Steps 61-99

61. NOTE: Install oil pump drive rotors with marks pointing outward.

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





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

Install the oil pump body and the bolts.





63. NOTE: Apply High Strength Threadlocker to the outer circumference of the leading edge of the crankshaft.

NOTE: The seal and wear sleeve must not be separated.

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





64. CAUTION: To prevent engine damage, always install four new bolts when installing the vibration damper.

NOTE: Do not use anti-seize compounds, grease or any lubricants. Lubricants have an adverse effect on the torque results.

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.





65. If equipped, install the dual generator pulley and bolts.





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

Install the coolant pump and bolts.





67. Install the coolant pump pulley and the bolts.





68. Install the RH high-pressure oil rail-to-valve cover gasket.





69. CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.

Install the RH valve cover.
^ Install the gasket.
^ Install the valve cover.
^ Install the bolts and stud bolts.
70. Cover the LH cylinder head with an appropriate covering.





71. Install the eight glow plugs.





72. NOTE: Clean and apply clean engine oil to the O-ring seals.

Using the special tool, install the glow plug harness.





73. CAUTION: To prevent engine damage, use only approved pump cover seal. Substitution can cause damage to the pump cover.

Install a new O-ring seal on the high-pressure oil pump.





74. Install the high-pressure tube assembly.





75. Install new lower O-ring seals.





76. Install the high-pressure pump and bolts.





77. Tighten the bolts for the high-pressure tube assembly.





78. Install a new press-in-place gasket in the high-pressure pump cover.





79. Clean the cover mounting surface and apply sealer at the seams.





80. CAUTION: To prevent engine damage, the high-pressure oil pump cover must be firmly seated on the O-ring seal to prevent cracking the cover plate.

NOTE: Apply clean engine oil to the high-pressure oil pump O-ring seal prior to installing the high-pressure pump cover.

Install the high-pressure oil pump cover and eight bolts.





81. Install the IPR valve.





82. Install the heat insulating wrap and fasten the snap.





83. Install the turbocharger heat shield and bolts.





84. Install the oil pump inlet strainer.





85. CAUTION: In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.

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





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





87. 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.





88. Install a new O-ring seal in the oil filter base.





89. Install the oil filter adapter and bolts.





90. Install the serpentine belt idler and bolt.





91. If equipped, install the belt tensioner and bolts.





92. NOTE: Install new sealing washers.

Install the left cylinder head fuel line.





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

Install the thermostat housing and the stud bolts.





94. Position back the fuel bracket and install the retaining nut.





95. Install the RH motor mount plate and bolts.





96. Install the special tools.





97. Install the special tool.
98. Install the lifting crane and remove the engine from the engine stand.





99. Install the flexplate and the new 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.