Part 6

Engine


















Engine Upper










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head










Engine Front










Timing Drive Components










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: 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.

171. Connect the turbocharger wastegate regulating valve electrical connector.





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





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





174. Connect the KS (Knock Sensor) sensor electrical connector.





175. Install the oil level indicator.





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

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





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

Install the EOP (Engine Oil Pressure) switch.

- To install, tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.






179. Using a new gasket, install the oil filter adapter and the 3 bolts.
- Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.






180. Connect the EOP (Engine Oil Pressure) electrical connector.
- Attach the EOP (Engine Oil Pressure) wiring harness retainer to the engine block.






181. 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).






182. Connect the generator electrical connector.





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






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






185. Attach the CMS (Catalyst Monitor Sensor) electrical connector to the A/C compressor bracket.





186. Connect the LH camshaft VCT (Variable Camshaft Timing) solenoid electrical connector.





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





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





189. Install the PCV tube and connect the 2 quick connect couplings.





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





191. 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 (Charge Air Cooler) tube nut to the intake manifold.
- Tighten to 6 Nm (53 lb-in).






192. 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).






193. 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).






194. NOTE: Align the index marks for the RH CAC (Charge Air Cooler) tube.

Install the RH CAC (Charge Air Cooler) tube to the RH turbocharger and tighten the clamp.

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






195. Connect the RH turbocharger bypass valve electrical connector.





196. 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).






197. Install the turbocharger wastegate regulating valve hoses to the turbocharger wastegate regulating valve and to the RH CAC (Charge Air Cooler) tube.





198. Connect the LH turbocharger bypass valve electrical connector.





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





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






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





202. 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).






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





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





205. Using the Floor Crane and Spreader Bar, remove the engine from the stand.





206. 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.






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





208. Install the crankshaft sensor ring.





209. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.

Install the flexplate and the 8 bolts.

- Tighten in the sequence shown to 80 Nm (59 lb-ft).