INSTALLATION




1. Make sure the crankshaft locking tool is in place.


2. Install the head gasket (1).
3. Install the cylinder head.


4. Install the cylinder head bolts in the illustrated pattern. Torque the bolts to 30 nm (22 lbs. ft.).
5. Repeat the pattern, turning the bolts an additional 85 degrees . Repeat the pattern twice more, turning 85 degrees each time for a total of 255 degrees .


6. Install the rocker arms (1) and hydraulic lifters (2). Make sure to return the lifters and arms to their original position.

NOTE: Observe the position marks on the cylinder head and camshaft cap. Always replace the camshaft cap to its original location.


7. Install the camshaft caps.


8. Loosely install the camshaft bolts finger tight.


9. Make sure that the timing dimples on the back of the camshaft gears are lined up horizontally.

NOTE: The engine is not in time with the camshaft dots facing each other. The camshafts are in time with each other. The camshafts are set so that the dots face each other, and then the camshaft locking tool ensures that the camshafts are properly positioned at 90 degrees ATDC.


10. Install the camshaft locking tool.


11. The camshaft bolts have 3 different bolt sizes.
12. Put a thin bead of Loctite 510 (or equivalent) on the front camshaft cap (the cap that are secured by bolts “b”).


13. Following the illustrated pattern, torque the camshaft cap bolts to 11 Nm (98 lbs. in.).


14. Install the intake camshaft oil seal.


15. Install the camshaft sprocket cover.
16. Install the camshaft sprocket (2). Torque the bolt to 64 Nm (47 lbs. ft.)
17. Install the exhaust camshaft oil seal (1).


18. Install the inner front cover. Torque the bolts to 11 Nm (97 lbs. in.).

NOTE: The crankshaft sprocket bolt is a L.H. thread.


19. Install the crankshaft sprocket. Torque the bolt to 64 Nm (45 Lbs. ft.).
20. Install the timing belt. (Refer to 9 - ENGINE/VALVE TIMING/TMNG BELT/CHAIN TENSIONER&PULLEY - ADJUSTMENTS)


21. Install the lower front cover. Torque the bolts to 11 Nm (97 lbs. in.).


22. Install the crankshaft damper. Torque the bolt to 32 Nm (23 lbs. ft.).


23. Install the upper front cover. torque the bolts to 11 nm (97 lbs. in.).


24. Install the idler pulley bracket (1) and torque the bolts to 45 nm (33 lbs. ft.).


25. Install the front engine lifting bracket and toque the bolts to 45 nm (33 lbs. ft.).


26. Install the CMP. Torque the SMP sensor bolt to 11 Nm (97 lbs. in.).
27. Connect the CMP.


28. Install the fuel injectors. Torque the fuel injector bolts to 33 Nm (24 lbs. ft.).
29. Connect the fuel injectors.


30. Install the vacuum line to the vacuum pump.
31. Install the vacuum line (2) to the camshaft cover.
32. Install the exhaust manifold gasket (3).


33. Install the exhaust manifold using the above sequence. Torque the bolts to 35 nm (29 lbs. ft.)


34. Install the turbocharge oil lines to the engine block. Torque the bolt to 32 Nm (23 lbs. ft.).


35. Install the turbocharger nuts and torque to 32 Nm (23 lbs. ft.).
36. Install the turbocharger oil feed line. Torque the oil feed line bolt to 24 Nm (18 lbs. ft.).


37. Install the turbocharger oil return line. Torque the oil return line bolts to 15 Nm (133 lbs. in.).


38. Connect the turbocharger module.


39. Install the intake manifold gasket.


40. Install the intake manifold.
41. Install the intake manifold bolts. Torque the intake manifold bolts to 36 Nm (26 lbs. ft.).


42. Install the glow plugs. Torque the glow plugs to 14 Nm (124 lbs. in.).
43. Position and connect the glow plug harness.


44. Install the fuel rail. Torque the fuel rail nuts to 24 Nm (18 lbs. ft.)
45. Loosely install the fuel lines (3) onto the fuel injectors and the fuel rail.
46. Torque the fuel lines at the fuel rail to 20 Nm (177 lbs. in.).
47. Torque the fuel lines at the fuel injectors to 28 Nm (20 lbs. in.).
48. Loosely install the high pressure fuel feed line to the high pressure pump and the fuel rail.
49. Torque the high pressure fuel line at the fuel rail to 20 Nm (15 lbs. ft.).
50. Torque the high pressure fuel line at the fuel pump to 28 Nm (20 lbs. ft.)
51. Install the high pressure fuel line bracket bolt and torque to 15 Nm (133 lbs. in.).
52. Connect the fuel rail solenoid (2).
53. Connect the fuel rail pressure sensor.


54. Install the generator bracket. Torque the bolts to 45 Nm (33 lbs. ft.).
55. Install the generator. Torque the bolts to 33 Nm (24 lbs. ft.)
56. Connect the generator connectors (4).
57. Connect the generator feed wire (3).


58. Connect the Baro sensor (1).
59. Install the Baro sensor.
60. Install the generator brace bolt (2).
61. Install the throttle plate assembly.


62. Install the thermostat housing.


63. Connect the coolant lines from the thermostat housing.


64. Install the EGR cooler. Torque the bolts to 11 nm (97 lbs. in.)
65. Install the EGR cooler coolant lines.
66. Install the fuel block.


67. Connect the fuel return lines.


68. Install the high pressure fuel feed line (2).
69. Install the generator brace bolt (1).


70. Install the charge air cooler inlet hose.


71. Install the charge air cooler outlet hose.


72. Install the accessory drive belt.
73. Install the intake air housing.
74. Fill the cooling system.
75. Connect the battery.