Installation

Installation

All vehicles





1. NOTE: The locating tabs on the gaskets must be positioned upward and toward the center of the engine, or a leak will occur.

Install the intake manifold gaskets and front module O-ring seal.





2. Install the intake manifold and bolts and tighten in the following sequence.
1 Loosely install bolts 1-8.
2 Tighten bolts 9-16 to 11 Nm (8 ft. lbs.).
3 Tighten all bolts to 11 Nm (8 ft. lbs.).





3. Slide the EGR cooler hose forward and rotate the flat to lock.





4. Install the turbocharger heat shield and nuts.





5. Install the secondary fuel filter assembly and bolts.





6. NOTE: Install new copper sealing washers.

Install the fuel line and banjo bolt.





7. Install the retaining nut and connect the fuel tube at the fuel filter assembly.





8. NOTE: Install new copper sealing washers on the banjo fitting.

Reposition and connect the fuel tubes at the fuel filter housing.





9. Install the secondary fuel filter and cover.





10. Connect the engine coolant vent hose.





11. Connect the MAP sensor hose.





12. Position back the engine wiring harness as needed. Connect the harness retainers.





13. NOTE: Only one injector shown, others are similar.

Connect the eight fuel injector electrical connectors.





14. Remove the plug or cap. Install the IAT2 sensor.





15. Connect the IAT2 sensor electrical connector.





16. Remove the plug or cap. Install the ECT sensor.





17. Connect the ECT sensor electrical connector and the pin-type retainer.





18. Connect the EOT sensor electrical connector.





19. Connect the EOP sensor electrical connector.





20. Connect the EGR valve electrical connector.





21. Connect the injector pressure regulator valve electrical connector and position back the heat insulating wrap. Install the wiring retainer and retaining nut.





22. NOTE: Install a new O-ring seal and apply clean engine coolant.

Install the heater tube and bolts.





23. Install the generator, ground wire and the three bolts.





24. Position back the transmission fluid indicator and tube and install the retaining nut. Connect the pushpin retainer.





25. Install the retaining nut for the transmission fluid indicator and tube.





26. Connect the generator B+ wire and electrical connector. Position back the boot. Connect the wiring pushpin.





27. NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler tube to prevent the tube from blowing off.

Position the charge-air-cooler tube, oil fill tube and bracket. Install the retaining nuts.





28. Connect the oil fill tube at the valve cover.





29. Install the bolts for the charge-air-cooler tube and oil fill tube.





30. Position the conduit and install the bolts.





31. Connect the push pin. Position back the MAP sensor assembly and install the bolt.





32. Connect the electrical connector pushpin. Position back the ground wire and install the bolt.

Vehicles with single generator





33. Install the accessory drive belt.

Vehicles with dual generator





34. Install the generator with mounting bracket and bolts.





35. Connect the generator B+ wire and electrical connector. Position the boot.





36. Install the accessory drive belt tensioner and bolts.





37. Position the accessory drive belt idler pulley. Install the bracket and bolts.





38. Install the accessory drive belt.





39. Install the accessory drive belt tensioner and bolt.





40. Install the accessory drive belt.

All vehicles
41. Install the cooling fan stator.
42. Install the turbocharger pedestal and turbocharger.
43. Connect the battery ground cable.