1-43

Engine





Special Tool(s)





Material

Installation

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.





2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.

Vehicles with automatic transmission
3. Align the torque converter studs with the holes in the engine flywheel, then lower the engine onto the engine mount towers.

Vehicles with manual transmission
4. Lower the engine onto the engine mount towers.

All vehicles
5. Remove the Heavy Duty Floor Crane and the Diesel Engine Lifting Bracket.

Vehicles with automatic transmission
6. Remove the transmission jack.





7. Install the transmission-to-engine mounting bolts.





8. Install the torque converter-to-flywheel retaining nuts.





9. Install the flywheel housing cover.

All vehicles





10. NOTE: LH shown, RH similar.

Install the LH and RH side engine mount retaining nuts.





11. Remove the engine lifting eye from the right side cylinder head.





12. Install the manufacturer's lifting bracket.





13. Remove the two engine lift adapters.





14. NOTE: Position back the starter wiring and block heater harness.

Install the transmission cooler tube bracket and nut.





15. Install the left rear valve cover stud.





16. Position the turbocharger adapter pipe.





17. NOTE: Left side shown, right side similar.

Loosely install the bolts for the turbocharger adapter pipe.





18. Install the starter if needed.





19. Connect the starter wiring and install the solenoid cap.





20. Connect the block heater electrical connector.





21. Connect the ground strap on the right head and install the bolt.

Vehicles with automatic transmission





22. Install the automatic transmission fluid indicator and tube.

All vehicles





23. Position the engine wiring harness back. Connect the Crankshaft Position (CKP) sensor electrical connector and wiring retainers.

Vehicles with A/C





24. Position the A/C compressor manifold and install the bolt.





25. Install the A/C compressor.





26. Connect the A/C high pressure switch and the clutch electrical connectors.





27. NOTE: Late build shown, early build similar.

Connect the RH glow plug electrical connector.

All vehicles





28. Install the nuts and the glow plug controller.





29. NOTE: Late build shown, early build similar.

Connect the glow plug module electrical connectors.





30. Connect the wiring retainers to the studs.





31. Connect the ground cable and the ground stud.





32. Install the battery cable bracket and the nut, and install the RH standoff for the stator.





33. NOTE: The lower bolts need to be installed evenly.

Position the power steering pump and install the lower bolts, and install the LH standoff for the stator.





34. Install the power steering pump upper bolts.





35. Connect the fuel lines and install the clips.





36. Install the intake manifold gaskets.
37. Install the intake manifold and loosely install the bolts.





38. Tighten the bolts in the following sequence.
1 Loosely install the bolts. Tighten bolts to 9-16 to 11 Nm (8 ft. lbs.).
2 Tighten all bolts to 11 Nm (8 ft. lbs.) in the sequence shown.





39. Install the gasket and the EGR cooler V-clamp.





40. Slide the EGR cooler hose up and rotate flat to lock.





41. Install the turbocharger heat shield and the nuts.





42. Install the fuel line.
^ Install new sealing washers.
^ Install the fuel line.
^ Install the banjo fitting and the bolt.





43. Install the oil filter return tube and bolt.
^ On new oil filter return tubes, tighten to 6 Nm (53 inch lbs.).
^ On used oil filter return tubes, tighten to 3 Nm (27 inch lbs.).