Part 3

Engine



















Engine Upper











Engine Upper - LH Cylinder Head











Engine Upper - RH Cylinder Head











Engine Front

NOTE: Early build shown, late build similar.













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: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

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. For additional information, refer to Engine.

104. Install the 6 new fuel injector clips.





105. 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.





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 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.





107. 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.





108. 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.





109. 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.





110. 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.





111. 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.





112. 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.





113. NOTE: Clean the fuel injection pump bolts and apply Thread Sealant with PTFE to the bolts.

NOTE: Start the fuel injection pump bolts by hand then simultaneously tighten to specifications.

Install the fuel injection pump and the 2 bolts.

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

- Tighten an additional 45 degrees.





114. Connect the high pressure fuel tube flare nut to the fuel injection pump. Connect the 2 high pressure fuel tube flare nuts to the fuel rails.
- Tighten to 30 Nm (22 lb-ft).





Late build vehicles

115. Install the bolt for the high pressure fuel tube to the LH cylinder head and connect the Fuel Rail Pressure (FRP) sensor electrical connector.
- Tighten to 6 Nm (53 lb-in).





Early build vehicles

116. Install the nut for the high pressure fuel tube to the LH valve cover stud bolt and connect the FRP sensor electrical connector.
- Tighten to 6 Nm (53 lb-in).





All vehicles

117. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten to 40 Nm (30 lb-ft).





118. Install the LH cylinder block drain plug.
- Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.





119. Attach the wiring harness retainer to the rear of the LH cylinder head.





120. Install the cover and the pin-type retainer.





121. Install the turbocharger coolant tube assembly and the bolt.
- Tighten to 10 Nm (89 lb-in).





122. Install the RH engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).





123. Install 8 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).





124. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Install a new gasket, RH exhaust manifold and 8 new nuts. Tighten in 2 stages in the sequence shown:

- Stage 1: Tighten to 15 Nm (133 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).





125. Install the oil supply tube filter, washer and bolt.

1. Install a new oil supply tube filter in the oil supply tube block.

2. Slide the new washer onto the oil supply tube block.

3. Install the banjo bolt into the oil supply tube block.





126. Install the RH turbocharger oil supply tube.
- Tighten the bolt to 35 Nm (26 lb-ft).





127. Install a new gasket, the turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.
- Tighten to 45 Nm (33 lb-ft).





128. Install the upper RH turbocharger-to-cylinder block bracket and the 3 bolts and position the bracket as far clockwise as possible and tighten the bolts in the following sequence:

1. Tighten the lower bolt to 26 Nm (19 lb-ft).

2. Tighten the upper bolt to 26 Nm (19 lb-ft).

3. Tighten the turbocharger bolt to 19 Nm (168 lb-in).





129. Using 2 new sealing washers, install the 2 RH turbocharger coolant tubes and banjo bolts.
- Tighten to 40 Nm (30 lb-ft).





130. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

Install the RH oil supply tube into the quick connect fitting.





131. Install the RH oil supply tube secondary latch.





132. NOTE: Lubricate the cylinder block bore with clean engine oil.

Using 2 new O-ring seals, install the RH turbocharger oil return tube in the cylinder block.





133. Install a new gasket and the RH turbocharger oil return tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





134. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.

Connect the turbocharger wastegate regulating valve hose to the RH turbocharger assembly.





135. NOTE: Make sure the heat shield does not contact the wastegate arm.

Install the 2 upper RH exhaust manifold heat shield and the 5 bolts.

- Tighten to 14 Nm (124 lb-in).





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





137. Connect the CKP sensor electrical connector.





138. Install the wiring harness grommet.





139. Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).





140. Install the heat shield and the nut.
- Tighten to 10 Nm (89 lb-in).





141. Install the LH turbocharger coolant tube bracket-to-cylinder head nut.
- Tighten to 10 Nm (89 lb-in).





142. Install 8 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).





143. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Install a new gasket, LH exhaust manifold and turbocharger assembly and 8 new nuts. Tighten the nuts in 2 stages in the sequence shown:

- Stage 1: Tighten to 15 Nm (133 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).





144. Install a new gasket the LH turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.
- Tighten to 45 Nm (33 lb-ft).





145. Install the oil supply tube filter, washer and bolt.

1. Install a new oil supply tube filter in the oil supply tube block.

2. Slide the new washer onto the oil supply tube block.

3. Install the bolt into the oil supply tube block.





146. Install the LH turbocharger oil supply tube.
- Tighten the bolt to 35 Nm (26 lb-ft).





147. Install the upper turbocharger bracket-to-cylinder block and the 2 bolts.
- Do not tighten the bolts at this time.





148. Install the lower turbocharger-to-cylinder block bracket and the 2 bolts.
- Do not tighten the bolts at this time.





NOTICE: The next 4 steps must be performed in order or damage to the turbocharger may occur.

149. Tighten the upper turbocharger bracket-to-turbocharger bolt.
- Tighten to 19 Nm (168 lb-in).





150. Tighten the upper turbocharger bracket-to-cylinder block bolt.
- Tighten to 25 Nm (18 lb-ft).





151. Tighten the lower turbocharger bracket-to-turbocharger bolt.
- Tighten to 19 Nm (168 lb-in).





152. Tighten the lower turbocharger bracket-to-cylinder block bolt.
- Tighten to 11 Nm (97 lb-in).





153. Using 2 new sealing washers, install the 2 LH turbocharger coolant tubes and the banjo bolts.
- Tighten to 40 Nm (30 lb-ft).





154. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

Install the LH oil supply tube into the quick connect fitting.





155. Install the LH oil supply tube secondary latch.





156. NOTE: Lubricate the oil pan bore with clean engine oil.

Using 2 new O-ring seals, install the LH turbocharger oil return tube in the oil pan.