Part 1
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 (Gross Vehicle Weight Rating) 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 should not be installed at this time. For additional information, refer to Engine - 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".
1. If removed, install a new cylinder block zero clearance patch on the engine.
2. If removed, install the turbocharger alignment dowels.
3. If removed, install the block heater.
- Tighten to 41 Nm (30 lb-ft).
4. NOTE: Only one pipe plug show.
If removed, install the pipe plugs.
- Refer to Specifications for the correct torque specification for each pipe plug.
5. Install the high-pressure fuel injection pump mounting bolts and front cover roll pin.
- Tighten to 48 Nm (35 lb-ft).
6. NOTE: Only one piston cooling tube shown.
NOTE: Apply clean engine oil to the outside of the piston cooling tubes prior to installation.
Install the 8 piston cooling tubes and 8 bolts.
- Tighten to 10 Nm (89 lb-in).
7. NOTICE: If the camshaft is being replaced, the camshaft bearings have to be replaced and machined by a machine shop. Failure to follow this may result in engine damage.
NOTICE: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage may occur.
NOTICE: Use the slide hammer as a handle for the camshaft. Using the slide hammer as intended may result in engine damage.
NOTE: Use care when installing the camshaft, the camshaft will slide out the other end of the cylinder block.
NOTE: Apply clean engine oil to the camshaft prior to installing.
Using the Camshaft Remover/Installer and the Slide Hammer, install the camshaft.
8. NOTE: Apply clean engine oil to both sides of the camshaft thrust plate prior to installing.
Install the camshaft thrust plate and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
9. NOTE: Use a suitable tool in the top camshaft gear hole to prevent the camshaft from turning. Make sure the suitable tool is secured against the cylinder block prior to tightening the camshaft bolt.
Install the camshaft gear and bolt. Tighten in 2 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 50 degrees.
10. NOTICE: The crankshaft bearings are tangless and must be positioned in the center of the bearing cap or engine damage may occur.
NOTE: Verify there is no debris in the saddles in the cylinder block or main bearing caps.
NOTE: Apply clean engine oil to the upper crankshaft bearing prior to installing the crankshaft.
Install the 5 new upper crankshaft main bearings into the cylinder block.
11. Position the camshaft with the 2 timing marks pointing up.
12. NOTE: Apply clean engine oil to the crankshaft bearing journals prior to installing.
Install the crankshaft into the cylinder block, aligning the with the 2 timing marks.
13. Verify the timing marks are properly aligned.
14. NOTE: Apply clean engine oil to the thrust faces of the crankshaft prior to installing the upper crankshaft main bearing thrust washers.
NOTE: Assemble the grooved side of the upper crankshaft main bearing thrust washer toward the crankshaft thrust surface.
Push the crankshaft rearward and install the upper crankshaft main bearing thrust washer to the rear of the number 5 bulkhead.
15. NOTE: Apply clean engine oil to the thrust faces of the crankshaft prior to installing the upper crankshaft main bearing thrust washer.
NOTE: Assemble the grooved side of the thrust washer toward the crankshaft thrust surface.
Push the crankshaft forward and install the upper crankshaft main bearing thrust washer to the front of the number 5 bulkhead.
16. NOTICE: The crankshaft bearings are tangless and must be positioned in the center of the bearing cap or engine damage may occur.
NOTE: Assemble the grooved side of the lower crankshaft main bearing thrust washer toward the crankshaft thrust surface.
NOTE: The thrust washer tang will be positioned in a groove.
NOTE: Only one upper bearing shown.
Install the 5 new lower crankshaft main bearings into the crankshaft main bearing caps. Position the lower crankshaft main bearing thrust washer on the number 5 crankshaft main bearing cap.
17. Position commercially available plastigage in the center of each main bearing cap.
18. NOTE: Apply clean engine oil to the lower crankshaft main bearing thrust washer and to the rear face of number 5 crankshaft main bearing cap. Align the tab on the thrust washer with the slot in the number 5 main bearing cap.
NOTE: Apply clean engine oil to the lower crankshaft main bearings.
NOTE: Do not use the bolts to seat the crankshaft main bearing caps.
Install the 5 crankshaft main bearing caps into the cylinder block.
19. NOTE: Lightly lubricate the main bearing cap bolt threads and flanges with clean engine oil.
Loosely install the 20 crankshaft main bearing cap bolts and 10 crankshaft main bearing cap side bolts. Tighten the crankshaft main bearing cap bolts in 7 stages, in the sequence shown:
- Stage 1: Snug all the bolts.
- Stage 2: Tighten bolts 1 through 20 to 20 Nm (177 lb-in).
- Stage 3: Tighten bolts 1 through 10 to 80 Nm (59 lb-ft).
- Stage 4: Tighten bolts 11 through 20 to 160 Nm (118 lb-ft).
- Stage 5: Tighten bolts 1 through 20 an additional 90 degrees.
- Stage 6: Tighten bolts 21 through 30 to 40 Nm (30 lb-ft).
- Stage 7: Tighten bolts 21 through 30 an additional 90 degrees.
20. NOTE: RH side shown, LH side similar.
Remove the 10 crankshaft main bearing cap side bolts.
21. Remove the 20 crankshaft main bearing cap bolts.
22. Remove the 5 crankshaft main bearing caps from the cylinder block.
23. Measure the clearances for the crankshaft main bearing cap and compare to Specifications. For additional information, refer to Specifications.
- Remove and discard the plastigage.
24. NOTE: Apply clean engine oil to the lower crankshaft main bearing thrust washer and to the rear face of number 5 crankshaft main bearing cap. Align the tab on the thrust washer with the slot in the number 5 main bearing cap.
NOTE: Apply clean engine oil to the lower crankshaft main bearings.
NOTE: Do not use the bolts to seat the crankshaft main bearing caps.
Install the 5 crankshaft main bearing caps into the cylinder block.
25. Loosely install the 20 crankshaft main bearing cap bolts and 10 crankshaft main bearing cap side bolts. Tighten the crankshaft main bearing cap bolts in 3 stages, in the sequence shown:
- Stage 1: Snug all the bolts.
- Stage 2: Tighten bolts 1 through 20 to 20 Nm (177 lb-in).
- Stage 3: Back off the number 9 and 10 bolts.
26. Push the crankshaft forward and the number 5 crankshaft main bearing cap rearward to align the crankshaft rear thrust washers.
- Continue to hold the crankshaft forward and the number 5 crankshaft main bearing cap rearward against the crankshaft thrust surface while tightening the outer bolts 9 and 10 on the crankshaft main bearing cap.
- Tighten to 20 Nm (177 lb-in).
27. Tighten the crankshaft main bearing cap bolts in 5 stages, in the sequence shown:
- Stage 1: Tighten bolts 1 through 10 to 80 Nm (59 lb-ft).
- Stage 2: Tighten bolts 11 through 20 to 160 Nm (118 lb-ft).
- Stage 3: Tighten bolts 1 through 20 an additional 90 degrees.
- Stage 4: Tighten bolts 21 through 30 to 40 Nm (30 lb-ft).
- Stage 5: Tighten bolts 21 through 30 an additional 90 degrees.
28. Using the Dial Indicator Gauge with Holding Fixture, measure the crankshaft end play. For additional information, refer to Specifications.
29. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play. For additional information, refer to Specifications.
30. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft gear backlash. For additional information, refer to Specifications.
31. NOTE: Apply clean engine oil to the O-ring seal prior to installation.
Using a new O-ring seal, install the high-pressure fuel injection pump and the 3 high-pressure fuel injection pump spacers.
- Tighten to 24 Nm (18 lb-ft).
32. Install the fuel rail supply tube bracket and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
33. NOTE: The crankshaft gear contains a single timing mark. The camshaft contains a single timing mark. The high-pressure fuel injection pump drive gear contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft drive gear is aligned with the double mark on the camshaft gear, and the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear. Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.
Install the high-pressure fuel injection pump drive gear and nut.
- Tighten to 80 Nm (59 lb-ft).
- Verify the timing marks are aligned.
34. Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure fuel injection pump drive gear backlash.
35. NOTICE: The connecting rods are powdered metal cracked rods. Make sure the connecting rod and cap are installed as a set or engine damage may occur.
NOTICE: The connecting rod bearings are tangless and must be positioned in the center of the bearing cap or engine damage may occur.
NOTE: Only one piston assembly shown.
NOTE: The dark bearing is the upper connecting rod bearing. The bright aluminum bearing is the lower connecting rod bearing.
Install the new connecting rod bearings.
36. NOTICE: Make sure the piston ring openings are 120 degrees from each other or engine damage may occur.
Install the piston rings as follows:
1. The top compression ring is identified with a orange stripe on the running surface.
2. The intermediate ring is identified with yellow stripe on the running surface. Install the ring with the under cut to the bottom.
3. Install the oil control ring. Make sure the oil ring gap is 180 degrees from the spring wire latch.
37. NOTE: Install the piston assembly with the arrow toward the front of the engine.
NOTE: Use care when installing the piston assembly to not damage the piston cooling tubes. If the tube is bent during installation of the piston assembly, install a new piston cooling tube.
NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.
Install the connecting rod and piston assemblies.
1. Coat the inside diameter of the Piston Ring Compressor with clean engine oil.
2. Insert the piston into the Piston Ring Compressor. Position the piston, connecting rod and Piston Ring Compressor into the cylinder bore.
- Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.
38. Position a piece of plastigage across the bearing surface.
39. NOTICE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage may occur.
NOTE: Lubricate the connecting rod bearings with clean engine oil prior to installation.
NOTE: Only one connecting rod cap shown.
Position the connecting rod cap and install the 2 bolts. Tighten in 2 stages:
- Stage 1: Tighten to 45 Nm (33 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
40. Remove the 2 bolts and the connecting rod cap.
41. Measure the clearances for the connecting rod cap and compare to Specifications. For additional information, refer to Specifications.
- Remove and discard the plastigage.
42. NOTICE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage may occur.
NOTE: Lubricate the connecting rod bearings with clean engine oil prior to installation.
NOTE: Only one connecting rod cap shown.
Position connecting rod caps and install the 2 bolts. Tighten in 2 stages:
- Stage 1: Tighten to 45 Nm (33 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
43. Using a Feeler Gauge Set, check the connecting rod side clearance. For additional information, refer to Specifications.
44. NOTICE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.
Using a new gasket, install the engine rear cover and the 10 bolts. Tighten in 2 stages, in the sequence shown.
- Stage 1: Tighten bolts 1-9 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolt 10 to 48 Nm (35 lb-ft).
45. NOTICE: Failure to install the rear crankshaft seal with the part numbers facing out may result in engine damage.
NOTICE: Do not use grease or petroleum jelly instead of oil. Failure to follow this may result in rear crankshaft seal leakage.
NOTE: Do not discard the installation sleeve provided with the rear crankshaft seal. It is used for installation of the rear crankshaft seal.
NOTE: Check for correct orientation of the installation sleeve prior to sliding the seal on the crankshaft.
NOTE: Apply clean engine oil to the outer diameter of the crankshaft seal and crankshaft sealing surface.
Position the installation sleeve onto the crankshaft, slide the new rear crankshaft seal over the installation sleeve onto the crankshaft.
- Remove the installation sleeve.
