Part 3
EngineSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Special Tool(s) (Part 3):
Material:
Assembly (Steps 79-117)
79. Position the fuel supply and return tubes and install the bolt.
^ Tighten to 31 Nm (23 lb-ft).
80. NOTE: Install a new O-ring seal on the tube and a new clamp on the hose.
NOTE: Hand start both bolts prior to tightening the bolts.
Install the EGR cooler tube and install the bolts.
^ Tighten to 13 Nm (115 lb-inch).
81. CAUTION: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.
Tighten the clamp for the EGR cooler hose.
^ Tighten to 4 Nm (35 lb-inch).
82. NOTE: Install a new O-ring seal.
Install the LH heater tube and bolts.
^ Tighten to 13 Nm (115 lb-inch).
83. CAUTION: The protruding hub of the high-pressure fuel injection pump drive gear must be facing the high pressure fuel injection pump. Failure to install the gear correctly will result in engine damage.
NOTE: The high-pressure fuel injection pump drive gear bolt is a LH thread.
NOTE: The bolt for the high-pressure fuel injection pump will not be tightened at this time.
If a new pump is being installed, install the high-pressure fuel injection pump drive gear and install the bolt finger tight.
84. Install the high-pressure fuel injection pump and bolts.
^ Tighten to 62 Nm (46 lb-ft).
85. NOTE: The high-pressure fuel pump drive gear bolt has a LH thread.
NOTE: Use a tool such as a Snap-On FRDHM15 torque adapter, or equivalent, to tighten the bolt.
If a new high-pressure fuel pump has been installed, tighten the drive gear bolt.
^ Tighten to 78 Nm (58 lb-ft).
86. Using the special tool, check the high-pressure fuel injection pump drive gear backlash.
87. Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams.
88. CAUTION: Inspect the volume control valve and the pressure control valve electrical connectors for damage or obstructions at the connector and mating high-pressure fuel injection pump connector. Verify that the connectors are completely latched to the valve housings or engine damage may occur.
Install a new gasket for the high-pressure fuel injection pump cover. Connect the pressure control valve and volume control valve electrical connectors.
89. Install a new press-in-place gasket in the high-pressure fuel injection pump cover.
90. NOTE: Do not remove the Fuel System Caps from the high-pressure fuel pump until the fuel rail supply tubes are ready to be installed.
Install the high-pressure fuel injection pump cover and bolts.
^ Tighten to 13 Nm (115 lb-inch).
91. 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 and engine damage may occur.
Install a new press-in-place gaskets, the oil cooler assembly and the bolts.
^ Tighten to 31 Nm (23 lb-ft).
92. NOTE: The old oil cooler cover screws or new self-tapping screws must be used to cut the threads in the new oil cooler cover.
Install the press-in-place gaskets, the oil filter base and the screws.
^ On a new oil cooler cover, tighten to 10 Nm (89 lb-inch).
^ On a used oil cooler cover, tighten to 7 Nm (62 lb-inch).
93. Install new O-ring seal and gasket in the oil filter base.
^ Apply clean engine oil to the O-ring seal and gasket.
94. Install the oil filter return tube assembly and screw.
^ On new oil return tubes, tighten to 7 Nm (62 lb-inch).
^ On used oil return tubes, tighten to 5 Nm (44 lb-inch).
95. Install the oil filter housing and the 4 bolts.
^ Tighten to 22 Nm (16 lb-ft).
96. NOTE: Install a new O-ring on the oil filter cap and apply clean engine oil.
Install a new oil filter element and the oil filter housing cap.
^ Tighten to 25 Nm (18 lb-ft).
97. NOTE: The 2 shoulder bolts go in the center holes on the sides.
Install a new press-in-place gasket, the turbocharger pedestal and bolts.
^ Tighten to 62 Nm (46 lb-ft).
98. NOTE: The locating tabs on the gaskets must be up and positioned toward the center of the engine or a leak will occur.
Install the intake manifold gaskets.
99. Install the intake manifold and bolts and tighten in 2 stages, in the sequence shown.
^ Stage 1: Loosely assemble all bolts in the sequence shown.
^ Stage 2: Tighten to 11 Nm (97 lb-inch).
100. CAUTION: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the high-pressure fuel injection pump.
Position the fuel injector return tube. Install the banjo fittings and new copper sealing washers at the cylinder heads.
^ Tighten to 38 Nm (28 lb-ft).
101. Position the retainers and install the bolts for the fuel injector return tube.
^ Tighten to 13 Nm (115 lb-inch).
102. Install the nut on the fuel injector return tube.
^ Tighten to 11 Nm (97 lb-inch).
103. Install the fuel filter module and bolts.
^ Tighten to 13 Nm (115 lb-inch).
104. CAUTION: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the high-pressure fuel injection pump.
Install the banjo fittings and new copper sealing washers at the fuel filter module.
^ Tighten the M14 banjo fitting to 47 Nm (35 lb-ft).
^ Tighten the M12 banjo fitting to 38 Nm (28 lb-ft).
105. Install the bolt for the fuel supply and return tube retainer.
^ Tighten to 31 Nm (23 lb-ft).
106. CAUTION: Do not bend or flex the heater supply tube or damage to the tube may occur.
NOTE: Install a new O-ring seal.
Install the RH heater supply tube, bolt and nut.
^ Tighten to 13 Nm (115 lb-inch).
107. Install the glow plug module bracket and bolts.
^ Tighten to 13 Nm (115 lb-inch).
108. NOTE: Use a back-up wrench on the high-pressure fuel injection pump fittings.
NOTE: Remove the protective caps from the high-pressure fuel pump.
Install new copper sealing washers, fuel injection pump supply tube, fuel injection pump-to-fuel cooler return tube and nuts at the high-pressure fuel injection pump.
^ Tighten to 38 Nm (28 lb-ft).
109. Install the retaining nuts for the fuel injection pump supply tube.
^ Tighten to 11 Nm (97 lb-inch).
110. NOTE: Remove the protective caps or plugs from the fuel tubes.
Connect the fuel injector return tube at the check valve.
^ Tighten to 28 Nm (21 lb-ft).
111. Position and connect the high-pressure fuel injection pump electrical connector. Connect the pushpin retainer.
112. NOTE: LH side shown, RH side similar.
Install the new fuel rail supply tubes.
1 Remove the Fuel System Caps from the fuel rail supply tube openings.
2 NOTE: Support the tubes while hand snugging the nut to make sure of assembly of the joints.
Position the fuel rail supply tubes between the high pressure fuel injection pump and high-pressure fuel rail. Fully hand start and seat the tube nuts onto the high pressure fuel injection pump and high-pressure fuel rail.
3 Snug the tube nuts.
^ Tighten to 2 Nm (18 lb-inch).
4 Pre-tighten the high-pressure fuel injection pump and high-pressure fuel rail tube nuts.
^ Tighten to 12 Nm (106 lb-inch).
5 NOTE: Place a visible mark with a permanent marker on the high-pressure fuel rail and high-pressure fuel pump threaded connection. Turning the tube nuts one flat of the nut is equal to 60 degrees.
Final-tighten the fuel rail supply tube nuts.
^ Tighten the tube nuts 60 degrees.
113. Install the bolts for the fuel rail supply tube retainers.
^ Tighten to 13 Nm (115 lb-inch).
114. CAUTION: Failure to correctly install the fuel pump heat shield may result in engine damage.
Install the fuel pump heat shield, fuel tube bracket and ground strap. Install the retaining nuts and bolt.
^ Tighten the fuel tube bracket nuts to 8 Nm (71 lb-inch).
^ Tighten the remaining fasteners to 13 Nm (115 lb-inch).
115. Position the engine wiring harness on the engine. Install the bolt.
^ Tighten to 13 Nm (115 lb-inch).
116. Connect the glow plug module and high-pressure fuel injection pump electrical connectors. Connect the pushpin retainers.
117. NOTE: Use a socket to aid in installing the pushnuts.
Position the glow plug module heat shield. Install the new pushnuts.
