Part 7

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.

157. 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 LH turbocharger assembly.






158. Install LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).






159. Connect the LH CMP (Camshaft Position) sensor electrical connector.





160. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.





161. Install the radio capacitor and the bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).






162. Install the RH CMP (Camshaft Position) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).






163. Connect the RH CMP (Camshaft Position) sensor electrical connector.





164. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

165. Connect the 3 RH ignition coil-on-plug electrical connectors.





166. Connect the RH VCT (Variable Camshaft Timing) solenoid electrical connector and attach the 2 wiring harness retainers.





167. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Make sure the fuel rail wiring harnesses are routed correct.

NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.

Using new intake manifold, coolant crossover and thermostat housing gaskets, install the intake manifold and the 12 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






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





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






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





171. Connect the turbocharger wastegate regulating valve electrical connector.





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





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





174. Connect the KS (Knock Sensor) sensor electrical connector.





175. Install the oil level indicator.





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

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





178. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP (Engine Oil Pressure) switch.

- To install, tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.






179. Using a new gasket, install the oil filter adapter and the 3 bolts.
- Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.






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






181. Install the stud, generator and the nut and bolt.
- Tighten the stud to 8 Nm (71 lb-in).

- Tighten the nut and bolt to 47 Nm (35 lb-ft).






182. Connect the generator electrical connector.





183. Connect the generator B+ cable and install the nut.
- Tighten to 17 Nm (150 lb-in).