Installation

Engine





Special Tool(s)





Material

Installation

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.





2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.

Vehicles with automatic transmission
3. Align the torque converter studs with the holes in the engine flywheel, then lower the engine onto the engine mount towers.

Vehicles with manual transmission
4. Lower the engine onto the engine mount towers.

All vehicles
5. Remove the Heavy Duty Floor Crane and the Diesel Engine Lifting Bracket.

Vehicles with automatic transmission
6. Remove the transmission jack.





7. Install the transmission-to-engine mounting bolts.





8. Install the new torque converter-to-flywheel retaining nuts.





9. Install the flywheel housing cover.

All vehicles





10. NOTE: RH shown, LH similar.

Install the LH and RH side engine mount retaining nuts.





11. Remove the engine lifting eye from the right side cylinder head.





12. Install the manufacturer's lifting bracket.





13. Remove the two engine lift adapters.





14. Position the turbocharger outlet pipe.





15. Install the transmission cooler tube bracket and nut.





16. Install the left rear valve cover stud.





17. Install the fuel injector control module bracket and nuts.

Late build vehicles





18. Connect the exhaust pressure sensor tube fitting to the exhaust manifold and install the exhaust pressure sensor retaining nut.





19. Connect the exhaust pressure sensor electrical connector.

All vehicles





20. Position the turbocharger adapter pipe.





21. NOTE: Left side shown, right side similar.

NOTE: Do not tighten bolts at this time.

NOTE: Apply anti-seize lubricant to the threads prior to installing the bolts.

Install the bolts for the turbocharger adapter pipe.
22. Position back the block heater and starter wiring.





23. Connect the block heater electrical connector.





24. Connect the starter wiring and install the solenoid cap.





25. Connect the ground strap on the right head and install the bolt.

Vehicles with automatic transmission





26. Install the automatic transmission fluid indicator and tube.

All vehicles





27. Position back the wiring and connect the crankshaft position (CKP) sensor electrical connector.

Vehicles with A/C





28. Install the A/C compressor and bolts.





29. Remove the cap or plug and install a new O-ring seal. Install the A/C hose and retaining nut.





30. Connect the A/C high-pressure switch and the clutch electrical connectors.

All vehicles





31. Connect the RH glow plug electrical connector and wire retainer.





32. Connect the glow plug module electrical connectors. Connect the pushpin retainer and the injection control pressure (ICP) sensor electrical connector.





33. NOTE: Only one retainer shown.

Connect the wire retainers on the valve cover studs.





34. Connect the ground cable and the ground stud.





35. Install the battery cable bracket and the nut.





36. Position the power steering pump and install the lower bolt.





37. Install the power steering pump upper bolts.





38. NOTE: Only one stand-off shown.

Install the stator stand-offs.





39. Connect the fuel lines and install the clips.





40. Install the lower radiator hose and clamp.





41. Connect the heater hose at the front cover.





42. Connect the camshaft position (CMP) sensor electrical connector.





43. Connect the 12-pin and 8-pin electrical connectors.





44. Connect the powertrain control module (PCM) electrical connector.





45. Connect the LH glow plug electrical connector.





46. Install the battery tray and bolts.
47. Install the intake manifold.





48. NOTE: LH shown; RH similar.

NOTE: Alternately tighten the bolts to specification.

Tighten the turbocharger adapter pipe at the flanges.





49. Tighten the nuts at the turbocharger adapter pipe flange.





50. Install the upper radiator support and bolts.





51. NOTE: Cover position back for clarity.

Connect the body feed cable and install the retaining nut.





52. Install the transmission oil cooler.





53. NOTE: Remove the caps or plugs as needed.

Connect the transmission cooler hoses.





54. Install the power steering cooler and bolts.





55. Position back the power steering cooler Pubes and install the tubes in the retaining clip.





56. NOTE: Remove the caps or plugs as needed.

Connect the power steering hoses and tighten the clamps.
57. Install the front bumper.
58. Install the radiator grille opening panel reinforcement.

Vehicles with A/C
59. Install the A/C condenser assembly.

All vehicles
60. Install the charge air cooler.
61. Install the air cleaner assembly.
62. Install the cooling fan stator.

Vehicles with manual transmission
63. Install the clutch disc and pressure plate.
64. Install the transmission.

All vehicles
65. Fill the motor with clean engine oil.
66. Connect the LH and RH battery cables.
67. Fill the cooling system.
68. Cycle the key three times prior to starting the vehicle to avoid the possibility of air lock in the fuel system.
69. Fill and bleed the power steering system.
70. Check and fill the transmission.