Part 2

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".


46. Using the Rear Crank Seal Installer, install the new rear crankshaft seal.





47. Position the crankshaft drive flats level to aid in installing the engine front cover.





48. NOTICE: Failure to properly align the engine front cover to the oil pan rail may result in engine damage.

NOTICE: Use care when installing the engine front cover not to scratch the crankshaft sealing surface.

NOTE: Use the Gauge Bar to align the bottom of the engine front cover to the oil pan rail prior to torquing the engine front cover.
Using new gaskets, install the new engine front cover and 14 bolts.
- Support the oil pump gerotor assembly in the engine front cover bore.

- Position the engine front cover assembly over the crankshaft without contacting the front sealing surface.

- Align the oil pump gerotor assembly with the crankshaft drive flats.

- Align the engine front cover assembly locating pin.

- Slide the front cover assembly over the crankshaft post to the cylinder block sealing surface.

- Hand start bolt numbers 1 and 2.

- Using the Gauge Bar, align the bottom of the engine front cover to the oil pan rail.

- Install the remaining engine front cover bolts. Tighten in the sequence shown.
- Tighten to 24 Nm (18 lb-ft).






49. As a post-check, use the Gauge Bar and Feeler Gauge Set and verify the alignment of the engine front cover to the oil pan rail is within 0.25 mm (0.009 in).
- If the engine front cover is not within specifications, loosen the bolts and repeat step 48.


50. NOTICE: Failure to install the front crankshaft seal with the part numbers facing out may result in engine damage.

NOTE: Do not discard the installation sleeve provided with the front crankshaft seal. It is used for installation of the front 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 seal and crankshaft sealing surface.
Position the installation sleeve onto the crankshaft, slide the new front crankshaft seal over the installation sleeve onto the crankshaft.
- Remove the installation sleeve.






51. Position the new front crankshaft slinger on the crankshaft.





52. Using the Front Crank Seal Installer, install a new front crankshaft seal and front crankshaft slinger.





53. Install a new upper oil pan gasket. Apply a dime-sized bead of sealant at the 4 cover joints.





54. NOTE: Final torque must be reached within 30 minutes of sealant application.
Install the upper oil pan and 25 bolts. Tighten in 2 stages, in the sequence shown.

- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 24 Nm (18 lb-ft).






55. Using a new gasket, install the oil filter adapter, 4 bolts and stud bolt.
- Tighten to 10 Nm (89 lb-in).






56. NOTICE: In the event of catastrophic engine failure, always install a new oil cooler assembly. Foreign material cannot be removed from the oil cooler and engine damage may occur.

Using new gaskets, install the oil cooler assembly and 7 bolts.
- Tighten finger-tight.






57. NOTICE: Failure to tighten the oil cooler nut first may result in oil cooler damage or leaks.

NOTE: On late build vehicles the internal nut is no longer on the oil cooler.
If equipped, install the oil cooler nut.
- Tighten to 24 Nm (18 lb-ft).






58. Tighten the 7 oil cooler bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).






59. NOTE: Use care when installing the hose on the oil cooler, damage to the oil cooler may occur during installation.
Install the oil cooler outlet hose assembly and connect the hose retainer.






60. On late build vehicles, apply a 3.4 mm (0.133 in) diameter bead of sealant 1.0 mm (0.039 in) outward of the chamfer on the lower oil pan sealing face.





61. NOTE: On early build vehicles, install a new gasket.
Install the lower oil pan and the 15 bolts. Tighten in the sequence shown.

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







62. NOTICE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original positions.

NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.

NOTE: Apply clean engine oil to the valve tappet bores prior to installing the valve tappets.

NOTE: Only one cylinder shown.
Apply clean engine oil to the 16 valve tappets and install into the valve tappet bores.






63. NOTE: Only one cylinder shown.
Install the 8 valve tappet guides.

- Verify that the retainer is fully seated.






64. NOTE: Only one cylinder head dowel shown.
Install the 4 new cylinder head dowels into the cylinder block.






65. NOTE: LH side shown, RH side similar.
Position the 2 new cylinder head gaskets onto the cylinder block.






66. NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: Inspect the cylinder heads. Make sure the cylinder heads are free of corrosion, cracks, damage, foreign material and the coolant ports are open.

NOTE: RH cylinder head shown, LH cylinder head similar.
Install the cylinder heads.






67. NOTICE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and result in poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads may affect the true torque value of the bolts.

NOTE: LH cylinder head shown, RH cylinder head similar.

NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
Install 36 new M12 cylinder head bolts and 9 M8 cylinder head bolts.
- Tighten finger-tight.






68. Tighten the LH cylinder head bolts in 8 stages, in the sequence shown.
- Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).

- Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).

- Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).

- Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).

- Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.

- Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.

- Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.

- Stage 8: Tighten bolts 19 through 23 to 30 Nm (22 lb-ft).






69. Tighten the RH cylinder head bolts in 8 stages, in the sequence shown.
- Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).

- Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).

- Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).

- Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).

- Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.

- Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.

- Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.

- Stage 8: Tighten bolts 19 through 22 to 30 Nm (22 lb-ft).






70. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.

NOTE: Only one cylinder shown.
Install the 32 push rods.
- Verify the push rod socket is engaged on the hydraulic lash adjuster.






71. NOTE: Apply clean engine oil to the push rod ball end prior to installing the rocker arm assembly.

NOTE: Apply clean engine oil to each rocker arm pivot ball prior to installing the rocker arm assembly.

NOTE: Verify the push rod socket is on the hydraulic lash adjuster prior to installing the rocker arm assembly.
Install the RH rocker arm assemblies in the following sequence.
1. Position the crankshaft with the cylinder number No. 1 approximately 155 degrees after Top Dead Center (TDC) by observing the crankshaft pulley dowel pin and clocking it to the 3:40 position (as viewed from the front of the engine).

2. Determine which cylinder is actually in the firing position by observing the push rods for the No. 1 exhaust push rods should be raised 1.0 mm (0.039 in) and No. 4 exhaust push rods should be raised 1.5 mm (0.059 in). If the push rods are not in the correct position, rotate the engine one revolution clockwise (360 degrees).

3. Install the rocker arm assemblies for the RH cylinder head (cylinder numbers 1, 2, 3 and 4). Tighten in 5 stages, in the sequence shown.
- Stage 1: Verify the top of the push rod engages the socket on each rocker arm.

- Stage 2: Tighten to 4 Nm (35 lb-in).

- Stage 3: Tighten to 8 Nm (71 lb-in).

- Stage 4: Tighten to 13 Nm (115 lb-in).

- Stage 5: Tighten a second time to 13 Nm (115 lb-in).

- Repeat Stage 5, if any fastener moves more than 5 degrees in Stage 5.






72. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.

If necessary, install a new O-ring seal on the RH oil spray bar. Install the RH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the RH oil spray bar nuts can be tightened.
- Tighten to 11 Nm (98 lb-in).






73. NOTE: Apply clean engine oil to each rocker arm pivot ball prior to installing the rocker arm assembly.

NOTE: Verify the push rod socket is on the hydraulic lash adjuster prior to installing the rocker arm assembly.
Install the LH rocker arm assemblies in the following sequence.
1. Rotate the crankshaft with the one revolution clockwise (360 degrees) to 155 degrees after TDC (Top Dead Center) by observing the crankshaft pulley dowel pin and clocking it to the 3:40 position (as viewed from the front of the engine).

2. Install the rocker arm assemblies for the LH cylinder head (cylinder numbers 5, 6, 7 and 8). Tighten in 5 stages, in the sequence shown.
- Stage 1: Verify the top of the push rod engages the socket on each rocker arm.

- Stage 2: Tighten to 4 Nm (35 lb-in).

- Stage 3: Tighten to 8 Nm (71 lb-in).

- Stage 4: Tighten to 13 Nm (115 lb-in).

- Stage 5: Tighten a second time to 13 Nm (115 lb-in).

- Repeat Stage 5, if any fastener moves more than 5 degrees in Stage 5.






74. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.

If necessary, install a new O-ring seal on the LH oil spray bar. Install the LH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the LH oil spray bar nuts can be tightened.
- Tighten to 11 Nm (98 lb-in).






75. NOTICE: Failure to install the fuel injectors during the valve cover installation may result in engine failure.

NOTE: The valve cover will have to be tightened a second time after the fuel injectors are installed.
Using a new valve cover gasket, install the RH valve cover, 2 stud bolts and 16 bolts. Tighten in the sequence shown.
- Tighten to 12 Nm (108 lb-in).







76. NOTICE: Failure to install the fuel injectors during the valve cover installation may result in engine failure.

NOTE: The valve cover will have to be tightened a second time after the fuel injectors are installed.
Using a new valve cover gasket, install the LH valve cover, 3 stud bolts and 15 bolts. Tighten in the sequence shown.
- Tighten to 12 Nm (108 lb-in).






77. NOTE: Do not apply engine oil to the fuel injectors.

NOTE: Only one fuel injector shown.

NOTE: If the fuel injector is being reused, make sure to install it in the original location.
Install a new copper combustion gasket, O-ring seal and fuel injector return fuel O-ring on the 8 fuel injectors.
- Position the 8 fuel injectors into the engine.






78. NOTICE: Failure to tighten the fuel injector correctly can lead to engine failure.

NOTE: Apply clean engine oil to the concave surface of the fuel injector hold-down clamp.
Install the 8 fuel injector hold-down clamps and 8 new fuel injector bolts. Tighten in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).

- Stage 2: Tighten an additional 90 degrees.






79. Final tighten the LH valve cover bolts in the sequence shown.
- Tighten to 12 Nm (108 lb-in).






80. Final tighten the RH valve cover bolts in the sequence shown.
- Tighten to 12 Nm (108 lb-in).







81. NOTE: Only one glow plug shown.
Install the 8 glow plugs.

- Tighten to 11 Nm (97 lb-in).






82. Install the new exhaust manifold stud(s) as needed.
- Tighten to 13 Nm (115 lb-in).






83. Using a new gasket, install the RH exhaust manifold, 8 spacers and 8 new nuts. Tighten the nuts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 30 Nm (22 lb-ft).

- Stage 3: Tighten a second time to 30 Nm (22 lb-ft).






84. Using a new gasket, install the LH exhaust manifold, 8 spacers and 8 new nuts. Tighten the nuts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 30 Nm (22 lb-ft).

- Stage 3: Tighten a second time to 30 Nm (22 lb-ft).






85. Install the RH exhaust manifold heat shield and 5 bolts.
- Tighten to 10 Nm (89 lb-in).






86. Install the LH exhaust manifold heat shield and 4 bolts.
- Tighten to 10 Nm (89 lb-in).






87. NOTICE: Do not use magnetic screwdrivers or other magnetic tools around the Crankshaft Position (CKP) sensor and the crankshaft sensor pulse ring or damage to the components may occur.

Install the Crankshaft Position (CKP) sensor and bolt.
- Tighten to 10 Nm (89 lb-in).






88. Install the crankshaft sensor pulse ring.





89. Install the flexplate and 10 new bolts. Tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 100 Nm (74 lb-ft).






90. Using a new gasket, install the vacuum pump and 4 bolts.
- Tighten to 10 Nm (89 lb-in).