Part 2 of 2

Engine Continued





41. NOTE: Install new O-ring seals and apply clean engine oil.

Install a crankcase-to-head tube assembly.





42. CAUTION: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.

NOTE: Lubricate the fuel injector and O-ring seals liberally with clean engine oil.

Install new O-ring seals and a copper washer on the fuel injector.





43. Install the fuel injector, the fuel injector hold-down and bolt.





44. CAUTION: Be sure the injector wiring is clear of all moving parts or engine damage can occur.

Install the fuel injector electrical connector into the rocker carrier.





45. NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high pressure oil rail.

Position the high pressure oil rail on the injectors.
^ Place the high pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle.
^ Insert three guide bolts, two on the ends of the straight side of the high pressure oil rail and one in the middle of the wavy side of the high pressure rail. Install the guide studs six to seven turns.
^ Press the high pressure oil rail into the fuel injectors.
^ Inspect that the high pressure oil rail mounting feet are flat against the mounting surface.
^ Loosely install the six bolts.





46. Install the remaining bolts and tighten.
^ Remove the three guide bolts.
^ Loosely install the three remaining bolts.
^ Tighten the nine bolts in the sequence shown.





47. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, therefore allowing alignment of the remaining bolts.

NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.

Install the left exhaust manifold and the bolts.





48. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, therefore allowing alignment of the remaining bolts.

NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.

Install the right exhaust manifold and the bolts.





49. Apply a bead of sealant at the back seam of the upper and lower crankcase.





50. Install the rear engine cover.
^ Install the press-in-place gasket.
^ Install the rear engine cover.
^ Install the bolts.





51. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.

NOTE: Apply a bead of threadlock around the circumference of the outer rear edge of the secondary crankshaft flange.

Using the special tools, install the crankshaft rear oil seal.





52. Install the flywheel adapter.





53. If removed, install the front cover crankcase dowels into the cylinder block.





54. Apply a bead of sealant at the front seam of the upper and lower crankcase.





55. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.

Install the guide studs and the front cover gasket.





56. Install the engine front cover and bolts.





57. NOTE: Install oil pump drive rotors with marks pointing outward.

Lubricate the inner drive rotor with a suitable lithium assembly grease and install onto the crankshaft. Lubricate the outer drive rotor with lithium assembly grease and mesh with the inner drive rotor in the oil pump housing. Wipe off excess assembly grease.





58. NOTE: Install a new O-ring seal.

Install the oil pump body and the bolts.





59. NOTE: Apply threadlock to the outer circumference of the leading edge of the crankshaft.

NOTE: The seal and wear sleeve must not be separated.

Using the special tool, install the oil seal and wear sleeve assembly.





60. CAUTION: To prevent engine damage, always install four new bolts when installing the vibration damper.

NOTE: Do not use anti-seize compounds, grease, or any lubricants. Lubricants have an adverse effect on the torque results.

Install the crankshaft vibration damper and bolts.
^ Tighten the bolts in the sequence shown.
^ Tighten the bolts to 68 Nm (50 ft. lbs.).
^ Tighten the bolts an additional 90 degrees.





61. If equipped, install the dual generator pulley and bolts.





62. NOTE: Install a new O-ring seal on the coolant pump.

Install the coolant pump and bolts.





63. Install the coolant pump pulley and the bolts.





64. Install the RH high pressure oil rail-to-valve cover gasket.





65. CAUTION: To prevent engine damage, do not use air powered tools when installing the valve cover.

Install the RH valve cover.
^ Install the gasket.
^ Install the valve cover.
^ Install the bolts and stud bolts.
66. Cover the LH cylinder head with an appropriate covering.





67. Install the eight glow plugs.





68. NOTE: Clean and inspect the glow plug connector O-ring seals and install new as necessary.

NOTE: Apply clean engine oil to the O-ring seals.

Install the glow plug harness.





69. Install a new O-ring seal.





70. Install the high-pressure oil pump and the bolts.





71. Install the high-pressure pump O-ring seal.





72. Position the high pressure discharge pipe and install the bolts.





73. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.





74. Install a new D-ring seal on the high-pressure discharge pipe.





75. Clean the cover mounting surface and apply sealant at the seams.





76. Install the high-pressure pump cover.
^ Install the press-in-place gasket.
^ Install the high pressure pump cover.
^ Install the bolts.





77. Install the turbocharger heat shield and bolts.





78. Install the oil pump inlet strainer.





79. CAUTION: In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.

Install the oil cooler assembly.
^ Install the gasket.
^ Install the oil cooler assembly.
^ Install the bolts.





80. Install the oil filter base.
^ Install the gasket.
^ Install the oil filter base.
^ Install the bolts.





81. Install the exhaust gas recirculation (EGR) cooler coolant supply port cover.
^ Install the gasket.
^ Install the EGR cooler coolant supply port cover.
^ Install the bolts.





82. Install a new O-ring seal in the oil filter base.





83. Install the oil filter adapter and bolts.





84. Install the serpentine belt idler and bolt.





85. If equipped, install the belt tensioner and bolts.





86. NOTE: Install new sealing washers.

Install the left cylinder head fuel line.





87. NOTE: Install a new O-ring seal on the thermostat.

Install the thermostat housing and the stud bolts.





88. Position back the fuel bracket and install the retaining nut.





89. Install the RH motor mount plate and bolts.





90. Install the special tools.





91. Install the special tool.
92. Install the lifting crane and remove the engine from the engine stand.





93. Install the flexplate and the bolts.
^ Tighten the bolts in this sequence.
^ Tighten all bolts to 5 Nm (44 inch lbs.).
^ Tighten all bolts to 94 Nm (69 ft. lbs.) in the sequence shown.