101603-2680 ZEXEL 9 400 615 060 BOSCH INJECTION-PUMP ASSEMBLY 9400615060 1016032680 220205750a

(1) Cylinder head bolts and nuts tightening procedure:1. Put engine oil on the threads of bolts and nuts. Tighten all bolts and nuts in number sequence to a torque of ... 45 N m (35 lb ft)2. Tighten all bolts and nuts in number sequence to a torque of ... 95 N m (70 lb ft)3. Again tighten all bolts and nuts in number sequence to a final torque of ... 135 N m (100 lb ft).Retighten the cylinder head bolts and nuts after the engine has run under partial load for approximately thirty minutes. The rocker shaft assembly has to be removed and valve lash adjusted again.a. If the bolts and nuts move before the correct final torque is reached, retighten everything in the sequence again to the final torque of 135 N m (100 lb ft).b. If the bolts and nuts do not move before the correct final torque is reached, back each one off 30 to 60° (with an 8T3052 Degree Wheel) and retighten again, in the sequence shown, to the final torque. After all the bolts and nuts are retightened, check the first 10 positions to make sure they are tightened to the correct torque.c. After 25 to 50 hours of service for a new or rebuilt engine, retorque the cylinder head bolts as shown in Step a above and adjust the valves again.New cylinder blocks have been introduced on the 4.236 engine. The new cylinder blocks have deeper cylinder head bolt holes and longer bolts. The old and new sizes are shown. The change became effective at engine serial number LD----U027631M and up. See General Information in Systems Operation for the engine serial number location. The new cylinder head bolts are not interchangeable between old and new bolts.(2) Torque for nuts that hold injectors ... 19 N m (14 lb ft)Replace the copper washer and rubber seal between the head and the injector every time the injector is removed. See Fuel Injector Installation in Testing And Adjusting.(3) Torque for fuel line nuts ... 20 N m (15 lb ft)(4) Torque for nuts that hold rocker shaft to head ... 75 N m (54 lb ft)(5) Valve lash [clearance (cold)], between rocker arm and valve: Intake ... 0.30 mm (0.012 in)Exhaust ... 0.30 mm (0.012 in)(6) Maximum permissible nozzle projection below cylinder head face after resurfacing ... 4.44 mm (0.175 in) Resurfacing allowance (maximum) ... 0.30 mm (0.012 in)(7) Depth of cylinder head (new) ... 103.188 0.38 mm (4.0625 0.015 in) Minimum depth of cylinder head (after resurfacing) ... 102.502 mm (4.0355 in)Maximum permissible amount of bow (curve of cylinder head):Across width (transverse) ... 0.09 mm (0.003 in)Across length (longitudinal) ... 0.15 mm (0.006 in)(See Cylinder Head Check in Testing And Adjusting)