Engine Mechanical - 6.6L (Unit Repair): Removal & Installation Chevrolet Silverado 2500

Crankshaft Balancer Removal

Tools Required

J 44643 Flywheel Hold Tool

Scheme 857

1. Install J 44643 to lock the flywheel.
2. Remove the crankshaft balancer bolt.
3. Remove the crankshaft balancer.

Engine Flywheel Removal (Automatic Transmission)

Tools Required

J 44643 Flywheel Hold Tool

Scheme 858

1. Remove the flywheel mounting bolts and discard.
2. Remove the flywheel washer.
3. Remove the J 44643 .
4. Remove the flywheel assembly.

Engine Flywheel Removal (Manual Transmission)

Tools Required

J 44643 Flywheel Hold Tool

Scheme 859

Scheme 860

Scheme 861

1. Install the J 44643 to the starter opening in order to hold the flywheel. Important: The dual mass flywheel may require re-indexing in order to access the flywheel to crankshaft bolts through the secondary ring of the flywheel. Important: Do not use the clutch pressure plate bolts. Use a bolt of the correct thread and a length that protrudes enough to use a pry bar.
2. Install two bolts into the clutch pressure plate mounting holes 180 degrees apart.
3. Using a long pry bar, turn the secondary ring of the dual mass flywheel clockwise until the flywheel mounting bolts can be accessed. It may require to turn the secondary ring past the bolt holes in order to compensate the spring tension.
4. Remove the flywheel mounting bolts and discard.
5. Remove the J 44643 . CAUTION: When removing or Installing the flywheel wear protective gloves. The teeth on the ring gear may be very sharp and may cut you.
6. Remove the flywheel.

Crankshaft Rear Oil Seal Removal

Tools Required

J 44641 Crankshaft Rear Oil Seal Remover

Scheme 862

1. Install the J 44641 to the crankshaft rear oil seal.
2. Remove the crankshaft rear oil seal using J 44641 .

Scheme 863

Scheme 864

Scheme 865

1. Remove the exhaust outlet heat shield bolts.
2. Remove the exhaust outlet heat shield.
3. Remove the exhaust outlet to right exhaust pipe bracket bolt.
4. Remove the exhaust outlet bolts and nuts in the proper sequence.
5. Remove the exhaust outlet and gasket.

Scheme 866

Scheme 867

Scheme 868

1. Remove the left exhaust pipe heat shield bolts.
2. Remove the left exhaust pipe heat shield.
3. Remove the exhaust pipe bolts in the proper sequence.
4. Remove the exhaust pipe and gaskets.

Scheme 869

Scheme 870

Scheme 871

Scheme 872

1. Remove the exhaust pipe bolts (Federal Emissions) in the proper sequence.
2. Remove the exhaust pipe bolts (California Emissions) in the proper sequence.
3. Remove the exhaust pipe, exhaust outlet bracket and gaskets (Federal Emissions).
4. Remove the exhaust pipe, exhaust outlet bracket and gaskets (California Emissions).

Oil Pan Removal - Lower

Tools Required

J 37228 Seal Cutter

Scheme 873

Scheme 874

1. Disconnect the oil level sensor.
2. Remove the lower oil pan bolts and nuts. Important: Do not damage the sealing surfaces when separating the lower oil pan from the upper oil pan.
3. Separate the lower oil pan from the upper oil pan using J 37228 .
4. Remove the lower oil pan.

Oil Pan Removal - Upper

Tools Required

J 37228 Seal Cutter

Scheme 875

Scheme 876

Scheme 877

1. Remove the oil level indicator tube bracket bolt.
2. Remove the oil level indicator tube.
3. Remove the two oil pan to flywheel housing bolts (denoted by black triangles).
4. Remove the 24 upper oil pan bolts using a long bit 6 mm hex driver.
5. Separate the upper oil pan from the engine block using J 37228 .
6. Remove the upper oil pan.

Engine Flywheel Housing Removal

Tools Required

J 37228 Seal Cutter

Scheme 878

Scheme 879

Scheme 880

Scheme 881

1. Remove the turbocharger oil return pipe nuts from the top of the flywheel housing.
2. Remove the turbocharger oil return pipe studs.
3. Remove the oil cooler adapter nuts.
4. Remove the oil cooler adapter studs.
5. Remove the flywheel housing bolts (denoted by a black circle).
6. Separate the flywheel housing from the cylinder block using J 37228 .
7. Remove the flywheel housing.
8. Remove the turbocharger oil return pipe gasket from the flywheel housing.
9. Remove the oil cooler adapter bolts.
10. Remove the oil cooler adapter with gaskets (1, 2).

Scheme 882

After the flywheel housing has been removed, mount the engine block to a suitable engine stand.

Scheme 883

Scheme 884

1. Disconnect the camshaft position sensor connector.
2. Remove the cooling fan pulley bolts and nuts.
3. Remove the cooling fan pulley and insulator pad.
4. Remove the camshaft position sensor retaining bolt.
5. Remove the camshaft position sensor.

Scheme 885

1. Remove the power steering pump mounting bracket bolts.
2. Remove the power steering pump mounting bracket.

Scheme 886

Scheme 887

Scheme 888

Scheme 889

1. Remove the crankcase ventilation hoses from the valve rocker arm covers.
2. Disconnect the crankcase vent hose from the engine block.
3. Remove the fuel injection control module harness bracket nuts (1).
4. Remove the fuel injection control module harness bracket (2).
5. Remove the Schrader valve (3).
6. Remove the Schrader valve bracket (4).
7. Remove the right idler pulley retaining bolt.
8. Remove the right idler pulley.
9. Remove the left idler pulley bolt.
10. Remove the left idler pulley.
11. Remove the tensioner pulley bolt.
12. Remove the tensioner pulley.
13. Remove the vacuum pump nuts - California Emissions.
14. Remove the vacuum pump - California Emissions.
15. Remove the drive belt tensioner and generator mounting bracket bolts.
16. Remove the drive belt tensioner and generator mounting bracket.

Scheme 890

1. Remove the fuel hoses.
2. Disconnect the fuel filter assembly connectors.
3. Remove the fuel filter bracket bolts.
4. Remove the fuel filter assembly.

Scheme 891

Scheme 892

Scheme 893

Scheme 894

Scheme 895

Scheme 896

Scheme 897

Scheme 898

Scheme 899

Scheme 900

Scheme 901

1. Disconnect the four injector harness connectors.
2. Disconnect the turbocharger boost sensor connector.
3. Disconnect the fuel injection control module connectors.
4. Disconnect the engine coolant temperature sensor connector.
5. Disconnect the crankshaft position sensor connector.
6. Remove the two engine block ground bolts from the right front side of the engine.
7. Remove the main engine harness connector hold down bolts (1, 2).
8. Remove the main engine harness connectors.
9. Remove the turbocharger coolant inlet hose from the turbocharger.
10. Remove the water outlet bolts.
11. Remove the water outlet.
12. Remove the O-ring from the water outlet and discard.
13. Disconnect the fuel rail pressure regulator valve connector.
14. Disconnect the fuel injection control module harness to the oil level sensor harness connector.
15. Disconnect the barometric pressure sensor connector.
16. Disconnect the fuel temperature sensor connector.
17. Disconnect the 3 fuel injector control module harness to glow plug controller connectors.
18. Remove the fuel injection control module harness assembly.
19. Remove the main engine harness connector bracket bolts.
20. Remove the main engine harness connector bracket.

Scheme 902

Scheme 903

1. Remove the eye bolts (4) and washers from the cooling hoses (3).
2. Remove the fuel injection control module bolts (5).
3. Remove the fuel injection control module (6) with mounting insulators (2).
4. Remove the fuel injection control module bracket bolts.
5. Remove the fuel injection control module bracket.

Scheme 904

Scheme 905

Scheme 906

1. Remove the exhaust manifold heat shield bolts.
2. Remove the exhaust manifold heat shield.
3. Remove the left exhaust manifold bolts and nuts in the proper sequence.
4. Remove the left exhaust manifold and gasket.

Scheme 907

Scheme 908

Scheme 909

1. Remove the exhaust manifold heat shield bolts.
2. Remove the exhaust manifold heat shield.
3. Remove the right exhaust manifold bolts and nuts in the proper sequence.
4. Remove the right exhaust manifold and gasket.

Scheme 910

Scheme 911

Scheme 912

Scheme 913

1. Remove the intake air heater connector.
2. Remove the glow plug harness bracket bolt.
3. Remove the glow plug harness nut from the left cylinder bank.
4. Remove the glow plug power feed wires from both cylinder banks.
5. Remove the glow plug controller nuts.
6. Remove the glow plug controller.
7. Remove the glow plug harness nuts from the left cylinder bank.
8. Remove the glow plug harness from the left cylinder bank - 1 California, 2 Federal.
9. Remove the glow plugs from the left cylinder bank.
10. Remove the glow plug harness nuts from the right cylinder bank.
11. Remove the glow plug harness from the right cylinder bank - 1 California, 2 Federal.
12. Remove the glow plugs from the right cylinder bank.

Scheme 914

Scheme 915

Scheme 916

Scheme 917

Scheme 918

1. Remove the turbocharger upper heat shield bolts.
2. Remove the turbocharger upper heat shield.
3. Remove the eye bolt and washers from the oil supply hose at the top of the turbocharger.
4. Loosen the hose clamp and remove the turbocharger cooling outlet hose.
5. Remove the turbocharger mounting bolts.
6. Remove the turbocharger assembly with the oil return pipe.
7. Remove the turbocharger lower heat shield from engine block.
8. Remove the turbocharger oil supply hose eye bolt and washers.
9. Remove the turbocharger oil supply hose.

Oil Fill Tube Removal

1. Remove the oil fill tube to thermostat housing bolt.
2. Remove the oil fill tube to engine front cover bolt.
3. Remove the oil fill tube.
4. Remove the O-ring and discard.

Scheme 919

Scheme 920

Scheme 921

Scheme 922

Scheme 923

Scheme 924

1. Remove the thermostat cover bolts.
2. Remove the thermostat cover.
3. Remove the thermostats with seals.
4. Remove the heater pipe to thermostat housing bolt.
5. Remove the heater pipe.
6. Remove the heater pipe O-ring and discard.
7. Remove the fuel pipe to thermostat housing bracket bolt.
8. Remove the thermostat housing bolts and nuts from the left cylinder head.
9. Remove the thermostat housing bolts and nuts from the right cylinder head.
10. Remove the bypass pipe to water pump bolts.
11. Loosen hose clamp and remove the turbocharger coolant outlet hose from the bypass pipe.
12. Remove the thermostat housing with the bypass pipe.
13. Remove the bypass pipe to water pump O-ring and discard.
14. Remove the bypass pipe from the thermostat housing.
15. Remove the O-ring from the bypass pipe and discard.
16. Remove the turbocharger coolant outlet pipe bracket bolts.
17. Remove the turbocharger coolant outlet pipe.
18. Disconnect the oil pressure sensor connector.
19. Remove the ground bolt from the left side of the block.
20. Remove the oil level sensor harness.

Scheme 925

Scheme 926

Scheme 927

Scheme 928

Scheme 929

Scheme 930

Scheme 931

Scheme 932

Scheme 933

Scheme 934

1. Remove the fuel return hose and clamp from the fuel injection pump.
2. Remove the fuel injection pump high pressure line from the fuel injection pump.
3. Remove the fuel inlet hose from the fuel injection pump.
4. Remove the fuel inlet distribution block bolt and nut.
5. Remove the fuel inlet distribution block from the fuel return distribution block.
6. Remove the fuel inlet to fuel return line clamp bolt.
7. Remove the fuel inlet to fuel return line clamp.
8. Remove the function block nuts.
9. Remove the fuel inlet pipe assembly.
10. Remove the left fuel rail high pressure line (1).
11. Remove the left cylinder head return line eye bolt and gasket (2).
12. Remove the right fuel rail high pressure line (1).
13. Remove the right cylinder head return line eye bolt and gasket (2)
14. Remove the fuel return line clamp bolt and clamp.
15. Remove the fuel pressure limiting valve bracket nut.
16. Remove the fuel pipes and function block assembly.
17. Remove the anti-rotation locks from the left bank injection pipes.
18. Remove the injection pipes from the left bank.
19. Remove the anti-rotation locks from the right bank injection pipes.
20. Remove the injection pipes from the right bank.
21. Remove the left fuel rail mounting bolts.
22. Remove the left fuel rail.
23. Remove the right fuel rail mounting bolts.
24. Remove the right fuel rail.

Scheme 935

Scheme 936

1. Remove the turbocharger boost sensor bracket bolt.
2. Remove the turbocharger boost sensor with bracket.
3. Remove intake air heater and gasket.
4. Remove the intake manifold tube bolts and nuts.
5. Remove the intake manifold tube.
6. Remove the intake manifold tube gaskets.

Scheme 937

Scheme 938

Scheme 939

1. Remove the turbocharger boost sensor bracket bolt.
2. Remove the turbocharger boost sensor with bracket.
3. Remove the intake air heater and gasket.
4. Remove the EGR cooling hose clamps.
5. Remove the EGR cooling hose.
6. Remove the EGR bolts and nuts.
7. Remove the EGR cooler bracket bolts.
8. Remove the EGR cooler bracket.
9. Remove the EGR and cooler.
10. Remove the intake manifold tube bolts and nuts.
11. Remove the intake manifold tube.
12. Remove the intake manifold tube gaskets.

Intake Manifold Removal - Left

Tools Required

J 37228 Seal Cutter

Scheme 940

1. Remove the left intake manifold bolts and nuts. Do not forget to remove the bolt inside the intake manifold tube.
2. Separate the intake manifold from the cylinder head using J 37228 .
3. Remove the left intake manifold.

Intake Manifold Removal - Right

Tools Required

J 37228 Seal Cutter

Scheme 941

1. Remove the right intake manifold bolts and nuts. Do not forget to remove the bolt inside the intake manifold tube.
2. Separate the intake manifold from the cylinder head using J 37228 .
3. Remove the right intake manifold.

Valve Rocker Arm Cover Removal - Upper Left

Tools Required

J 37228 Seal Cutter

Scheme 942

1. Remove the left upper valve rocker arm cover screws.
2. Separate the upper valve rocker arm cover from the lower valve rocker arm cover using J 37228 .
3. Remove the left upper valve rocker arm cover.

Valve Rocker Arm Cover Removal - Upper Right

Tools Required

J 37228 Seal Cutter

Scheme 943

1. Remove the right upper valve rocker arm cover screws.
2. Separate the upper valve rocker arm cover from the lower valve rocker arm cover using J 37228 .
3. Remove the right upper valve rocker arm cover.

Scheme 944

Scheme 945

1. Remove the injector harness bracket bolts for both injector harnesses.
2. Loosen the encapsulated injector terminal nuts on each injector.
3. Remove both injector harnesses.
4. Remove the left lower valve rocker arm cover screws.
5. Remove the left lower valve rocker arm cover.
6. Remove the left lower valve rocker arm cover gasket.

Scheme 946

Scheme 947

1. Remove the injector harness bracket bolts for both injector harnesses.
2. Loosen the encapsulated injector terminal nuts on each injector.
3. Remove both injector harnesses.
4. Remove the right lower valve rocker arm cover screws with insulators.
5. Remove the lower valve rocker arm cover.
6. Remove the lower valve rocker arm cover gasket.

Fuel Injectors Removal

Tools Required

J 44639 Injector Removal Tool

Scheme 948

Scheme 949

Scheme 950

Scheme 951

1. Remove the fuel injector return pipe eye bolts and gaskets.
2. Remove the fuel injector return pipe assembly.
3. Remove the fuel injector bracket bolts.
4. Install the J 44639 to the fuel injector brackets.
5. Pull back on the J 44639 in one steady motion, until the fuel injector breaks free from its seat.
6. Remove the J 44639 .
7. Remove the fuel injectors with the fuel injector brackets.
8. Remove the injector bracket pins.
9. Remove the copper washer from the injector bore and discard.
10. Remove the O-ring from the injector and discard.

Fuel Injector Sleeve Removal

Tools Required

J 45910 Fuel Injector Sleeve Remover/Installer

Scheme 952

Scheme 953

Scheme 954

Scheme 955

Scheme 956

Scheme 957

1. Install J 45910 into the fuel injector sleeve.
2. Tighten the nut while holding J 45910 .
3. Install J 45910-2 over J 45910-1 which are both part of kit J 45910 , and add the washer and nut.
4. Hold J 45910 while turning the nut to remove the fuel injector sleeve.
5. Remove J 45910 with the fuel injector sleeve.
6. Remove the O-rings (1).

Scheme 958

Scheme 959

1. Loosen the valve clearance lock nuts on each rocker arm.
2. Loosen the valve clearance adjusting screw on each rocker arm to relieve tension on the valve train.
3. Remove the rocker arm shaft assembly bolts in the proper sequence.
4. Remove the rocker arm shaft assembly from the cylinder head.
5. Remove the valve bridge pins.
6. Remove the valve bridges.
7. Remove the pushrods.

Cylinder Head Removal - Left

1. Remove the cylinder head bolts in the proper sequence.
2. Discard the large M12 bolts.
3. Remove the left cylinder head assembly.
4. Remove the left cylinder head gasket.

Scheme 960

1. Remove the cylinder head bolts in the proper sequence.
2. Discard the large M12 bolts.
3. Remove the right cylinder head assembly.
4. Remove the right cylinder head gasket.

Valve Lifter Removal

1. Loosen the valve lifter guide hold down bracket bolts.
2. Remove the valve lifter guide hold down brackets.
3. Remove the valve lifter guides.
4. Remove the valve lifters.

Scheme 961

1. Remove the four fuel injection pump bolts.
2. Remove the fuel injection pump.

Scheme 962

Scheme 963

1. Remove the engine coolant pipe to water pump nuts.
2. Remove the water pump bolts.
3. Remove the water pump assembly.
4. Remove the water pump seal and discard.
5. Remove the engine coolant pipe gasket and discard.

Scheme 964

1. Remove the engine coolant pipe.
2. Remove the engine coolant pipe O-ring and discard.
3. Remove the five oil filter adapter and oil cooler assembly bolts (1).
4. Remove the oil filter adapter and oil cooler assembly.

Crankshaft Front Oil Seal Removal

Tools Required

J 44644 Crankshaft Front Oil Seal Remover

Scheme 965

1. Install the J 44644 to the crankshaft front oil seal.
2. Remove crankshaft front oil seal using J 44644 .

Engine Front Cover Removal

Tools Required

J 37228 Seal Cutter

Scheme 966

Scheme 967

1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
3. Remove the crankshaft position sensor spacer bolts.
4. Remove the crankshaft position sensor spacer.
5. Remove the O-rings from the crankshaft position sensor and spacer and discard.
6. Remove the engine front cover bolts.
7. Separate the engine front cover from the cylinder block using J 37228 .
8. Remove the engine front cover.

Scheme 968

1. Remove the oil pump pipe and screen assembly bolts and nuts.
2. Remove the oil pump pipe and screen assembly.
3. Remove the oil pump pipe and screen assembly gasket and discard.

Oil Pump Removal

Note. Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft.

Scheme 969

Scheme 970

Scheme 971

Scheme 972

1. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut.
2. Remove the oil pump driven gear. Important: Do not damage the crankshaft sensor reluctor teeth.
3. Remove the oil pump drive gear and crank sensor reluctor assembly.
4. Remove the oil pump bolts.
5. Remove the oil pump.
6. Remove the O-ring and discard.

Scheme 973

1. Rotate crankshaft as necessary to obtain access to piston oil cooling nozzles.
2. Remove the piston oil cooling nozzle eye bolt.
3. Remove the piston oil cooling nozzle.

Piston, Connecting Rod & Bearing Removal

Tools Required

J 24270 Ridge Reamer

1. Rotate the crankshaft to place the piston at the bottom of the piston stroke.
2. Place a cloth on top of the piston.
3. Use the J 24270 to remove the ridge at the top of the cylinder bore.
4. Remove cloth.
5. Remove cutting debris from the cylinder and piston.
6. Remove the connecting rod cap bolts. Set the bolts aside for use in plastic gauging if needed. New bolts will be used for final assembly.
7. Remove the connecting rod cap.
8. Remove the bearing insert from connecting rod.
9. Push piston assembly out of cylinder.
10. Reassemble the connecting rod bearing, cap, and bolts upon removal.

Camshaft Removal

Tools Required

J 7872 Dial indicator set.

Scheme 974

Scheme 975

Scheme 976

Scheme 977

1. Measure the camshaft end play using J 7872 . The production value is 0.050-0.114 mm (0.002-0.0045 in) and service limit is 0.20 mm (0.008 in). Replace the camshaft or the camshaft thrust plate if the measured value exceeds the service limit.
2. Block the crankshaft from turning with a wooden handle.
3. Loosen the camshaft gear bolt and leave the bolt finger tight.
4. Remove the camshaft exciter ring bolts.
5. Remove the camshaft exciter ring.
6. Remove the camshaft thrust plate bolts through the holes in the camshaft gear.
7. Remove the camshaft with the camshaft gear attached.
8. Remove the camshaft gear bolt and washer.
9. Remove the camshaft gear.
10. Remove the camshaft thrust plate.

Crankshaft & Bearings Removal

Tools Required

J 7872 Dial Indicator Set

Scheme 978

Scheme 979

1. Remove the oil pressure sensor (1).
2. Remove the oil pressure sensor adapter bolt (2).
3. Remove the oil pressure sensor adapter (4) and washers (3).
4. Measure crankshaft end play using J 7872 . The production value is 0.04-0.205 mm (0.0016-0.0081 in) and the service limit is 0.54 mm (0.0213 in). Replace the thrust bearings upon reassembly if the measured value exceeds the service limit.
5. Remove the crankshaft bearing cap side bolts.
6. Remove the crankshaft bearing cap bolts.
7. Set the bolts aside for use in plastic gauging if needed.
8. Remove the crankshaft assembly.
9. Remove the crankshaft bearings from the engine block and the bearing caps.
10. Mark crankshaft bearings and caps so they may be installed in their original position.

Camshaft Bearing Removal

Important: Care must be taken to ensure that the camshaft bearing tool is driven straight and not allowed to tilt in the bore.

1. Remove the camshaft bearings from the engine block using a suitable tool. Follow the instructions supplied by the tool manufacturer.
2. Discard the camshaft bearings.

Scheme 980

Scheme 981

1. Remove the engine block heater.
2. Remove the O-ring from the block heater and discard.
3. Remove the oil gallery plugs.
4. Remove the left engine mount bolts.
5. Remove the left engine mount.
6. Remove the right engine mount bolts.
7. Remove the right engine mount.
8. Clean the sealing material from the gasket mating surfaces of the block.
9. Clean the block in cleaning solvent.
10. Flush the engine block with clean water or steam.
11. Clean the oil passages.
12. Clean the cylinder bores.
13. Inspect the block for cracks. Use the Magnaflux Spot check dye method, or the equivalent. Inspect the cylinder walls. Inspect the coolant jackets. Inspect the crankshaft bearing webs.
14. Inspect the crankshaft bearing bores and caps. The crankshaft bearing bore inside diameters should be round and uniform at all of the bearing supports.
15. Inspect the area where the crankshaft bearing inserts contact the crankshaft bearing bore. This area must be free of burrs and scratches.
16. Inspect the engine mount bosses.
17. Inspect the cylinder head gasket mating surfaces for pitting.
18. Inspect the engine block to cylinder head gasket surface area for warping. Use a straight edge and feeler gauge. Replace the block if it is warped more than 0.15 mm (0.006 in) longitudinally or more than 0.08 mm (0.003 in) transversely.
19. Apply sealer to the oil gallery plugs.
20. Install the oil gallery plugs. Tighten the oil gallery plugs to 53 N.m (39 ft lbs).
21. Install the engine block coolant plugs. Tighten the engine block coolant plugs to 18 N.m (13 ft lbs).
22. Install the left engine mount and engine mount bolts. Tighten the engine mount bolts to 58 N.m (43 ft lbs).
23. Install the right engine mount and engine mount bolts. Tighten the right engine mount bolts to 58 N.m (43 ft lbs).
24. Install a new O-ring to the block heater.
25. Lubricate the O-ring with engine coolant.
26. Install the engine block heater.

Scheme 982

1. Clean the upper oil pan.
2. Carefully clean the sealer from the threaded holes.
3. Inspect the upper oil pan for cracks.
4. Inspect the upper oil pan sealing surfaces for damage.
5. Replace the upper oil pan if any damage is found.

Camshaft Bearing Installation

Important: Care must be taken to ensure that the camshaft bearing tool is driven straight and not allowed to tilt in the bore.

Note. The oil hole in the camshaft bearing must be properly aligned with the oil passage from the main bearing bore. Improper alignment of the oil hole will cause insufficient lubrication to the camshaft journal. Insufficient lubrication will cause severe engine damage.

Scheme 983

1. Position the camshaft bearing so that the oil hole is aligned with the oil passage from the main bearing bore.
2. Install the camshaft bearing into the engine block using a suitable tool. Follow the instructions supplied by the tool manufacturer.
3. Repeat steps 1 and 2 for each camshaft bearing.

Crankshaft & Bearings Installation

Tools Required

J 36660-A Torque/Angle Meter

Scheme 984

Scheme 985

Scheme 986

Scheme 987

Scheme 988

Scheme 989

1. Install the upper crankshaft bearings into the cylinder block. The bearing halves to be inserted into the crankshaft main bearing saddle have a wide groove and oil hole in the center of the bearing (1).
2. Install the lower crankshaft bearings into the crankshaft bearing caps. The bearing halves to be inserted into the crankshaft main bearing caps do NOT have an oil hole or groove in the bearing (2).
3. Install the upper thrust bearings to the cylinder block. There are two thrust bearings (1 and 3) in the cylinder block and one lower thrust bearing in the No. 5 crankshaft bearing cap (2).
4. Lubricate the crankshaft bearing surfaces with engine oil.
5. Install the crankshaft into the cylinder block.
6. Install the No. 5 crankshaft bearing cap with the lower thrust bearing (2).
7. Install the remaining four crankshaft bearing caps. NOTE: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
8. Install the NEW crankshaft bearing cap bolts.
9. Tighten the crankshaft bearing cap bolts in the proper sequence. 1st step 98 N.m (72 ft lbs). 2nd step 132 N.m (97 ft lbs). 3rd step 30 degrees using J 36660-A .
10. Clean the crankshaft bearing side cap bolts and apply GM P/N 97720043, (Canadian P/N 88901148) to the bolt flange.
11. Install the ten bolts. Tighten the crankshaft bearing cap side bolts to 78 N.m (58 ft lbs).
12. Install the oil pressure sensor adapter and washers (3, 4).
13. Install the oil pressure sensor adapter bolt (2) in sequence. Tighten the bolt in sequence to 38 N.m (28 ft lbs).
14. Install the oil pressure sensor (1).

Camshaft Installation

Tools Required

J 7872 Dial Indicator Set

Scheme 990

Scheme 991

Scheme 992

1. Install the camshaft thrust plate to the camshaft.
2. Install the camshaft driven gear.
3. Install a new camshaft driven gear bolt. Leave the bolt finger tight.
4. Install the camshaft and gear assembly into the cylinder block, aligning the camshaft gear to the crankshaft gear as shown.
5. Install the camshaft thrust plate bolts. Tighten the camshaft thrust plate bolts to 22 N.m (16 ft lbs).
6. Install the camshaft position sensor exciter ring to the camshaft gear.
7. Install the camshaft position sensor exciter ring bolts. Tighten the camshaft position sensor exciter ring bolts to 9 N.m (80 in lbs).
8. Block the crankshaft from turning using a wooden handle.
9. Install the new camshaft gear bolt. Tighten the new camshaft gear bolt to 234 N.m (173 ft lbs).
10. Measure the camshaft end play with J 7872 . The production value is 0.050-0.114 mm (0.0020-0.0045 in) and service limit is 0.2 mm (0.0079 in). Replace the camshaft gear or the camshaft thrust plate if measured value exceeds the service limit.

Piston, Connecting Rod & Bearing Installation

Tools Required

1. J 8037 Piston Ring Compressor
2. J 36660-A Torque/Angle Meter

Important: The connecting rod bearing with the notch all the way out against the edge of the bearing (2) is the connecting rod cap bearing. The connecting rod bearing with the notch "in board" (1) is the connecting rod bearing.

Scheme 993

Scheme 994

Scheme 995

1. Select the connecting rod bearing according to the «Connecting Rod Bearings Selection Specifications»(ref-176272-S25669283312005050400000) .
2. Position the crankshaft so the connecting rod journal is opposite the piston and connecting rod assembly being installed.
3. Install the connecting rod bearing inserts.
4. Lubricate the cylinder wall and piston rings with engine oil.
5. Install the J 8037 to the piston to compress the piston rings.
6. Orientate the piston front mark and the piston inside mark to the engine block. NOTE: The chamfered side of the connecting rod large journal ends must face away from each other on a common crankshaft journal. Placement of the chamfered side of the connecting rod large journal ends in any other direction or combination will cause damage to the crankshaft, connecting rod and connecting rod bearing.
7. Push the piston and connecting rod assembly into the engine.
8. Install the gauging plastic onto the connecting rod journal. Install the gauging plastic the full width of the journal.
9. Install the connecting rod cap with its stamped cylinder number aligned with the stamped cylinder number on the connecting rod.
10. Install the original connecting rod cap bolts for the plastic gauging. NEW bolts will be used for final assembly.
11. Tighten the bolts in three steps. 11.1. 1st step 64 N.m (47 ft lbs) 11.2. 2nd step 30 degrees using J 36660-A 11.3. 3rd step 30 degrees using J 36660-A
12. Remove the connecting rod cap bolts.
13. Compare the width of the gauging plastic with the scale printed on the gauging plastic container. The connecting rod bearing clearance should be 0.10 mm (0.0039 in).
14. Discard the original connecting rod bolts once the plastic gauging is completed. NEW connecting rod bolts will be used for final assembly.
15. Carefully clean the gauging plastic from the bearing surface and the crankpin.
16. Lubricate the connecting rod bearing inserts with engine oil.
17. Install the connecting rod caps with the stamped cylinder number aligned with the stamped cylinder number on the connecting rods. NOTE: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
18. Install NEW connecting rod cap bolts.
19. Tighten the connecting rod cap bolts in three steps. 19.1. 1st step 64 N.m (47 lb ft) 19.2. 2nd step 30 degrees using J36660-A 19.3. 3rd step 30 degrees using J 36660-A

Scheme 996

Scheme 997

1. Install the piston oil cooling nozzle. NOTE: The piston oil cooling nozzle must be aligned to direct oil towards the oil inlet hole on the bottom of the piston. Improper alignment of the piston oil cooling nozzle will allow insufficient oil lubrication to the piston and cause severe engine damage.
2. Install the piston oil cooling nozzle bolt. Tighten the piston oil cooling nozzle bolts to 21 N.m (15 ft lbs).

Scheme 998

Scheme 999

Scheme 1000

Scheme 1001

1. Install a new O-ring to the engine block.
2. Lubricate the O-ring with engine oil.
3. Install the oil pump.
4. Install the oil pump bolts. Tighten the oil pump bolts to 21 N.m (15 ft lbs). Important: Do not damage the crankshaft sensor reluctor teeth.
5. Install the oil pump drive gear and crank sensor reluctor assembly.
6. Install the oil pump driven gear. NOTE: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft.
7. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the oil pump driven gear nut to 100 N.m (74 ft lbs).

Scheme 1002

1. Install the oil pump pipe and screen gasket.
2. Install the oil pump pipe and screen.
3. Install the oil pump pipe and screen assembly bolts and nuts. Tighten the oil pump pipe and screen assembly bolts to 25 N.m (18 ft lbs). Tighten the oil pump pipe and screen assembly nuts to 25 N.m (18 ft lbs).

Scheme 1003

Scheme 1004

Scheme 1005

Scheme 1006

1. Install the relief valve O-ring to the engine front cover.
2. Lubricate the O-ring with engine oil.
3. Apply a 2-3 mm wide and 0.5-1.5 mm high bead of P/N 97720043 sealant to the mating surfaces of the engine front cover.
4. Install the engine front cover.
5. Install the engine front cover bolts. Tighten the engine front cover bolts to 21 N.m (15 lb ft).
6. Install a new O-ring to the crankshaft position sensor spacer.
7. Lubricate the O-ring with engine oil.
8. Install the crankshaft position sensor spacer.
9. Install the crankshaft position sensor spacer bolts. Tighten the crankshaft position sensor spacer bolts to 10 N.m (89 in lbs).
10. Install a new O-ring to the crankshaft position sensor.
11. Lubricate the O-ring with engine oil.
12. Install the crankshaft position sensor.
13. Install the crankshaft position sensor bolt. Tighten the crankshaft position sensor bolt to 10 N.m (89 in lbs).

Crankshaft Front Oil Seal Installation

Tools Required

J 44645 Crankshaft Front Oil Seal Installer

1. Lubricate the crankshaft sealing surface with engine oil.
2. Place the crankshaft front oil seal onto the crankshaft.
3. Install the J 44645 to the crankshaft.
4. Press the crankshaft front oil seal onto the crankshaft with the J 44645 until the tool bottoms out.
5. Remove the J 44645 .

Scheme 1007

Scheme 1008

1. Install new O-rings (2) to the oil filter adapter and oil cooler assembly. Lubricate the O-rings with engine oil.
2. Apply sealer GM P/N 97720043 (Canadian P/N 88901148) to the O-ring sealing area (1).
3. Install the oil filter adapter and oil cooler assembly.
4. Install the five oil filter adapter and oil cooler assembly bolts (1). Tighten the oil filter adapter and oil cooler assembly bolts to 25 N.m (18 ft lbs).
5. Install a new O-ring onto the engine coolant pipe.
6. Lubricate the O-ring with engine coolant. Do not use oil or grease.
7. Install the engine coolant pipe to the oil filter adapter and oil cooler assembly.

Scheme 1009

Scheme 1010

1. Lubricate the water pump O-ring with engine oil.
2. Install the engine coolant pipe gasket.
3. Install the water pump seal.
4. Install the water pump. Be sure the water pump studs align with the coolant tube.
5. Install the water pump bolts. Tighten the water pump bolts to 21 N.m (15 ft lbs).
6. Install the water pump to coolant tube nuts. Tighten the water pump to coolant tube nuts to 25 N.m (18 ft lbs).

Scheme 1011

1. Lubricate the O-ring on the fuel injection pump adapter with engine oil.
2. Install the fuel injection pump and adapter assembly
3. Install the fuel injection pump bolts. Tighten the fuel injection pump bolts to 21 N.m (15 ft lbs)

Scheme 1012

1. Install the valve lifter.
2. Install the valve lifter guides.
3. Install the valve lifter guide hold down bracket.
4. Install the valve lifter guide hold down bracket bolt. Tighten the valve lifter guide hold down bracket bolt to 11 N.m (97 in lbs).

Cylinder Head Installation - Left

Tools Required

J 36660-A Torque/Angle Meter

Note. The left and right cylinder head gaskets are not interchangeable. Improper placement of the cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.

Scheme 1013

Scheme 1014

1. Install the left cylinder head gasket of the correct grade. The left and right cylinder head gaskets are not interchangeable. Refer to «Cylinder Head Gasket Selection Specifications»(ref-176272-S06986673122005050400000) .
2. Install the left cylinder head. NOTE: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
3. Install the NEW M12 cylinder head bolts. Reuse the M8 bolts. Tighten the M12 cylinder head bolts in three steps: 3.1. 1st step 50 N.m (37 ft lbs) 3.2. 2nd step 80 N.m (59 ft lbs) 3.3. 3rd step tighten 60 degrees using J 36660-A 3.4. 4th step tighten 60 degrees using J 36660-A
4. Tighten the M8 cylinder head bolts to 25 N.m (18 ft lbs).

Cylinder Head Installation - Right

Tools Required

J 36660-A Torque/Angle Meter

Note. The left and right cylinder head gaskets are not interchangeable. Improper placement of the cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.

Scheme 1015

Scheme 1016

1. Install the right cylinder head gasket of the correct grade. The left and right cylinder head gaskets are not interchangeable. Refer to «Cylinder Head Gasket Selection Specifications»(ref-176272-S06986673122005050400000) .
2. Install the right cylinder head. NOTE: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
3. Install the NEW M12 cylinder head bolts. Reuse the M8 bolts. Tighten the M12 cylinder head bolts in three steps: 3.1. 1st step 50 N.m (37 ft lbs) 3.2. 2nd step 80 N.m (59 ft lbs) 3.3. 3rd step tighten 60 degrees using J 36660-A 3.4. 4th step tighten 60 degrees using J 36660-A
4. Tighten the M8 cylinder head bolts to 25 N.m (18 ft lbs).

Scheme 1017

Scheme 1018

Scheme 1019

1. Install the valve bridge.
2. Install the valve bridge pins
3. Install the pushrods. NOTE: The pushrods must be correctly seated in the valve lifter and valve rocker arms before the rocker arm shaft assembly is torqued into place. Improper seating of the pushrods can cause damage to the pushrods or the valve rocker arm shaft assembly components.
4. Install the rocker arm shaft assembly.
5. Install the rocker arm shaft assembly bolts. Tighten the rocker arm shaft assembly bolts in the proper sequence. Tighten the rocker arm shaft bolts to 41 N.m (30 ft lbs).

Scheme 1020

Scheme 1021

Scheme 1022

1. Rotate the crankshaft to bring the number 1 cylinder at the top dead center of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine.
2. Loosen the valve adjusting screws.
3. Insert a feeler gauge between the tip of the rocker arm and the valve bridge.
4. Adjust the valve lash to 0.3 mm (0.012 in). Refer to «Valve Clearance Adjustment Specifications»(ref-176272-S32176456602005050400000) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 N.m (16 ft lbs).
5. Rotate the crankshaft one revolution to bring the number 1 cylinder at Top Dead Center of the exhaust stroke.
6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to «Valve Clearance Adjustment Specifications»(ref-176272-S32176456602005050400000) to determine which valves that can be adjusted when the engine is at Top Dead Center.
7. Tighten the valve lash lock nut to 22 N.m (16 ft lbs).

Fuel Injector Sleeve Installation

Tools Required

J 45910 Fuel Injector Sleeve Remover/Installer

Important: Inspect the seating surface on the fuel injector sleeve and the fuel injector sleeve bore in the cylinder head for debris or damage. If the fuel injector sleeve bore is damaged, the cylinder may need to be replaced.

Scheme 1023

Scheme 1024

Scheme 1025

Scheme 1026

1. Clean the fuel injector sleeve lower sealing area (1) and the sleeve bore with GM P/N 12377981 (Canadian P/N 10953463).
2. Lubricate and install new O-rings (1) on the fuel injector sleeve (2).
3. Install the fuel injector sleeve onto J 45910 .
4. Apply GM P/N 12345493, (Canadian P/N 10953488) or equivalent to the fuel injector sleeve lower sealing area (1).
5. Install the fuel injector sleeve with J 45910 into the cylinder head.
6. Lightly tap on J 45910 with a hammer to install and seat the fuel injector sleeve.
7. Remove J 45910 from the fuel injector sleeve.

Scheme 1027

Scheme 1028

1. Install a new O-ring onto the fuel injector.
2. Lubricate the O-ring with engine oil.
3. Install a new copper washer into the fuel injector bore in the cylinder head.
4. Install the fuel injector bracket pin.
5. Install the fuel injector with fuel injector bracket.
6. Install the fuel injector bracket bolt. Tighten the fuel injector bracket bolt to 50 N.m (37 ft lbs).
7. Install the fuel injector return pipe assembly.
8. Install the fuel injector return line to injector eye bolts and washers. Lubricate the washers with diesel fuel before installing. Tighten the fuel injector return line to injector eye bolts to 16 N.m (12 ft lbs).
9. Install the fuel injector return line to cylinder head eye bolts and washers. Lubricate the washers with diesel fuel before installing. Tighten the fuel injector return line to cylinder head eye bolts to 17 N.m (12 ft lbs).

Scheme 1029

Scheme 1030

Scheme 1031

1. Install the lower valve rocker arm cover gasket.
2. Install the lower valve rocker arm cover.
3. Install the lower valve rocker arm cover screws. Tighten the lower valve rocker arm cover screws in the proper sequence to 10 N.m (89 in lbs). Retighten the lower valve rocker arm cover screws in the proper sequence to the same torque, 10 N.m (89 in lbs).
4. Install the injector harnesses.
5. Install the injector harness bracket bolts. Tighten the injector harness bracket bolts to 9 N.m (80 in lbs).
6. Install the injector harness connectors to the injectors. Tighten the injector terminal nuts to 2 N.m (18 in lbs).

Scheme 1032

Scheme 1033

Scheme 1034

1. Install the lower valve rocker arm cover gasket.
2. Install the lower valve rocker arm cover.
3. Install the lower valve rocker arm cover screws. Tighten the lower valve rocker arm cover screws in the proper sequence to 10 N.m (89 in lbs). Retighten the lower valve rocker arm cover screws in the proper sequence to the same torque, 10 N.m (89 in lbs).
4. Install the injector harnesses.
5. Install the injector harness bracket bolts. Tighten the injector harness bracket bolts to 9 N.m (80 in lbs).
6. Install the injector harness connectors to the injectors. Tighten the injector terminal nuts to 2 N.m (18 in lbs).

Scheme 1035

Scheme 1036

Scheme 1037

1. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of P/N 97720043 sealant to the mating surface of the upper valve rocker arm cover.
2. Install the upper valve rocker arm cover.
3. Install the upper valve rocker arm cover screws. Tighten the upper valve rocker arm cover screws to 8 N.m (71 in lbs).

Scheme 1038

Scheme 1039

Scheme 1040

1. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of P/N 97720043 sealant to the mating surface of the upper valve rocker arm cover.
2. Install the upper valve rocker arm cover.
3. Install the upper valve rocker arm cover screws. Tighten the upper valve rocker arm cover screws in the proper sequence to 8 N.m (71 in lbs).

Scheme 1041

Scheme 1042

Scheme 1043

1. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of P/N 97720043 sealant on the intake manifold mating surface.
2. Install the intake manifold.
3. Install the intake manifold bolts and nuts. Tighten the intake manifold bolts and nuts to 21 N.m (15 ft lbs).

Scheme 1044

Scheme 1045

Scheme 1046

1. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of P/N 97720043 sealant on the intake manifold mating surface.
2. Install the intake manifold.
3. Install the intake manifold bolts and nuts. Tighten the intake manifold bolts and nuts to 21 N.m (15 ft lbs).

Scheme 1047

Scheme 1048

1. Install the intake manifold tube gasket.
2. Install the intake manifold tube.
3. Install the intake manifold tube nuts and bolts in sequence. Tighten the intake manifold tube nuts and bolts to 10 N.m (89 in lbs).
4. Install the intake air heater with gasket. Tighten the intake heater to 50 N.m (37 ft lbs).
5. Install the turbocharger boost sensor to the intake manifold tube.
6. Install the turbocharger boost sensor bracket bolt. Tighten the turbocharger boost sensor bracket bolt to 10 N.m (89 in lbs).

Scheme 1049

Scheme 1050

1. Install the intake manifold tube gasket.
2. Install the intake manifold tube.
3. Install the intake manifold tube nuts and bolts in sequence. Tighten the intake manifold tube nuts and bolts to 10 N.m (89 in lbs).
4. Install the intake air heater with gasket. Tighten the intake heater to 50 N.m (37 ft lbs).
5. Install the turbocharger boost sensor to the intake manifold tube.
6. Install the turbocharger boost sensor bracket bolt. Tighten the turbocharger boost sensor bracket bolt to 10 N.m (89 in lbs).
7. Install the EGR cooler bracket.
8. Install the EGR and cooler.
9. Install the EGR cooler bracket bolts. Tighten the EGR cooler bracket bolts to 20 N.m (15 ft lbs).
10. Install the EGR bolts and nuts. Tighten the EGR bolts to 20 N.m (15 ft lbs). Tighten the EGR nuts to 19 N.m (14 ft lbs). Install the EGR cooling hose and clamps.

Scheme 1051

Scheme 1052

Scheme 1053

Scheme 1054

Scheme 1055

Scheme 1056

Scheme 1057

Scheme 1058

Scheme 1059

Scheme 1060

Scheme 1061

Scheme 1062

1. Install the right fuel rail.
2. Install the right fuel rail mounting bolts. Tighten the right fuel rail mounting bolts to 25 N.m (18 ft lbs).
3. Install the left fuel rail.
4. Install the left fuel rail mounting bolts. Tighten the left fuel rail mounting bolts to 25 N.m (18 ft lbs). CAUTION: Improper torque methods of the fuel lines will result in fuel leaks and possible damage to the engine. Failure to follow proper fuel line fitting torque methods could result in serious personal injury.
5. Install the injection pipes to the right bank. Tighten the injection pipes to 41 N.m (30 ft lbs)
6. Install the anti-rotation locks to the right bank injection pipes. Tighten the anti-rotation lock screws to 4 N.m (35 in lbs) CAUTION: Improper torque methods of the fuel lines will result in fuel leaks and possible damage to the engine. Failure to follow proper fuel line fitting torque methods could result in serious personal Injury.
7. Install the injection pipes to the left bank. Tighten the injection pipes to 41 N.m (30 ft lbs)
8. Install the anti-rotation locks to the left bank injection pipes. Tighten the anti-rotation lock screws to 4 N.m (35 in lbs)
9. Install the fuel pipes and function block assembly.
10. Install the fuel pressure limiting valve bracket nut. Tighten the fuel pressure limiting valve bracket nut to 10 N.m (89 in lbs).
11. Install the fuel return line clamp bolt and clamp. Tighten the fuel return line clamp bolt to 10 N.m (89 in lbs).
12. Install the right cylinder head return line eye bolt and gasket (2). Tighten the right cylinder head return line eye bolt to 17 N.m (12 ft lbs).
13. Install the right fuel rail high pressure line (1). Tighten the high pressure line to right fuel rail nut to 41 N.m (30 ft lbs). Tighten the high pressure line to function block nut to 41 N.m (30 ft lbs).
14. Install the left cylinder head return line eye bolt and gasket (2). Tighten the left cylinder head return line eye bolt to 17 N.m (12 ft lbs).
15. Install the left fuel rail high pressure line (1). Tighten the high pressure line to left fuel rail nut to 41 N.m (30 ft lbs). Tighten the high pressure line to function block nut to 41 N.m (30 ft lbs).
16. Install the fuel inlet pipe and function block.
17. Install the function block nuts. Tighten the function block nuts to 25 N.m (18 ft lbs)
18. Install the fuel inlet to fuel return line clamp.
19. Install the fuel inlet to fuel return line clamp bolt. Tighten the fuel inlet to fuel return line clamp bolt to 21 N.m (15 ft lbs).
20. Install the fuel inlet distribution block to the fuel return distribution block.
21. Install the fuel inlet distribution block bolt and nut. Tighten the fuel inlet distribution block bolt and nut to 25 N.m (18 ft lbs).
22. Install the fuel injection pump high pressure line to the fuel injection pump. Tighten the high pressure line to 41 N.m (30 ft lbs).
23. Install the fuel return hose and clamp to the fuel injection pump.
24. Install the fuel inlet hose and clamp to the fuel injection pump.

Scheme 1063

1. Install the fuel filter assembly.
2. Install the fuel filter attaching bolts. Tighten the fuel filter bolts to 21 N.m (15 ft lbs).

Scheme 1064

Scheme 1065

Scheme 1066

Scheme 1067

Scheme 1068

1. Install the oil level sensor harness.
2. Install the ground bolt to the left side of the block. Tighten the ground bolt to 34 N.m (25 ft lbs).
3. Connect the oil pressure sensor connector.
4. Install the turbocharger coolant outlet pipe.
5. Install the turbocharger coolant outlet pipe bracket bolts. Tighten the turbocharger coolant outlet pipe bracket bolts to 21 N.m (15 ft lbs).
6. Install a new O-ring to the bypass pipe. Lubricate the O-ring with engine coolant.
7. Install the bypass pipe to the thermostat housing.
8. Install new thermostat housing gaskets.
9. Install the thermostat housing with the bypass pipe.
10. Install the bypass pipe to water pump bolts. Tighten the bypass pipe to water pump bolts to 21 N.m (15 ft lbs).
11. Install the thermostat housing bolts and nuts. Tighten the thermostat housing bolts and nuts in sequence to 25 N.m (18 ft lbs).
12. Install the right fuel rail high pressure pipe to the thermostat housing bracket bolt. Tighten the high pressure pipe bracket bolt to 21 N.m (15 ft lbs).
13. Install a new O-ring on the heater pipe. Lubricate the O-ring with engine coolant.
14. Install the heater pipe.
15. Install the heater pipe bracket bolt. Tighten the heater pipe bracket bolt to 21 N.m (15 ft lbs).
16. Install the heater pipe to thermostat housing bolt. Tighten the heater pipe to thermostat housing bolt to 21 N.m (15 ft lbs).
17. Install the thermostats.
18. Install the thermostat cover and gasket.
19. Install the thermostat cover bolts. Tighten the thermostat cover bolts to 21 N.m (15 ft lbs).
20. Install a new O-ring to the water outlet pipe.
21. Lubricate the water outlet pipe o-ring with engine coolant.
22. Install the water outlet pipe.
23. Install the water outlet pipe bolts. Tighten the water outlet pipe bolts to 21 N.m (15 ft lbs).

Scheme 1069

1. Install a new O-ring to the oil fill tube. Lubricate the O-ring with engine oil.
2. Install the oil fill tube.
3. Install the oil fill tube to engine front cover bolt.
4. Install the oil fill tube to thermostat housing bolt. Tighten the oil fill tube to engine front cover bolt to 21 N.m (15 ft lbs). Tighten the oil fill tube to thermostat housing bolt to 21 N.m (15 ft lbs).

Scheme 1070

Scheme 1071

Scheme 1072

Scheme 1073

Scheme 1074

1. Install the turbocharger oil supply line to the engine block.
2. Install the turbocharger oil supply line eye bolt and washers. Lubricate the washers with diesel fuel before installing. Tighten the turbocharger oil supply line eye bolt to 34 N.m (25 ft lbs).
3. Install the turbocharger lower heat shield to the engine block.
4. Install the turbocharger assembly with the oil return pipe.
5. Install the turbocharger mounting bolts. Tighten the turbocharger mounting bolts to 108 N.m (80 ft lbs).
6. Install the turbocharger cooling outlet hose and tighten hose clamp.
7. Install the oil supply line eye bolt and washers to the turbocharger. Lubricate the washers with diesel fuel before installing. Tighten the oil supply hose eye bolt to 34 N.m (25 ft lbs).
8. Install the turbocharger heat shield.
9. Install the turbocharger upper heat shield bolts. Tighten the turbocharger upper heat shield bolts to 9 N.m (80 in lbs).

Scheme 1075

Scheme 1076

Scheme 1077

Scheme 1078

1. Install the glow plugs to the right cylinder bank. Tighten the glow plugs to 18 N.m (13 ft lbs).
2. Install the glow plug harness to the right cylinder bank (1 California, 2 Federal).
3. Install the glow plug power feed wire to the right cylinder bank.
4. Install the glow plug harness nuts to the right cylinder bank. Tighten the glow plug harness nuts to 2 N.m (18 in lbs).
5. Install the glow plugs to the left cylinder bank. Tighten the glow plugs to 18 N.m (13 ft lbs).
6. Install the glow plug harness to the left cylinder bank (1 California, 2 Federal).
7. Install the glow plug controller.
8. Install the glow plug controller nuts. Tighten the glow plug controller nuts to 25 N.m (18 ft lbs).
9. Install the glow plug power feed wire to the left cylinder bank.
10. Install the glow plug harness nuts to the left cylinder bank. Tighten the glow plug harness nuts to 2 N.m (18 in lbs).
11. Install the glow plug harness bracket bolt. Tighten the glow plug harness bracket bolt to 21 N.m (15 ft lbs).
12. Install the intake air heater connector.

Scheme 1079

Scheme 1080

Scheme 1081

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts and nuts. Tighten the exhaust manifold bolts and nuts to 38 N.m (28 ft lbs) in the proper sequence.
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 8 N.m (71 in lbs).

Scheme 1082

Scheme 1083

Scheme 1084

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts and nuts. Tighten the exhaust manifold bolts and nuts to 38 N.m (28 ft lbs) in the proper sequence.
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 8 N.m (71 in lbs).

Scheme 1085

1. Install the fuel injection control module bracket.
2. Install the fuel injection control module bracket bolts. Tighten the fuel injection control module bracket bolts to 21 N.m (15 ft lbs).
3. Install the fuel injection control module (6) with mounting insulators (2).
4. Install the fuel injection control module bolts (5). Tighten the fuel injection control module bolts to 20 N.m (14 ft lbs).
5. Install the eye bolts (4), washers and spacers to the fuel injection control module cooling hoses (3). Lubricate the washers with diesel fuel before installing. Tighten the eye bolts to 34 N.m (25 ft lbs).

Scheme 1086

Scheme 1087

Scheme 1088

Scheme 1089

Scheme 1090

Scheme 1091

Scheme 1092

Scheme 1093

Scheme 1094

Scheme 1095

1. Install the main engine harness connector bracket.
2. Install the main engine harness connector bracket bolts. Tighten the bracket bolts to 21 N.m (15 ft lbs).
3. Install the fuel injection control module harness assembly.
4. Connect the 3 fuel injector control module harness to glow plug controller connectors.
5. Connect the fuel temperature sensor connector.
6. Connect the barometric pressure sensor connector.
7. Connect the fuel injection control module harness to the oil level sensor harness connector.
8. Connect the fuel rail pressure regulator valve connector.
9. Connect the fuel rail pressure sensor.
10. Connect the fuel filter assembly connectors.
11. Install a new O-ring to the water outlet and lubricate with engine coolant.
12. Install the water outlet.
13. Install the water outlet bolts. Tighten the water outlet bolts to 24 N.m (17 ft lbs).
14. Install the turbocharger coolant inlet hose to the turbocharger.
15. Install the main engine harness connectors.
16. Install the main engine harness connector hold down bolts (1, 2). Tighten the main engine harness connector hold down bolts to 10 N.m (89 in lbs).
17. Install the two engine block ground bolts to the right front side of the engine. Tighten the engine block ground bolts to 34 N.m (25 ft lbs).
18. Connect the crankshaft position sensor connector.
19. Connect the engine coolant temperature sensor connector.
20. Connect the fuel injection control module connectors.
21. Connect the turbocharger boost sensor connector.
22. Connect the four injector harness connectors.

Scheme 1096

Scheme 1097

Scheme 1098

Scheme 1099

Scheme 1100

Scheme 1101

1. Install the drive belt tensioner and generator mounting bracket.
2. Install the drive belt tensioner and generator mounting bracket bolts. Tighten the drive belt tensioner and generator mounting bracket bolts to 50 N.m (37 ft lbs).
3. Install the vacuum pump - California Emissions.
4. Install the vacuum pump nuts - California Emissions. Tighten the vacuum pump nuts to 22 N.m (16 ft lbs).
5. Install the tensioner pulley.
6. Install the tensioner pulley bolt. Tighten the tensioner pulley bolt to 50 N.m (37 ft lbs).
7. Install the left idler pulley.
8. Install the left idler pulley bolt. Tighten the left idler pulley bolt to 50 N.m (37 ft lbs).
9. Install the right idler pulley.
10. Install the right idler pulley bolt. Tighten the right idler pulley bolt to 50 N.m (37 ft lbs).
11. Install the Schrader valve bracket (4).
12. Install the Schrader valve (3).
13. Install the fuel injection control module harness bracket (2).
14. Install the fuel injection control module harness bracket nuts (1).
15. Connect the crankcase vent hose to the engine block.
16. Install the crankcase ventilation hoses to the valve rocker arm covers.

Scheme 1102

1. Install the power steering pump mounting bracket.
2. Install the power steering pump mounting bracket bolts. Tighten the power steering pump mounting bracket bolts to 46 N.m (34 ft lbs).

Scheme 1103

1. Lubricate the camshaft position sensor O-ring with engine oil.
2. Install the camshaft position sensor.
3. Install the camshaft position sensor retaining bolt. Tighten the camshaft position sensor retaining bolt to 10 N.m (89 in lbs).
4. Install the cooling fan pulley.
5. Install the cooling fan pulley bolts and nuts. Tighten the cooling fan pulley bolts and nuts to 41 N.m (30 ft lbs).
6. Connect the camshaft position sensor connector.

Engine Removal from Stand

Tools Required

J 36857 Engine Lift Bracket

1. Bolt J 36857 to the ends of the cylinder heads.
2. Lift the engine and the engine stand with a suitable hoist.
3. Remove the engine stand from the engine adapter.
4. Lower the engine to the floor. Support the engine with blocks.
5. Remove the engine adapter.

Scheme 1104

Scheme 1105

Scheme 1106

Scheme 1107

Scheme 1108

1. Install the oil cooler adapter with gaskets (1, 2) to the oil cooler.
2. Install the oil cooler adapter to oil cooler bolts. Tighten the oil cooler adapter to oil cooler bolts to 21 N.m (15 ft lbs).
3. Install the two O-rings (1, 2) to the flywheel housing.
4. Apply a 2 mm wide bead of sealant to the flywheel housing sealing surfaces (3), including the upper oil pan to flywheel housing sealing area.
5. Install the flywheel housing to the cylinder block.
6. Install the flywheel housing bolts, denoted by a black circle. Tighten the flywheel housing bolts to 90 N.m (67 ft lbs)
7. Install the oil cooler adapter to flywheel housing studs. Tighten the oil cooler adapter studs to 10 N.m (89 in lbs).
8. Install the oil cooler adapter to flywheel housing nuts. Tighten the oil cooler adapter nuts to 25 N.m (18 ft lbs).
9. Install a new gasket to the turbocharger oil return pipe.
10. Install the turbocharger oil return pipe to flywheel housing studs. Tighten the turbocharger oil return pipe to flywheel housing studs to 10 N.m (89 in lbs).
11. Install the turbocharger oil return pipe nuts. Tighten the turbocharger oil return pipe nuts to 25 N.m (18 ft lbs).

Scheme 1109

Scheme 1110

Scheme 1111

1. Apply a 2-3 mm wide by 0.5-1.5 mm bead of P/N 97720043 sealant to the upper oil pan mating surfaces.
2. Install the upper oil pan to the engine block.
3. Install the upper oil pan bolts. Tighten the upper oil pan bolts in sequence to 20 N.m (15 ft lbs).
4. Install the two flywheel housing to upper oil pan bolts denoted by the two black triangles. Tighten the two flywheel housing to upper oil pan bolts to 50 N.m (37 ft lbs)
5. Install the oil level indicator tube.
6. Install the oil level indicator tube bracket bolt. Tighten the oil level indicator tube bracket bolt to 21 N.m (15 ft lbs).

Scheme 1112

Scheme 1113

Scheme 1114

Scheme 1115

1. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of P/N 97720043 sealant to the lower oil pan mating surface.
2. Install the lower oil pan.
3. Install the lower oil pan bolts and nuts in sequence. Tighten the lower oil pan bolts and nuts to 10 N.m (89 in lbs).
4. Connect the oil level sensor.

Exhaust Pipe Installation - Left

Important: Position the exhaust pipe gaskets with the tabs as shown. Failure to do so will cause improper alignment of the gaskets and result in exhaust leaks.

Scheme 1116

Scheme 1117

Scheme 1118

1. Install the exhaust pipe with gaskets.
2. Install the exhaust pipe to turbocharger bolts.
3. Install the exhaust pipe to exhaust manifold bolts. Tighten the exhaust pipe bolts to 53 N.m (39 ft lbs) in the proper sequence.
4. Install the exhaust pipe heat shield.
5. Install the exhaust pipe heat shield bolts. Tighten the exhaust pipe heat shield bolts to 8 N.m (71 in lbs).

Exhaust Pipe Installation - Right

Important: Position the exhaust pipe gaskets with the tabs as shown. Failure to do so will cause improper alignment of the gaskets and result in exhaust leaks.

Scheme 1119

Scheme 1120

Scheme 1121

Scheme 1122

1. Install the exhaust pipe with gaskets - Federal Emissions.
2. Install the exhaust outlet bracket.
3. Install the exhaust pipe to turbocharger bolts. Important: Position the exhaust pipe gaskets with the tabs as shown. Failure to do so will cause improper alignment of the gaskets and result in exhaust leaks.
4. Install the exhaust pipe with gaskets - California Emissions.
5. Install the exhaust outlet bracket.
6. Install the exhaust pipe to turbocharger bolts.
7. Install the exhaust pipe to exhaust manifold bolts - Federal Emissions in sequence. Tighten the exhaust pipe bolts to 53 N.m (39 ft lbs).
8. Install the exhaust pipe to exhaust manifold bolts - California Emissions in sequence. Tighten the exhaust pipe bolts to 53 N.m (39 ft lbs).

Scheme 1123

Scheme 1124

Scheme 1125

1. Install the exhaust outlet gasket.
2. Install the exhaust outlet.
3. Install the exhaust outlet bolts and nuts. Tighten the exhaust outlet bolts and nuts to 53 N.m (39 ft lbs) in the proper sequence.
4. Install the exhaust outlet to right exhaust pipe bracket bolt. Tighten the exhaust outlet to right exhaust pipe bracket bolt to 34 N.m (25 ft lbs).
5. Install the exhaust outlet heat shield.
6. Install the exhaust outlet heat shield bolts. Tighten the exhaust outlet heat shield bolts to 8 N.m (71 in lbs).

Crankshaft Rear Oil Seal Installation

Tools Required

J 44642 Crankshaft Rear Oil Seal Installer

1. Place the crankshaft rear oil seal onto the crankshaft. Important: The J 44642 must be fully secured to the crankshaft to ensure proper seal depth.
2. Install the J 44642 to the crankshaft.
3. Press the crankshaft rear oil seal into position using the J 44642 . The J 44642 will bottom out when the seal reaches the proper depth.
4. Remove the J 44642 .

Engine Flywheel Installation (Automatic Transmission)

Tools Required

1. J 44643 Flywheel Hold Tool
2. J 36660-A Torque/Angle Meter

Scheme 1126

Scheme 1127

1. Install the flywheel to the crankshaft.
2. Install the flywheel washer to the flywheel with the beveled side facing the engine. NOTE: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
3. Install NEW flywheel bolts.
4. Install the J 44643 to lock the flywheel.
5. Tighten the flywheel bolts in the proper sequence. 1st step 79 N.m (59 ft lbs). 2nd step 60 degrees using J 36660-A . 3rd step 60 degrees using J 36660-A .

Engine Flywheel Installation (Manual Transmission)

Tools Required

1. J 44643 Flywheel Hold Tool
2. J 36660-A Torque/Angle Meter

Scheme 1128

Scheme 1129

1. Install the pilot bearing in the flywheel. CAUTION: When removing or installing the flywheel wear protective gloves. The teeth on the ring gear may be very sharp and may cut you.
2. Install the flywheel assembly. NOTE: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
3. Loosely install NEW flywheel bolts.
4. Install the J 44643 to hold the flywheel from rotating.

Crankshaft Balancer Installation

Tools Required

J 44643 Flywheel Hold Tool

1. Lightly lubricate the crankshaft balancer internal hub with engine oil.
2. Install the crankshaft balancer to the crankshaft.
3. Lightly lubricate the crankshaft balancer bolt with engine oil.
4. Install the crankshaft balancer bolt and washer. Tighten the bolt to 353 N.m (260 ft lbs).
5. Remove the J 44643 .

Scheme 1130

1. Install the starter motor to the flywheel housing.
2. Install the starter motor bolts. Tighten the starter bolts to 78 N.m (58 ft lbs).