Part 3
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".
91. NOTICE: To prevent engine damage, always install 4 new bolts when installing the crankshaft pulley.
NOTE: Use the Strap Wrench to prevent the engine from turning while tightening the bolts.
Position the crankshaft pulley and install 4 new bolts. Tighten in 2 stages, in the sequence shown.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
92. Using new gaskets, install the coolant crossover manifold assembly and 5 bolts.
- Finger-tighten the bolts.
93. NOTE: Inspect the thermostat seal for tears, nicks or cuts. Replace if necessary.
Install the thermostat, thermostat housing and 3 bolts.
- Finger-tighten the bolts.
94. Tighten the 5 coolant crossover bolts and the 3 thermostat housing bolts.
- Tighten to 10 Nm (89 lb-in).
95. Position the RH fuel rail and loosely install the 2 bolts.
96. Position the LH fuel rail and loosely install the 2 bolts.
97. NOTE: LH side shown, other connectors similar.
Position the fuel rail supply tube assembly. Hand start the 6 fuel rail supply tube assembly connectors.
98. NOTE: Only 1 fuel injector supply tube shown.
Install the 8 fuel injector supply tubes.
- Start from front to rear of engine.
- Hand start only.
99. Install the 5 fuel rail supply tube assembly bolts.
- Hand start only.
100. NOTE: LH side shown, RH side similar.
Tighten the 4 fuel rail bolts.
- Tighten to 24 Nm (18 lb-ft).
101. Tighten the 4 LH fuel injector supply tubes in the sequence shown.
- Tighten to 20 Nm (177 lb-in).
102. Tighten the 4 RH fuel injector supply tubes in the sequence shown.
- Tighten to 20 Nm (177 lb-in).
103. Tighten the 6 fuel rail supply tube assembly connectors in the sequence shown.
- Tighten to 20 Nm (177 lb-in).
104. Tighten the 4 LH fuel injector supply tubes in the sequence shown.
- Tighten to 35 Nm (26 lb-ft).
105. Tighten the 4 RH fuel injector supply tubes in the sequence shown.
- Tighten to 35 Nm (26 lb-ft).
106. Tighten the 6 fuel rail supply tube assembly connectors in the sequence shown.
- Tighten to 35 Nm (26 lb-ft).
107. Tighten the 2 fuel rail supply tube connectors at the high-pressure fuel injection pump.
- Tighten to 40 Nm (30 lb-ft).
108. Tighten the 5 fuel rail supply tube assembly bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
109. 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.
110. 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.
111. 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).
112. Install the turbocharger coolant tube.
113. Install the secondary fuel filter assembly and 3 bolts.
- Tighten to 10 Nm (89 lb-in).
114. NOTE: Only 2 bolts shown.
Using new gaskets, install the crankcase vent oil separator and 4 bolts.
- Tighten to 10 Nm (89 lb-in).
115. 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).
116. Install the fuel injection pump supply tube assembly stud bolt.
- Tighten to 10 Nm (89 lb-in).
117. Install the 2 fuel injection pump supply tube assembly bolts.
- Tighten to 10 Nm (89 lb-in).
118. 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.
119. Connect the fuel injection pump hose to the fuel rail.
120. Install the power steering pump mounting bracket and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).
121. Position the engine wire harness over the engine. Connect the 2 retainers and install the bolt.
- Tighten to 10 Nm (89 lb-in).
122. NOTE: Only one retainer shown.
Connect the 6 retainers to the fuel supply manifolds.
123. Position the engine wire harness on the LH valve cover and connect the 3 wire retainers.
124. NOTE: Only one fuel injector and glow plug electrical connector shown.
Connect the 8 fuel injectors and the 8 glow plug electrical connectors.
125. NOTE: Only one wire retainer shown.
Connect the CKP (Crankshaft Position) sensor electrical connector and the 3 wire retainers.
126. Install the cylinder block opening cover.
127. Connect the fuel pressure control valve electrical connector.
128. Connect the Fuel Rail Pressure (FRP) sensor electrical connector and 2 retainers.
129. Connect the fuel pressure switch and the fuel temperature sensor electrical connectors. Connect the wire retainer.
130. Connect the Engine Coolant Temperature (ECT) sensor electrical connector and wire retainer.
131. Connect the turbocharger wastegate control valve vacuum and electrical connector.
132. Connect the vacuum hose retainer to the secondary fuel filter stud.
133. Connect the fuel volume control valve electrical connector.
134. Connect the Camshaft Position (CMP) sensor electrical connector and the 3 pin type retainers.
135. Install the lower intake manifold and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).
136. NOTE: It may be necessary to rotate the locking collar to connect the oil separator hose to the lower intake.
Connect the crankcase vent oil separator hose to the lower intake manifold. Connect the crankcase vent oil separator outlet hose sensor electrical connector.
