Part 5
Engine
Engine Upper
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
Engine Front
Timing Drive Components
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: 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.
105. NOTE: RH shown, LH similar.
NOTE: The anti rotation device on the fuel injector has to slip into the groove of the fuel rail cup.
Install the 6 fuel injectors into the fuel rails and connect the 6 electrical connectors.
106. NOTICE: It is very important to visually inspect the routing of the wire harness to make sure that the wire harness will not be pinched or damaged between the fuel rail and the cylinder head during installation.
Install the 6 bolts and the RH fuel rail assembly.
- Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and then proceed inward.
- To install, tighten to 10 Nm (89 lb-in).
- Tighten an additional 45 degrees.
107. NOTICE: It is very important to visually inspect the routing of the wire harness to make sure that the wire harness will not be pinched and damaged between the fuel rail and the cylinder head during installation.
Install the 6 bolts and the LH fuel rail assembly.
- Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and proceed inward.
- To install, tighten to 10 Nm (89 lb-in).
- Tighten an additional 45 degrees.
108. NOTE: The cam lobe for the fuel injection pump must be at Bottom Dead Center (BDC) for the fuel injection pump installation.
Using the crankshaft pulley bolt, turn the crankshaft until the fuel injection pump cam lobe is at BDC (Bottom Dead Center).
109. NOTE: Valve cover is removed for clarity.
NOTE: Apply clean engine oil to the fuel injection pump mounting pedestal bore.
Install the fuel injection pump roller tappet.
110. NOTE: Apply clean engine oil to the fuel injection pump mounting plate seal.
Inspect the fuel injection pump mounting plate-to-valve cover gasket and replace if necessary.
111. NOTE: Apply clean engine oil to the fuel injection pump mounting plate O-ring seals.
Inspect the 2 fuel injection pump mounting plate O-ring seals and replace if necessary.
112. NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.
Install the fuel injection pump on the fuel injection pump mounting plate.
113. 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.
114. 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).
115. Install the high-pressure fuel tube bracket nut.
- Tighten to 8 Nm (71 lb-in).
116. 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).
117. Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
118. Attach the wiring harness retainer to the rear of the LH cylinder head.
119. Install the cover and the pin-type retainer.
120. Install the turbocharger coolant tube assembly and the bolt.
- Tighten to 10 Nm (89 lb-in).
121. Install the RH engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
122. Install 8 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
123. 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).
124. 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.
125. Install the RH turbocharger oil supply tube.
- Tighten the bolt to 35 Nm (26 lb-ft).
126. Install a new gasket, the turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.
- Tighten to 45 Nm (33 lb-ft).
127. 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).
128. Using 2 new sealing washers, install the 2 RH turbocharger coolant tubes and banjo bolts.
- Tighten to 40 Nm (30 lb-ft).
129. 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.
130. Install the RH oil supply tube secondary latch.
