Part 4
Engine
Assembly
161. NOTICE: Do not bend or twist the turbocharger inlet pipe or damage to the turbocharger inlet pipe may occur.
Install new gaskets for the exhaust manifolds. Install the turbocharger inlet pipes, bracket, new turbocharger gaskets and loosely install the 6 new bolts.
162. NOTE: LH side shown, RH side similar.
Loosely install the 6 new nuts for the turbocharger inlet pipes.
163. Tighten the 3 LH turbocharger inlet pipe bolts and 3 nuts.
1. Tighten the bolts to 25 Nm (18 lb-ft).
2. Tighten the nuts to 31 Nm (23 lb-ft).
164. Tighten the 3 RH turbocharger inlet pipe bolts and 3 nuts.
1. Tighten the bolts to 25 Nm (18 lb-ft).
2. Tighten the nuts to 31 Nm (23 lb-ft).
165. NOTICE: Make sure the correct bolts are installed in the bracket or damage to the bracket can occur.
NOTE: Turbocharger side shown, exhaust manifold side similar.
Position the EGR-Oxidation Catalytic Converter (OC) pipe and loosely install the 2 new bracket bolts. Install new gaskets and loosely install the 4 new bolts.
166. Install the bracket, washers and 2 new bolts for the EGR-OC pipe.
- Tighten finger-tight.
167. Tighten the 2 bolts at the EGR cooler.
- Tighten the bolts to 31 Nm (23 lb-ft).
168. Tighten the 2 EGR-OC-to-RH turbocharger inlet pipe bolts.
- Tighten to 31 Nm (23 lb-ft).
169. Tighten the 2 bolts for the EGR-OC pipe bracket at the turbocharger.
- Tighten to 31 Nm (23 lb-ft).
170. NOTICE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
Tighten the bolt and nut for the EGR-OC pipe bracket.
- Tighten to 31 Nm (23 lb-ft).
171. NOTICE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
Tighten the bolt for the EGR-OC pipe bracket.
- Tighten to 62 Nm (46 lb-ft).
172. Connect the EGRT sensor electrical connector.
173. Connect the EP sensor tube.
- Tighten to 20 Nm (177 lb-in).
174. NOTE: LH shown, RH similar.
NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.
Install the 2 cylinder block coolant drain plugs.
- Tighten to 20 Nm (177 lb-in).
175. Using the Heavy Duty Floor Crane, remove the engine from the Car/Truck Engine Stand.
176. NOTICE: The engine mount bracket bolts must be discarded and new bolts installed, or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
NOTICE: The engine mount bracket bolts must not be tightened more than 90 degrees after initial torque or damage to the bolts may occur.
NOTICE: Clean the engine mount mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine mount bracket or engine mount damage.
NOTE: Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
Install the LH engine mount bracket and 4 new bolts. Tighten in 2 stages:
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten a minimum of an additional 60 degrees.
177. NOTE: Lower radiator hose shown, upper radiator hose similar.
Install the upper and lower radiator hoses. Install the clips.
178. Install the engine fill hose.
179. Install the 2 stator stand offs.
- Tighten to 47 Nm (35 lb-ft).
180. NOTICE: The engine mount bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
NOTICE: The engine mount bracket bolts must not be tightened more than 90 degrees after initial torque or damage to the bolts may occur.
NOTICE: Clean the engine mount mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine mount bracket or engine mount damage.
NOTE: Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
Install the RH engine mount bracket and 4 new bolts. Tighten in 2 stages:
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten a minimum of an additional 60 degrees.
181. NOTICE: Only use hand tools when installing the center bolt or damage to the center bolt may occur.
Install the RH engine mount and new center bolt.
- Tighten to 350 Nm (258 lb-ft).
Vehicles with A/C
182. Install the A/C compressor and 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
183. Connect the A/C compressor clutch electrical connector and wire retainer.
184. Connect the A/C pressure switch electrical connector.
All vehicles
185. Install the Front End Accessory Drive (FEAD) assembly, 2 nuts and 2 bolts.
- Tighten to 47 Nm (35 lb-ft).
186. Connect the wire retainer and the plug for the generator. Install the nut for the generator wiring and position the boot back.
- Tighten to 8 Nm (71 lb-in).
187. Install the accessory drive belt idler pulley and bolt.
- Tighten to 47 Nm (35 lb-ft).
188. NOTE: When installing the pump, raise the supply tube up to clear the ECT sensor connector.
NOTE: Make sure the power steering pressure tube retainer is on the retaining stud prior to tightening the bolts for the power steering pump.
Install the power steering pump and 3 bolts. Secure the hose on the engine.
- Tighten to 25 Nm (18 lb-ft).
189. Install the retaining nut for the power steering hose and tube.
- Tighten to 25 Nm (18 lb-ft).
Vehicles with A/C
190. Install the A/C drive belt.
All vehicles
191. Install the accessory drive belt.
192. Install the engine cooling fan stator, 2 nuts and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
193. NOTE: The cooling fan has LH threads.
Using the Fan Clutch Nut Wrench and Fan Hub Nut Wrench, install the engine cooling fan.
- Tighten to 150 Nm (111 lb-ft).
194. Install the cooling fan electrical connector into the stator. Connect the electrical connector for the engine cooling fan.
195. Install the starter and 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
