Part 2

Engine













Crankshaft, Camshaft and Piston









Front Cover, Rear Cover and Oil Components









Cylinder Head and Rocker Arm Carrier









Valve Cover










51. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.

NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.

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

Install the LH exhaust manifold, 8 spacers and the 8 new bolts. Tighten in the sequence shown.

- Tighten to 38 Nm (28 lb-ft).





52. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.

NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.

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

Install the RH exhaust manifold, 8 spacers and the 8 new bolts. Tighten in the sequence shown.

- Tighten to 38 Nm (28 lb-ft).





53. Apply a bead of sealant at the back seam of the upper and lower crankcase.





54. NOTICE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.

NOTE: Prior to installing the engine rear cover, check that the alignment dowels are centered so that 10 mm (0.39 in) of the dowel extends toward the engine and 10 mm (0.39 in) extends toward the transmission.

Install the new press-in-place gasket, the engine rear cover and the 8 bolts.

- Tighten to 24 Nm (18 lb-ft).





55. NOTE: A redesigned seal will have a flanged wear ring and pre-applied threadlock.

Remove the new crankshaft rear seal and wear ring assembly and plastic step-up tool from the packing. Separate the plastic step-up tool (if installed on the crankcase rear seal) from the crankcase rear seal and wear ring assembly.





56. NOTICE: The crankshaft rear seal and wear ring are a one-piece design and need to be installed as an assembly. Do not separate the wear ring from the crankshaft rear seal or damage to the seal may occur.

Identify the metal face of the wear ring. This face must be installed so it is on the outside of the engine (facing the transmission).





57. 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.

Lubricate the outer diameter of the rubber seal with a solution of dish soap and water.





58. NOTICE: Make sure the crankshaft alignment dowel fits in the dowel recess hole in the Crankshaft Rear Seal and Wear Ring Installer base or engine damage may occur.

Install the Crankshaft Rear Seal and Wear Ring Installer base and 2 bolts to the crankshaft flange.





59. NOTE: When positioning the crankshaft rear seal and wear ring assembly on the Crankshaft Rear Seal and Wear Ring Installer base, align it to the opening on the engine rear cover and manually start the crankcase rear seal installation.

Position the crankshaft rear seal and wear ring assembly on the Crankshaft Rear Seal and Wear Ring Installer base.





60. NOTICE: The plastic step-up tool increases the flat surface area of the Crankshaft Rear Seal and Wear Ring Installer. Failure to use the plastic step-up tool during installation will result in damage to the crankshaft rear seal and wear ring assembly.

Insert the plastic step-up tool into the Crankshaft Rear Seal and Wear Ring Installer with the step-edge toward the installer.





61. NOTICE: The crankshaft rear seal face and the wear ring must be flush with the rear engine cover or damage to the crankshaft rear seal or wear ring may occur.

NOTICE: Do not allow the engine to rotate during the installation of the crankshaft rear seal and wear ring assembly or damage to the crankshaft rear seal or wear ring may occur.

Using the Crankshaft Rear Seal and Wear Ring Installer, install the new crankshaft rear seal and wear ring assembly until the installation tool contacts the rear engine cover.





62. Install the flywheel front adapter.





63. If removed, install the front cover crankcase dowels into the cylinder block.





64. Apply a bead of sealant at the front seam of the upper and lower crankcase.





65. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.

Install the guide studs and the new front cover gasket.





66. Install the engine front cover and the 17 bolts.
- Tighten to 24 Nm (18 lb-ft).





67. NOTE: If reusing the original oil pump drive rotors, install the oil pump drive rotors with the marks pointing outward. Replacement oil pump drive rotors will have no marks and orientation is not necessary.

Lubricate the inner drive rotor with clean engine oil and install onto the crankshaft. Lubricate the outer drive rotor with clean engine oil and mesh with the inner drive rotor in the oil pump housing.





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

Install the oil pump body and the 5 bolts.

- Tighten to 13 Nm (115 lb-in).





69. NOTE: Apply threadlock to the outer circumference of the leading edge of the crankshaft.

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

Using the Crankshaft Front Seal and Wear Ring Installer, install the new oil seal and wear sleeve assembly.





70. NOTICE: 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 4 new bolts in 2 stages, in the sequence shown.

- Stage 1: Tighten to 68 Nm (50 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





71. If equipped, install the dual generator pulley and the 3 bolts.
- Tighten to 47 Nm (35 lb-ft).





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

Install the coolant pump and the 4 bolts.

- Tighten to 23 Nm (17 lb-ft).





73. Install the coolant pump pulley and the 4 bolts.
- Tighten to 31 Nm (23 lb-ft).





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





75. NOTICE: To prevent engine damage, do not use air-powered tools when installing the valve cover.

Install the gasket, the RH valve cover and the 5 bolts and 6 stud bolts.

- Tighten to 9 Nm (80 lb-in).





76. Cover the LH cylinder head with an appropriate covering.

77. Install the 8 glow plugs.
- Tighten to 19 Nm (168 lb-in).





78. NOTE: Clean and apply clean engine oil to the O-ring seals.

Using the Glow Plug Connector Remover/Installer, install the glow plug harness.





79. NOTICE: To prevent engine damage, use only an approved pump cover seal. Substitution can cause damage to the pump cover.

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





80. Install new lower O-ring seals.





81. Install the high-pressure oil pump and bolts.
- Tighten to 31 Nm (23 lb-ft).





82. Install the high-pressure oil branch tube adapter bolts.
- Tighten to 14 Nm (124 lb-in).





83. Position the Dial Indicator Gauge with Holding Fixture and check the oil pump drive gear backlash.





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





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





86. NOTICE: 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 the 8 bolts.

- Tighten to 11 Nm (97 lb-in).





87. Using the Injection Pressure Regulator Socket, install the Injection Pressure Regulator (IPR) valve.
- Tighten to 50 Nm (37 lb-ft).





88. Position the turbocharger heat shield and install the 3 bolts.

1. Tighten to 49 Nm (36 lb-ft).

2. Tighten to 11 Nm (97 lb-in).





89. Install the oil pump inlet strainer.





90. NOTICE: In the event of a catastrophic engine failure, always install a new oil cooler. Foreign material cannot be removed from the oil cooler and engine damage may occur.

NOTE: If the oil cooler was not replaced, install a new gasket in the oil cooler assembly cover.

Install the oil cooler assembly and the 10 bolts.

- Tighten to 22 Nm (16 lb-ft).





91. Install new O-ring seals in the oil filter base.





92. Install the oil filter adapter and the 4 bolts.
- Tighten to 15 Nm (133 lb-in).





93. Install the accessory drive belt idler pulley and the bolt.
- Tighten to 47 Nm (35 lb-ft).





94. If equipped, install the belt tensioner and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





95. NOTE: Install new sealing washers.

Install the LH cylinder head fuel tube.

- For Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).

- For copper sealing washers, tighten to 38 Nm (28 lb-ft).





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

Install the thermostat housing and the 2 stud bolts.

- Tighten to 23 Nm (17 lb-ft).





97. Position the fuel tube support bracket and install the nut.





98. Install the RH motor mount plate and the 4 bolts.
- Tighten to 80 Nm (59 lb-ft).





99. Install the Adapter for 303-D043.





100. Install the Adapter for 303-D043.





101. Remove the engine from the engine stand.

102. Install the flexplate and the 10 new bolts. Tighten in the sequence shown, in 2 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 94 Nm (69 lb-ft).