Steps 61-112

61. Install the engine front cover and bolts.





62. NOTE: Install oil pump drive rotors with marks pointing outward.

Lubricate inner drive rotor with a suitable lithium assembly grease and install onto crankshaft. Lubricate outer drive rotor with lithium assembly grease and mesh with inner drive rotor in oil pump housing. Wipe off excess assembly grease.





63. NOTE: Install a new O-ring seal.

Install the oil pump body and the bolts.





64. NOTE: Apply high strength thread locker to the outer circumference of the leading edge of the crankshaft.

NOTE: The seal and wear sleeve must not be separated.

Using the special tool, install the oil seal and wear sleeve assembly.





65. CAUTION: To prevent engine damage, you must always install four new bolts when installing the vibration damper.

NOTE: Do not use anti-seize compounds, grease, or any lubricants. Lubricants have an adverse effect on the torque results.

Install the crankshaft vibration damper and bolts.
^ Tighten in the sequence shown.
^ Tighten to 68 Nm (50 ft. lbs.).
^ Tighten an additional 90 degrees.





66. If equipped, install the dual generator pulley and bolts.





67. NOTE: Install a new O-ring on the coolant pump.

Install the coolant pump and bolts.





68. Install the coolant pump pulley and the bolts.





69. Install the RH high-pressure oil rail to valve cover gasket.





70. CAUTION: To prevent engine damage, do not use air powered tools when installing the valve cover.

NOTE: RH side shown, LH side similar.

Install the valve covers.
^ Install the gaskets.
^ Install the valve covers.
^ Install the bolts and stud bolts.





71. NOTE: Clean and inspect the O-ring.

Install the Injection Control Pressure (ICP) sensor.





72. Install the eight glow plugs.





73. NOTE: Clean and apply clean engine oil to the O-rings.

Using the special tool, install the glow plug harness.

Early build vehicles





74. Install a new O-ring seal.





75. Install the high-pressure oil pump and the bolts.





76. Install the high-pressure pump O-ring seal.





77. Position back the high-pressure discharge pipe and install the bolts.





78. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.





79. Install a new D-ring seal on the high-pressure discharge pipe.





80. Clean the cover mounting surface and apply sealant at the seams.





81. Install the high-pressure pump cover.
^ Install the press-in-place gasket.
^ Install the high-pressure pump cover.
^ Install the bolts.

Late build vehicles





82. CAUTION: To prevent engine damage, use only approved pump cover seal. Substitution can cause damage to the pump cover.

Install a new O-ring seal on the high-pressure oil pump.





83. Install the high-pressure tube assembly.





84. Install new lower O-ring seals.





85. Install the high-pressure pump and bolts.





86. Tighten the bolts for the high-pressure tube assembly.





87. Install a new press-in-place gasket in the high-pressure pump cover.





88. Clean the cover mounting surface and apply sealer at the seams.





89. CAUTION: To prevent engine damage, the high-pressure oil pump cover must be firmly seated on the O-ring seal to prevent cracking the cover plate.

NOTE: Apply clean engine oil to the high-pressure oil pump O-ring seal prior to installing the high-pressure pump cover.

Install the high-pressure oil pump cover and bolts.





90. Install the IPR valve.





91. Install the heat insulating wrap and fasten the snap.

All vehicles





92. Install the turbocharger heat shield and bolts.





93. Install the oil pump inlet strainer.





94. CAUTION: In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.

Install the oil cooler assembly.
^ Install the gasket.
^ Install the oil cooler assembly.
^ Install the bolts.





95. Install the oil filter base.
^ Install the gasket.
^ Install the oil filter base.
^ Install the bolts.





96. Install the Exhaust Gas Recirculation (EGR) cooler coolant supply port cover.
^ Install the gasket.
^ Install the EGR cooler coolant supply port cover.
^ Install the bolts.





97. Install new O-ring in the oil filter base.





98. Install the serpentine belt idler and bolt.





99. Install the belt tensioner and bolts.





100. NOTE: Install new sealing washers.

Install the left cylinder head fuel line.





101. NOTE: Install a new O-ring on the thermostat.

Install the thermostat housing and the stud bolts.





102. Position the exhaust pressure bracket assembly and install the retaining nuts.





103. Tighten the exhaust pressure tube at the exhaust manifold.





104. Install the fuel lines and bracket bolt.





105. NOTE: Install a new O-ring on the oil indicator and tube. Apply clean engine oil to the O-ring.

Install the oil level indicator tube and nut. Connect the wiring harness retainer.





106. NOTE: LH shown, RH similar.

NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.

Install the cylinder block drain plugs.





107. Install the starter and the three bolts.





108. Install the special tool.





109. Install the special tool.
110. Install the lifting crane and remove the engine from the engine stand.





111. NOTE: LH side shown, RH side similar.

Install the LH and RH motor mounts and bolts.





112. Install the flexplate and the new bolts.
^ Tighten in the following sequence.
^ Tighten to 5 Nm (44 inch lbs.).
^ Tighten to 94 Nm (69 ft. lbs.) in the sequence shown.