Engine - Installation

INSTALLATION - ENGINE





1. Remove cylinder head bolts (1,3) according to the diagram. Install special Tool 9009 (2). Torque bolts to 105 Nm (77 ft. lbs.)
2. Lower engine into the engine compartment and install the engine mount through bolts and nuts.
3. Tighten the mount through bolts and nuts to 88 Nm (65 ft. lbs) torque.
4. Remove the engine lifting device (Tool 9009).
5. Check cylinder head capscrew length and install into cylinder head.
6. Torque in 4 steps to:
- Step 1-Tighten to 70 Nm (52 ft. lbs.) torque.
- Step 2-Back off 360°.
- Step 3-Tighten to 105 Nm (77 ft. lbs.) torque.
- Step 4-Rotate 90°.

7. Install rocker housing. Torque to 24 Nm (18 ft. lbs). Refer to Cylinder Head Cover - Installation .
8. Replace injector o-ring and sealing washer on injectors # 5 and # 6. Install injectors and torque using the following steps:
- Step 1-Install injector hold-down capscrews and torque to 5 Nm (44 in. lbs.) torque.
- Step 2-Loosen injector hold-down capscrews.
- Step 3-Install HPC connector tube and nut. Torque nut to 15 Nm (11 ft. lbs.) torque.
- Step 4-Torque injector hold-down capscrews to 10 Nm (89 in. lbs.) torque.
- Step 5-Torque HPC connector tube nut to 50 Nm (37 ft. lbs.) torque.

9. Install rear engine lift bracket. Torque to 77 Nm (57 ft. lb).
10. Install # 5 and # 6 high pressure fuel lines. Follow correct torque sequence. Torque fuel line fittings to 40 Nm (35 ft. lb).




11. Install push tubes, rocker arms (1), and pedestals (2) for cylinders # 4, # 5, and # 6. Torque the mounting bolts to 36 Nm (27 ft. lbs).
12. Reset valve lash on cylinders # 4, # 5, and # 6. Torque adjusting nuts to 24 Nm (18 ft. lbs).
13. Set the valve lash for the intake valve at 0.254 (.010 in. lbs.) and exhaust valve at 0.66 mm (.026 in. lbs).
14. Install injector wiring/gasket.




15. Install cylinder head cover carrier gasket (2).
16. Connect injector harness nuts to injectors (1). Torque to 1.25 Nm (11 in. lbs. )
17. Connect injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).




18. Install cylinder head cover (1) Cylinder Head Cover - Installation .
19. Connect CCV tube (4) and lube oil drain tube (2) to cylinder head cover (1).




20. Connect fuel supply and return hoses.
21. Connect ECM power connector.
22. Install the power steering pump.
23. Install the damper. Torque to 40 Nm (30 ft. lb) plus 60 degrees.
24. Install lower fan shroud bracket (3). Torque to 24 Nm (18 ft. lb).




25. Install upper fan shroud brackets, but do not tighten fasteners at this time.
26. Connect the engine block heater connection.
27. Connect the A/C compressor and pressure sensor connectors
28. Install the charge air cooler (2). Install and tighten the charge air cooler mounting bolts (1) to 2 Nm (17 in. lbs).
29. Connect the charge air cooler tubes (4). Torque all clamps to 8 Nm (72 in. lbs).




30. Install the a/c condenser (1).
31. Connect the a/c refrigerant lines to the a/c condenser.
32. Install the radiator upper support panel.
33. Install radiator.
34. Connect the transmission quick-connect oil cooler lines.
35. Raise vehicle.
36. Connect a/c compressor suction/discharge hose (if equipped).
37. Install the radiator lower hose and clamps.
38. Install the battery negative cables to the engine block on the driver and passenger side.
39. Install the transmission adapter with a new camshaft rectangular ring seal. Torque to 77 Nm (57 ft. lb).
40. Install the flywheel and adapter or flexplate. Torque to 137 Nm (101 ft. lb).

NOTE: If the engine is equipped with a flexplate or crankshaft adapter, a new clamp ring must be used. If the engine has a flywheel with washers, the washers can be reused.

41. Install the starter motor (2). Torque to 43 Nm (32 ft. lb).
42. Connect engine to vehicle harness connectors.
43. Install the transmission and transfer case (if equipped).
44. Using a new clamp, connect the exhaust pipe to the turbocharger elbow.
45. Connect the transmission auxiliary oil cooler lines (if equipped).
46. Lower the vehicle.
47. Connect the heater core supply and return hoses.




48. Install the cooling fan (3) and fan drive (2).




49. Install the fan shroud mounting bracket (3) and shroud.
50. Install the windshield washer bottle.
51. Install the upper radiator hose and clamps.
52. Raise vehicle.
53. Change oil filter and install new engine oil.
54. Fill the cooling system with coolant. Service and Repair .
55. Connect grid heater harness at grid heater relay.
56. Connect electrical connections to rear of alternator.
57. Start the engine and inspect for engine oil, coolant, and fuel leaks.