Part 5

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.

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).