Right Side

REMOVAL 

1. Remove the right camshaft. Refer to CAMSHAFT, ENGINE, REMOVAL AND INSTALLATION .

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2. Remove the bolts (1a) and the right turbocharger air inlet connector (1b) complete with gasket (1c).

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3. Disconnect the generator wire harness connector (1).
4. Remove the guard (2a), the nut (2b) and disconnect the generator power supply lead (2c).

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5. Remove the bolts (1a) and the generator (1b).

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6. Remove the bolt (1) and disconnect the water delivery pipe to the turbocharger complete with O-ring.
7. Remove the bolt (2) and disconnect the engine side oil return pipe from the turbocharger complete with O-ring.

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8. Loosen the band and disconnect the turbocharger water return pipe (1).

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9. Remove the nuts (1a) and the turbocharger complete with pipes (1b).
10. Remove the gasket.

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11. Remove the bolt (1a), the connector (1b) and the water return hose from the turbocharger (1c).
12. Remove the banjo bolt (2a) and disconnect the degassing pipe (2b) from the cylinder head.

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13. Remove the bolt (1a) and release the fuel pressure sensor connector retaining bracket (1b).

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14. Remove the bolts (1a) and the right cylinder head timing chain fixed pad (1b).

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15. Remove the bolt (1) securing the right cylinder head to the engine block.

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16. Remove the nuts (1a) and the right cylinder head (1b).

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17. Remove the right cylinder head gasket (1).

INSTALLATION 

1. Clean the gasket sealing surfaces. Refer to appropriate service information .
2. Install a NEW  right cylinder head gasket.
3. Install the right cylinder head.
4. Dry fit the washers with the ground parts in contact with the cylinder head.
5. Lubricate the cylinder head nuts (M12 x 1.25) threads, their lower parts and the stud side, with Molycote® BR2 grease.
6. Install the nuts securing the cylinder head to the engine block, without tightening them.
   Fig 1: Cylinder Head Nuts Tightening Sequence

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7. Using the tightening sequence shown in illustration, tighten the central nuts (1-2-3-4), the front nuts (5-6) and rear nuts (7-8) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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8. Tighten the M6 bolt (1) and securing the right cylinder head to the engine block to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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9. Install the right head timing chain fixed pad (1a) and tighten the bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
10. Install the fuel pressure sensor connector retaining bracket and securely tighten the bolt.

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11. Using NEW  gaskets, install the cylinder head degassing pipe (1a) and tighten the banjo bolt (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
12. Using NEW  gaskets, install the turbocharger water return hose (2a), tighten the banjo (2b) to the proper, and securely tighten intermediate bracket bolt (2c). Refer to TORQUE SPECIFICATIONS .
13. Install a NEW  exhaust manifold gasket.
    Fig 2: Turbocharger Assembly With Pipes Nuts Tightening Sequence

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14. Using NEW  nuts, install the turbocharger assembly complete with pipes and tighten the nuts finger tight.
15. Using the tightening sequence shown in illustration, tighten the NEW  nuts to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
16. Connect the turbocharger water return hose and tighten the relative band.

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17. Using a NEW  O-ring, install the turbocharger water supply pipe and tighten the bolt (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
18. Using a NEW  O-ring, install the turbocharger oil return pipe and tighten the bolt (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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19. Install the generator (1a) and tighten the bolts (1b) to the. Refer to TECHNICAL SPECIFICATIONS .
20. Connect the generator power supply lead and securely tighten the nut, and close the guard.
21. Connect the generator wire harness connector.

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22. Using a NEW  gasket, Install the turbocharger air inlet connector (1a) and tighten the bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
23. Install the right camshaft. Refer to CAMSHAFT, ENGINE, REMOVAL AND INSTALLATION .