Installation

Installation
All vehicles





1. NOTE: The locating tabs on the gaskets must be up and toward the center of the engine, or a leak will occur.

Install the intake manifold gaskets and front module O-ring seal.





2. NOTE: To keep the EGR gasket in place when installing the manifold, apply a slight amount of all purpose grease to the mating surface of the EGR tube.

NOTE: Install the EGR cooler V-clamp loosely in place on the turbo adapter pipe.

Install the intake manifold and loosely install the bolts. Tighten the intake manifold bolts in the sequence shown.
1 Tighten bolts 9-16 to 11 Nm (8 ft. lbs.).
2 Tighten all bolts to 11 Nm (8 ft. lbs.) in the sequence shown.
3. Position the EGR cooler V-clamp over the EGR tube.





4. Tighten the gasket and the EGR cooler V-clamp.





5. If equipped, install the turbocharger heat shield and the nuts.





6. Slide the EGR cooler hose forward and rotate flat to lock.





7. Install the fuel line.
^ Install new sealing washers.
^ Install the fuel line.
^ Install the banjo fitting and the bolt.





8. Install the oil filter return tube and bolt.
^ On new oil filter return tubes, tighten to 6 Nm (53 inch lbs.).
^ On used oil filter return tubes, tighten to 3 Nm (27 inch lbs.).





9. Install the oil filter housing and the four bolts.
^ Clean and inspect the housing O-rings. Install new O-rings if necessary.





10. NOTE: Install new sealing washers on the banjo fitting.

Connect the fuel line fittings.





11. Position the fuel injector harness and install the retaining nut. Connect the eight fuel injectors electrical connectors.





12. Connect the exhaust pressure sensor electrical connector.





13. Connect the IAT2 sensor electrical connector.





14. Connect the Engine Coolant Temperature (ECT) sensor and the pin-type retainer.





15. If equipped, connect the EGR throttle position sensor electrical connector.





16. If equipped, connect the EGR throttle position control module electrical connector.





17. Connect the Engine Oil Temperature (EOT) sensor electrical connector.





18. Connect the Engine Oil Pressure (EOP) sensor electrical connector.





19. Connect the EGR valve electrical connector.





20. Connect the wiring retainer and IPR valve electrical connector. Position back the heat insulating wrap.





21. Install the top two bolts to the injector IPR heat shield.
22. Install the fuel injector control module.





23. Connect the engine coolant vent hose and clamp.





24. Connect the MAP sensor hose.





25. NOTE: Install a new O-ring on the heater hose tube.

Install the heater hose tube and bolts.





26. NOTE: Engine side shown, charge air cooler side similar.

Install the charge air cooler duct and tighten the clamp.
27. Install the turbocharger pedestal and turbocharger.





28. Tighten the nuts and bolts in the adapter pipe.





29. Install the generator and the three bolts.





30. Connect the generator B+ wire land electrical connector and position the boot back.

Vehicles with single generator





31. Install the accessory drive belt.

Vehicles with dual generators





32. Install the generator with mounting bracket and bolts.





33. Connect the B+ wire, generator electrical connector and wire retainer.





34. Install the accessory drive belt tensioner and bolts.





35. Position the accessory drive belt idler pulley. Install the bracket and bolts.





36. Install the accessory drive belt.





37. Install the accessory drive belt tensioner and bolt.





38. Install the accessory drive belt.

All vehicles





39. NOTE: Engine side shown, charge air cooler side similar.

Install the turbocharger-to-charge air cooler duct.





40. Install the upper radiator hose.
41. Install the degas bottle.
42. Install the auxiliary battery.
43. Install the cooling fan stator-6.0L diesel engine.