Part 4

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.

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





158. 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 LH turbocharger assembly.





159. Install LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).





160. Connect the LH CMP sensor electrical connector.





161. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.





162. Install the radio capacitor and the bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).





163. Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).





164. Connect the RH CMP sensor electrical connector.





165. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

166. Connect the 3 RH ignition coil-on-plug electrical connectors.





167. Connect the RH VCT solenoid electrical connector and attach the 2 wiring harness retainers.





168. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Make sure the fuel rail wiring harnesses are routed correct.

NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.

Using new intake manifold, coolant crossover and thermostat housing gaskets, install the intake manifold and the 12 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





169. Connect the 2 turbocharger coolant hoses to the intake manifold.





170. Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt.
- Tighten to 10 Nm (89 lb-in).





171. Attach the 2 wire harness-to-intake manifold retainers.





172. Connect the turbocharger wastegate regulating valve electrical connector.





173. Connect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.





174. Connect and attach the 2 fuel injector wiring harness electrical connectors.





175. Connect the KS sensor electrical connector.





176. Install the oil level indicator.





177. Attach all the wiring harness retainers to the LH valve cover and stud bolts.

178. Connect the 3 LH ignition coil-on-plug electrical connectors.





179. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.

Install the EOP switch.

- Tighten to 18 Nm (159 lb-in).





180. Using a new gasket, install the oil filter adapter and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





181. Connect the EOP electrical connector.
- Attach the EOP wiring harness retainer to the engine block.





182. Install the stud, generator and the nut and bolt.
- Tighten the stud to 8 Nm (71 lb-in).

- Tighten the nut and bolt to 47 Nm (35 lb-ft).





183. Connect the generator electrical connector.





184. Connect the generator B+ cable and install the nut.
- Tighten to 17 Nm (150 lb-in).





185. Connect the A/C compressor electrical connector.
- Attach the wiring harness retainer from the to the A/C stud bolt.





186. Attach the CMS electrical connector to the A/C compressor bracket.





187. Connect the LH camshaft VCT solenoid electrical connector.





188. Connect the Throttle Position (TP) sensor and electronic Throttle Body (TB) electrical connectors.





189. Connect the electrical connector and install the noise insulator shield for the fuel injection pump.





190. If equipped, connect the 2 heated PCV electrical connectors.





191. Install the PCV tube and connect the 2 quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction.





192. Install the lower radiator hose to the thermostat housing.





193. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.
Install the RH Charge Air Cooler (CAC) tube and turbocharger intake tube as an assembly and install the RH CAC tube nut to the intake manifold.
- Tighten to 6 Nm (53 lb-in).





194. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Install the RH turbocharger intake tube nut.

- Tighten to 6 Nm (53 lb-in).





195. NOTE: Align the index marks for the RH turbocharger intake pipe.

Install the RH turbocharger intake pipe to the RH turbocharger and tighten the clamp.

- Tighten to 5 Nm (44 lb-in).





196. NOTE: Align the index marks for the RH CAC tube.
Install the RH CAC tube to the RH turbocharger and tighten the clamp.
- Tighten to 5 Nm (44 lb-in).





197. Connect the RH turbocharger bypass valve electrical connector.





198. NOTE: Align the index marks for the LH turbocharger intake tube.

Install the LH turbocharger intake tube to the LH turbocharger and tighten the clamp.

- Tighten to 5 Nm (44 lb-in).





199. Install the turbocharger wastegate regulating valve hoses to the turbocharger wastegate regulating valve and to the RH CAC tube.





200. Connect the LH turbocharger bypass valve electrical connector.





201. Connect the brake vacuum tube to the intake manifold.





202. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).





203. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.





204. Using a new O-ring seal and gasket seal, connect the A/C tube to the compressor and install the nut.
- Tighten to 15 Nm (133 lb-in).





205. If equipped, connect the block heater electrical connector and install the heat shield.





206. Install the Engine Lift Eye on the LH cylinder head.





207. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.





208. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.





209. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.





210. Install the crankshaft sensor ring.





211. Install the flexplate and the 8 bolts.
- Tighten to 80 Nm (59 lb-ft).