Steps 121-160
Engine
Engine Upper
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
Engine Front
Timing Drive Components - Roller Timing Chain
NOTE: Stamped steel RH timing chain guide shown, composite guide similar.
Timing Drive Components - Inverted Tooth Timing Chain
Lower Engine Block (View 1)
Lower Engine Block (View 2)
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.
NOTE: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain. The roller timing chain engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All roller timing chain engine replacement RH timing chain guides will be the stamped steel design.
NOTE: Early build engine cylinder heads and fuel injectors differ in design than late build engines. Although these parts are serviced in the same way, the parts are not interchangeable between early build and late build engines. The level of cylinder heads and fuel injectors can be determined by inspecting the engine code label. Early build engines are built through 09/14/2010 (0S 490 BA) and late build engines are built on or after 09/15/2010 (1S 490 BA).
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System - General Information Procedures.
121. NOTE: Clean the fuel injection pump bolts and apply Thread Sealant with PTFE to the bolts.
Install the fuel injection pump and the 2 bolts finger-tight.
- Tighten to 10 Nm (89 lb-in).
- Tighten an additional 45 degrees.
122. NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts.
Install the high-pressure fuel tube and tighten the 3 flare nuts in the following 3 stages.
- Stage 1: Tighten to 32 Nm (24 lb-ft).
- Stage 2: Wait 10 minutes to minimize pre-stress.
- Stage 3: Tighten to 32 Nm (24 lb-ft).
123. Install the high-pressure fuel tube bracket nut.
- Tighten to 8 Nm (71 lb-in).
124. 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).
125. Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
126. Attach the wiring harness retainer to the rear of the LH cylinder head.
127. Install the cover and the pin-type retainer.
128. Install the turbocharger coolant tube assembly and the bolt.
- Tighten to 10 Nm (89 lb-in).
129. Install the RH engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
130. Install 8 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
131. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Install a new gasket, RH exhaust manifold and 8 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
132. Install the oil supply tube filter, washer and bolt.
1. Install a new oil supply tube filter in the oil supply tube block.
2. Slide the new washer onto the oil supply tube block.
3. Install the banjo bolt into the oil supply tube block.
133. Install the RH turbocharger oil supply tube.
- Tighten the bolt to 35 Nm (26 lb-ft).
134. Install a new gasket, the turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.
- Tighten to 45 Nm (33 lb-ft).
135. Install the upper RH turbocharger-to-cylinder block bracket and the 3 bolts and position the bracket as far clockwise as possible and tighten the bolts in the following sequence:
1. Tighten the lower bolt to 26 Nm (19 lb-ft).
2. Tighten the upper bolt to 26 Nm (19 lb-ft).
3. Tighten the turbocharger bolt to 19 Nm (168 lb-in).
136. Using 2 new sealing washers, install the 2 RH turbocharger coolant tubes and banjo bolts.
- Tighten to 40 Nm (30 lb-ft).
137. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.
Install the RH oil supply tube into the quick connect fitting.
138. Install the RH oil supply tube secondary latch.
139. NOTE: Lubricate the cylinder block bore with clean engine oil.
Using 2 new O-ring seals, install the RH turbocharger oil return tube in the cylinder block.
140. Install a new gasket and the RH turbocharger oil return tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
141. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.
Connect the turbocharger wastegate regulating valve hose to the RH turbocharger assembly.
142. NOTE: Make sure the heat shield does not contact the wastegate arm.
Install the 2 upper RH exhaust manifold heat shield and the 5 bolts.
- Tighten to 14 Nm (124 lb-in).
143. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).
144. Connect the CKP sensor electrical connector.
145. Install the wiring harness grommet.
146. Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).
147. Install the heat shield and the nut.
- Tighten to 10 Nm (89 lb-in).
148. Install the LH turbocharger coolant tube bracket-to-cylinder head nut.
- Tighten to 10 Nm (89 lb-in).
149. Install 8 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
150. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Install a new gasket, LH exhaust manifold and turbocharger assembly and 8 new nuts. Tighten the nuts in 2 stages in the sequence shown:
- Stage 1: Tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
151. Install a new gasket the LH turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.
- Tighten to 45 Nm (33 lb-ft).
152. Install the oil supply tube filter, washer and bolt.
1. Install a new oil supply tube filter in the oil supply tube block.
2. Slide the new washer onto the oil supply tube block.
3. Install the bolt into the oil supply tube block.
153. Install the LH turbocharger oil supply tube.
- Tighten the bolt to 35 Nm (26 lb-ft).
154. Install the upper turbocharger bracket-to-cylinder block and the 2 bolts.
- Do not tighten the bolts at this time.
155. Install the lower turbocharger-to-cylinder block bracket and the 2 bolts.
- Do not tighten the bolts at this time.
NOTICE: The next 4 steps must be performed in order or damage to the turbocharger may occur.
156. Tighten the upper turbocharger bracket-to-turbocharger bolt.
- Tighten to 19 Nm (168 lb-in).
157. Tighten the upper turbocharger bracket-to-cylinder block bolt.
- Tighten to 25 Nm (18 lb-ft).
158. Tighten the lower turbocharger bracket-to-turbocharger bolt.
- Tighten to 19 Nm (168 lb-in).
159. Tighten the lower turbocharger bracket-to-cylinder block bolt.
- Tighten to 11 Nm (97 lb-in).
160. Using 2 new sealing washers, install the 2 LH turbocharger coolant tubes and the banjo bolts.
- Tighten to 40 Nm (30 lb-ft).
