50-98
Engine - Early Build con't
50. NOTE: When installing the exhaust manifolds, only use prevailing torque hex flange bolts with an interference fit.
NOTE: Start installing the bolts with the second bolt from the rear on the top. The whole diameter is smaller, therefore allowing alignment of the retaining bolt.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
Install the left exhaust manifold and the bolts.
51. NOTE: When installing the exhaust manifolds, only use prevailing torque hex flange bolts with an interference fit.
NOTE: Start installing the bolts with the second bolt from the rear on the top. The whole diameter is smaller, therefore allowing alignment of the retaining bolt.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
Install the right exhaust manifold and the bolts.
52. Apply a bead of sealant at the back seam of the upper and lower crankcase.
53. Install the rear engine cover.
^ Install the press-in-place gasket.
^ Install the rear engine cover.
^ Install the bolts.
54. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.
NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50 mix) prior to assembly. Do not use any other type of lubricant.
NOTE: Apply a bead of threadlock 262(R) around the circumference of the outer rear edge of the secondary crankshaft flange.
Using the special tools, install the crankshaft rear oil seal.
55. Install the flywheel adapter.
56. If removed, install the front cover crankcase dowels into the cylinder block.
57. Apply a bead of sealant at the front seam of the upper and lower crankcase.
58. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
Install the guide studs and the front cover gasket.
59. Install the engine front cover and bolts.
60. NOTE: Install oil drive rotors with marks pointing outward.
Lubricate inner drive rotor with a suitable lithium assembly grease and install onto crankshaft. Lubricate outer drive rotor with lithium assembly grease and mesh with inner drive rotor in oil pump housing. Wipe off excess assembly grease.
61. NOTE: Install a new O-ring seal.
Install the oil pump body and the bolts.
62. NOTE: Apply threadlock 2629 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.
63. CAUTION: To prevent engine damage, you must 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.
64. If equipped, install the dual generator pulley and bolts.
65. NOTE: Install a now O-ring on the coolant PUMP.
Install the coolant pump and bolts.
66. Install the coolant pump pulley and the bolts.
67. CAUTION: To prevent engine damage, do not use air powered tools when installing the valve covers.
NOTE: LH side shown, RH side similar.
Install the valve covers.
^ Install the gaskets.
^ Install the valve covers.
^ Install the bolts and stud bolts.
68. Install the eight glow plugs.
69. NOTE: Left side shown, right side similar.
NOTE: Inspect the buss bar O-rings and install new as needed.
NOTE: Apply clean engine oil to the O-rings.
Install the glow plug buss bar.
70. Install a new O-ring seal.
71. Install the high-pressure oil pump and the bolts.
72. Install the high-pressure pump O-ring seal.
73. Install the high-pressure discharge pipe and the bolts.
74. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
75. Install a new D-ring seal on the high-pressure discharge pipe.
76. Clean the cover mounting surface and apply sealant at the scams.
77. Install the high-pressure pump cover. Install the press-in-place gasket. Install the high pressure pump cover. Install the bolts.
78. Install the turbocharger heat shield and bolts.
79. Install the oil pump inlet strainer.
80. CAUTION: In the event of a catastrophic engine failure, always install the 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.
81. Install the oil filter base.
^ Install the gasket.
^ Install the oil filter base.
^ Install the bolts.
82. 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.
83. Install new O-ring in the oil filter base.
84. Install the serpentine belt idler and bolt.
85. Install the belt tensioner and bolts.
86. NOTE: Install new sealing washers.
Install the left cylinder head fuel line.
87. Install the fuel lines and bracket bolt.
88. NOTE: Install a new O-ring on the thermostat.
Install the thermostat housing and stud bolts.
89. Position the exhaust backpressure bracket assembly and install the retaining nuts.
90. Tighten the exhaust backpressure tube at the exhaust manifold.
91. NOTE: Install a new O-ring on the oil indicator and tube. Apply clean engine oil to the O-ring.
Install the oil level indicator tube and nut.
92. Install the glow plug mounting bracket and the nuts.
93. NOTE: Left side shown; right side similar.
Install the LH and RH motor mounts and bolts.
94. Install the starter and the three bolts.
95. Install the special tool.
96. Install the special tool.
97. Install the lifting crane and remove the engine from the engine stand.
98. Install the flexplate flywheel and the bolts.
^ Tighten the bolts in the following sequence.
^ Tighten all bolts to 5 Nm (44 inch lbs.).
^ Tighten all bolts to 94 Nm (69 ft. lbs.) in the sequence shown.