Part 3
EngineAssembly (Steps 53-78)
53. Apply clean engine oil to the top fuel injector O-ring seals.
54. 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 4 single ball tubes are engaging the fuel injector lead angle.
^ Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 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 6 bolts.
55. Remove the 3 guide bolts, install the remaining bolts and tighten the 9 bolts in the sequence shown.
^ Tighten to 13 Nm (10 ft. lbs.).
56. NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installation.
Install the crankcase-to-head tube assembly.
^ Tighten to 82 Nm (60 ft. lbs.).
57. Apply a bead of sealant at the back seam of the upper and lower crankcase.
58. Install a new press-in-place gasket, the rear engine cover and the bolts.
^ Tighten to 24 Nm (18 ft. lbs.).
59. 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 around the circumference of the outer rear edge of the secondary crankshaft flange.
Using the special tools, install a new crankshaft rear oil seal.
60. Install the flywheel adapter.
61. If removed, install the front cover crankcase dowels into the cylinder block.
62. Apply a bead of sealant at the front seam of the upper and lower crankcase.
63. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
Install the guide studs and the front cover gasket.
64. Install the engine front cover and the bolts.
^ Tighten to 24 Nm (18 ft. lbs.).
65. NOTE: Install oil pump 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.
66. NOTE: Install a new O-ring seal.
Install the oil pump body and the 5 bolts.
^ Tighten to 13 Nm (10 ft. lbs.).
67. NOTE: Apply Threadlock 262 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 a new oil seal and wear sleeve assembly.
68. CAUTION: To prevent engine damage, always install 4 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 tighten the new bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 68 Nm (50 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
69. If equipped, install the dual generator pulley and the 3 bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
70. NOTE: Install a new O-ring seal on the coolant pump.
Install the coolant pump and the 4 bolts.
^ Tighten to 23 Nm (17 ft. lbs.).
71. Install the coolant pump pulley and the 4 bolts.
^ Tighten to 31 Nm (23 ft. lbs.).
72. Install the RH high-pressure oil rail-to-valve cover gasket.
73. CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
NOTE: RH shown, LH similar.
Install the RH and LH valve covers.
^ Install new gaskets.
^ Install the valve covers.
^ Install the bolts and stud bolts.
^ Tighten to 9 Nm (80 inch lbs.).
74. NOTE: Clean and inspect the O-ring seal.
Install the injection control pressure (ICP) sensor.
^ Tighten to 12 Nm (9 ft. lbs.).
75. Install the 8 glow plugs.
^ Tighten to 19 Nm (14 ft. lbs.).
76. NOTE: Clean and apply clean engine oil to the O-ring seals.
Using the special tool, Install the glow plug harness.
77. CAUTION: To prevent engine damage, use only approved pump cover seal. Substitution can cause damage to the pump cover.
Install a new O-ring seal on the high-pressure oil pump.
78. Install the high-pressure tube assembly.