Part 6

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.

131. 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.






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






133. 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.






134. 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).






135. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).






136. Connect the CKP (Crankshaft Position) sensor electrical connector.





137. Install the wiring harness grommet.





138. Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).






139. Install the heat shield and the nut.
- Tighten to 10 Nm (89 lb-in).






140. Install the LH turbocharger coolant tube bracket-to-cylinder head nut.
- Tighten to 10 Nm (89 lb-in).






141. Install 8 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).






142. 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).






143. Install a new gasket the LH turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.
- Tighten to 45 Nm (33 lb-ft).






144. 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.






145. Install the LH turbocharger oil supply tube.
- Tighten the bolt to 35 Nm (26 lb-ft).






146. Install the upper turbocharger bracket-to-cylinder block and the 2 bolts.
- Do not tighten the bolts at this time.






147. 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.

148. Tighten the upper turbocharger bracket-to-turbocharger bolt.
- Tighten to 19 Nm (168 lb-in).






149. Tighten the upper turbocharger bracket-to-cylinder block bolt.
- Tighten to 25 Nm (18 lb-ft).






150. Tighten the lower turbocharger bracket-to-turbocharger bolt.
- Tighten to 19 Nm (168 lb-in).






151. Tighten the lower turbocharger bracket-to-cylinder block bolt.
- Tighten to 11 Nm (97 lb-in).






152. Using 2 new sealing washers, install the 2 LH turbocharger coolant tubes and the banjo bolts.
- Tighten to 40 Nm (30 lb-ft).






153. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.
Install the LH oil supply tube into the quick connect fitting.






154. Install the LH oil supply tube secondary latch.





155. 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.






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