Andrew Burrows Oil pump / Tightening torques 03/02/16

Lubrication components, tightening torques

Oil pump

The item numbers indicate the tightening sequence.

Oil pump securing bolts 244 Nm

Oil filler pipes

Plastic lock 272 Nm
Dipstick guide bolts 204 Nm

Valve body
Valve body mounting bolts 488 Nm
Clamp screw 244 Nm

Oil strainer
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Andrew Burrows Oil pump / Tightening torques 03/02/16

Oil strainer securing bolts 244 Nm

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Andrew Burrows Engine block stiffener / Tightening torques 03/02/16

Cylinder block reinforcement, tightening torques

The item numbers indicate the tightening sequence.

Cylinder block stiffener securing bolts 488 Nm

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Andrew Burrows Cylinder head / Tightening torques 03/02/16

Cylinder head, tightening torques

The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply engine oil to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.

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Andrew Burrows Cylinder head / Tightening torques 03/02/16

Tap the screw-threads in the cylinder block then blow through with compressed air.

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Andrew Burrows Cylinder head / Tightening torques 03/02/16

The cylinder head must be positioned and tightened in accordance with the instructions given in the method (see page ).
The item numbers indicate the tightening sequence.
Stage1 655 Nm
Stage2 (check tightening) 655 Nm
Stage3 1205
Stage4 905
Bolts M8 securing the unit pump injectors wiring harness bracket 244 Nm

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Andrew Burrows Cylinder head / Tightening torques 03/02/16

The bolts M8 can be re-used 5 times. If they are, do not apply any product to the screw-threads.Do not apply any product to new bolts, which
are already pre-coated.

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Andrew Burrows Blanking plug / cap / Tightening torques 03/02/16

Cylinder head plugs, tightening torques

Plug M10 x 1.00 204 Nm
Pre-coated plug M14 x 1.50 303 Nm
Pre-coated plug M10 x 1.00 102 Nm
Pre-coated straight union 10 Nm

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Andrew Burrows Camshaft / Tightening torques 03/02/16

Rocker shaft and camshaft bearing caps, tightening torques

The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply engine oil to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.

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Andrew Burrows Camshaft / Tightening torques 03/02/16

Stage 1: bolts (1 7) 253 Nm

Stage 2: bolts (9 - 11 - 13) 905 Nm

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Andrew Burrows Camshaft / Tightening torques 03/02/16

For the 2nd stage, tighten the bolts gradually, starting with bolt (11), so the rocker shaft descends without distorting.
Stage 3: bolts (8 - 10 - 12 - 14) 605 Nm
Stage 4: bolts (9 - 11 - 13) Loosen the bolts
Stage 5: bolts (9 - 11 - 13) 605 Nm
Stage 6: bolts (1 7) 905
Stage 7: bolts (8 14) 1005

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Andrew Burrows Rocker arms / Tightening torques 03/02/16

Rocker arms, tightening torques

Valve play adjusting screw locknut 384 Nm
Exhaust valves play adjusting shim securing bolts (Optibrake retarder) 384 Nm
Unit pump injector pre-travel adjusting screw locknut 524 Nm

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Andrew Burrows Cylinder head cover / Tightening torques 03/02/16

Cylinder head cover, tightening torques

The item numbers indicate the tightening sequence.

Cylinder head cover securing bolts 244 Nm

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Andrew Burrows Exhaust manifold / Tightening torques 03/02/16

Exhaust manifold, tightening torques

Stage 1: bolts (1 - 8 - 3 - 10 - 5 - 12) 102 Nm

Stage 2: bolts (2 - 7 - 4 - 9 - 6 - 11 - 1 - 8 - 3 - 10 - 5 - 12) 488 Nm

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Andrew Burrows Intake manifold / Tightening torques 03/02/16

Intake manifold, tightening torques

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Apply "
SILICONE 7091
".

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Andrew Burrows Intake manifold / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Intake manifold securing bolts 244 Nm
Plug M10 203 Nm
Boost air pressure / temperature sensor 3.3 Nm

Consumables
Automotive part N Industrial reference N
56 89 501 292 Silicon adhesive 7091

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Andrew Burrows Heater / Tightening torques 03/02/16

Heater, tightening torques

The item numbers indicate the tightening sequence.

Stage1 102 Nm
Stage2 243 Nm
Intake air heater supply cable securing nut 101.5 Nm

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Andrew Burrows Engine flywheel / Tightening torques 03/02/16

Engine flywheel, tightening torques

The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply engine oil to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.

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Andrew Burrows Engine flywheel / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Stage1 605 Nm
Stage2 13510

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Andrew Burrows Damper / Tightening torques 03/02/16

Damper, tightening torques

The item numbers indicate the tightening sequence.

Stage1 404 Nm
Stage2 9010 Nm

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Andrew Burrows Damper / Tightening torques 03/02/16

Damper, tightening torques

The item numbers indicate the tightening sequence.

Stage1 404 Nm
Stage2 9010 Nm

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Andrew Burrows Water pump / Tightening torques 03/02/16

Cooling system, tightening torques

Water pump

The item numbers indicate the tightening sequence.

Water pump securing bolts 244 Nm

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Andrew Burrows Water pump / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Casing securing bolts M10 488 Nm
Water pump pulley securing bolts 244 Nm
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Andrew Burrows Water pump / Tightening torques 03/02/16

Water pump drive belt tensioner bracket securing bolts M16 27545 Nm
Water pump drive belt tensioner bracket securing bolts M10 488 Nm
Free pulley securing bolts M10 488 Nm
Tensioner roller securing bolts M10 488 Nm

Viscous coupling
Viscous coupling fan to hub securing nuts 244 Nm
Viscous coupling hub to water pump casing securing nut 488 Nm

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Andrew Burrows Crankshaft / Tightening torques 03/02/16

Crankshaft bearing caps, tightening torques

The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply engine oil to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.
Stage1 15020 Nm
Stage2 1205

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Andrew Burrows Connecting rods / pistons / Tightening torques 03/02/16

Big end caps, tightening torques

The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply
Molycote
grease to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.

Tighten in diagonally opposed sequence.

Use a hexagon socket.

Stage1 303 Nm
Stage2 1806

Consumables
Automotive part N Industrial reference N
50 00 336 962 Molykote lubricant

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Andrew Burrows Connecting rods / pistons / Tightening torques 03/02/16

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Andrew Burrows Engine block stiffener / Tightening torques 03/02/16

Cylinder block reinforcement, tightening torques

The item numbers indicate the tightening sequence.

Cylinder block stiffener securing bolts 488 Nm

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Andrew Burrows Casing / Tightening torques 03/02/16

Engine flywheel housing, tightening torques

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Apply "
SILICONE 7091
".

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Andrew Burrows Casing / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Stage 1: bolts M8 - M12 - M14 244 Nm
Stage 2: bolts M12 8515 Nm
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Andrew Burrows Casing / Tightening torques 03/02/16

Stage 3: bolts M14 14015 Nm

Consumables
Automotive part N Industrial reference N
56 89 501 292 Silicon adhesive 7091

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Andrew Burrows Casing / Tightening torques 03/02/16

Crankshaft sealed casing, tightening torques

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Apply "
SILICONE 7091
".

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Andrew Burrows Casing / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Sump attachment bolts
Stage 1: bolts (2 - 7) 244 Nm
Stage 2: bolts (1 8) 244 Nm

Consumables
Automotive part N Industrial reference N
56 89 501 292 Silicon adhesive 7091

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Andrew Burrows Distribution / Tightening torques 03/02/16

Timing system, tightening torques

Apply a bead of silicone dia. 2 mm (E) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
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Andrew Burrows Distribution / Tightening torques 03/02/16

Apply "
SILICONE 7091
".

The item numbers indicate the tightening sequence.

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Andrew Burrows Distribution / Tightening torques 03/02/16

The bolts can be re-used 5 times. If they are, do not apply any product to the screw-threads.Do not apply any product to new bolts, which are
already pre-coated.
Timing plate securing bolts 284 Nm

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Andrew Burrows Distribution / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Crankshaft pinion securing bolt (A) 244 Nm
Intermediate pinion hub securing bolts(B)Stage1Stage2 253 Nm1105
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Andrew Burrows Distribution / Tightening torques 03/02/16

Adjustable intermediate pinion hub securing bolts(C)Stage1Stage2 354 Nm1205

Camshaft pinion securing bolts(D)Stage1Stage2 455 Nm905

Apply a bead of silicone dia. 2 mm (F) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Apply "
SILICONE 7091
".

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Andrew Burrows Distribution / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Timing case bolts
Stage 1 122 Nm
Stage 2 244 Nm

Consumables
Automotive part N Industrial reference N
56 89 501 292 Silicon adhesive 7091

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Andrew Burrows Casing / Tightening torques 03/02/16

Oil pan, tightening torques

The item numbers indicate the tightening sequence.

Oil sump securing bolts 244 Nm
Oil sump drain plug 605 Nm
Oil dipstick securing bolt 101 Nm

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Andrew Burrows Oil pump / Tightening torques 03/02/16

Lubrication components, tightening torques

Oil pump

The item numbers indicate the tightening sequence.

Oil pump securing bolts 244 Nm

Valve body

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Andrew Burrows Oil pump / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Oil strainer bracket securing bolts 488 Nm
Oil strainer securing bolts 244 Nm
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Andrew Burrows Oil pump / Tightening torques 03/02/16

Oil pressure safety valve cover securing bolts 102 Nm

Oil jets
Oil jet securing bolts 244 Nm

The bolts can be re-used 5 times. If they are, do not apply any product to the screw-threads.Do not apply any product to new bolts, which are
already pre-coated.
Oil cooler
Oil cooler securing bolts 274 Nm

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Andrew Burrows Oil pump / Tightening torques 03/02/16

Begin by tightening bolts (11 - 14 - 3) to a torque of 244 Nm, then tighten all the bolts in the specified sequence.
Oil cooler casing securing bolts 244 Nm
Oil cooler casing plug 303 Nm
Oil cooler casing water circuit drainage union 404 Nm

Oil filter bracket

Euro 3 / 4
Oil filter 255 Nm

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Andrew Burrows Oil pump / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Oil filter bracket unit securing bolts 255 Nm

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Andrew Burrows Oil pump / Tightening torques 03/02/16

Plugs (1) 555 Nm

Plug (2) 404 Nm
Plug (3) 505 Nm
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Andrew Burrows Oil pump / Tightening torques 03/02/16

Plug (4) 555 Nm

Plugs (5) 555 Nm
Bolt (6) dia. M6 102 Nm

Euro 5

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Andrew Burrows Oil pump / Tightening torques 03/02/16

The item numbers indicate the tightening sequence.

Oil filter bracket unit securing bolts 255 Nm

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Andrew Burrows / Tightening torques 03/02/16

Oil filter nipple, tightening torque

Assembly A.

Union 48 Nm
Assembly B.

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Andrew Burrows / Tightening torques 03/02/16

Union 60 Nm

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Andrew Burrows Turbocharger / Tightening torques 03/02/16

Turbocharger, tightening torques

Turbocharger to exhaust manifold securing bolts 488 Nm
Turbocharger oil supply pipe union 255 Nm
Turbocharger oil supply tube union (on oil filter bracket) 405 Nm
Turbine casing exhaust pressure regulator 242 Nm

Stage 1: bolts (1 - 3) 12 Nm
Stage 2: bolts (2 - 4 - 1 - 3) 242 Nm

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Andrew Burrows Air compressor / Tightening torques 03/02/16

Air compressor, tightening torques

Air compressor 636 cm drive pinion securing nut 200+50 Nm
Air compressor 636 cm securing nut 8515 Nm
Union(s) 253 Nm

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Andrew Burrows Low pressure pump / Tightening torques 03/02/16

Fuel supply pump, tightening torques

Fuel feed pump securing bolt 8+2 Nm
Fuel feed pump banjo unions 405 Nm

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Andrew Burrows Steering pump / Tightening torques 03/02/16

Steering pump, tightening torques

Steering pump drive pinion securing nut 10010 Nm
Steering pump securing bolts 244 Nm

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Andrew Burrows Exhaust brake solenoid valve / Tightening torques 03/02/16

"Optibrake" retarder, tightening torques

Control solenoid valve 244 Nm
Power supply wires securing nut 1.80.3 Nm

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Andrew Burrows Injectors / Tightening torques 03/02/16

Pump injector mounting stirrup, tightening torques

Assembly type A
A = Socket with boss.
Tightening procedure for already used copper injector sleeves
Stage1 20+5 Nm
Stage2 605

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Andrew Burrows Injectors / Tightening torques 03/02/16

Assembly type B
A = Double groove flat socket with washer.
Tightening procedure for new copper injector sleeves
Stage1 20+5 Nm
Stage2 1805
Fully loosen the yoke securing bolt before proceeding with stage 3.
Stage3 20+5 Nm
Stage4 905

At each disassembly operation, change the washer.

Tightening procedure for a used injector socket or removing an injector.
Stage1 20+5 Nm
Stage2 1805
Fully loosen the yoke securing bolt before proceeding with stage 3.
Stage3 20+5 Nm
Stage4 905

At each disassembly operation, change the washer.

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Andrew Burrows Injectors / Tightening torques 03/02/16

Retightening at valve maintenance

Injector flange attachment bolts 45+5 Nm

Wiring harness bracket

Wiring harness bracket securing bolts 244 Nm

The bolts M8 can be re-used 5 times. If they are, do not apply any product to the screw-threads.Do not apply any product to new bolts, which
are already pre-coated.

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Andrew Burrows Filter / Tightening torques 03/02/16

Oil separator, tightening torques

Union(s) 255 Nm

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Andrew Burrows Fuel circuit / Tightening torques 03/02/16

Low-pressure fuel circuit, tightening torques

Bolt dia. M8x1.25 244 Nm

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Andrew Burrows Fuel circuit / Tightening torques 03/02/16

Bolt dia. M6x1.00 101.5 Nm

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Andrew Burrows Starter / Tightening torques 03/02/16

Starter, tightening torques

Starter securing nuts 455 Nm
Starter control wire securing nut 30.6 Nm
Starter power cable securing nut M10 183.6 Nm

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Andrew Burrows Alternator / Tightening torques 03/02/16

Alternator, tightening torques

Bolt dia. M10 488 Nm
Bolt dia. M12 8515 Nm
Tensioner roller securing bolts 488 Nm

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