Steps 41-100
Engine - Body On
Installation
41. NOTE: Engine removed from the vehicle for clarity.
Install the fuel line bracket and the ground strap. Install the 5 retaining nuts and bolt for the high-pressure fuel injection pump heat shield.
- Tighten the fuel line bracket nuts to 7 Nm (62 lb-in).
- Tighten the remaining fasteners to 13 Nm (115 lb-in).
42. Install the new gasket and 3 new exhaust manifold flange studs for the RH turbocharger inlet pipe.
- Tighten to 18 Nm (159 lb-in).
43. NOTICE: Do not bend or twist the turbocharger inlet pipe or damage to the turbocharger inlet pipe may occur.
NOTE: To aid in installation, replace the top stud with bolt part number W302649.
NOTE: It will be necessary to position the EGR-OC pipe as needed.
Position the LH turbocharger inlet pipe in the vehicle. Install the new gasket and 2 new exhaust manifold flange studs for the LH turbocharger inlet pipe. Loosely install the bolt.
- Tighten the studs to 18 Nm (159 lb-in).
44. NOTE: LH side shown, RH side similar.
NOTE: Do not tighten the nuts at this time.
Install the 5 new lower turbocharger inlet pipe nuts.
45. NOTICE: The engine mount bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. The bolts are a torque-to-yield design and cannot be used.
NOTICE: The engine mount bracket bolts must not be tightened more than 90 degrees after initial torque or damage to the bolts may occur.
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 new LH engine mount bracket bolt. Tighten the 4 engine mount bracket bolts in 2 stages:
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten a minimum of an additional 60 degrees.
46. Install the 2 new studs for the RH engine mount.
- Tighten to 80 Nm (59 lb-ft).
47. NOTICE: Only use hand tools when installing the engine mount retaining nuts or damage to the engine mount may occur.
Install the 4 new retaining nuts for the RH engine mount.
- Tighten to 115 Nm (85 lb-ft).
48. NOTICE: Only use hand tools when installing the engine mount retaining nuts or damage to the engine mount may occur.
Tighten the 3 new retaining nuts for the LH engine mount.
- Tighten to 200 Nm (148 lb-ft).
Vehicles with automatic transmission
49. NOTICE: Only use hand tools when installing the transmission mount retaining nuts or damage to the transmission mount may occur.
Remove and discard the 2 transmission retaining nuts. Install 2 new retaining nuts on the transmission mount.
- Tighten to 115 Nm (85 lb-ft).
50. Install 8 new torque converter nuts.
- Tighten to 35 Nm (26 lb-ft).
51. Install the flexplate access cover.
All vehicles
52. Connect the fuel hoses.
53. If equipped, connect the block heater cord.
54. Position the starter wiring. Install the 2 retaining nuts for the starter solenoid wiring.
- Tighten the large nut to 12 Nm (106 lb-in).
- Tighten the small nut to 6 Nm (53 lb-in).
55. Install the cover for the starter terminals.
56. Position the battery cable bracket and install the nut.
- Tighten to 25 Nm (18 lb-ft).
57. Install the EGRT sensor.
- Tighten to 44 Nm (32 lb-ft).
58. Install the RH splash shield.
59. Connect the EGRT sensor electrical connector.
60. Install the new low-pressure turbocharger drain tube in the turbocharger.
61. NOTE: Install new O-ring seals and lubricate with clean engine oil prior installing the tubes.
Install the high-pressure turbocharger drain tube.
62. NOTICE: Failure to use the turbocharger lifting bracket during the removal, handling or installation of the turbocharger could result in damage to the low pressure-to-high pressure turbocharger seal.
NOTICE: Make sure the turbocharger assembly is kept level with the engine during removal and installation. Failure to follow this instruction may result in damage to the high-pressure oil drain tube.
NOTE: Use care when installing the turbocharger. The crossover tube should not be removed, it has one-time-use seals.
Using the Turbocharger Lifting Bracket, install the turbocharger assembly.
63. NOTE: The top bolt holes remain open on the turbocharger.
Remove the Turbocharger Lifting Bracket.
64. Install the 2 turbocharger hold downs and 2 retaining bolts.
- Tighten to 201 Nm (148 lb-ft).
65. Install the new turbocharger inlet pipe gaskets, bracket and loosely install the 6 new bolts.
- Tighten the top 4 bolts to 25 Nm (18 lb-ft).
66. NOTICE: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
NOTE: To complete this step, it will be necessary to use the following tools:
- A 3/8-in drive torque wrench that is 241.3 mm (9.5 in) or 368.3 mm (14.5 in) from center of the handle to the center of the square drive.
- One of the 10-mm/12-mm Half-moon wrenches listed in the following chart.
- A 12-mm Allen socket (to drive the Half-moon wrench).
NOTE: To obtain the required torque value of 25 Nm (18 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.
Tighten the turbocharger inlet pipes-to-turbocharger bottom 2 bolts.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
67. NOTE: LH shown, RH similar.
Tighten the 5 lower turbocharger inlet pipe nuts.
- Tighten to 31 Nm (23 lb-ft).
68. NOTICE: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
NOTE: To complete this step, it will be necessary to use the following tools:
- A 3/8-in drive torque wrench that is 368.3 mm (14.5 in) or 381.0 mm (15.0 in) from the center of the handle to the center of the square drive.
- One of the 10-mm/12-mm Half-moon wrenches listed in the following chart.
- A 12-mm Allen socket (to drive the Half-moon wrench).
NOTE: To obtain the required torque value of 31 Nm (23 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.
Tighten the LH turbocharger inlet pipe-to-LH exhaust manifold bolt.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
69. NOTICE: Make sure the correct bolts are installed in the bracket or damage to the bracket can occur.
Position the EGR-OC pipe and loosely install the 2 new bracket bolts. Install new gasket and loosely install the 2 new bolts.
70. 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.
Install the bracket, washers and 2 new bolts for the EGR-OC pipe.
- Tighten finger-tight.
71. Install the new gasket and 2 new bolts at the EGR cooler.
- Tighten to 31 Nm (23 lb-ft).
72. Tighten the EGR-OC pipe bolts at the RH turbocharger inlet pipe.
- Tighten to 31 Nm (23 lb-ft).
73. Tighten the 2 bolts for the EGR-OC pipe bracket at the turbocharger.
- Tighten to 31 Nm (23 lb-ft).
74. 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 31 Nm (23 lb-ft).
75. 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.
NOTICE: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
NOTE: To complete this step, it will be necessary to use the following tools:
- A 3/8-in drive torque wrench that is 368.3 mm (14.5 in) or 381.0 mm (15.0 in) from the center of the handle to the center of the square drive.
- One of the 11-mm/13-mm Half-moon wrenches listed in the following chart.
- An 11-mm Allen socket (to drive the Half-moon wrench).
NOTE: To obtain the required torque value of 63 Nm (46 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.
Tighten the EGR-OC pipe bracket-to-LH cylinder head bolt.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
76. Install the fitting for the Exhaust Pressure (EP) tube.
- Tighten to 27 Nm (20 lb-ft).
77. Install the EP tube assembly and nut.
- Tighten to 9 Nm (80 lb-in).
78. Connect the EP tube at the EGR-OC pipe.
- Tighten to 20 Nm (177 lb-in).
79. Connect the EP sensor electrical connector and retaining clip.
80. NOTE: Rear bolts shown, front bolts similar.
Position the front fuel cooler bracket. Install the 4 bolts for the turbocharger crossover tube.
- Tighten to 31 Nm (23 lb-ft).
81. Connect the turbocharger actuator electrical connector and pushpin retainer.
82. Position the fuel cooler bracket.
83. Position back the turbocharger actuator cooler, fuel cooler and coolant expansion tank. Install the 3 bolts for the fuel cooler expansion tank.
- Tighten to 9 Nm (80 lb-in).
84. Install the 2 retaining nuts for the fuel cooler.
- Tighten to 19 Nm (168 lb-in).
85. NOTE: It may be necessary to loosen the front bolts of the turbocharger crossover in order to get correct alignment of the holes for the fuel cooler.
Install the 2 studs for the fuel cooler.
- Tighten to 38 Nm (28 lb-ft).
86. Install the 2 bolts for the fuel cooler.
- Tighten to 9 Nm (80 lb-in).
87. NOTE: Turbocharger actuator cooler removed for clarity.
Position the turbocharger actuator cooler and install the 3 bolts. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Finger-tighten the bolts.
- Stage 2: Tighten to 7 Nm (62 lb-in).
Vehicles with automatic transmission
88. Position back the transmission fluid indicator and tube and install the nut.
- Tighten to 8 Nm (71 lb-in).
All vehicles
89. Install the new gasket and clamp for the turbocharger downpipe.
- Tighten to 15 Nm (133 lb-in).
- Make sure the exhaust downpipe clip is over the lip on the turbocharger.
- Align the new exhaust downpipe-to-turbocharger clamp so that the exhaust downpipe clip and the opening in the exhaust downpipe-to-turbocharger clamp are aligned and tightened to maintain position.
- Align the downpipe so that the area just above the flat in the pipe is approximately 20 mm (0.787 in) from the frame.
90. Install the turbocharger heat shield and 5 bolts.
- Tighten to 11 Nm (97 lb-in).
91. Install a new press-in-place gasket. Position the crankcase vent oil separator on the right valve cover. Install the 4 bolts.
- Tighten to 13 Nm (115 lb-in).
92. Connect the crankcase vent oil separator drain tube.
93. Install new O-ring seal and gasket in the oil filter base.
- Apply clean oil to the O-ring seal and gasket.
94. Install the oil filter return tube and bolt.
- On new oil return tubes, tighten to 7 Nm (62 lb-in).
- On used oil return tubes, tighten to 5 Nm (44 lb-in).
95. Install the oil filter housing and the 4 bolts.
- Tighten to 22 Nm (16 lb-ft).
96. NOTE: Install a new O-ring on the oil filter cap and apply clean engine oil.
Install a new oil filter element and the oil filter housing cap.
- Tighten to 25 Nm (18 lb-ft).
97. NOTE: Install a new O-ring seal and apply clean engine oil.
Install the turbocharger oil supply tube and bolt.
- Tighten to 13 Nm (115 lb-in).
98. Prelubricate the oil inlet holes of the turbocharger assembly with clean oil and spin the compressor wheel several times to coat the bearings with oil.
99. NOTICE: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the turbochargers.
NOTICE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.
NOTE: Use a back-up wrench to prevent the fittings from turning.
NOTE: The back banjo bolt will require a torque adapter to be tightened properly.
Install new sealing washers and banjo bolts on the turbocharger oil supply fittings.
- For Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).
- For copper sealing washer, tighten to 38 Nm (28 lb-ft).
- Move the turbocharger actuator linkage through the full range of motion and verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
100. NOTE: Position the fuel supply hose on the fuel filter module before installing the bolts.
Install the fuel filter module and 3 bolts.
- Tighten to 13 Nm (115 lb-in).
