Installation
EngineSpecial Tool(s):
Material:
Installation
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
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.
^ Tighten to 47 Nm (35 ft. lbs.).
8. Install the new torque converter-to-flywheel retaining nuts.
^ Tighten to 35 Nm (26 ft. lbs.).
9. Install the flywheel housing cover.
All vehicles
10. NOTE: RH shown, LH similar.
Install the 4 LH and 4 RH engine mount nuts.
^ Tighten to 103 Nm (76 ft. lbs.).
11. Remove the engine lifting eye from the right side cylinder head.
12. Install the manufacturer's lifting bracket.
13. Remove the 2 engine lift adapters.
14. Position the turbocharger outlet pipe.
15. Install the transmission cooler tube bracket and nut.
^ Tighten to 10 Nm (89 inch lbs.).
16. Install the left rear valve cover stud.
^ Tighten to 9 Nm (80 inch lbs.).
17. Install the fuel injector control module support bracket and the nuts.
^ Tighten to 8 Nm (71 inch lbs.).
18. Connect the exhaust pressure (EP) sensor tube fitting to the exhaust manifold and install the EP sensor retaining nut.
1 Tighten to 30 Nm (22 ft. lbs.).
2 Tighten to 13 Nm (10 ft. lbs.).
19. Install the heat shield and bolts.
1 Tighten to 49 Nm (36 ft. lbs.).
2 Tighten to 11 Nm (8 ft. lbs.).
20. Position the turbocharger adapter pipes. Install the gasket and bolts.
^ Tighten to 27 Nm (20 ft. lbs.).
21. Position the turbocharger adapter pipe.
22. NOTE: LH shown, RH similar.
NOTE: Do not tighten bolts at this time.
NOTE: Apply anti-seize lubricant to the threads prior to installing the bolts.
Install the bolts for the turbocharger adapter pipe.
23. Position back the block heater and starter wiring.
24. Connect the block heater electrical connector.
25. Connect the starter wiring and install the solenoid cap.
1 Tighten to 6 Nm (53 inch lbs.).
2 Tighten to 12 Nm (9 ft. lbs.).
26. Connect the ground strap to the RH cylinder head and install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
Vehicles with automatic transmission
27. Install the automatic transmission fluid indicator and tube.
^ Tighten to 8 Nm (71 inch lbs.).
All vehicles
28. Position back the wiring and connect the crankshaft position (CKP) sensor electrical connector.
Vehicles with A/C
29. Position the A/C compressor and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
30. Remove the cap or plug and install a new O-ring seal. Install the A/C hose and retaining nut.
^ Tighten to 8 Nm (71 inch lbs.).
31. Connect the A/C high-pressure switch and the clutch electrical connectors.
All vehicles
32. Connect the RH glow plug electrical connector and wire retainer.
33. Connect the glow plug module electrical connectors. Connect the pushpin retainer and the injection control pressure (ICP) sensor electrical connector.
34. NOTE: Only one retainer shown.
Connect the wire retainers on the valve cover studs.
35. Connect the ground cable and the ground stud.
^ Tighten to 47 Nm (35 ft. lbs.).
36. Install the battery cable bracket and the nut.
^ Tighten to 47 Nm (35 ft. lbs.).
37. Position the power steering pump and install the lower bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
38. Install the power steering pump upper bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
39. NOTE: Only one stand-off shown.
Install the stator stand-offs.
^ Tighten to 47 Nm (35 ft. lbs.).
40. Connect the fuel tube spring lock couplings. For additional information, refer to Fuel Delivery and Air Induction.
41. Install the lower radiator hose and clamp.
42. Connect the heater hose at the front cover.
43. Connect the camshaft position (CMP) sensor electrical connector.
44. Connect the 12-pin and 8-pin electrical connectors.
45. Connect the powertrain control module (PCM) electrical connector.
46. Connect the LH glow plug electrical connector.
47. Install the battery tray and bolts.
^ Tighten to 16 Nm (12 ft. lbs.).
48. Install the intake manifold.
49. NOTE: LH shown, RH similar.
NOTE: Alternately tighten the bolts to specification.
Tighten the turbocharger adapter pipe at the flanges.
^ Tighten to 27 Nm (20 ft. lbs.).
50. Tighten the nuts at the turbocharger adapter pipe flange.
^ Tighten to 47 Nm (35 ft. lbs.).
51. Install the upper radiator support and bolts.
^ Tighten to 12 Nm (9 ft. lbs.).
52. NOTE: Cover position back for clarity.
Connect the body feed cable and install the nut.
^ Tighten to 8 Nm (71 inch lbs.).
53. Install the transmission oil cooler.
^ Tighten to 8 Nm (71 inch lbs.).
54. NOTE: Remove the caps or plugs as needed.
Connect the transmission cooler hoses.
55. Install the power steering cooler and bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
56. Position back the power steering cooler tubes and install the tubes in the retaining clip.
57. NOTE: Remove the caps or plugs as needed.
Connect the power steering hoses and tighten the clamps.
58. Install the front bumper.
59. Install the radiator grille opening panel reinforcement.
Vehicles with A/C
60. Install the A/C condenser assembly. For additional information, refer to Heating and Air Conditioning.
All vehicles
61. Install the charge air cooler. For additional information, refer to Fuel Delivery and Air Induction.
62. Install the air cleaner assembly. For additional information, refer to Fuel Delivery and Air Induction.
63. Install the cooling fan stator. For additional information, refer to Cooling System.
Vehicles with manual transmission
64. Install the clutch disc and pressure plate.
65. Install the transmission.
All vehicles
66. Fill the motor with clean engine oil.
67. Connect the LH and RH battery cables. For additional information, refer to Battery.
68. Fill the cooling system. For additional information, refer to Cooling System.
69. Cycle the key 3 times prior to starting the vehicle to avoid the possibility of air lock in the fuel system.
70. Fill and bleed the power steering system.
71. Check and fill the transmission.