Steps 101-150

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".

101. Tighten the 4 LH fuel injector supply tubes in the sequence shown.
- Tighten to 35 Nm (26 lb-ft).





102. Tighten the 4 RH fuel injector supply tubes in the sequence shown.
- Tighten to 35 Nm (26 lb-ft).





103. Tighten the 6 fuel rail supply tube assembly connectors in the sequence shown.
- Tighten to 35 Nm (26 lb-ft).





104. Tighten the 2 fuel rail supply tube connectors at the high-pressure fuel injection pump.
- Tighten to 40 Nm (30 lb-ft).





105. Tighten the 5 fuel rail supply tube assembly bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





106. NOTE: RH valve cover shown, other retaining clips similar.

Position the fuel injector return hose and vacuum hose assembly on the engine and connect the retaining clips.





107. Connect the 8 fuel injector return hose fittings to the fuel injectors.
- Push down on the center of the fuel injector return hose fitting to lock the fitting.





108. NOTE: Lubricate the O-ring seal with coolant prior to installing the heater supply tube.

Using a new O-ring seal, install the heater supply tube and the 2 bolts.

- Tighten to 10 Nm (89 lb-in).





109. Install the turbocharger coolant tube.





110. Install the secondary fuel filter assembly and 3 bolts.
- Tighten to 10 Nm (89 lb-in).





111. NOTE: Only 2 bolts shown.

Using new gaskets, install the crankcase vent oil separator and 4 bolts.

- Tighten to 10 Nm (89 lb-in).





112. NOTE: Apply clean engine oil to the O-ring seal prior to installing the fuel injection pump supply tube.

Using a new O-ring seal, install the fuel injection pump supply tube and bolt.

- Tighten to 10 Nm (89 lb-in).





113. Install the fuel injection pump supply tube assembly stud bolt.
- Tighten to 10 Nm (89 lb-in).





114. Install the 2 fuel injection pump supply tube assembly bolts.
- Tighten to 10 Nm (89 lb-in).





115. Connect the fuel injector return hose and retainer to the secondary fuel filter. Connect the secondary outlet hose to the fuel injection pump supply tube.





116. Connect the fuel injection pump hose to the fuel rail.





117. Install the power steering pump mounting bracket and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).





118. Position the engine wire harness over the engine. Connect the 2 retainers and install the bolt.
- Tighten to 10 Nm (89 lb-in).





119. NOTE: Only one retainer shown.

Connect the 6 retainers to the fuel supply manifolds.





120. Position the engine wire harness on the LH valve cover and connect the 3 wire retainers.





121. NOTE: Only one fuel injector and glow plug electrical connector shown.

Connect the 8 fuel injectors and the 8 glow plug electrical connectors.





122. NOTE: Only one wire retainer shown.

Connect the CKP sensor electrical connector and the 3 wire retainers.





123. Install the cylinder block opening cover.





124. Connect the fuel pressure control valve electrical connector.





125. Connect the Fuel Rail Pressure (FRP) sensor electrical connector and 2 retainers.





126. Connect the fuel pressure switch and the fuel temperature sensor electrical connectors. Connect the wire retainer.





127. Connect the Engine Coolant Temperature (ECT) sensor electrical connector and wire retainer.





128. Connect the turbocharger wastegate control valve vacuum and electrical connector.





129. Connect the vacuum hose retainer to the secondary fuel filter stud.





130. Connect the fuel volume control valve electrical connector.





131. Connect the Camshaft Position (CMP) sensor electrical connector and the 3 pin type retainers.





132. Install the lower intake manifold and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).





133. Connect the crankcase vent oil separator-to-lower intake manifold hose.





134. Connect the Throttle Body (TB) electrical connector.





135. Using new gaskets, install the EGR cooler assembly and the 7 bolts. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





136. Install the 2 engine wire harness bolts to the EGR cooler.
- Tighten to 10 Nm (89 lb-in).





137. Connect the wire retainer and the vacuum hose. Connect the EGR valve, bypass solenoid and EGR ECT sensor electrical connectors.





138. Connect the 2 wire harness retainers.





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

Install the 2 ground straps and 2 bolts to the back of the cylinder heads.

- Tighten to 10 Nm (89 lb-in).





140. Using new gaskets, install the EGR bypass outlet tube and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





141. Connect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector and wire retainer.





142. NOTE: Exhaust side shown, EGR cooler side similar.

Using new gaskets, install the EGR valve inlet tube and the 4 bolts. Tighten the bolts in the following sequence.

- Tighten the bolts at the exhaust manifold to 10 Nm (89 lb-in).

- Tighten the bolts at the EGR cooler to 10 Nm (89 lb-in).





143. NOTE: Apply threadlock to the EGR cooler side bolt threads prior to installation.

Install the EGR valve inlet tube bracket and the 2 new bolts. Tighten in 4 stages:

- Stage 1: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler to 10 Nm (89 lb-in).

- Stage 2: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler an additional 45 degrees.

- Stage 3: Tighten the EGR valve inlet tube bracket bolt to 10 Nm (89 lb-in).

- Stage 4: Tighten the EGR valve inlet tube bracket bolt an additional 45 degrees.





144. NOTE: Apply clean engine oil to the O-ring seals prior to installing the oil level indicator tube.

NOTE: Verify that the oil level indicator tube is fully seated in the rear engine cover.

Using new O-ring seals, install the oil level indicator tube.





145. Using a new O-ring seal, install the oil fill pipe and bolt.
- Tighten to 10 Nm (89 lb-in).





146. Position the lower engine wire harness on the engine. Install the 2 front retaining nuts.
- Tighten to 12 Nm (108 lb-in).





147. Install the lower engine wire harness nut.
- Tighten to 12 Nm (108 lb-in).





148. Install the lower engine wire harness nut at the oil filter adapter.
- Tighten to 12 Nm (108 lb-in).





149. Connect the Engine Oil Temperature (EOT) sensor and the Engine Oil Pressure (EOP) switch electrical connectors.





150. NOTE: Power steering pump mounting bracket removed for clarity.

Install the 2 lower engine wire harness bolts.

- Tighten to 12 Nm (108 lb-in).