Engine - Installation

INSTALLATION










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

7. Replace injector o-ring and sealing washer on injectors # 5 and # 6. Install injectors and tighten using the following steps:
- Step 1-Install the injector hold-down capscrews and tighten to 5 Nm (44 in. lbs.).
- Step 2-Loosen the injector hold-down capscrews.
- Step 3-Install the HPC connector tube and nut. Tighten nut to 15 Nm (11 ft. lbs.).
- Step 4-Tighten the injector hold-down capscrews to 10 Nm (89 in. lbs.).
- Step 5-Tighten the HPC connector tube nut to 50 Nm (37 ft. lbs.).

8. Remove the front and rear engine lift bracket.
9. Install the # 5 and # 6 high pressure fuel lines. Follow correct torque sequence. Tighten fuel line fittings to 40 Nm (35 ft. lb).










10. Install the pushrods, rocker arms (1), and pedestals (2) for cylinders # 4, # 5, and # 6. Tighten the mounting bolts to 36 Nm (27 ft. lbs).
11. Reset the valve lash on cylinders # 4, # 5, and # 6. Tighten adjusting nuts to 24 Nm (18 ft. lbs).
12. Set the valve lash for the intake valve at 0.254 mm (0.010 in.) and exhaust valve at 0.66 mm ( 0.026 in.).





13. Install the coolant filter from the cylinder head.
14. Install the EGR cooler.
15. Install the EGR control valve and tube assembly.
16. Install the coolant hose at the EGR cooler outlet.
17. Install the coolant hose at the EGR cooler inlet.










18. Install the cylinder head cover/injector wiring gasket (2).
19. Install the injector harness nuts to injectors (1). Tighten to 1.25 Nm (11 in. lbs. ).
20. Connect the injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).





21. Install the cylinder head cover (1) Tighten to 24 Nm (18 ft. lbs).Cylinder Head Cover(s) - Installation.
22. Connect the CCV tube (4) and lube oil drain tube (2) to cylinder head cover (1).





23. Connect the fuel supply and return lines from the fuel filter housing.










24. Install the A/C condenser (1).
25. Install the radiator upper support panel.
26. Connect the transmission quick-connect oil cooler lines.





27. Connect the injector harness connectors.
28. Connect the heater core supply and return hoses.
29. Using a new clamp, install the exhaust pipe to the turbocharger elbow (1).





30. Connect left side ground wire.
31. Connect the engine block heater connection.
32. Connect the generator feed wire.










33. Install the battery negative cables to the engine block on the driver and passenger side.
34. Connect the intake heater connector.
35. Install the starter motor (2). Tighten to 43 Nm (32 ft. lb). Starter - Installation.
36. Install the starter cable at the left battery and power distribution center.





37. Connect the ECM power connector and the engine to vehicle wiring harness connectors.
38. Install the crankshaft damper. Tighten to 40 Nm (30 ft. lb) plus 60 degrees.





39. Install the drive belt tensioner.
40. Install the radiator bracket shroud.
41. Connect the A/C compressor and pressure sensor connectors.





42. Install the power steering pump.
43. Install the serpentine drive belt.Serpentine Accessory Drive Belt - Installation










44. Install the cooling fan (3) and fan drive (2). Cooling Fan - Installation










45. Install the fan shroud mounting bracket (3) and shroud. Cooling Fan - Installation
46. Install the Radiator.
47. Position the power steering cooler and install the bolts.










48. Install the charge air cooler (2). Install and tighten the charge air cooler mounting bolts (1) to 2 Nm (17 in. lbs).
49. Install the charge air inlet and outlet tubes (4). Tighten all clamps to 8 Nm (72 in. lbs).
50. Install the radiator lower hose.
51. Install the charge air hose/condenser bolts.
52. Install the charge air hose at the cooler.





53. Connect the A/C lines to the condenser.





54. Install the right side air deflector.
55. Install the windshield washer bottle (2).
56. Install the coolant recovery bottle hose (3).
57. Install the upper radiator hoses.
58. Automatic transmission models: Connect transmission oil cooler lines from in front of radiator using special tool #6931
59. Evacuate and recharge A/C system. Refrigerant System Charge










60. Raise vehicle.
61. Install the rack and pinion bolts.
62. Install the engine motor mount bolts.





63. Install the transmission collar (1), if equipped and then flywheel housing (2). Tighten to 77 Nm (57 ft. lb).
64. Connect the transmission wiring harness connector.
65. Install the left ground strap.
66. Install the bell housing retaining bolts.






NOTE: A new clamping ring must be used any time the flex plate or flywheel adapter is removed.

67. Install the flywheel and adapter or flexplate. Tighten to 137 Nm (101 ft. lb).





68. Install the torque converter bolts.
69. Install the bell housing access plate.
70. Change the oil filter and fill with new engine oil.
71. Fill the cooling system with coolant. Service and Repair





72. Connect the electrical connections to rear of alternator.
73. Install the intake air box and tube.





74. Connect the battery cables (1, 3).
75. Start the engine and inspect for engine oil, coolant, and fuel leaks.





76. Position the hood and connect hood support struts.
77. Install the engine cover.
78. Close the hood.