Part 3

Engine

















Assembly

111. NOTICE: Do not bend or flex the heater supply tube or damage to the tube may occur.

NOTE: Install a new O-ring seal.

Install the RH heater supply tube, bolt and nut.

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






112. Install the glow plug module bracket and 3 bolts.
- Tighten to 13 Nm (115 lb-in).





113. NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in Fuel Delivery and Air Induction.

NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.

NOTE: Remove the protective caps from the high-pressure fuel pump.

Install new sealing washers, fuel injection pump supply tube, fuel injection pump-to-fuel cooler return tube and 2 nuts at the high-pressure fuel injection pump.
- For Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).

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





114. Install the 2 retaining nuts for the fuel injection pump supply tube.
- Tighten to 11 Nm (97 lb-in).





115. NOTE: Remove the protective caps or plugs from the fuel tubes.

NOTE: Use a crowfoot wrench to aid in tightening the fitting.

Connect the fuel injector return tube at the check valve.

- Calculate the correct torque wrench setting for the following torque.

- Tighten to 28 Nm (21 lb-ft).





116. Position and connect the high-pressure fuel injection pump electrical connector. Connect the pushpin retainer.





117. NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in Fuel Delivery and Air Induction.

NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.

NOTE: Use a crowfoot wrench to aid in tightening the fuel rail supply tube.

NOTE: LH side shown, RH side similar.

Install the new fuel rail supply tubes in the following sequence.

1. Remove the Fuel System Caps from the fuel rail supply tube openings.

2. NOTE: Support the tubes while hand snugging the nut to make sure of assembly of the joints.

Position the fuel rail supply tubes between the high-pressure fuel injection pump and high-pressure fuel rail. Fully hand start and seat the tube nuts onto the high-pressure fuel injection pump and high-pressure fuel rail.

3. Snug the tube nuts.
- Calculate the correct torque wrench setting for the following torque.

- Tighten to 2 Nm (18 lb-in).

4. Pre-tighten the high-pressure fuel injection pump and high-pressure fuel rail tube nuts.
- Calculate the correct torque wrench setting for the following torque.

- Tighten to 12 Nm (106 lb-in).

5. NOTE: Place a visible mark with a permanent marker on the high-pressure fuel rail and high-pressure fuel pump threaded connection. Turning the tube nuts one flat of the nut is equal to 60 degrees.

Final-tighten the fuel rail supply tube nuts.
- Tighten the tube nuts 60 degrees.





118. Install the 2 bolts for the fuel rail supply tube retainers.
- Tighten to 13 Nm (115 lb-in).





119. NOTICE: Failure to correctly install the high-pressure fuel injection pump heat shield may result in engine damage.

Install the high-pressure fuel injection pump heat shield, fuel tube bracket and ground strap. Install the 5 retaining nuts and bolt.

- Tighten the fuel tube bracket nuts to 8 Nm (71 lb-in).

- Tighten the remaining fasteners to 13 Nm (115 lb-in).





120. Position the engine wiring harness on the engine. Install the bolt.
- Tighten to 13 Nm (115 lb-in).





121. Connect the glow plug module and high-pressure fuel injection pump electrical connectors. Connect the pushpin retainers.





122. NOTE: Use a socket to aid in installing the pushnuts.

Position the glow plug module heat shield. Install the 3 new pushnuts.





123. Connect the RH fuel charging harness electrical connector. Connect the Manifold Absolute Pressure (MAP) sensor and Intake Air Temperature 2 (IAT2) sensor electrical connectors.





124. Connect the glow plug harness electrical connector and retainer on the RH valve cover.





125. Connect the CKP sensor and retainer.





126. Connect the pushpin retainers to the oil drain back tube brackets.





127. NOTE: Make sure the harness is positioned on the stud at the fuel filter prior to installing the bolt.

Install the bolt for the engine harness. Connect the Engine Oil Pressure (EOP) switch and the Engine Oil Temperature (EOT) sensor electrical connectors.





128. Connect the Engine Coolant Temperature (ECT) sensor electrical connector and wire retainer.





129. Connect the fuel temperature sensor electrical connector.





130. Connect the LH fuel charging harness electrical connector. Position the harness in the retaining clip and connect the pushpin retainers.





131. Connect the CMP sensor electrical connector and pushpin retainer.





132. Connect the glow plug harness electrical connector and pushpin retainers.





133. Connect the Exhaust Pressure (EP) sensor electrical connector and retaining clip.





134. Install a new press-in-place gasket. Install the intake throttle adapter and loosely install the 4 bolts.





135. Connect the EGR valve and Throttle Body (TB) electrical connectors.





136. NOTE: Install a new horizontal EGR cooler gasket prior to installing the vertical EGR cooler.

Position the vertical EGR cooler assembly and loosely install the 5 bolts.





137. Install a new vertical EGR cooler gasket and the stud.
- Tighten to 17 Nm (150 lb-in).





138. Install the nut and bolt for the EGR cooler.
- Tighten to 31 Nm (23 lb-ft).





139. Connect the coolant hose to the vertical EGR cooler.





140. Connect the EGRT sensor electrical connector.





141. NOTICE: Do not bend or twist the Exhaust Gas Recirculation (EGR) cooler bellows or damage to the EGR cooler may occur.

NOTE: Inspect the corrugation of the vertical EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.

Install the 2 nuts for the vertical EGR cooler.

- Tighten to 31 Nm (23 lb-ft).

- Inspect the corrugation of the EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.





142. NOTICE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps could result in a hose joint failure.

NOTE: Install a new clamp on the EGR cooler hose.

Connect the EGR cooler hose and tighten the clamp.

- Tighten to 4 Nm (35 lb-in).





143. NOTE: Do this step only if the horizontal EGR cooler was removed from the mounting bracket.

Tighten the clamps for the horizontal EGR cooler.

- Tighten to 10 Nm (89 lb-in).

- Loosen the clamps 720 degrees.

- Tighten to 8 Nm (71 lb-in).





144. NOTE: Do this step only if the vertical EGR cooler was removed from the mounting bracket.

Tighten the clamps for the vertical EGR cooler.

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

- Loosen the clamps 720 degrees.

- Tighten to 7 Nm (62 lb-in).





145. Tighten the 5 vertical EGR cooler mounting bracket bolts.
- Tighten the M8 bolts to 31 Nm (23 lb-ft).

- Tighten the M10 bolt to 62 Nm (46 lb-ft).





146. NOTE: Vertical EGR cooler removed for clarity.

Tighten the 4 bolts for the intake throttle adapter.

- Tighten to 10 Nm (89 lb-in).





147. NOTE: RH heater tube removed for clarity.

NOTE: Install a new O-ring seal.

Install the vertical EGR cooler tube and bolt.

- Tighten to 10 Nm (89 lb-in).





148. Install the new low-pressure turbocharger drain tube in the turbocharger.





149. NOTE: Install new O-ring seals and apply clean engine oil prior to installing the high-pressure turbocharger drain tube.

Install the high-pressure turbocharger drain tube.





150. NOTICE: Failure to use the turbocharger lifting bracket during 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 to the engine during removal or installation. Failure to follow these instructions may result in damage to the high-pressure oil drain tube.

Using the Turbocharger Lifting Bracket, install the turbocharger assembly.





151. NOTE: The top bolt holes remain open on the turbocharger.

Remove the Turbocharger Lifting Bracket.

152. Install the 2 turbocharger hold downs and 2 retaining bolts.
- Tighten to 201 Nm (148 lb-ft).





153. Install the turbocharger heat shield and 5 bolts.
- Tighten to 11 Nm (97 lb-in).





154. NOTE: Rear bolts shown, front bolts similar.

Install the 4 bolts for the turbocharger crossover tube.

- Tighten to 31 Nm (23 lb-ft).





155. Connect the turbocharger actuator electrical connector and pushpin retainer.





156. NOTE: Install a new O-ring seal and apply clean engine oil.

Install the turbocharger oil feed tube and bolt.

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





157. 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.

158. 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.

Install new sealing washers and banjo bolts on the turbocharger oil feed 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.





159. 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).





160. Connect the crankcase vent oil separator drain tube.