Part 2
(Engine Assembly Part 2)50. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
Install the fuel injector electrical connector into the rocker carrier.
51. Apply clean engine oil to the top fuel injector O-ring seals.
52. CAUTION: Using the bolts to push the high pressure oil rail into the fuel injectors can damage the fuel injectors and high pressure oil rail.
NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high-pressure oil rail.
Position the high-pressure oil rail on the injectors.
^ Place the high-pressure oil rail on top of the carrier so that the 4 single ball tubes are engaging the fuel injector lead angle.
^ Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
^ Manually press the high-pressure oil rail into the fuel injectors.
^ Inspect that the high pressure oil rail mounting feet are flat against the mounting surface.
^ Loosely install the 6 bolts.
53. Remove the 3 guide bolts, install the remaining bolts and tighten the 9 bolts in the sequence shown.
^ Tighten to 13 Nm (10 ft. lbs.).
54. NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installation.
Install the crankcase-to-head tube assembly.
^ Tighten to 82 Nm (60 ft. lbs.).
55. Apply a bead of sealant at the back seam of the upper and lower crankcase.
56. Install a new press-in-place gasket, the rear engine cover and the bolts.
^ Tighten to 24 Nm (18 ft. lbs.).
57. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.
NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50 mix) prior to assembly. Do not use any other type of lubricant.
NOTE: Apply a bead of Threadlock 262 around the circumference of the outer rear edge of the secondary crankshaft flange.
Using the special tools, install a new crankshaft rear oil seal.
58. Install the flywheel adapter.
59. If removed, install the front cover crankcase dowels into the cylinder block.
60. Apply a bead of sealant at the front seam of the upper and lower crankcase.
61. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
Install the guide studs and the front cover gasket.
62. Install the engine front cover and the bolts.
^ Tighten to 24 Nm (18 ft. lbs.).
63. 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.
64. NOTE: Install a new O-ring seal.
Install the gerotor cover and the 5 bolts.
^ Tighten to 13 Nm (10 ft. lbs.).
65. NOTE: Apply Threadlock 262 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 a new oil seal and wear sleeve assembly.
66. CAUTION: To prevent engine damage, always install 4 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 tighten the new bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 68 Nm (50 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
67. If equipped, install the dual generator pulley and the 3 bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
68. NOTE: Install a new O-ring seal on the coolant pump.
Install the coolant pump and the 4 bolts.
^ Tighten to 23 Nm (17 ft. lbs.).
69. Install the coolant pump pulley and the 4 bolts.
^ Tighten to 31 Nm (23 ft. lbs.).
70. Install the RH high-pressure oil rail-to-valve cover gasket.
71. CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
NOTE: RH shown, LH similar.
Install the RH and LH valve covers.
^ Install new gaskets.
^ Install the valve covers.
^ Install the bolts and stud bolts.
^ Tighten to 9 Nm (80 inch lbs.).
72. NOTE: Clean and inspect the O-ring seal.
Install the injection control pressure (ICP) sensor.
^ Tighten to 12 Nm (9 ft. lbs.).
73. Install the 8 glow plugs.
^ Tighten to 19 Nm (14 ft. lbs.).
74. NOTE: Clean and apply clean engine oil to the O-ring seals.
Using the special tool, install the glow plug harness.
75. 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.
76. Install the high-pressure tube assembly.
77. Install new lower O-ring seals.
78. Install the high-pressure pump and bolts.
^ Tighten to 31 Nm (23 ft. lbs.).
79. Install the high-pressure tube assembly bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
80. Position the special tool and check the oil pump drive gear backlash.
81. Install a new press-in-place gasket in the high-pressure pump cover.
82. Clean the cover mounting surface and apply sealer at the seams.
83. 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.
^ Tighten to 11 Nm (8 ft. lbs.).
84. Using the special tool, install the injection pressure regulator (IPR) valve.
^ Tighten to 50 Nm (37 ft. lbs.).
85. If equipped, install the heat insulating wrap and fasten the snap.
86. Install the oil pump inlet strainer.
87. 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 a new press-in-place gasket, the oil cooler assembly and the bolts.
^ Tighten to 22 Nm (16 ft. lbs.).
88. NOTE: The old oil cooler cover bolts or new self-tapping bolts must be used to cut the threads in the new oil cooler cover.
Install the press-in-place gasket, the oil filter base and the bolts.
1 Tighten to 22 Nm (16 ft. lbs.).
2 Tighten to 10 Nm (89 inch lbs.).
89. Install a new press-in-place gasket, the exhaust gas recirculation (EGR) cooler coolant supply port cover and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
90. Install new O-ring seals in the oil filter base.
91. Install the accessory drive idler pulley and bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
92. Install the belt tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
93. NOTE: Install new sealing washers.
Install the LH cylinder head fuel tube.
^ Tighten to 38 Nm (28 ft. lbs.).
94. Install the fuel tubes and bracket bolt.
^ Tighten to 13 Nm (10 ft. lbs.).
95. NOTE: Install a new O-ring seal on the thermostat.
Install the thermostat housing and the bolts.
^ Tighten to 23 Nm (17 ft. lbs.).
96. NOTE: Install a new O-ring seal on the oil indicator and tube. Apply clean engine oil to the O-ring seal.
Position the oil level indicator tube and install the nut. Connect the wiring harness retainer to the stud bolt.
97. Install the glow plug mounting bracket and the nuts.
^ Tighten to 9 Nm (80 inch lbs.).
98. NOTE: LH shown, RH similar.
Install the LH and RH motor mounts and bolts.
^ Tighten to 62 Nm (46 ft. lbs.).
99. NOTE: LH shown, RH similar.
NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.
Install the cylinder block coolant drain plugs.
^ Tighten to 20 Nm (15 ft. lbs.).
100. Position the starter motor and install the 3 bolts in 3 stages.
^ Stage 1: Install the 3 bolts finger tight.
^ Stage 2: Tighten the upper bolt to 25 Nm (18 ft. lbs.).
^ Stage 3: Tighten the 2 lower bolts to 25 Nm (18 ft. lbs.).
101. Install the special tool.
102. Install the special tool.
103. Install the lifting crane and remove the engine from the engine stand.
104. Position the flexplate or flywheel and install the new bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 94 Nm (69 ft. lbs.).
