Body Off

Engine - Body Off









Installation

NOTICE: Change the engine oil any time the turbocharger is removed from the engine. The passages in the block, located underneath the turbocharger, are direct passages to the lubrication system. Debris and/or coolant may enter the lubrication system and engine damage may occur.

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Engine - Body On Body On.

1. NOTICE: Prior to installation of the engine, lubricate the torque converter pilot hub or damage to the torque converter or the engine crankshaft can occur.

Lubricate the torque converter pilot hub with multi-purpose grease and align the paint dot on the torque converter in the 12 o'clock position.





2. NOTE: Use caution to ensure the torque converter studs align with the holes in the flexplate while joining the engine to the transmission.

Using the Heavy Duty Floor Crane, install the engine into the vehicle and join the engine to the transmission.

3. Install the 5 upper transmission-to-engine mounting bolts.
- Tighten to 48 Nm (35 lb-ft).

- Remove the transmission jack.





4. Install the 4 lower transmission-to-engine mounting bolts.
- Tighten to 48 Nm (35 lb-ft).





5. NOTICE: Failure to replace the engine support insulator cross bolts may result in engine support insulator damage.

NOTICE: Only use hand tools when installing the engine support insulator cross bolts or damage to the engine support insulator cross bolts may occur.

NOTE: If it is necessary to loosen the engine support insulator nuts, new nuts must be installed. For additional information, refer to Engine Support Insulators Removal and Replacement.

Lower the engine onto the engine support insulators and install the 2 new engine support insulator cross bolts.
- Tighten to 350 Nm (258 lb-ft).





6. Remove the ratchet strap from the engine.

7. Remove the upper Front End Accessory Drive (FEAD) bracket mounting bolt and the Lifting Eye.





8. Install the upper FEAD bracket mounting bolt.
- Tighten to 24 Nm (18 lb-ft).





9. NOTE: The turbocharger must be positioned forward, and then set down on the locating dowel pins.

NOTE: Clean and inspect the sealing surfaces of the engine block and the turbocharger.

Using a new gasket, install the turbocharger and the 2 turbocharger inlet boots.

10. NOTE: The turbocharger mounting bolts are torque-to-yield design and cannot be reused.

NOTE: Turbocharger removed for clarity.

Install the 4 new turbocharger mounting bolts and tighten in 3 stages in the sequence shown.

- Stage 1: Tighten finger tight.

- Stage 2: Tighten to 15 Nm (133 lb-in).

- Stage 3: Tighten to 55 Nm (41 lb-ft).





11. Tighten the 4 turbocharger inlet boot clamps.
- Tighten to 4 Nm (36 lb-in).





12. Connect the turbocharger coolant outlet tube to the turbocharger.
- Make sure the turbocharger coolant return tube is fully seated in the fitting and the retaining clip is in place.





13. Install and connect the Charge Air Cooler (CAC) tube to the turbocharger.





14. NOTICE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

NOTE: Left side shown, right side similar.

Using 2 new gaskets and 2 new clamps, install the 2 turbocharger inlet pipes.

- Loosely position the 2 clamps.





15. NOTE: Left side shown, right side similar.

Install the 3 new nuts to each turbocharger inlet pipe.

- Tighten to 25 Nm (18 lb-ft).





16. NOTE: The Exhaust Pressure (EP) sensor and tube are attached to the RH turbocharger inlet pipe.

Connect the EP sensor electrical connector.

- Position the EP sensor electrical connector heat shield over the electrical connector.





17. NOTE: Left side shown, right side similar.

Tighten the 2 turbocharger inlet pipe clamps.

- Tighten to 15 Nm (133 lb-in).





18. NOTE: Remove the covers or tape from the rocker covers and the lower intake.

Using new intake manifold gaskets, install the upper intake manifold, and the 15 bolts in the sequence shown.

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





19. Install the engine and transmission oil level indicator tube bolts.
- Tighten the transmission oil level indicator tube bolt to 11 Nm (97 lb-in).

- Tighten the engine oil level indicator tube bolt to 10 Nm (89 lb-in).

- Connect the wastegate vacuum line to the wastegate actuator.





20. Connect the Manifold Absolute Pressure (MAP) and the turbocharger actuator electrical connectors.
- Connect the 2 wiring harness retainers.





21. NOTE: Only one retainer shown, 3 other retainers similar.

Connect the power steering pressure line to the 4 retainers.





22. Position the fuel line bracket to the left side of the transmission and install the 2 fuel line bracket bolts.
- Tighten to 48 Nm (35 lb-ft).





23. Install the 2 fuel line bracket bolts to the transmission bellhousing.
- Tighten to 48 Nm (35 lb-ft).





24. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.

Connect the fuel supply tube quick connect coupling to the secondary fuel filter. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

- Connect the fuel return tube quick connect coupling to the fuel injection pump return tube. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.





25. Position the transmission cooler lines to the RH side of the engine and install the bracket nut.
- Tighten to 12 Nm (106 lb-in).





26. Install the cooling fan stator and the 4 nuts.
- Tighten to 17 Nm (150 lb-in).





27. Install the engine wiring harness bracket bolt and the ground wire bolt.
- Tighten the 2 bolts to 25 Nm (18 lb-ft).





28. Install the 8 new torque converter nuts.
- Tighten nuts to 48 Nm (35 lb-ft).





29. Install the flexplate access cover and the 2 retainers.





30. Install the starter motor. For additional information, refer to Starting System - Diesel Engine Service and Repair.

31. If equipped, connect the block heater cord.





32. Install the turbocharger downpipe and position a new clamp.





33. Loosely install the turbocharger downpipe bracket bolt.





34. Loosely install the 2 turbocharger downpipe flange bolts.





35. Tighten the turbocharger downpipe clamp.
- Tighten to 15 Nm (133 lb-in).





36. Tighten the turbocharger downpipe bracket bolt.
- Tighten to 25 Nm (18 ft-lb).





37. Tighten the 2 turbocharger downpipe flange bolts.
- Tighten to 40 Nm (30 lb-ft).





38. If necessary, install 2 new transmission support insulator studs.
- Tighten to 75 Nm (55 lb-ft).

39. NOTICE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.

NOTICE: Only use hand tools when installing the transmission support insulator nuts or damage to the transmission support insulator may occur.

Install the 2 new transmission support insulator nuts.

- Tighten to 115 Nm (85 lb-ft).





40. Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in).

- Tighten an additional 180 degrees.

41. Fill the engine with the correct motor oil for the climate. For additional information, refer to Engine Engine.

42. Install the body. For additional information, refer to Full Frame and Body Mounting Body.