Steps 51-100

Engine













Crankshaft, camshaft, piston and engine covers









Cylinder heads and oil pans









Fuel injection pump, engine wire harness and misc.









Upper engine view













Upper engine view with under 14,000 Gross Vehicle Weight Rating (GVWR) lower intake and turbocharger













Over 14,000 GVWR lower intake and turbocharger









Assembly

NOTE: This procedure assumes the engine will be installed using the recommended body off engine installation procedure. If it will be necessary to install the engine using the alternate body on engine installation procedure, some of the components in this procedure should not be installed at this time. For additional information, refer to Engine - Body On Body On.

NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US EPA or CARB Regulations".

51. Position the new front crankshaft slinger on the crankshaft.





52. Using the Front Crank Seal Installer, install a new front crankshaft seal and front crankshaft slinger.





53. Install a new upper oil pan gasket. Apply a dime-sized bead of sealant at the 4 cover joints.





54. NOTE: Final torque must be reached within 30 minutes of sealant application.

NOTE: Do not remove the zero leak plug from the oil pan.

Install the upper oil pan and 25 bolts. Tighten in 2 stages, in the sequence shown.

- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 24 Nm (18 lb-ft).





55. Using a new gasket, install the oil filter adapter, 4 bolts and stud bolt.
- Tighten to 10 Nm (89 lb-in).





56. NOTICE: In the event of catastrophic engine failure, always install a new oil cooler assembly. Foreign material cannot be removed from the oil cooler and engine damage may occur.

Using new gaskets, install the oil cooler assembly and 7 bolts.

- Tighten finger-tight.





57. NOTICE: Failure to tighten the oil cooler nut first may result in oil cooler damage or leaks.

Install the oil cooler nut.

- Tighten to 24 Nm (18 lb-ft).





58. Tighten the 7 oil cooler bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





59. NOTE: Use care when installing the hose on the oil cooler, damage to the oil cooler may occur during installation.

Install the oil cooler outlet hose assembly and connect the hose retainer.





60. Using a new gasket, install the lower oil pan and the 15 bolts. Tighten in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





61. NOTICE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original positions.

NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.

NOTE: Apply clean engine oil to the valve tappet bores prior to installing the valve tappets.

NOTE: Only one cylinder shown.

Apply clean engine oil to the 16 valve tappets and install into the valve tappet bores.





62. NOTE: Only one cylinder shown.

Install the 8 valve tappet guides.

- Verify that the retainer is fully seated.





63. NOTE: Only one cylinder head dowel shown.

Install the 4 new cylinder head dowels into the cylinder block.





64. NOTE: LH side shown, RH side similar.

Position the 2 new cylinder head gaskets onto the cylinder block.





65. NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: RH cylinder head shown, LH cylinder head similar.

Install the cylinder heads.





66. NOTICE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and result in poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads may affect the true torque value of the bolts.

NOTE: LH cylinder head shown, RH cylinder head similar.

NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.

Install 36 new M12 cylinder head bolts and 9 M8 cylinder head bolts.

- Tighten finger-tight.





67. Tighten the LH cylinder head bolts in 8 stages, in the sequence shown.
- Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).

- Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).

- Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).

- Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).

- Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.

- Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.

- Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.

- Stage 8: Tighten bolts 19 through 23 to 30 Nm (22 lb-ft).





68. Tighten the RH cylinder head bolts in 8 stages, in the sequence shown.
- Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).

- Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).

- Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).

- Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).

- Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.

- Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.

- Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.

- Stage 8: Tighten bolts 19 through 22 to 30 Nm (22 lb-ft).





69. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.

NOTE: Only one cylinder shown.

Install the 32 push rods.

- Verify the push rod socket is engaged on the hydraulic lash adjuster.





70. NOTE: Apply clean engine oil to the push rod ball end prior to installing the rocker arm assembly.

NOTE: Apply clean engine oil to each rocker arm pivot ball prior to installing the rocker arm assembly.

NOTE: Verify the push rod socket is on the hydraulic lash adjuster prior to installing the rocker arm assembly.

Install the RH rocker arm assemblies in the following sequence.

1. Position the crankshaft with the cylinder number No. 1 approximately 155 degrees after Top Dead Center (TDC) by observing the crankshaft pulley dowel pin and clocking it to the 3:40 position (as viewed from the front of the engine).

2. Determine which cylinder is actually in the firing position by observing the push rods for the No. 1 exhaust push rods should be raised 1.0 mm (0.039 in) and No. 4 exhaust push rods should be raised 1.5 mm (0.059 in). If the push rods are not in the correct position, rotate the engine one revolution clockwise (360 degrees).

3. Install the rocker arm assemblies for the RH cylinder head (cylinder numbers 1, 2, 3 and 4). Tighten in 5 stages, in the sequence shown.
- Stage 1: Verify the top of the push rod engages the socket on each rocker arm.

- Stage 2: Tighten to 4 Nm (35 lb-in).

- Stage 3: Tighten to 8 Nm (71 lb-in).

- Stage 4: Tighten to 13 Nm (115 lb-in).

- Stage 5: Tighten a second time to 13 Nm (115 lb-in).

- Repeat Stage 5, if any fastener moves more than 5 degrees in Stage 5.





71. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.

If necessary, install a new O-ring seal on the RH oil spray bar. Install the RH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the RH oil spray bar nuts can be tightened.

- Tighten to 11 Nm (98 lb-in).





72. NOTE: Apply clean engine oil to each rocker arm pivot ball prior to installing the rocker arm assembly.

NOTE: Verify the push rod socket is on the hydraulic lash adjuster prior to installing the rocker arm assembly.

Install the LH rocker arm assemblies in the following sequence.

1. Rotate the crankshaft with the one revolution clockwise (360 degrees) to 155 degrees after TDC by observing the crankshaft pulley dowel pin and clocking it to the 3:40 position (as viewed from the front of the engine).

2. Install the rocker arm assemblies for the LH cylinder head (cylinder numbers 5, 6, 7 and 8). Tighten in 5 stages, in the sequence shown.
- Stage 1: Verify the top of the push rod engages the socket on each rocker arm.

- Stage 2: Tighten to 4 Nm (35 lb-in).

- Stage 3: Tighten to 8 Nm (71 lb-in).

- Stage 4: Tighten to 13 Nm (115 lb-in).

- Stage 5: Tighten a second time to 13 Nm (115 lb-in).

- Repeat Stage 5, if any fastener moves more than 5 degrees in Stage 5.





73. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.

If necessary, install a new O-ring seal on the LH oil spray bar. Install the LH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the LH oil spray bar nuts can be tightened.

- Tighten to 11 Nm (98 lb-in).





74. Using a new valve cover gasket, install the RH valve cover, 2 stud bolts and 16 bolts. Tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 12 Nm (108 lb-in).

- Stage 2: Tighten a second time to 12 Nm (108 lb-in).





75. Using a new valve cover gasket, install the LH valve cover, 3 stud bolts and 15 bolts. Tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 12 Nm (108 lb-in).

- Stage 2: Tighten a second time to 12 Nm (108 lb-in).





76. NOTE: Only one glow plug shown.

Install the 8 glow plugs.

- Tighten to 11 Nm (97 lb-in).





77. NOTE: Do not apply engine oil to the fuel injectors.

NOTE: Only one fuel injector shown.

Install a new copper combustion gasket, O-ring seal and fuel injector return fuel O-ring on the 8 fuel injectors.

- Position the 8 fuel injectors into the engine.





78. NOTICE: Failure to tighten the fuel injector correctly can lead to engine failure.

NOTE: Apply clean engine oil to the concave surface of the fuel injector hold-down clamp.

Install the 8 fuel injector hold-down clamps and 8 new fuel injector bolts. Tighten in 2 stages.

- Stage 1: Tighten to 30 Nm (22 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





79. Install the new exhaust manifold stud(s) as needed.
- Tighten to 13 Nm (115 lb-in).





80. Using a new gasket, install the RH exhaust manifold, 8 spacers and 8 new nuts. Tighten the nuts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 30 Nm (22 lb-ft).

- Stage 3: Tighten a second time to 30 Nm (22 lb-ft).





81. Using a new gasket, install the LH exhaust manifold, 8 spacers and 8 new nuts. Tighten the nuts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 30 Nm (22 lb-ft).

- Stage 3: Tighten a second time to 30 Nm (22 lb-ft).





82. Install the RH exhaust manifold heat shield and 5 bolts.
- Tighten to 10 Nm (89 lb-in).





83. Install the LH exhaust manifold heat shield and 4 bolts.
- Tighten to 10 Nm (89 lb-in).





84. Install the Crankshaft Position (CKP) sensor and bolt.
- Tighten to 10 Nm (89 lb-in).





85. Install the crankshaft sensor pulse ring.





86. Install the flexplate and 10 new bolts. Tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 100 Nm (74 lb-ft).





87. Using a new gasket, install the vacuum pump and 4 bolts.
- Tighten to 10 Nm (89 lb-in).





88. NOTICE: To prevent engine damage, always install 4 new bolts when installing the crankshaft pulley.

NOTE: Use the Strap Wrench to prevent the engine from turning while tightening the bolts.

Position the crankshaft pulley and install 4 new bolts. Tighten in 2 stages, in the sequence shown.

- Stage 1: Tighten to 30 Nm (22 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





89. Using new gaskets, install the coolant crossover manifold assembly and 5 bolts.
- Finger-tighten the bolts.





90. NOTE: Inspect the thermostat seal for tears, nicks or cuts. Replace if necessary.

Install the thermostat, thermostat housing and 3 bolts.

- Finger-tighten the bolts.





91. Tighten the 5 coolant crossover bolts and the 3 thermostat housing bolts.
- Tighten to 10 Nm (89 lb-in).





92. Position the RH fuel rail and loosely install the 2 bolts.





93. Position the LH fuel rail and loosely install the 2 bolts.





94. NOTE: LH side shown, other connectors similar.

Position the fuel rail supply tube assembly. Hand start the 6 fuel rail supply tube assembly connectors.





95. NOTE: Only 1 fuel injector supply tube shown.

Install the 8 fuel injector supply tubes.

- Start from front to rear of engine.

- Hand start only.





96. Install the 5 fuel rail supply tube assembly bolts.
- Hand start only.





97. NOTE: LH side shown, RH side similar.

Tighten the 4 fuel rail bolts.

- Tighten to 24 Nm (18 lb-ft).





98. Tighten the 4 LH fuel injector supply tubes in the sequence shown.
- Tighten to 20 Nm (177 lb-in).





99. Tighten the 4 RH fuel injector supply tubes in the sequence shown.
- Tighten to 20 Nm (177 lb-in).





100. Tighten the 6 fuel rail supply tube assembly connectors in the sequence shown.
- Tighten to 20 Nm (177 lb-in).