Part 2
Engine
Assembly
51. NOTE: The terminals in the fuel charging harness plug are not serviced, install a new the fuel charging harness if damaged.
NOTE: Inspect the O-ring seals for damage or swelling prior to installing, install a new O-ring seal if necessary.
Install the 2 fuel charging harness electrical connectors into the valve cover bases.
52. NOTE: RH side shown, LH side similar.
Position the fuel charging harness on the high-pressure fuel rail and connect the 8 fuel injector electrical connectors. Connect the Fuel Rail Pressure (FRP) sensor electrical connector.
53. Install the 8 glow plugs.
- Tighten to 14 Nm (124 lb-in).
54. NOTICE: To prevent engine damage, do not use air-powered tools when installing the valve cover.
NOTE: Alternate tightening the bolts to tighten evenly.
NOTE: RH shown, LH similar.
Install new press-in-place gaskets. Install the valve covers, 6 bolts and 4 stud bolts.
- Tighten to 9 Nm (80 lb-in).
55. Position the crankcase vent oil separator tube. Install the 2 bolts and nut.
- Tighten the nut to 13 Nm (115 lb-in).
- Tighten the bolts to 25 Nm (18 lb-ft).
56. Connect the crankcase vent oil separator tube at the crankcase.
57. Position the LH valve cover bracket and the Exhaust Pressure (EP) tube assembly. Install the 4 retaining nuts.
- Tighten to 9 Nm (80 lb-in).
58. NOTE: Only one glow plug connector shown.
Install the glow plug harnesses and connect the retainers.
- Make sure the seals are securely seated in the valve covers.
59. NOTE: Install a new O-ring seal on the oil indicator and tube. Apply clean engine oil to the O-ring seal.
Install the oil indicator and tube. Install the bolt.
- Tighten to 13 Nm (115 lb-in).
60. Install the retaining nut for the oil level indicator and tube.
- Tighten to 31 Nm (23 lb-ft).
61. Apply a dime-sized bead of sealant at the back seam of the upper and lower crankcase.
62. NOTICE: To prevent 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.
NOTE: Manual transmission shown, automatic transmission similar.
Install a new press-in-place gasket, the engine rear cover and the bolts.
1. For all vehicles, install the 8 bolts. Tighten to 31 Nm (23 lb-ft).
2. For manual transmission vehicles, install the 3 additional bolts. Tighten to 62 Nm (46 lb-ft).
63. 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.
64. NOTICE: The crankshaft rear seal and wear ring are one-piece 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).
65. 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.
66. 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.
67. 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.
68. 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.
69. 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.
70. If equipped, install the flywheel front adapter.
71. Position the flexplate or flywheel and install the 10 new bolts. Tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 94 Nm (69 lb-ft).
72. Apply a dime-sized bead of sealant at the front seam of the upper and lower crankcase.
73. NOTICE: Failure to use guide pins to position the front cover gasket can lead to oil in the coolant.
NOTE: Use guide pins to aid in installation. Pins must be fabricated locally.
Position the new front cover gasket on the engine and install threaded guide pins to hold the gasket in position.
74. Position the engine front cover and loosely install the 10 bolts.
75. Install a new O-ring seal. Install the coolant inlet port and bolt.
- Tighten to 13 Nm (115 lb-in).
76. 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.
77. Install a new press-in-place gasket, the oil pump housing and the 11 bolts.
- Tighten the 7 long bolts to 31 Nm (23 lb-ft).
- Tighten the 4 short bolts to 22 Nm (16 lb-ft).
78. Tighten the 10 engine front cover bolts.
- Tighten to 31 Nm (23 lb-ft).
79. 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 Seal Installer, install a new crankshaft front seal and wear sleeve assembly.
80. NOTICE: To prevent engine damage, always install 4 new bolts when installing the vibration damper.
NOTE: Apply a light coat of engine oil to the bolts prior to installing the bolts.
NOTE: Use the Strap Wrench to stop the engine from moving during tightening.
Install the crankshaft vibration damper and 4 new bolts. Tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 68 Nm (50 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
81. NOTE: Install a new O-ring seal on the coolant pump.
Install the coolant pump and the 5 bolts.
- Tighten to 31 Nm (23 lb-ft).
82. Install the coolant pump pulley and the 4 bolts.
- Tighten to 31 Nm (23 lb-ft).
83. Install a new press-in-place gasket. Install the thermostat housing, collar and 4 bolts.
- Tighten to 13 Nm (115 lb-in).
84. Position the fuel supply and return tubes and install the bolt.
- Tighten to 31 Nm (23 lb-ft).
85. NOTE: Install a new O-ring seal on the tube and a new clamp on the hose.
NOTE: Hand start both bolts prior to tightening the bolts.
Install the EGR cooler tube and install the 2 bolts.
- Tighten to 13 Nm (115 lb-in).
86. 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 may result in hose joint failure.
Tighten the clamp for the EGR cooler hose.
- Tighten to 4 Nm (35 lb-in).
87. NOTE: Install a new O-ring seal.
Install the LH heater tube and 2 bolts.
- Tighten to 13 Nm (115 lb-in).
88. NOTICE: The protruding hub of the high-pressure fuel injection pump drive gear must be facing the high-pressure fuel injection pump. Failure to install the gear correctly will result in engine damage.
NOTE: The high-pressure fuel injection pump drive gear bolt is a LH thread.
NOTE: The bolt for the high-pressure fuel injection pump will not be tightened at this time.
If a new pump is being installed, install the high-pressure fuel injection pump drive gear and install the bolt finger-tight.
89. Install the high-pressure fuel injection pump and 3 bolts.
- Tighten to 62 Nm (46 lb-ft).
90. NOTE: The high-pressure fuel pump drive gear bolt has a LH thread.
NOTE: Use a tool such as a Snap-On FRDHM15 torque adapter, or equivalent, to tighten the bolt.
If a new high-pressure fuel pump has been installed, tighten the drive gear bolt.
- Calculate the correct torque wrench setting for the following torque.
- Tighten to 78 Nm (58 lb-ft).
91. Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure fuel injection pump drive gear backlash.
92. Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams.
93. NOTICE: Inspect the volume control valve and the pressure control valve electrical connectors for damage or obstructions at the connector and mating high-pressure fuel injection pump connector. Verify that the connectors are completely latched to the valve housings or engine damage may occur.
Install a new gasket for the high-pressure fuel injection pump cover. Connect the pressure control valve and volume control valve electrical connectors.
94. Install a new press-in-place gasket in the high-pressure fuel injection pump cover.
95. NOTE: Do not remove the Fuel System Caps from the high-pressure fuel pump until the fuel rail supply tubes are ready to be installed.
Install the high-pressure fuel injection pump cover and 5 bolts.
- Tighten to 13 Nm (115 lb-in).
96. NOTICE: 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 and engine damage may occur.
Install a new press-in-place gaskets, the oil cooler assembly and the 8 bolts.
- Tighten to 31 Nm (23 lb-ft).
97. NOTE: The old oil cooler cover screws or new self-tapping screws must be used to cut the threads in the new oil cooler cover.
Install the new press-in-place gaskets, the oil filter base and the 10 screws.
- On a new oil cooler cover, tighten to 10 Nm (89 lb-in).
- On a used oil cooler cover, tighten to 7 Nm (62 lb-in).
98. Install new O-ring seal and gasket in the oil filter base.
- Apply clean engine oil to the O-ring seal and gasket.
99. Install the oil filter return tube assembly and screw.
- On new oil return tubes, tighten to 7 Nm (62 lb-in).
- On used oil return tubes, tighten to 5 Nm (44 lb-in).
100. Install the oil filter housing and the 4 bolts.
- Tighten to 22 Nm (16 lb-ft).
101. 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).
102. NOTE: The 2 shoulder bolts go in the center holes on the sides.
Install a new press-in-place gasket, the turbocharger pedestal and 7 bolts.
- Tighten to 62 Nm (46 lb-ft).
103. NOTE: The locating tabs on the gaskets must be up and positioned toward the center of the engine or a leak will occur.
Install the intake manifold gaskets.
104. Install the intake manifold and bolts and tighten in 2 stages, in the sequence shown.
- Stage 1: Loosely assemble all bolts in the sequence shown.
- Stage 2: Tighten to 11 Nm (97 lb-in).
105. 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 high-pressure fuel injection pump.
Position the fuel injector return tube. Install the banjo bolts and new sealing washers at the cylinder heads.
- For Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).
- For copper sealing washer, tighten to 38 Nm (28 lb-ft).
106. Position the retainers and install the 2 bolts for the fuel injector return tube.
- Tighten to 13 Nm (115 lb-in).
107. Install the nut on the fuel injector return tube.
- Tighten to 11 Nm (97 lb-in).
108. Install the fuel filter module and 3 bolts.
- Tighten to 13 Nm (115 lb-in).
109. 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 high-pressure fuel injection pump.
Install the banjo fittings and new sealing washers at the fuel filter module.
- For M14 banjo bolt with Viton(R) sealing washers, tighten to 28 Nm (21 lb-ft).
- For M14 banjo bolt with copper sealing washer, tighten to 47 Nm (35 lb-ft).
- For M12 banjo bolt with Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).
- For M12 banjo bolt with copper sealing washer, tighten to 38 Nm (28 lb-ft).
110. Install the bolt for the fuel supply and return tube retainer.
- Tighten to 31 Nm (23 lb-ft).
