Part 4
EngineAssembly (Steps 79-105)
79. Install new lower O-ring seals.
80. Install the high-pressure pump and bolts.
^ Tighten to 31 Nm (23 ft. lbs.).
81. Install the high-pressure tube assembly bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
82. Install a new press-in-place gasket in the high-pressure pump cover.
83. Clean the cover mounting surface and apply sealer at the seams.
84. CAUTION: To prevent engine damage, the high-pressure oil pump cover must be firmly seated on the O-ring seal to prevent cracking the cover plate.
NOTE: Apply clean engine oil to the high-pressure oil pump O-ring seal prior to installing the high-pressure pump cover.
Install the high-pressure oil pump cover and bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
85. Using the special tool, install the injection pressure regulator (IPR) valve.
^ Tighten to 50 Nm (37 ft. lbs.).
86. If equipped, install the heat insulating wrap and fasten the snap.
87. Install the oil pump inlet strainer.
88. 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 a new press-in-place gasket, the oil cooler assembly and the bolts.
^ Tighten to 22 Nm (16 ft. lbs.).
89. Install the press-in-place gasket, the oil filter base and the bolts.
1 Tighten to 22 Nm (16 ft. lbs.).
2 Tighten to 10 Nm (89 inch lbs.).
90. Install a new press-in-place gasket, the exhaust gas recirculation (EGR) cooler coolant supply port cover and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
91. Install new O-ring seals in the oil filter base.
92. Install the serpentine belt idlers and bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
93. Install the belt tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
94. NOTE: Install new sealing washers.
Install the LH cylinder head fuel tube.
^ Tighten to 38 Nm (28 ft. lbs.).
95. Install the fuel tubes and bracket bolt.
^ Tighten to 13 Nm (10 ft. lbs.).
96. NOTE: Install a new O-ring seal on the thermostat.
Install the thermostat housing and the bolts.
^ Tighten to 23 Nm (17 ft. lbs.).
97. NOTE: Install a new O-ring seal on the oil indicator and tube. Apply clean engine oil to the O-ring seal.
Position the oil level indicator tube and install the nut. Connect the wiring harness retainer to the stud bolt.
98. Install the glow plug mounting bracket and the nuts.
^ Tighten to 9 Nm (80 inch lbs.).
99. NOTE: LH shown, RH similar.
Install the LH and RH motor mounts and bolts.
^ Tighten to 62 Nm (46 ft. lbs.).
100. NOTE: LH shown, RH similar.
NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.
Install the cylinder block coolant drain plugs.
^ Tighten to 20 Nm (15 ft. lbs.).
101. Position the starter motor and install the 3 bolts in 3 stages.
^ Stage 1: Install the 3 bolts finger tight.
^ Stage 2: Tighten the upper bolt to 25 Nm (18 ft. lbs.).
^ Stage 3: Tighten the 2 lower bolts to 25 Nm (18 ft. lbs.).
102. Install the special tool.
103. Install the special tool.
104. Install the lifting crane and remove the engine from the engine stand.
105. Position the flexplate or flywheel and install the new bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 94 Nm (69 ft. lbs.).