Part 5

Engine


















Engine Upper










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head










Engine Front










Timing Drive Components










Lower Engine Block (View 1)










Lower Engine Block (View 2)









NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

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.

93. Install the 3 LH ignition coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).






94. Install the 3 RH ignition coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).






95. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
Using the Fuel Injector Brush, clean the fuel injector orifices.






96. NOTICE: Do not attempt to cut the lower Teflon(R) seal without first pulling it away from the fuel injector or damage to the injector may occur.

NOTE: Be very careful when removing the lower Teflon(R) seals, not to scratch, nick or gouge the fuel injectors.
Pull the Teflon(R) seal away from the injector with narrow tip pliers.






97. Carefully cut and remove the 6 lower fuel injector Teflon(R) seals.
- Discard the 6 lower fuel injector Teflon(R) seals.






98. NOTE: Do not lubricate the 6 new lower Teflon(R) fuel injector seals.

NOTE: The original lower Teflon(R) fuel injector seals may be either black or white. When installing new seals, always use the black Teflon(R) fuel injector seals.
Install the new Teflon(R) seals on the narrow end of the Arbor (part of the Fuel Injector Seal Installer), then install the Arbor on the fuel injector tips.






99. Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon(R) seals off of the Arbor and into the groove on the fuel injectors.





100. Place the Adjustment Ring (part of the Fuel Injector Seal Installer) beveled side first, over the fuel injector tip until it bottoms out against the fuel injector and turn 180 degrees.
- After one minute, turn the Adjustment Ring back 180 degrees and remove.






101. NOTICE: It is very important to note the routing of the fuel charge wiring harnesses on the fuel rails and index-mark the location of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct fuel charge wire harness routing and tie strap positioning for installation.

Install the fuel charge wire harnesses and tie straps to the index-marked locations on the fuel rails. Start by attaching the first tie strap farthest down the wire harness and continue to the connector end of the harness, leaving ample slack between the fuel injectors.






102. NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: To install, apply clean engine oil to the 6 new upper fuel injector O-ring seals only. Do not lubricate the lower fuel injector Teflon(R) seals.

NOTE: Inspect the fuel injector support disks and replace if necessary.
Install the 6 new upper fuel injector O-ring seals.






103. Install the 6 new fuel injector clips.





104. NOTE: RH shown, LH similar.

NOTE: The anti rotation device on the fuel injector has to slip into the groove of the fuel rail cup.
Install the 6 fuel injectors into the fuel rails and connect the 6 electrical connectors.






105. NOTICE: It is very important to visually inspect the routing of the wire harness to make sure that the wire harness will not be pinched or damaged between the fuel rail and the cylinder head during installation.

Install the 6 bolts and the RH fuel rail assembly.
- Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and then proceed inward.

- To install, tighten to 10 Nm (89 lb-in).

- Tighten an additional 45 degrees.






106. NOTICE: It is very important to visually inspect the routing of the wire harness to make sure that the wire harness will not be pinched and damaged between the fuel rail and the cylinder head during installation.

Install the 6 bolts and the LH fuel rail assembly.
- Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and proceed inward.

- To install, tighten to 10 Nm (89 lb-in).

- Tighten an additional 45 degrees.






107. NOTE: The cam lobe for the fuel injection pump must be at Bottom Dead Center (BDC) for the fuel injection pump installation.
Using the crankshaft pulley bolt, turn the crankshaft until the fuel injection pump cam lobe is at BDC (Bottom Dead Center).






108. NOTE: Valve cover is removed for clarity.

NOTE: Apply clean engine oil to the fuel injection pump mounting pedestal bore.
Install the fuel injection pump roller tappet.






109. NOTE: Apply clean engine oil to the fuel injection pump mounting plate seal.
Inspect the fuel injection pump mounting plate-to-valve cover gasket and replace if necessary.






110. NOTE: Apply clean engine oil to the fuel injection pump mounting plate O-ring seals.
Inspect the 2 fuel injection pump mounting plate O-ring seals and replace if necessary.






111. NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.
Install the fuel injection pump on the fuel injection pump mounting plate.






112. NOTE: Clean the fuel injection pump bolts and apply Thread Sealant with PTFE to the bolts.
Install the fuel injection pump and the 2 bolts finger-tight.

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

- Tighten an additional 45 degrees.






113. NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts.
Install the high-pressure fuel tube and tighten the 3 flare nuts in the following 3 stages.

- Stage 1: Tighten to 32 Nm (24 lb-ft).

- Stage 2: Wait 10 minutes to minimize pre-stress.

- Stage 3: Tighten to 32 Nm (24 lb-ft).






114. Install the high-pressure fuel tube bracket nut.
- Tighten to 8 Nm (71 lb-in).






115. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.

- Tighten the block heater to 40 Nm (30 lb-ft).