Body On

Engine - Body On









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 can be removed, refer to Engine - Body Off Body Off.

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."

1. Clean the engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation of the engine.

2. 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.





3. NOTICE: During installation of the engine, the engine oil cooler will pass very close to the frame crossmember. Install the engine slowly, continually checking to make sure the engine oil cooler does not hit the frame crossmember, or component damage may occur.

NOTE: Use caution to make sure 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.

4. Install the 2 upper transmission bellhousing bolts.
- Tighten to 48 Nm (35 lb-ft).





5. Remove the transmission jack.

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: Transmission not shown for clarity.

Using 2 new O-rings install the engine oil indicator tube to the engine.





10. Position the ground strap to the LH side of the cowl and install the ground strap bolt.
- Tighten to 10 Nm (89 lb-in).





11. Position the 3 ground straps to the RH side of the firewall and install the 3 ground strap bolts.
- Tighten to 10 Nm (89 lb-in).





12. Connect the 2 engine wiring harness electrical connectors at the rear of the RH battery tray.





13. If equipped, connect the secondary generator electrical connector at the front of the RH battery tray.





14. Connect the RH positive battery cable clamp.
- Tighten to 7 Nm (62 lb-in).

- Connect the 2 battery cable retainers.





15. Connect the 2 positive power distribution cables and install the 2 nuts.
- Tighten to 9 Nm (80 lb-in).





16. Install the power distribution cover.





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





18. Install the PCM, the bracket, and the 2 nuts.
- Tighten to 7 Nm (62 lb-in).





19. Connect the 3 PCM electrical connectors and wiring harness retainers.





20. Install the crankcase vent oil separator. For additional information, refer to Engine Emission Control Service and Repair.

21. Remove the caps or plugs as needed. Using a new O-ring seal and gasket, position the evaporator-to-compressor suction tube fitting and install the nut.
- Tighten to 15 Nm (133 lb-in).





22. Install the Exhaust Gas Recirculation (EGR) cooler. For additional information, refer to Engine Emission Control Exhaust Gas Recirculation (EGR) Cooler.

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





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

- Tighten an additional 180 degrees.

25. Install the 9 transmission bellhousing bolts.
- Tighten to 48 Nm (35 lb-ft).





26. If necessary, install 2 new engine support insulator studs.
- Tighten to 80 Nm (59 lb-ft).

27. NOTICE: Failure to replace the engine support insulator nuts may result in engine support insulator damage.

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

Install the 4 new RH engine support insulator nuts.

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





28. NOTICE: Failure to replace the engine support insulator nuts may result in engine support insulator damage.

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

Install the 3 new LH engine support insulator nuts.

- Tighten to 200 Nm (148 lb-ft).





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

30. 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 2 new transmission support insulator nuts.

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





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





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





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





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

35. If equipped, connect the block heater cord.





36. NOTE: Position the turbocharger on the locating dowels before installation.

NOTE: The turbocharger is a tight fit between the cowl and the fuel rail supply tube. It is not necessary to remove the fuel rail supply tube.

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

Using a new gasket, install the turbocharger to the engine.

37. 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).





38. Connect the turbocharger actuator electrical connector and position the wiring harness heat shield back over the electrical connector.





39. Using a new O-ring, install the heater core inlet tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

- Connect the heater core inlet tube fitting.





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

Using a new gasket, install the LH turbocharger inlet pipe and the 3 new nuts.

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





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

Install a new LH turbocharger inlet pipe clamp.

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





42. Install the turbocharger downpipe and loosely install the 2 bolts to the turbocharger downpipe flange.





43. Loosely install the turbocharger downpipe bracket bolt.





44. Install a new turbocharger downpipe clamp.
- Tighten to 15 Nm (133 lb-in).





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





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





47. Install the RH fender splash shield. For additional information, refer to Front End Body Panels Fender Splash Shield.

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

Using a new gasket, install the RH turbocharger inlet pipe and the 3 new nuts.

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





49. Connect the Exhaust Pressure (EP) sensor electrical connector.
- Position the EP sensor electrical connector heat shield over the electrical connector.





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

Install a new RH turbocharger inlet pipe clamp.

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





51. 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.





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





53. NOTE: It may be necessary to rotate the locking collar to connect the oil separator hose to lower intake manifold.

Connect the oil separator hose to the lower intake manifold.





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





55. NOTE: The 2 upper bolts are shown, the 2 lower bolts are similar.

Using 2 new gaskets, install the EGR outlet pipe and the 4 bolts.

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





56. Connect the Exhaust Gas Recirculation Temperature (EGRT) electrical connector and wiring harness retainer.





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





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

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

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





59. 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.





60. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
- Connect the 2 wiring harness retainers.





61. Connect the lower radiator hose sections.





62. Connect the lower radiator hose retainers to the lower radiator support.





63. 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.





64. Install and connect the upper radiator hose.





65. Install the LH battery tray assembly and the 4 bolts.
- Tighten to 18 Nm (159 lb-in).





66. Connect the 2 coolant hoses to the coolant reservoir.





67. Connect the wiring harness retainer to the LH battery tray.





68. Connect the power steering return hose to the power steering pump.





69. Using 2 new O-rings, connect the power steering pressure tube to the power steering pump and install the power steering pressure tube bolt.
- Tighten to 12 Nm (106 lb-in).





70. Fill the power steering system. For additional information, refer to Steering System Power Steering System Filling.

71. Install the Charge Air Cooler (CAC) and the 2 mounting bolts.
- Tighten to 12 Nm (106 lb-in).





72. Install the LH battery. For additional information, refer to Battery, Mounting and Cables Battery and Battery Tray.

73. Connect the CAC outlet tube to the TB and connect the Charge Air Cooler Temperature (CACT) sensor.





74. Connect the 2 coolant hoses to the CAC.





75. Connect the CAC inlet tube to the turbocharger.





76. NOTE: Fan clutch has RH threads.

NOTE: Use torque conversion table quick link to determine torque wrench setting.

Using the Fan Clutch Nut Wrench and the Wrench, install the cooling fan and clutch.

- Calculate the correct torque wrench setting for the following torque.Refer to the Torque Wrench Adapter Formulas in the Appendix.

- Tighten to 133 Nm (98 lb-ft).





77. NOTE: The wiring harness bracket bolt is hidden behind the serpentine belt.

Install the cooling fan clutch wiring harness bracket bolt and connect the cooling fan clutch electrical connector.

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





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





79. Install the cooling module. For additional information, refer to Engine Cooling - Diesel Engine Cooling Module.

80. Connect the negative battery cables. For additional information, refer to Battery, Mounting and Cables Battery Disconnect / Connect.

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