 9 - ENGINE/CYLINDER HEAD -
STANDARD PROCEDURE). Inspect facing cylinder
head contact surface.
(1) Position the cylinder head and gasket properly
on engine using the dowel pins as a guide (Fig. 15).
CAUTION: The M12 cylinder head bolts must be
torqued in 3 stages.
NOTE: Add a small amount of clean engine oil to
the cylinder head bolt threads prior to installation.
Fig. 16 CYLINDER HEAD FRONT COVER
1 - TOP GUIDE RAIL
2 - CYLINDER HEAD COVER
3 - LOCKING PAWL
4 - DOWEL PIN5 - CYLINDER HEAD FRONT COVER
6 - SEAL
7 - TIMING CHAIN TENSIONER
8 - VACUUM PUMP
9 - 26 ENGINEVA

(2) Hand start clean head bolts and tighten per
the following procedure:
²Install M12 cylinder head bolts finger tight (Fig.
15).
²Tighten bolts in numeric order starting with
number 1 to 15 N´m (133 lbs.in.) (Fig. 17).
²Tighten bolts in numeric order starting with
number 1 to 60 N´m (44 lbs.ft.) (Fig. 17).
²Install M8 timing chain cover to cylinder head
bolts. Tighten to 20N´m (177 lbs.in.).
²Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É (Fig.
17).
²Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É again
(4 stages). (Fig. 17).
(3) Install fuel return flow line between rail and
high pressure pump (Fig. 14).
(4) Connect the coolant hoses to the thermostat
housing (Fig. 14).
(5) Connect the coolant pipe at the cylinder head
(Fig. 14).
(6) Reconnect transmission oil level indicator tube.
Tighten to 14 N´m (124 lbs. in.) (Fig. 14).
(7) Reconnect the turbocharger to the exhaust
manifold. Tighten to 30N´m (22 lbs.ft.) (Fig. 14).
(8) Install oil return flow line with new seals at
turbocharger. Tighten bolt of supply line to turbo-
charger to 18N´m (160 lbs. in.) and bolt of supply line
to cylinder head to 9N´m (80 lbs. in.) (Fig. 14)
(9) Install charge air distribution pipe (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
INSTALLATION).
(10) Install and properly route the engine wiring
harness, making appropriate connections.
(11) Install high pressure fuel pump intermediate
gear (Fig. 14).(12) Install high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(13) Install the camshaft housing with tappets to
cylinder head (Fig. 14).
(14) Install camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(15) Install top guide rail (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).
(16) Install front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - INSTALLATION).
(17) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).
(19) Install timing chain tensioner with new gas-
ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
Tighten to 80N´m (59 lbs.ft.).
(20) Remove retaining lock for crankshaft/starter
ring gear.
(21) Install air intake tube at turbocharger (Refer
to 11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM - INSTALLATION).
(22) Install the fasteners retaining the front
exhaust pipe to the support bracket at the read of
the engine.
(23) Install the upper support bracket fastener.
(24) Install the lower turbo support bracket bolt.
(25) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
NOTE: DO NOT pressure test cooling system until
engine has reached operating temperature.
(26) Refill cooling system with proper coolant mix-
ture to proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(27) Connect negative battery cable.
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) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING)
Fig. 17 CYLINDER HEAD BOLT TORQUE
SEQUENCE
VAENGINE 9 - 27

INSTALLATION - CYLINDER HEAD FRONT
COVER
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
NOTE: Dowel pins are used as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
(1) Apply sealant to the marked surfaces with a
bead thickness of 1.5   0.5 mm (Fig. 18).
NOTE: Install front cover of cylinder head within 10
minutes after applying sealant. Do not spread seal-
ing bead.
(2) Raise locking pawl of top guide rail and guide
front cover onto guide pins.
(3) Install bolts attaching front cover (Fig. 16)
Tighten bolts to 14N´m (124 lbs. in.).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
REMOVE SOURCES OF IGNITION FROM THE AREA.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY FROM SKIN
AND EYE CONTACT WITH FUEL. POUR FUELS
ONLY INTO SUITABLE AND APPROPRIATELY
MARKED CONTAINERS.
(4) Install vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
INSTALLATION).NOTE: Timing chain tensioner must be installed
with a new gasket.
(5) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(6) Connect negative battery cable.
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.
(7) Start the engine and inspect for leaks. Care
must be taken to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING)
INSTALLATION - CYLINDER HEAD GUIDE RAIL
(1) Carefully position the top guide rail onto the
guide pins.
(2) Counter hold the camshaft with an open end
wrench and install driver of inlet camshaft sprocket.
Tight bolt to 50N´m (37 lbs. ft.).
(3) Remove camshaft sprocket locking pin.
(4) Carefully raise locking pawl of top guide rail
and install front cover at cylinder head (Fig. 16).
(5) Install timing chain tensioner with new gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLA-
TION).
(6) Install engine cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
(7) Reconnect negative battery cable.
WARNING: US 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.
(8) Start engine and inspect for leaks.
CAMSHAFT(S)
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING CAM-
SHAFT POSITION
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
Fig. 18 CYLINDER HEAD COVER SEALING
SURFACE
1 - CYLINDER HEAD FRONT COVER
2 - SEALANT BEAD
9 - 28 ENGINEVA

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
NO WEAR LOOSE CLOTHING.
(11) Start the engine and inspect for leaks.
STANDARD PROCEDURE - INSPECTING TAP-
PET CLEARANCE
(1) Check engine oil level, adjust as necessary.
(2) Warm engine to operating temperature
(approx. 80ÉC, 176ÉF).
(3) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(4) Rotate the engine by the crankshaft until the
camshaft, at the tappet to be tested, is at it's base
circle (camshaft nose must point upward) (Fig. 20).
NOTE: Do not use a tool that will mar or damage
the tappet surface. If applied pressure is too strong
the tappet will appear to drop, but what happens is,
the valve opens.
(5) Use a pressing tool and apply pressure to the
tappet by hand (Fig. 20).
(6) If the tappet drops faster in comparison to the
other tappets, remove the camshaft and replace the
tappet.
REMOVAL
NOTE: Tappets are serviced Only when replacing
the camshaft housing. Inspect tappet clearance
(Refer to 9 - ENGINE/CYLINDER HEAD/CAM-
SHAFT(S) - STANDARD PROCEDURE).
(1) Disconnect negative battery cable.
(2) Remove engine cover. (Refer to 9 - ENGINE -
REMOVAL).
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
(3) Remove high pressure lines and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(4) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
NOTE: Rotate engine at the crankshaft only. DO
NOT rotate the engine at the camshaft. DO NOT
rotate the engine backward.
(5) Position piston of cylinder #1 to ignition TDC.
(6) Lock inlet camshaft (Fig. 21).
Fig. 20 TAPPET CLEARANCE
1 - CAMSHAFT
2 - PRESSURE APPLICATION POINT
3 - HYDRAULIC TAPPET
4 - CAMSHAFT HOLD DOWN
9 - 30 ENGINEVA

NOTE: The piston of cylinder #1 must be positioned
at ignition TDC when the inlet camshaft is locked.
(8) Insert locking pin through the first camshaft
bearing cap into the whole in the camshaft sprocket.
NOTE: Do Not use old camshaft sprocket bolts.
(9) Fit camshaft sprocket with timing chain fitted
on, onto exhaust camshaft paying attention to posi-
tion of dowel pin. Tighten bolt to 18N´m (159 lbs.in.).
(10) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(11) Inspect/Set basic position of camshafts (Refer
to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) -
STANDARD PROCEDURE).
(12) Insert slide rail and bolt the driver into the
inlet camshaft. Tighten bolt driver to 50N´m (37 lbs.
in.).
(13) Install front cover at cylinder head.
(14) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
NOTE: Refer to the appropriate injector servicing
procedures for cleaning of injectors and recesses.
(15) Clean and install injectors (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE), (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).
(16) Reconnect negative battery cable.WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).
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 CLOTHING.
(17) Start engine and inspect for leaks.Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
(18) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect the air inlet and set aside.
(3) Detach hose from oil separator.
(4) Disconnect the camshaft position sensor.
(5) Disconnect fuel injector and glow plug harness
and set aside.
(6) Remove fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(7) Disconnect the out let line.
(8) Remove cylinder head cover retaining bolts and
remove cover (Fig. 25).
Fig. 24 CAMSHAFT BEARING TIGHTENING
SEQUENCE #2
VAENGINE 9 - 33

INSTALLATION
NOTE: Do Not tighten the cylinder head cover first.
The fuel injectors are aligned by way of the cylinder
head cover.
(1) Fit cylinder head cover with new gasket and
install bolts, hand tight (Fig. 25).
(2) Insert all fuel injectors, tensioning claws and
lines. Insert new bolts and tighten. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).
(3) Tighten cylinder head cover bolts to 9 N´m (80
lbs. in.).
(4) Install and properly route fuel injector and
glow plug wiring harness, making appropriate con-
nections.
(5) Connect the camshaft position sensor.
(6) Connect the return flow line.
(7) Attach oil separator hose.
(8) Connect negative battery cable.
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN A DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(9) Start engine and inspect for leaks. Care must
be take to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
VALVE STEM SEALS
DESCRIPTION
The valve stem seals are made of Viton rubber. The
seals are positioned over the valve stem and seated
on the valve guide. For servicing of the valve seals
(Refer to 9 - ENGINE/CYLINDER HEAD/VALVE
SPRINGS - REMOVAL).
Fig. 25 CYLINDER HEAD COVER
1 - ENGINE WIRING HARNESS 7 - GASKET
2 - GLOW PLUG CONNECTOR 8 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR 9 - CRANKCASE VENT LINE
4 - OUTLET LINE 10 - GASKET
5 - INTAKE MANIFOLD 11 - FUEL INJECTOR
6 - GASKET 12 - GROUND
9 - 34 ENGINEVA