Steps 201-217

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.

201. NOTE: Align the index marks for the RH turbocharger intake pipe.

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

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





202. 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).





203. Connect the RH turbocharger bypass valve electrical connector.





204. NOTE: Align the index marks for the LH turbocharger intake tube.

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

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





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





206. Connect the LH turbocharger bypass valve electrical connector.





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





208. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).





209. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.





210. 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).





211. If equipped, connect the block heater electrical connector and install the heat shield.





212. Install the Engine Lift Eye on the LH cylinder head.





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





214. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.





215. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.





216. Install the crankshaft sensor ring.





217. 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).