Tightening Torques

184/193Hp - 135/142KW

Component	Instructions	Torque Specification
Cylinder head instructions
Cylinder head	Renew bolts	Yes
	Tighten	40 Nm
	Tighten	80 Nm
	Slacken off	180°
	Tighten	50 Nm
	Tighten	90°
	Tighten	90°
Other engine tightening torques
Main bearings	Renew bolts/nuts	Yes
Main bearings - Stage 1	Tighten	20 Nm
Main bearings - Stage 2	Tighten	70°
Big end bearings	Renew bolts/nuts	Yes
Big end bearings - Stage 1	Tighten	15 Nm
Big end bearings - Stage 2	Tighten	20 Nm + 70°
Oil pump to cylinder block	Tighten	22 Nm
Sump bolts	Apply sealant	M6 8.8 = 10 Nm M6 10.9 = 12 Nm M8 = 22 Nm
Sump drain bolt	-	M12 = 35 Nm M22 = 60 Nm
Flywheel/driveplate	Tighten	105 Nm / 120 Nm
Clutch pressure plate	-	8.8 = 24 Nm 10.9 = 34 Nm
Crankshaft pulley/damper center bolt	Use new bolts and tighten in the following stages	40 Nm 60° 60°
Camshaft sprocket/gear	Tighten	20 Nm + 50°
Camshaft carrier/cap	-	M6 = 10 Nm M7 = 15 Nm M8 = 20 Nm
Camshaft/rocker cover	-	M6 = 10 Nm M7 = 15 Nm
Inlet manifold to cylinder head	-	M6 = 10 Nm M7 = 15 Nm M8 = 22 Nm
Exhaust manifold to cylinder head	-	M6 = 10 Nm M7 = 15 Nm
Injector/clamp	Tighten	10 Nm
Injector pipe unions	Tighten	25 Nm
Fuel/injection pump sprocket/gear	Tighten	65 Nm
Glow plugs	Tighten	18 Nm
Engine coolant temperature (ECT) sensor	Tighten	13 Nm
Engine oil pressure switch	Tighten	14 Nm

204/218Hp-150/160Kw

Component	Instructions	Torque Specification
Cylinder head instructions
Cylinder head	Renew bolts	Yes
	Tighten	40 Nm
	Tighten	80 Nm
	Slacken off	180°
	Tighten	50 Nm
	Tighten	90°
	Tighten	90°
Other engine tightening torques
Main bearings	Renew bolts/nuts
Main bearings - Stage 1	Tighten	Yes
Main bearings - Stage 2	Tighten	23 Nm
Big end bearings	Renew bolts/nuts	90°
Big end bearings - Stage 1	Tighten	Yes
Big end bearings - Stage 2	Tighten	5 Nm
Oil pump to cylinder block	Tighten	20 Nm + 70°
Sump bolts	Apply sealant	23 Nm
Sump drain bolt	-	M6 8.8 = 10 Nm M6 10.9 = 12 Nm M8 = 22 Nm
Flywheel/driveplate	Tighten	M12 = 5 Nm M18 = 35 Nm M22 = 60 Nm
Clutch pressure plate	-	105 Nm / 120 Nm
Crankshaft pulley/damper center bolt	Use new bolts and tighten in the following stages	8.8 = 24 Nm 10.9 = 34 Nm
Camshaft sprocket/gear	Tighten	40 Nm 60° 60°
Camshaft carrier/cap	-	20 Nm + 50°
Camshaft/rocker cover	-	M6 = 10 Nm M7 = 15 Nm M8 = 20 Nm
Inlet manifold to cylinder head	-	M6 = 10 Nm M7 = 15 Nm
Exhaust manifold to cylinder head	-	M6 = 10 Nm M7 = 15 Nm M8 = 22 Nm
Injector/clamp	Tighten	M6 = 10 Nm M7 = 15 Nm M8 = 22 Nm
Injector pipe unions	Tighten	9 Nm
Fuel/injection pump sprocket/gear	Tighten	23 Nm
Glow plugs	Tighten	65 Nm
Engine coolant temperature (ECT) sensor	Tighten	18 Nm
Engine oil pressure switch	Tighten	13 Nm

231/235Hp - 170-173Kw

Component	Instructions	Torque Specification
Cylinder head instructions
Cylinder head	Renew bolts	Yes
	Tighten	40 Nm
	Tighten	80 Nm
	Slacken off	180°
	Tighten	50 Nm
	Tighten	90°
	Tighten	90°
Other engine tightening torques
Main bearings	Renew bolts/nuts	Yes
Main bearings - Stage 1	Tighten	50 Nm
Main bearings - Stage 2	Tighten	90°
Big end bearings	Renew bolts/nuts	Yes
Big end bearings - Stage 1	Tighten	10 Nm
Big end bearings - Stage 2	Tighten	20 Nm + 70°
Oil pump to cylinder block	Tighten	23 Nm
Sump bolts		M6: 8 Nm, M8 x 30 mm: 19 Nm, M8 x 50 mm: 19 Nm
Sump drain bolt		M12: 25 Nm, M18: 35 Nm, M22: 60 Nm
Flywheel/driveplate	Tighten	120 Nm / 121 Nm
Clutch pressure plate		M8 8.8: 25 Nm, M8 10.9: 34 Nm, M8 10.9 ZNS: 15 Nm + 90° ±5°
Crankshaft pulley/damper centre bolt	Tighten	40 Nm + 60° + 60°
Camshaft sprocket/gear	Tighten	14 Nm
Camshaft carrier/cap		M6: 10 Nm, M7: 15 Nm, M8: 20 Nm
Camshaft/rocker cover	Tighten	15 Nm, M6: 10 Nm
Inlet manifold to cylinder head		M6: 10 Nm, M7: 15 Nm, M8: 22 Nm
Exhaust manifold to cylinder head	Tighten	20 Nm
Water pump	Tighten	13 Nm
Injector/clamp	Tighten	9 Nm
Injector pipe unions	Tighten	23 Nm
Fuel/injection pump sprocket/gear	Tighten	65 Nm
Fuel/injection pump mounting	Tighten	12 Nm
Glow plugs	Tighten	13 Nm
Engine coolant temperature (ECT) sensor	Tighten	13 Nm
Knock sensor (KS)	Tighten	20 Nm
Engine oil pressure switch	Tighten	27 Nm
Oil filter	Tighten	25 Nm

272Hp - 200Kw

Component	Instructions	Torque Specification
Cylinder head instructions
Cylinder head	Renew bolts	Yes
	Tighten	40 Nm
	Tighten	80 Nm
	Slacken off	180°
	Tighten	50 Nm
	Tighten	90°
	Tighten	90°
Other engine tightening torques
Main bearings	Renew bolts/nuts	Yes
Main bearings - Stage 1	Tighten	23 Nm
Main bearings - Stage 2	Tighten	90°
Big end bearings	Renew bolts/nuts	Yes
Big end bearings - Stage 1	Tighten	15 Nm
Big end bearings - Stage 2	Tighten	20 Nm + 70°
Oil pump to cylinder block	Tighten	23 Nm
Sump bolts		M6: 8 Nm, M8 x 30 mm: 19 Nm, M8 x 50 mm: 19 Nm
Sump drain bolt	Tighten	25 Nm
Flywheel/driveplate	Tighten	120 Nm / 121 Nm
Clutch pressure plate		8.8: 24 Nm, 10.9: 34 Nm
Crankshaft pulley/damper centre bolt	Tighten	40 Nm + 60° + 60°
Camshaft sprocket/gear	Tighten	14 Nm
Camshaft carrier/cap		M6: 10 Nm, M7: 15 Nm, M8: 20 Nm
Camshaft/rocker cover		M6: 10 Nm, M7: 15 Nm
Inlet manifold to cylinder head		M6: 10 Nm, M7: 15 Nm, M8: 22 Nm
Exhaust manifold to cylinder head	Tighten	20 Nm
Water pump
Injector/clamp	Tighten	9 Nm
Injector pipe unions	Tighten	23 Nm
Fuel/injection pump sprocket/gear	Tighten	65 Nm
Fuel/injection pump mounting	Tighten	12 Nm
Glow plugs	Tighten	13 Nm
Crankshaft position (CKP) sensor/engine speed (RPM) sensor	Tighten	10 Nm
Camshaft position (CMP) sensor	Tighten	10 Nm
Engine coolant temperature (ECT) sensor	Tighten	20 Nm
Knock sensor (KS)	Tighten	20 Nm
Engine oil pressure switch	Tighten	27 Nm
Oil filter	Tighten	25 Nm

286Hp - 210Kw

Component	Instructions	Torque Specification
Cylinder head instructions
Cylinder head	Renew bolts	Yes
	Tighten	40 Nm
	Tighten	80 Nm
	Slacken off	180°
	Tighten	50 Nm
	Tighten	90°
	Tighten	90°
Other engine tightening torques
Main bearings	Renew bolts/nuts	Yes
Main bearings - Stage 1	Tighten	50 Nm
Main bearings - Stage 2	Tighten	90°
Big end bearings	Renew bolts/nuts	Yes
Big end bearings - Stage 1	Tighten	10 Nm
Big end bearings - Stage 2	Tighten	20 Nm + 70°
Oil pump to cylinder block	Tighten	23 Nm
Sump bolts	Tighten	-
Sump drain bolt	Tighten	25 Nm
Flywheel/driveplate	Tighten	120 Nm / 121 Nm
Clutch pressure plate	Tighten	-
Crankshaft pulley/damper bolts	Tighten	40 Nm + 120°
Camshaft sprocket/gear	Tighten	14 Nm
Camshaft carrier/cap	Tighten	-
Camshaft/rocker cover	Tighten	15 Nm, M6: 10 Nm
Inlet manifold to cylinder head	Tighten	-
Exhaust manifold to cylinder head	Tighten	20 Nm
Water pump	Tighten	13 Nm
Injector/clamp	Tighten	9 Nm
Injector pipe unions	Tighten	23 Nm
Fuel/injection pump sprocket/gear	Tighten	65 Nm
Fuel/injection pump mounting	Tighten	12 Nm
Glow plugs	Tighten	13 Nm
Crankshaft position (CKP) sensor/engine speed (RPM) sensor	Tighten	10 Nm
Camshaft position (CMP) sensor	Tighten	3 Nm
Engine coolant temperature (ECT) sensor	Tighten	20 Nm
Knock sensor (KS)	Tighten	20 Nm
Engine oil pressure switch	Tighten	27 Nm
Oil filter	Tighten	25 Nm