Part 2

Engine Continued





49. Install the high pressure oil line.

Left Side:

50. Install the left exhaust manifold and the bolts.

Right Side:

51. Install the right exhaust manifold and the bolts.





52. Apply a bead of sealant at the back seam of the upper and lower crankcase.





53. Install the rear engine cover.
^ Install the press-in-place gasket.
^ Install the rear engine cover.
^ Install the bolts.





54. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly. Apply a bead of threadlock around the circumference of the outer rear edge of the secondary crankshaft flange.

Using the special tools, install the crankshaft rear oil seal.





55. Install the flywheel adapter.





56. Apply a bead of sealant at the front seam of the upper and lower crankcase.





57. Install the guide bolts and the front cover gasket.





58. Install the engine front cover and bolts.





59. NOTE: Install gears with marks pointing outward.

Lubricate inner gear with a suitable lithium assembly grease and install onto crankshaft. Lubricate outer gear with lithium assembly grease and mesh with inner gear rotor in oil pump housing. Wipe off excess assembly grease.





60. NOTE: Install a new O-ring seal.

Install the gerotor cover and the bolts.





61. NOTE: Apply threadlock to the outer circumference of the leading edge of the crankshaft. The seal and wear sleeve must not be separated.

Using the special tool, install the oil seal and wear sleeve assembly.





62. NOTE: New bolts must always be installed.

Install the crankshaft vibration damper and bolts.
^ Tighten the bolts in the sequence shown.
^ Tighten the bolts to 68 Nm (50 ft. lbs.).
^ Tighten the bolts an additional 90 degrees.





63. NOTE: Install a new O-ring on the coolant pump.

Install the coolant pump and bolts.





64. Install the coolant pump pulley and the bolts.





65. NOTE: Left side shown; right side similar.

Install the valve covers.
^ Install the gaskets.
^ Install the valve covers.
^ Install the bolts and stud bolts.





66. Install the eight glow plugs.





67. NOTE: Left side shown, right side similar. Inspect the buss bar O-rings and replace as needed. Apply clean engine oil to the O-rings.

Install the glow plug buss bar.





68. Install a new O-ring seal.





69. Install the high-pressure oil pump and the bolts.





70. Install the high-pressure pump O-ring seal.





71. Install the oil discharge pipe and the bolts.





72. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.





73. Install a new D-ring seal on the high-pressure discharge pipe.





74. Clean the cover mounting surface and apply sealant at the seams.





75. Install the high-pressure pump cover.
^ Install the press-in-place gasket.
^ Install the high pressure pump cover.
^ Install the bolts.





76. Install the turbocharger heat shield and bolts.





77. Install the oil pump inlet strainer.





78. Install the oil cooler assembly.
^ Install the gasket.
^ Install the oil cooler assembly.
^ Install the bolts.





79. Install the oil filter base.
^ Install the gasket.
^ Install the oil filter base.
^ Install the bolts.





80. Install the Exhaust Gas Recirculation (EGR) cooler coolant supply port cover.
^ Install the gasket.
^ Install the EGR cooler coolant supply port cover.
^ Install the bolts.





81. install new O-ring in the oil filter base.





82. Install the belt idler and bolt.





83. Install the belt tensioner and bolts.





84. NOTE: Install new sealing washers.

Install the left cylinder head fuel line.





85. Install the fuel lines and bracket bolt.





86. NOTE: Install a new O-ring on the thermostat.

Install the thermostat housing, the bolt and the stud bolt.





87. Position the exhaust backpressure assembly and install the retaining nut.





88. Tighten the exhaust backpressure tube at the exhaust manifold.





89. NOTE: Install a new O-ring on the oil indicator and tube.

Install the oil level indicator tube and nut.





90. Install the glow plug mounting bracket and the nuts.





91. NOTE: Left side shown; right side similar.

Install the LH and RH motor mounts and bolts.





92. Install the starter and the three bolts.





93. Install the special tool.





94. Install the special tool.
95. Install the lifting crane and remove the engine from the engine stand.





96. Install the flexplate flywheel and the bolts.
^ Tighten the bolts in the following sequence.
^ Tighten all bolts to 5 Nm (44 inch lbs.).
^ Tighten all bolts to 94 Nm (69 ft. lbs.) in the sequence shown.