Steps 41-76

Oil Pan













NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

41. Connect the 2 turbocharger coolant hoses to the intake manifold.





42. Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt.
- Tighten to 10 Nm (89 lb-in).





43. Attach the 2 wire harness-to-intake manifold retainers.





44. Connect the turbocharger wastegate regulating valve electrical connector.





45. Connect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.





46. Connect and attach the 2 fuel injector wiring harness electrical connectors.





47. Install the oil level indicator.





48. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
- Tighten to 8 Nm (71 lb-in).





49. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.

50. Install the engine cover mounting stud to the LH valve cover stud bolt.
- Tighten to 6 Nm (53 lb-in).





51. Install the lower radiator hose to the thermostat housing.





52. Connect the 3 LH ignition coil-on-plug electrical connectors.





53. Connect the Engine Oil Pressure (EOP) electrical connector.
- Attach the wiring harness retainer to the block.





54. Connect the LH VCT solenoid electrical connector.





55. Connect the Throttle Position (TP) and electronic Throttle Body (TB) electrical connectors.





56. Connect the electrical connector and install the noise insulator shield for the fuel injection pump.





57. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Install the RH Charge Air Cooler (CAC) tube and turbocharger intake tube as an assembly and install the RH CAC tube nut to the intake manifold.

- Tighten to 6 Nm (53 lb-in).





58. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Install the nut to the RH valve cover stud bolt for the RH turbocharger intake tube.

- Tighten to 6 Nm (53 lb-in).





59. NOTE: Align the index marks for the turbocharger intake pipe.

Install the RH turbocharger intake pipe to the RH turbocharger and tighten the clamp.

- Tighten to 5 Nm (44 lb-in).





60. NOTE: Align the index marks for the RH CAC tube.

Install the RH CAC tube to the RH turbocharger and tighten the clamp.

- Tighten to 5 Nm (44 lb-in).





61. Connect the RH turbocharger bypass valve electrical connector.





62. NOTE: Lubricate the oil pan bore with clean engine oil.

Using 2 new O-ring seals, install the LH turbocharger oil return tube in the oil pan.





63. Install a new gasket, turbocharger oil return tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





64. NOTE: Align the index marks for the turbocharger intake tube.

Install the turbocharger intake tube to the LH turbocharger and tighten the clamp.

- Tighten to 5 Nm (44 lb-in).





65. Install the 2 turbocharger wastegate regulating valve hoses to the turbocharger wastegate regulating valve and to the RH CAC tube.





66. Connect the LH turbocharger bypass valve electrical connector.





67. Install the PCV tube and connect the 2 quick connect couplings. For additional information, refer to Fuel System - General Information Service and Repair.





68. Connect the brake vacuum tube to the intake manifold.





69. Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.





70. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.

- Tighten the block heater to 40 Nm (30 lb-ft).





71. If equipped, connect the block heater electrical connector and install the heat shield.
- Attach all the engine block heater wiring harness retainers.





72. Using a new O-ring seal and gasket seal, connect the A/C tube to the compressor and install the nut.
- Tighten to 15 Nm (133 lb-in).





73. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.





74. Install the crankshaft sensor ring.





75. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.

Install the flexplate and the 8 bolts.

- Tighten in the sequence shown to 80 Nm (59 lb-ft).





76. Install the engine in the vehicle. For additional information, refer to Engine Engine - Removal.