Part 4

Engine














Engine - External Components










Engine - Front and Upper Components










Engine - Lower Block Components









NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

106. Tighten the 2 high pressure fuel tube flare nuts in 2 stages.
- Stage 1: Tighten to 15 Nm (133 lb-in).

- Stage 2: Tighten an additional 30 degrees.






107. Tighten the 2 high pressure fuel tube bracket bolts to 10 Nm (89 lb-in).





108. Install the fuel injection pump insulator.
- Connect the fuel injection pump electrical connector.






109. Install the fuel rail insulator and the 2 pin-type retainers.





110. Install the fuel charge wiring harness and connect the 4 fuel injector electrical connectors.





111. Inspect and, if necessary, install a crankcase vent oil separator gasket.





112. Install the coolant bypass hose and the 2 clamps.
- Install the crankcase vent oil separator and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).







113. NOTICE: The forward KS (Knock Sensor) must be installed in the 6 o'clock position and the rearward KS (Knock Sensor) must be installed in the 3 o'clock position as shown in the graphic. Failure to follow these instructions may result in damage to the engine.

Install the 2 KS (Knock Sensor) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).

- Connect the 2 KS (Knock Sensor) electrical connectors.







114. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.






115. Position the intake manifold and attach the 2 KS (Knock Sensor) wiring harness retainers to the intake manifold.
- Connect the TB (Throttle Body) electrical connector and attach the wiring harness retainer to the TB (Throttle Body).

- Connect the PCV hose.






116. Install the intake manifold and the 5 bolts.
- Tighten in the sequence shown to 18 Nm (159 lb-in).






117. Connect the 2 vacuum hoses to the intake manifold.
- Attach the vacuum tube retainer to the intake manifold.






118. Connect the MAP (Manifold Absolute Pressure) sensor, the FRP (Fuel Rail Pressure) sensor and fuel charge harness electrical connectors.





119. Connect the 2 brake vacuum tube quick connect couplings.
- Insert the brake vacuum tube into the intake manifold quick connect fitting.






120. Install the EVAP (Evaporative Emission) canister purge valve and tube assembly.
- Connect the EVAP (Evaporative Emission) canister purge valve electrical connector.






121. Connect the EVAP (Evaporative Emission) tube quick connect coupling.
- Attach the 2 EVAP (Evaporative Emission) tube retainers.






122. Using a new gasket, install the oil filter adapter and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).

- Connect the EOP (Engine Oil Pressure) switch electrical connector.






123. Install the CAC (Charge Air Cooler) outlet tube and clamp.
- Tighten to 5 Nm (44 lb-in).

- Connect the EVAP (Evaporative Emission) tube quick connect coupling.

- Install the heater hose and clamp.

- Attach the heater hose retainer to the intake manifold.






124. NOTE: Lubricate the coolant pump O-ring seal with clean engine coolant prior to installation.
Using a new O-ring seal, install the coolant pump and the 3 bolts.

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


- Install the idler pulley and bracket assembly, the bolt and the nut.
- Tighten to 25 Nm (18 lb-ft).







125. Install the coolant pump pulley and the 3 bolts.
- Tighten to 20 Nm (177 lb-in).

- Install the power steering pump bracket and the 4 bolts.
- Tighten to 25 Nm (18 lb-in).

- Install the generator and the 3 bolts.
- Tighten to 25 Nm (18 lb-in).







126. Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-in).






127. Install the accessory drive belt, the accessory drive belt tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-in).






128. Install the RH halfshaft bracket and the 2 bolts.
- Tighten to 25 Nm (18 lb-in).






129. Connect the CKP (Crankshaft Position) sensor electrical connector.
- Attach the 2 wiring harness retainers.

- Install the ground strap and nut.
- Tighten to 9 Nm (80 lb-in).







130. Connect the CHT (Cylinder Head Temperature) sensor electrical connector and slide the insulator down.
- Attach the wiring harness retainer.

- Connect the ECT (Engine Coolant Temperature) sensor electrical connector.

- Install the ground wire and bolt.
- Tighten to 20 Nm (177 lb-in).







131. Install 4 new turbocharger-to-cylinder head studs.
- Tighten to 17 Nm (150 lb-in).

- Install a new turbocharger gasket.






132. Install the turbocharger and 4 new nuts.
- Tighten in the sequence shown to 50 Nm (37 lb-ft).






133. Install the turbocharger heat shield and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






134. NOTE: Do not reuse the turbocharger oil return tube/gaskets, new parts must be installed.
Using 2 new gaskets, install a new turbocharger oil return tube and the 4 bolts.

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






135. Install a new turbocharger oil filter.





136. NOTE: Do not reuse the turbocharger oil supply tube/gaskets, new parts must be installed.
Using 4 new gaskets, install a new turbocharger oil supply tube and the 2 banjo bolts.

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






137. Connect the 2 turbocharger control vacuum hoses and clamps.





138. Connect the 2 turbocharger control vacuum hoses and 2 electrical connectors.





139. Using 2 new gaskets, install the turbocharger coolant tube and the 2 banjo bolts.
- Tighten to 28 Nm (21 lb-ft).

- Connect the turbocharger coolant tube and the 2 clamps.






140. Install the turbocharger inlet tube, bolt and the stud bolt.
- Tighten to 5 Nm (44 lb-in).






141. Position the EVAP (Evaporative Emission) canister purge valve and install the engine appearance cover mounting stud.
- Tighten to 5 Nm (44 lb-in).






142. Tighten the turbocharger inlet tube clamp to 5 Nm (44 lb-in).





143. Install the turbocharger outlet tube and the 2 bolts.
- Tighten to 5 Nm (44 lb-in).






144. Tighten the turbocharger outlet tube clamp to 5 Nm (44 lb-in).





145. Remove the engine from the Engine Stand.

146. NOTE: Special bolts are used for installation. Do not use standard bolts.
Install the flexplate, the 6 new bolts and the Flywheel Holding Tool.

- Tighten in the sequence shown in 3 stages:
- Stage 1: Tighten to 50 Nm (37 lb-ft).

- Stage 2: Tighten to 80 Nm (50 lb-ft).

- Stage 3: Tighten to 112 Nm (83 lb-ft).