Document ID: 5639089

Crankshaft and Bearing Removal and Installation

Single Use Fasteners and Components

Automatic Transmission Flex Plate Bolt[8x]
Camshaft Housing Gasket[8x]
Camshaft Sprocket Bolt[2x]
Connecting Rod Bolt[12x]
Crankshaft Bearing Cap Bolt[14x]
Crankshaft Front Oil Seal
Crankshaft Position Sensor Seal
Engine Coolant Thermostat Housing Gasket
Engine Coolant Thermostat Gasket[3x]
Engine Oil Cooler Gasket-Large
Engine Oil Cooler Gasket-Small
Exhaust Gas Recirculation Cooler Inlet Pipe Gasket
Exhaust Manifold Gasket
Fuel Injector Bolt[6x]
Fuel Injector Seal[6x]
Fuel Injector Washer[6x]
Glow Plug[6x]
High Pressure Diesel Fuel Feed to Injector Pipe[6x]
High Pressure Diesel Fuel Feed to Rail Pipe[2x]
Intake Manifold Runner Control Valve Gasket[6x]
Lower Crankcase Extension Bolt- M8 [7x]
Lower Oil Pan
Oil Filter
Oil Level Indicator Seal
Oil Pump Gasket[3x]
Radiator Outlet Pipe Seal
Seal Ring[6x]
Upper Oil Pan Gasket
Timing Chain Lower Cover
Timing Chain Tensioner Gasket
Turbocharger Coolant Feed and Return Pipe Gasket[2x]
Turbocharger Gasket
Turbocharger Nut[3x]
Turbocharger Oil Return Pipe Gasket[2x]
Water Pump Gasket

Special ToolsEngine Mechanical – LM2:

EN-956-1 Extension
EN-8087 Cylinder Bore Gauge
EN-37228 Separating Tool
EN-41556 Connecting Rod Guide
EN-45299 Engine Preluber
EN-47634 Camshaft Sprocket Holder
EN-49979 Holder
EN-49979-100 Holder Adapter Pins
EN-52234 Timing Chain Tensioner Retaining Pins
EN-52445 Camshaft Tool
EN-52446 Rear Crankshaft Seal Installer
EN-52449 Engine Stand Adaptor
EN-52452 Front Crankshaft Seal Installer
EN-52474 Engine Lift Hook Set
EN-52586 Crankshaft Fixing Pin
J-41818 Crankshaft Bearing Cap Remover
J-43301 Coil Pack Pullers
J-6125-1B Slide Hammer

Equivalent regional tools:Special Tools

Engine Controls and Fuels – LM2:

CH-44581 Fuel Line Disconnect Tool
EN-51146 Injector Remover/Installer
EN-52074 Glow Plug Bore Reamer
EN-52448 High Pressure Fuel Pump Tool

Equivalent regional tools:Special Tools

Removal Procedure

Engine»Remove—Engine Removal and Installation
Remove the EN-52474 Engine Lift Hook Set.

Place a drain pan underneath the oil pan. Allow the oil to drain completely.
Oil Pan Drain Plug(1)»Remove
Oil Pan Drain Plug Seal(2)»Remove
Oil Filter(3)»Remove and DISCARD

Thermostat Bypass Pipe Bolt(2)»Remove
Thermostat Bypass Hose Clamp(3)»Release—Hose Clamp Replacement Guidelines - Spring Type
Thermostat Bypass Hose(1)»Remove

Thermostat Bypass Pipe Bolt(3)»Remove[2x]
Thermostat Bypass Hose Clamp(1)»Release—Hose Clamp Replacement Guidelines - Spring Type
Thermostat Bypass Hose(2)»Remove
Engine Coolant Thermostat Gasket(4)»Remove and DISCARD

Clip(3)@Exhaust Gas Recirculation Cooler Outlet Pipe»Disengage
Engine Coolant Air Bleed Hose Clamp(1)»Release—Hose Clamp Replacement Guidelines - Spring Type
Engine Coolant Air Bleed Pipe(2)»Remove

Remove the fuel injector wiring harness connector (1) from the engine coolant air bleed hose.
Remove the wiring harness clip (2) from the engine coolant air bleed hose.

Note: Some components not shown for graphic clarity.

Engine Coolant Air Bleed Pipe Bolt(1)»Remove[2x]
Engine Coolant Air Bleed Hose Stud(2)»Remove
Engine Coolant Air Bleed Hose(3)»Remove

Turbocharger Coolant Feed and Return Pipe Gasket(1)»Remove and DISCARD[2x]

Engine Coolant Outlet Pipe Bracket Bolt(2)»Remove
Engine Coolant Air Bleed Hose(1)»Remove

Note: Support the exhaust gas recirculation cooler inlet pipe when applying torque to the bolts.

Note: Considering the reduced clearance, carefully remove the bolts to ensure the tool does not contact the pipe.

Exhaust Gas Recirculation Cooler Bolt(1)»Remove[2x]
Exhaust Gas Recirculation Cooler Inlet Pipe(2)»Remove
Exhaust Gas Recirculation Cooler Inlet Pipe Gasket(3)»Remove and DISCARD

Oil Level Indicator(2)»Remove
Oil Level Indicator Tube Bolt(3)»Remove[2x]
Clip(4)@Oil Level Indicator Tube»Remove

Oil Level Indicator Tube(1)»Remove
Oil Level Indicator Seal(2)»Remove and DISCARD

Exhaust Gas Recirculation Valve Cooling Feed Hose Clamp(1)»Release—Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Valve Cooling Feed Hose(2)»Remove

Exhaust Gas Recirculation Valve Bolt(1)»Remove[2x]
Exhaust Gas Recirculation Valve(2)»Remove
Exhaust Gas Recirculation Valve Inlet Gasket(3)»Remove and DISCARD

Turbocharger Oil Feed Pipe Bolt(7)»Remove[2x]
Turbocharger Oil Feed Pipe Bracket Bolt(9)»Remove
Turbocharger Oil Return Pipe Bolt(8)»Remove[2x]
Turbocharger Nut(2, 4)»Remove and DISCARD[3x]
Turbocharger Assembly(1)»Remove
Turbocharger Gasket(3)»Remove and DISCARD
Turbocharger Oil Return Pipe Gasket(6)»Remove and DISCARD
Turbocharger Oil Return Pipe Gasket(5)»Remove and DISCARD

Exhaust Manifold Heat Shield Bolt(1)»Remove
Exhaust Manifold Heat Shield»Remove

Exhaust Manifold Flange Bolt(1)»Remove[12x]
Exhaust Manifold(2)»Remove
Exhaust Manifold Gasket(3)»Remove and DISCARD

Diesel Glow Plug Wiring Harness(1)@Intake Manifold»Remove

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

Intake Manifold Cover Retainer(2)»Remove[2x]
Intake Manifold Cover(1)»Remove

Intake Manifold Bolt(2)»Remove[9x]
Intake Manifold(1)»Remove
Intake Manifold Runner Control Valve Gasket(3)»Remove and DISCARD[6x]

Engine Oil Cooler Bolt(1)»Remove[5x]

Engine Oil Cooler(1)»Remove
Engine Oil Cooler Gasket(2)»Remove and DISCARD
Engine Oil Cooler Gasket(3)»Remove and DISCARD

Engine Coolant Flow Control Valve Bolt(3)»Remove[6x]
Engine Coolant Flow Control Valve(2)»Remove
Engine Coolant Thermostat Housing Gasket(1)»Remove and DISCARD

Install the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3)
Crankshaft Pulley Bolt(2)»Loosen[4x]

Automatic Transmission Flex Plate Bolt(2)»Remove and DISCARD[8x]
Automatic Transmission Flex Plate(1)»Remove

Remove the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).

Crankshaft Pulley Bolt(2)»Remove[4x]
Crankshaft Pulley(1)»Remove

Water Pump Bolt(6)»Remove[2x]
Water Pump Inlet Pipe(1)»Remove
Radiator Outlet Pipe Seal(2)»Remove and DISCARD
Water Pump Bolt(5)»Remove[4x]
Water Pump(4)»Remove
Water Pump Gasket(3)»Remove and DISCARD

Engine Front Cover Bolt(1)»Remove[8x]

Note: It is likely you will bend the crankshaft front oil seal during the removal. Use care to not damage the engine block.

Using the EN-37228 separating tool, loosen the crankshaft front oil seal (2) carefully from the engine block.
Crankshaft Front Oil Seal(2)»Remove and DISCARD

Crankshaft Pulley Bolt(1)»Install[4x]
Rotate the crankshaft with a suitable tool in the direction of the arrow at the crankshaft pulley bolts (1), until the crankshaft locking divot (2) aligns with the engine block (3).
Install the EN-52586 Crankshaft Fixing Pin (4).

Wiring Harness Connector(1)@Fuel Injector Wiring Harness»Disconnect[6x]
Retaining Clip(2)@Fuel Injector Wiring Harness»Remove[8x]
Fuel Injector Wiring Harness(3)»Remove

Push the 6 fuel injection fuel return pipe locking springs (1) in the direction shown and remove the fuel injection fuel return pipe from the fuel injectors.
Fuel Injection Fuel Return Pipe Clip(4)@High Pressure Diesel Fuel Injection Rail»Remove
Unlock the fuel injection fuel return pipe clip (5) by pressing the spring notch in direction of the arrow, and remove the hose from the diesel fuel separator.
Unclip the fuel injection fuel pipe retainer (3) from the high pressure fuel feed pipe.
Fuel Injection Fuel Return Pipe(2)»Remove
Seal Ring(6)»Remove and DISCARD[6x]

Heater Outlet Pipe Bolt(1)@Diesel Fuel Separator»Remove
Fuel Return Hose Connector Retainer(4)»Disengage
Disconnect the fuel return front pipe (3). Metal Collar Quick Connect Fitting Service
Diesel Fuel Separator(2)»Remove

High Pressure Diesel Fuel Feed to Rail Pipe(1)@High Pressure Diesel Fuel Injection Rail(5)»Disconnect[2x]
High Pressure Diesel Fuel Feed to Rail Pipe(1)@High Pressure Diesel Fuel Pump(4)»Disconnect[2x]
Fuel Feed Pipe Clip Bolt(2, 3)»Remove[4x]
High Pressure Diesel Fuel Feed to Rail Pipe(1)»Remove and DISCARD[2x]

Fuel Return Pipe Clip Bolt(1)»Remove[2x]
Fuel Injector Fuel Return Hose Bracket(2)»Remove

Fuel Injection Fuel Feed and Return Pipe Retainer Bolt(2)»Remove
Fuel Injection Fuel Feed Pipe Bracket(1)»Remove

High Pressure Diesel Fuel Feed to Injector Pipe(1)»Remove and DISCARD[6x]

Clip(1)@Diesel Glow Plug Wiring Harness»Unclip[3x]
Electrical Connector(2)@Glow Plug»Disconnect[6x]
Diesel Glow Plug Wiring Harness(3)»Remove

Fuel Injection Fuel Rail Nut(3)»Remove[3x]
High Pressure Diesel Fuel Injection Rail(2)»Remove
Charge Air Cooler Bracket(1)»Remove

Fuel Injector Bolt(1)»Remove and DISCARD[6x]
Multiport Fuel Injector Bracket(2)»Remove[6x]

Pull out the 6 fuel injectors (2) with the EN-52451 Injector Remover (3) and J-6125-1B Slide Hammer (1).

High Pressure Diesel Fuel Injector(1)»Remove[6x]
Fuel Injector Seal(2)»Remove and DISCARD[6x]
Fuel Injector Washer(3)»Remove and DISCARD[6x]

Note: Camshaft housing cover bolts are captured in the camshaft housing cover.

Camshaft Housing Cover Bolt(1)»Loosen[7x]
Camshaft Housing Cover Bolt(2)»Loosen[3x]
Camshaft Housing Cover Bolt(3)»Loosen[9x]
Camshaft Housing Cover Bolt(4)»Loosen[7x]

Camshaft Housing(1)»Remove
Camshaft Housing Gasket(2)»Remove and DISCARD[2x]
Clean around each of the glow plugs.

Caution: Ensure each glow plug is fully intact when removed from the cylinder head. A broken tip could remain within the combustion chamber, which may not be obvious during removal. Damage to the engine may result if a broken glow plug tip remains within the engine.

Note:

Glow plugs must be DISCARDED whenever removed, and replaced with NEW.
If the cylinder head is removed, the accompanying glow plugs must be DISCARDED and replaced with NEW.
Do not use power tools to install glow plugs.
Use a suitable, commercially available glow plug socket.
Cylinder head removal may be required to retrieve a broken tip.

Glow Plug(1)»Remove and DISCARD[6x]
Inspect each glow plug tip and ensure the glow plug is not broken. If a broken tip is suspected, inspect the combustion chamber for the glow plug tip.

Timing Chain Cover Bolt(3)»Remove[4x]
Timing Chain Cover Bolt(4)»Remove[2x]
Timing Chain Upper Cover(1)@Cylinder Head»Remove
Engine Front Cover Locating Pin(2)@Cylinder Head»Remove[2x]

Remove the 16 timing chain cover bolts (1,2).

Note: Avoid prying close to the transmission locating pins.

Using a suitable tool at the locations indicated by the arrows to pry, loosen the timing chain lower cover carefully from the engine block.

Timing Chain Lower Cover(1)»Remove and DISCARD

Timing Chain Tensioner(2)»Remove
Timing Chain Tensioner Gasket(1)»Remove and DISCARD

Ensure the EN-52586 Crankshaft Fixing Pin (1) is installed and locking the crankshaft.

Ensure that the camshaft notches (1) are in the 12 o'clock position.
If the camshaft notches are not in the 12 o'clock position, remove the EN-52586 Crankshaft Fixing Pin and rotate the crankshaft until the camshaft notch stands in the 12 o'clock position, and the crankshaft aligns with the EN-52586 Crankshaft Fixing Pin locking location.
Install the EN-52586 Crankshaft Fixing Pin with the camshaft notches (1) in the 12 o'clock position.

Install the EN-52445-2 Camshaft Tool (1,2) to the camshafts.

Camshaft Sprocket Bolt(3)»Remove and DISCARD
Camshaft Position Sensor Exciter Wheel(1)»Remove
Camshaft Sprocket(2)»Remove

Timing Chain Guide Bolt(2)»Remove[2x]
Timing Chain Guide(1)»Remove

Secondary Timing Chain(1)»Remove

Camshaft Sprocket Bolt(1)»Remove and DISCARD
Camshaft Sprocket(2)»Remove

Timing Chain Tensioner Shoe Bolt(2)»Remove
Timing Chain Guide(1)»Remove

Install the EN-47634 Holder (1) to the EN-956 Extension (4).
Using the EN-47634 Camshaft Sprocket Holder to hold the oil pump sprocket (2), loosen the oil pump drive bolt (3).
Remove the EN-47634 Camshaft Sprocket Holder and the EN-956 Extension.

Oil Pump Drive Bolt(3)»Remove
Remove the oil pump sprocket (2) and oil pump belt (1).

Push the timing chain guide (1) in direction of the arrow to compress the tensioner piston.
Install one EN-52234 Timing Chain Tensioner Retaining Pin (2) to lock the timing chain tensioner in position.
Timing Chain Tensioner Bolt(3)»Remove[2x]
Timing Chain Tensioner(4)»Remove

Timing Chain Guide Bolt(2)»Remove[2x]
Timing Chain Guide(1)»Remove

Timing Chain Guide(1)»Remove

Crankshaft Position Sensor Bolt(3)»Remove
Crankshaft Position Sensor(2)»Remove
Crankshaft Position Sensor Seal(1)»Remove and DISCARD

Note: Install the EN-49979 Holder (1) with the EN-49979-100 Holder Pins (2) to the outer hole pattern.

Install the EN-49979 Holder (1) with the EN-49979-100 Holder Adapter Pins (2) and EN-956-1 Extension (4) to hold the fuel injection pump driven sprocket.
Fuel Injection Pump Bolt(3)»Loosen
Remove the EN-49979 Holder, EN-49979-100 Holder Adapter Pins, and EN-956-1 Extension.

Fuel Injection Pump Bolt(1)»Remove and DISCARD

Install the EN-52448-3 nut (2) to the fuel injection pump driven sprocket (3).
Install the EN-52448-2 screw (1) to the fuel injection pump driven sprocket (3).
Using the EN-52448-3 nut (2) and EN-52448-2 screw (1), press out the fuel injection pump sprocket (3).

Slide the fuel injection pump driven sprocket (1) back slightly and disengage the sprocket from the timing chain (2).
Fuel Injection Pump Driven Sprocket(1)»Remove
Remove the EN-52448-2 screw.
Remove the EN-52448-3 nut.

Remove the EN-52586 Crankshaft Fixing Pin (1).

Crankshaft Pulley Bolt(1)»Remove[4x]

Timing Chain(1)»Remove

Oil Pan Bolt(1)»Remove[23x]

Note: Ensure that the two lower crankcase extension pins (3) do not get damaged while loosening.

Use the EN-37228 Separating Tool (1) to carefully loosen the lower oil pan (2) evenly all the way around. Avoid the locations near the lower crankcase extension pins.

Lower Oil Pan(1)»Remove and DISCARD

Disconnect the electrical connector.(1)

Oil Pump Bolt(1)»Remove[4x]

Note: Ensure that the pump shaft coupling is aligned vertically, parallel with the oil pump bolts.

Oil Pump(2)»Remove
Oil Pump Gasket(3)»Remove and DISCARD[2x]

Note: Components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.

Lower Crankcase Extension Bolt— M6 (1)»Remove
Lower Crankcase Extension Bolt— M6 (2)»Remove[12x]
Lower Crankcase Extension Bolt— M6 (3)»Remove
Lower Crankcase Extension Bolt— M8 (4)»Remove and DISCARD[7x]

Note: Ensure that the two lower crankcase extension pins (2, 4) do NOT get damaged while loosening.

Use the EN-37228 Separating Tool (3) to carefully loosen the lower crankcase extension (1) evenly all the way around. Avoid the lower crankcase extension pin locations.

Note: Pry carefully at the locations as shown (1, 3).

Lower Crankcase Extension(2)»Remove
Upper Oil Pan Gasket(4)»Remove and DISCARD
Oil Pump Gasket(5)»Remove and DISCARD

Note:

Many internal engine components will develop specific wear patterns on their friction surfaces.
Components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.
Tag or mark each part immediately when removed. Indicate the location, direction, or orientation when necessary.
The shear surfaces of the connecting rod and the connecting rod cap form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.

Remove and DISCARD the 4 connecting rod bearing cap bolts (3, 4) from cylinder 2 and cylinder 5.
Remove the 2 connecting rod caps (2) from cylinder 2 and cylinder 5.
Remove the 2 connecting rod lower bearings (1).

Remove and DISCARD the 4 connecting rod bolts (3, 4) from cylinder 1 and cylinder 6.
Remove the 2 connecting rod caps (2) from cylinder 1 and cylinder 6.
Remove the 2 connecting rod lower bearings (1).

Remove and DISCARD the 4 connecting rod bolts (4) from cylinder 3 and cylinder 4.
Remove the 2 connecting rod caps (3, 5) from cylinder 3 and cylinder 4.
Remove the 2 connecting rod lower bearings (1, 2).

Note:

Many internal engine components will develop specific wear patterns on their friction surfaces.
Components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.
Tag or mark each part immediately when removed. Indicate the location, direction, or orientation when necessary.

Crankshaft Bearing Cap Bolt(1)»Remove[14x]
Crankshaft Bearing Cap(2)»Remove[7x]

Note:

Mind the guide lug (2) for the installation procedure.
Mark the installation position of the crankshaft lower bearing. Lay aside in order removed.

Crankshaft Lower Bearing(1)@Crankshaft Bearing Cap(3)»Remove[7x]

Note: Mark the installation position of the crankshaft upper bearings and the crankshaft thrust bearings. Lay aside in order removed.

Crankshaft(1)»Remove
Crankshaft Upper Bearing(3)»Remove[7x]
Crankshaft Thrust Bearing(2)»Remove[2x]

Cleaning and Inspection Procedure - Required

Clean the automatic transmission flex plate (3) in solvent.

Warning: Refer to Safety Glasses and Compressed Air Warning

Dry the flex plate (3) with compressed air.
Inspect the flex plate (3) for the following conditions:

Stress cracks around the flex plate to torque converter mounting bolt hole locations (1) and flex plate to crankshaft (2, 4)

Note: Do not attempt to repair the welded areas that retain the ring gear to the flex plate. Install a NEW flex plate.

Cracks at welded areas that retain the ring gear onto the flex plate (3)
Damaged or missing ring gear teeth (5)

Clean the camshaft sprocket (1) surfaces.
Inspect the camshaft sprocket (1) for grooves, excessive wear, chipping, or embedded bearing material.
Replace the camshaft sprocket (1) if damaged.

Clean the crankshaft (1) with solvent.
Thoroughly clean all oil passages and inspect for restrictions or burrs.

Warning: Refer to Safety Glasses and Compressed Air Warning

Dry the crankshaft (1) with compressed air.
Inspect the 7 crankshaft bearing journals (2) and 6 connecting rod bearing journals (3) for wear:

Grooves or scoring
Scratches
Pitting or embedded bearing material

Inspect for grooves, scoring, scratches, pitting, or embedded bearing material in the following components:

Oil pump drive belt sprocket teeth
Crankshaft sensor sprocket teeth
Timing chain sprocket teeth

Damaged or missing crankshaft gear teeth (4)

Inspect crankshaft bearings (1) for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.

Inspect the crankshaft bearings (1) for excessive scoring or discoloration.
Inspect the crankshaft bearings (1) for dirt or debris embedded into the bearing material.

Inspect the crankshaft bearings (1) for improper seating indicated by bright, polished sections of the bearing.

Note:

The crankshaft main bearings are a precision insert type. Main bearing caps are machined with the engine block, for proper clearance, and cannot be shimmed or filed for bearing fit. If the clearances are found to be excessive, new bearings and/or engine block and cap repair or replacement may be required.
Do not rotate the crankshaft while gaging plastic is between the crankshaft journal and the bearing surface.
The crankshaft bearing clearances are critical. Excessive bearing clearance may affect crankshaft position sensor signals and may affect diagnostics and system operation.
Remove the bearing cap side bolts prior to cap removal.

Remove the bearing caps, bearing half, and bolts.
Install gaging plastic (1) onto the crankshaft journal. Install the gaging plastic the full width of the crankshaft bearing journal.
Install and tighten the bearing caps, bearing half, and bolts. Engine Mechanical Specifications
Remove the bearing caps, bearing half, and bolts.

Using the scale supplied with the plastic gaging kit, measure the gaging plastic (1) at its widest area.

If the gaging plastic (1) shows irregularity in the journal, exceeding 0.025 mm (0.001 in), remove the crankshaft and measure the journal with a micrometer.
If clearance cannot be brought to specifications, replace the crankshaft or engine block as required. Engine Mechanical Specifications

Note: Different classes of bearing can be used for a crankshaft bearing to reduce bearing clearance. The stronger of the two bearing must be inserted in the crankshaft bearing cap.

Crankshaft bearing clearance is calculated by using:

Crankshaft bearing bore diameter
Crankshaft bearing journal diameter
Crankshaft bearing thickness

Measure the crankshaft bearing play:

Compare the width of the flattened plastic thread to the measuring scale.
For the permissible crankshaft bearing clearance. Engine Mechanical Specifications

Clean the crankshaft pulley (1).
Inspect the crankshaft pulley (1) for damage to belt drive surface and to crankshaft pulley hub.
Inspect the crankshaft pulley (1) hub groove for damage or wear.
Replace the crankshaft pulley (1) if any damage is found.

Clean the crankshaft sprocket (1) surfaces.
Inspect the crankshaft sprocket (1) for grooves, excessive wear, chipping, or embedded bearing material.
Replace the crankshaft sprocket (1) if damaged.

Clean the fuel injection pump driven sprocket (1) surfaces.
Inspect the fuel injection pump driven sprocket (1) for grooves, excessive wear, chipping, or embedded bearing material.
Replace the fuel injection pump driven sprocket (1) if damaged.

Note: DO NOT soak or submerge the fuel rail or injectors in solvent.

Clean the exterior of the high pressure diesel fuel injection rail (4) and high pressure diesel fuel injectors in solvent.
Inspect the high pressure diesel fuel injection rail (4) and components for the following conditions:

Damage, debris, or restrictions to the high pressure diesel fuel injection rail (4)
Damage, debris, or restrictions to the fuel ports (2) at the high pressure diesel fuel injection rail (4)
Damage to the mounting area or threads on the high pressure diesel fuel injection rail (4)
Damage to the holes of the high pressure diesel fuel sensor (1) and fuel pressure regulator (3)

Clean the oil pump sprocket (1) surfaces.
Inspect the oil pump sprocket (1) for grooves, scoring, scratches, pitting, or embedded bearing material.
Replace the oil pump sprocket (1) if damaged.

Inspect the oil pump belt (1) for grooves, pitting, fraying, or missing teeth.
Replace the oil pump belt (1) if damaged.

Clean the timing chain (1) surfaces.
Inspect the timing chain (1) for signs of excessive wear, chipping, or seizure of the timing chain links.
Replace the timing chain (1) if damaged.

Clean the timing chain guide (1) surfaces.
Inspect the timing chain guide (1) for signs of cracking or wear.
Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in) of depth on the chain guide surface.

Clean the secondary timing chain (1) surfaces.
Inspect the timing chain (1) for signs of excessive wear, chipping, or seizure of the timing chain links.
Replace the timing chain (1) if damaged.

Clean the secondary timing chain guide (1) surfaces.
Inspect the timing chain guide (1) for signs of cracking or wear.
Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in) of depth on the chain guide surface.

Clean the primary timing chain tensioner (1) surfaces.
Inspect the timing chain tensioner (1) for wear.
Replace the timing chain tensioner (1) if damaged.

Clean the secondary timing chain tensioner (1) surfaces.
Inspect the timing chain tensioner (1) for wear.
Replace the timing chain tensioner (1) if damaged.

Caution: The glow plug bore MUST be cleaned prior to glow plug installation. If the glow plug bore is not cleaned of carbon buildup prior to glow plug installation, it may cause severe damage to the glow plug. If the glow plug is damaged, the glow plug bore and combustion chamber must be cleaned of all debris, and the glow plug must be replaced.

Using the EN-52074 Glow Plug Bore Reamer (1), clean the glow plug bore. Hole must be free of lubricant and grease.

Cleaning and Inspection Procedure - Conditional

Note: The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation.

Clean the camshaft housing (1) in solvent.
Inspect the camshaft housing (1) for damage or cracking. A cracked or damaged camshaft housing may:

Leak engine oil
Affect crankcase ventilation
Interfere with the camshafts
Allow water or condensation to enter the engine

Inspect the exterior of the camshaft housing (1) for the following conditions:

Damage to the camshaft housing bolt holes (2)
Damage to the camshaft housing injector bracket bolt holes (3)
Damage to the positive crankcase ventilation valve (4).

Inspect the interior of the camshaft housing for the following conditions:

Inspect the camshaft housing for cracks, casting imperfections, or damage.
Inspect the camshaft housing seal locations (2) for cracks or damage.
Inspect the crankcase ventilation oil separator cover (1) for cracks or damage.

Clean the camshaft components in solvent.

Warning: Refer to Safety Glasses and Compressed Air Warning

Dry the components with compressed air.
Inspect the camshaft bearing journals (1) and camshaft lobes (3) for following conditions:

Excessive scoring or pitting
Discoloration from overheating
Deformation from excessive wear, especially the camshaft lobes (3)

Inspect the hexagon (2) for damage.
Inspect the threaded hole (4) for damage.
If any of the conditions above exist on the camshafts, replace the camshafts.

Clean the engine coolant flow control valve (1).
Inspect the engine coolant flow control valve (1).
Replace the engine coolant flow control valve (1) if any damage is found.

Clean the exhaust gas recirculation valve (1).
Inspect the exhaust gas recirculation valve (1).
Replace the exhaust gas recirculation valve (1) if any damage is found.

Clean the engine oil cooler (1,2).
Inspect the engine oil cooler (1,2).
Replace the engine oil cooler (1,2) if any damage is found.

Clean the exhaust manifold (1) in solvent.

Warning: Refer to Safety Glasses and Compressed Air Warning

Dry the exhaust manifold (1) with compressed air.
Inspect the exhaust manifold (1) for damage.

Using a straightedge (2) and a feeler gauge, measure the exhaust manifold mounting face (3) for warpage. An exhaust manifold face with warpage in excess of 0.2 mm (0.008 in) may cause an exhaust leak and may effect diagnostics and system performance.
An exhaust manifold (1) which does not fall within the specifications must be replaced.

Caution: The fuel injector must be cleaned with the proper cleaning equipment. DO NOT use abrasive cleaning methods, such as a metallic brush, to remove deposits. Cleaning an injector with improper tools will damage the fuel injector.

Using a soft bristle non-metallic brush and top engine cleaner, remove any deposits from the high pressure diesel fuel injector nozzle tip (1) and the copper washer sealing area before installation.
Inspect the high pressure diesel fuel injector nozzle tip (1) for cracks, dents, or other damage.
Inspect the high pressure diesel fuel injector nozzle tip (1) for any signs of discoloration.

Clean the intake manifold mating surfaces.
Inspect the intake manifold (1) for damage.
Inspect the intake manifold (1) for cracks and fractures.
Inspect all 12 intake runner valves (5) for damage.
Clean the throttle body sealing surface (3).
Clean the exhaust gas recirculation cooler outlet pipe sealing surface (2).
Clean the intake manifold to cylinder head sealing surface (4).
Replace the intake manifold (1) as necessary.

Visually inspect the intake manifold mounting face (1) for cracks, warpage, or damage. If any damage is found replace the intake manifold. An intake manifold face with cracks warpage or damage may cause an intake leak and may effect diagnostics and system performance.

Clean the lower crankcase extension (1) in solvent.
Inspect all sealing and mating surfaces for damage, and repair or replace the lower crankcase extension (1) if necessary.
Inspect all threaded and through holes for damage or excessive debris.
Check for roughness or end play in the oil pump drive shaft bearing (1).

Clean the oil pump (1) sealing surfaces with solvent.
Dry the oil pump (1) sealing surfaces.
Inspect the oil pump (1) sealing surfaces.
Rotate the oil pump drive shaft and check for roughness.

Clean the timing chain upper cover (1).
Inspect the timing chain upper cover (1) mating surfaces for damage.
Replace the timing chain upper cover (1) if damaged.

Clean all threads on the compressor air intake turbocharger, if necessary.
Clean all sealing surfaces.
Inspect the wastegate regulator mechanism (1) for functionality.
Inspect the turbine blades for damage or foreign material.
Inspect the turbine blade shaft for excessive radial and axial end play.
Inspect the compressor air intake turbocharger for cracks or other damage.
Inspect the compressor air intake turbocharger mating surface for flatness.

Clean and inspect the water pump (1).
Clean and inspect the water pump mating surfaces.
Inspect the water pump impeller for damage.
Inspect the water pump shaft for looseness.
Replace the water pump (1) if damaged.

Assemble Procedure

Note:

Ensure that the guide lugs (3) are seated properly.
When using the original crankshaft bearing, ensure it is installed in the same position as removed.

Lubricate the crankshaft upper bearings with engine oil. Adhesives, Fluids, Lubricants, and Sealers
Install the 2 crankshaft thrust bearings (2).

Lubricate the crankshaft with engine oil. Adhesives, Fluids, Lubricants, and Sealers
Crankshaft(1)»Install

Check the 2 crankshaft thrust bearings (1) for proper seat.

Note:

Ensure that the guide lugs (2) are seated properly.
When using the original crankshaft bearing, ensure it is installed in the same position as removed.

Lubricate the crankshaft lower bearings with engine oil. Adhesives, Fluids, Lubricants, and Sealers
Crankshaft Lower Bearing(1)@Crankshaft Bearing Cap(3)»Install[7x]

Note:

When using the original crankshaft bearing cap, ensure it is installed in the same position as removed.
The arrow (3) on the crankshaft bearing cap must shown in the front direction of the engine.

Crankshaft Bearing Cap(2)»Install[7x]
Crankshaft Bearing Cap Bolt(1)»Install NEW[14x]—Fastener Specifications
Coat the following components with engine oil:

Connecting rods
Connecting rod bearings

Note:

If the old connecting rod bearing caps will be reused, install in the original position.
If the old bearing will be reused, install in the original position.
Ensure that the connecting rod marks (4) are oriented toward rear of engine.

Install the 2 connecting rod bearing caps (2) along with the 2 connecting rod bearings (1) on the connecting rods at cylinder 2 and cylinder 5.Fastener Specifications
Turn the crankshaft 120 degrees.

Note:

If the old connecting rod bearing caps will be reused, install in their original position.
If the old bearing will be reused, install in the original position.
Ensure that the connecting rod marks (4) are oriented toward rear of engine.

Install the 2 connecting rod bearing caps (3, 6) along with the 2 connecting rod bearings (1, 2) on the connecting rods at cylinder 3 and cylinder 4.Fastener Specifications

Note: Ensure that the sealing surface is clear of oil, grease and old sealant material.

Clean all sealing surfaces.
Ensure proper use of room temperature vulcanizing (RTV) sealant.Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

Note:

Install and align the lower crankcase extension to the engine block within 8 minutes after applying the sealer.
The bolts must be installed and fastened to final torque specification immediately after the component is installed.

Apply a 4 mm (0.158 in) bead of sealer (1) along the perimeter of the sealing surface and at the center location, dimension a.Adhesives, Fluids, Lubricants, and Sealers
Apply a 6 mm (0.236 in) bead of sealer (2) at 4 locations on each end of the perimeter sealing surface, dimension b. Adhesives, Fluids, Lubricants, and Sealers

Oil Pump Gasket(5)»Install NEW
Upper Oil Pan Gasket(4)»Install NEW

Note: Check that the 2 guide pins (1, 3) from the lower crankcase extension sit correctly in the engine block.

Lower Crankcase Extension(2)»Install

Note: Install all lower crankcase extension bolts hand tight only prior to the tightening sequence.

Lower Crankcase Extension Bolt—M8 (4)»Install NEW[7x]

Note: Take note that there are different bolt lengths.

Lower Crankcase Extension Bolt—M6 (1, 2, 3)»Install and hand tighten[14x]
Lower Crankcase Extension Bolt—M6 (1, 2, 3)»Tighten in sequence[14x]—Fastener Specifications

Oil Pump Gasket(2, 5)»Install NEW[2x]

Note: Ensure that the pump shaft coupling is aligned vertically, parallel with the oil pump bolts.

Oil Pump(1)»Install
Check that the oil pump drive gear (3) sits correct in the oil pump drive shaft (4).

Oil Pump Bolt(1)»Install and hand tighten[4x]

Connect the electrical connector.(1)

Oil Pump Bolt(1)»Tighten in sequence[4x]—Fastener Specifications

Note: Ensure that the sealing surface is clear of oil, grease and old sealant material.

Clean all sealing surfaces.
Ensure proper use of room temperature vulcanizing (RTV) sealant.Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

Note:

Install and align the oil pan to the lower crankcase extension within 8 minutes after applying the sealer.
The bolts must be installed and fastened to final torque specification immediately after the component is installed.

Apply a 4.0 mm (0.158 in) bead of sealer (1) to the oil pan sealing surface.Adhesives, Fluids, Lubricants, and Sealers

Note: Ensure the alignment pins (2, 3) are properly aligned when installing the oil pan.

Lower Oil Pan(1)»Install NEW

Oil Pan Bolt(1)»Install and tighten[23x]—Fastener Specifications

Timing Chain Guide(1)»Install

Install the timing chain (1) to the fuel injection pump driven sprocket (2).
Lubricate the high pressure diesel fuel pump shaft. Adhesives, Fluids, Lubricants, and Sealers

Install the timing chain (1) and the fuel injection pump driven sprocket (2) as an assembly.

Timing Chain Guide(1)»Install
If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:

Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
Apply thread locking adhesive to the external threads of the components.Adhesives, Fluids, Lubricants, and Sealers
Ensure there are no gaps in the thread locking adhesive once applied to the component.

Caution: Refer to Fastener Caution.

Timing Chain Guide Bolt(2)»Install and tighten[2x]—Fastener Specifications

Observe the alignment of the timing links on the timing chain for installation:

Timing link (1) will align with the fuel injection pump driven sprocket
Timing link (2) will align with the primary timing chain fixed guide
Timing link (3) will align at the lower position at the crankshaft sprocket

Note: The link at the crankshaft is difficult to see.

If the 3 color links are not aligned, rotate the fuel injection pump shaft until alignment is achieved.

If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:

Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
Apply thread locking adhesive to the external threads of the components.Adhesives, Fluids, Lubricants, and Sealers
Ensure there are no gaps in the thread locking adhesive once applied to the component.

Install a NEW fuel injection pump bolt (1) and hand tighten.

Timing Chain Guide(1)»Install
If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:

Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
Apply thread locking adhesive to the external threads of the components.Adhesives, Fluids, Lubricants, and Sealers
Ensure there are no gaps in the thread locking adhesive once applied to the component.

Timing Chain Guide Bolt(2)»Install and tighten—Fastener Specifications

Timing Chain Tensioner(4)»Install
Timing Chain Tensioner Bolt(3)»Install and tighten[2x]—Fastener Specifications
Remove the EN-52234 Timing Chain Tensioner Retaining Pin (2).

Tighten the fuel injection pump bolt (1). Fastener Specifications

Crankshaft Position Sensor Seal(1)»Install NEW
Crankshaft Position Sensor(2)»Install
Crankshaft Position Sensor Bolt(3)»Install and tighten—Fastener Specifications

Oil Pump Belt(1)@Oil Pump Sprocket(2)»Install
Oil Pump Belt(1)@Crankshaft»Install
Oil Pump Sprocket(2)»Install

Install the EN-47634 Holder (1) to the oil pump sprocket (2).
Oil Pump Drive Bolt(3)»Install and tighten—Fastener Specifications
Remove the EN-47634 Holder (1) and the EN-956 Extension (4).

Camshaft Sprocket(2)»Install

Note: Final torque for camshaft sprockets is completed after secondary timing chain and exhaust camshaft sprocket is installed.

Camshaft Sprocket Bolt(1)»Install NEW and hand tighten

Secondary Timing Chain(1)»Install
Ensure that the timing chain slack is on the secondary timing chain tensioner side.

Camshaft Sprocket(2)»Install
Camshaft Position Sensor Exciter Wheel(1)»Install
Camshaft Sprocket Bolt(3)»Install NEW and hand tighten

Timing Chain Guide(1)»Install

If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
Apply thread locking adhesive to the external threads of the components.Adhesives, Fluids, Lubricants, and Sealers
Ensure there are no gaps in the thread locking adhesive once applied to the component.

Timing Chain Guide Bolt(2)»Install and tighten[2x]—Fastener Specifications

Note: Check that the nose of the EN-52445-3 Camshaft Tool (1) sits correct in the gap (2) of the camshaft position sensor exciter wheel (3).

Install the EN-52445-3 Camshaft Tool (1) to both camshafts.

Timing Chain Tensioner Gasket(1)»Install NEW

Caution: Refer to Component Fastener Tightening Caution.

Timing Chain Tensioner(2)»Install and tighten—Fastener Specifications

Camshaft Sprocket Bolt(1)»Tighten[2x]—Fastener Specifications

RemoveEN-52445-3 Camshaft Tool Holder (2).
Remove EN-52445-2 Camshaft Tool Holder (1,3)

EN-52586 Crankshaft Fixing Pin(4)»Remove
Rotate the engine by hand to ensure there is no interference.
Crankshaft Pulley Bolt(1)»Remove[4x]

Note: If service part comes with seal protector then use inner seal protector ring to slip the seal lip over the crankshaft snout, instead of EN-52446-2 Seal Protector.

Install the EN-52446-2 Seal Protector (1) to the crankshaft.
Install the 4 EN-52446-4 Studs (2).
Install the 4 EN-52446-5 Nuts (3) and hand tighten.

Note:

Observe the locations for additional sealer (2) while applying the sealant path.
The bolts must be installed and fastened to final torque specification immediately after the component is installed.

Clean all sealing surfaces.
Ensure proper use of room temperature vulcanizing (RTV) sealant.Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
Apply a 4.0 mm (0.158 in) bead of sealer along the timing chain lower cover sealing path (1), dimension a. Increase the bead to 6.0 mm (0.236 in) at the two locations (2), dimension b. Adhesives, Fluids, Lubricants, and Sealers

Note: If service part comes with seal protector then use inner seal protector ring to slip the seal lip over the crankshaft snout, instead of EN-52446-2 Seal Protector.

Align the timing chain lower cover (1) with the two transmission locating pins (2).
Timing Chain Lower Cover(1)»Install NEW
Check that the crankshaft rear oil seal sits correct on the crankshaft.
Remove the EN-52446-2 Seal Protector (3).

Timing Chain Cover Bolt(1,2)»Install and tighten—Fastener Specifications

Note: Ensure that the sealing surface is clear of oil, grease and old sealant material.

Clean all sealing surfaces.
Ensure proper use of room temperature vulcanizing (RTV) sealant.Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

Note:

Observe the locations for additional sealer while applying the sealant path.
Install and align the timing chain upper cover to the cylinder head within 8 minutes after applying the sealer.
The bolts must be installed and fastened to final torque specification immediately after the component is installed.

Apply a bead of sealant (1) to the timing chain upper cover sealing surface using the following procedure: Adhesives, Fluids, Lubricants, and Sealers

Begin applying a 6.0 mm (0.236 in) bead, dimension a, as shown.
Continue to apply the bead, decreasing to a 4.0 mm (0.158 in) bead, dimension b, for the remaining bead path, until near the end.
At the end of the bead path, increase to a 6.0 mm (0.236 in) bead, dimension a, as shown.

Engine Front Cover Locating Pin(2)@Cylinder Head»Install[2x]
Timing Chain Upper Cover(1)@Cylinder Head»Install

Note: Take note that there are different bolt lengths.

Apply sealant to the front threads of the 2 timing chain cover bolts (4).
Timing Chain Cover Bolt(3,4)»Install and tighten[6x]—Fastener Specifications
Clean off the excess sealant residue between the timing chain upper cover and the cylinder head.
Clean the glow plugs and mating hole, it must be free of lubricant and grease.

Note: The ceramic glow plug technology is sensitive to collision, drops, or general impact. Avoid side force or the bending of the tip during the installation in the head. Replace the glow plug if one or more of these conditions is suspected.

Glow plugs must be discarded whenever removed, and replaced with NEW.
If the cylinder head is removed, the accompanying glow plugs must be discarded and replaced with NEW.
Handle with extreme care, do not allow glow plugs to touch each other.
Do not use power tools to install glow plugs.
Use a suitable, commercially available glow plug socket.
First install glow plugs by hand at least 3 turns into the cylinder head.
Avoid canting of the glow plugs during the insertion process into the cylinder head.

Glow Plug(1)»Install NEW and tighten[6x]—Fastener Specifications

Clean the camshaft housing gasket surface on the cylinder head.
If the camshaft housing is reused, clean the camshaft housing seal groove.
Camshaft Housing Gasket(1)@Camshaft Housing»Install NEW[2x]

Inspect each of the 26 camshaft housing bolts (2) in the camshaft housing (4). Ensure the correct seat of the 26 camshaft housing bolt bushings (3) and the camshaft housing cover insulator (1) with the camshaft housing gasket (5).

Note:

Install and align the camshaft housing to the cylinder head within 8 minutes after applying the sealer.
The bolts must be installed and fastened to final torque specification immediately after the component is installed.

Apply a bead of sealant (1) to the camshaft housing sealing locations where the timing chain upper cover joins the cylinder head. Adhesives, Fluids, Lubricants, and Sealers

Camshaft Housing(1)@Cylinder Head»Install
Camshaft Housing Bolt(2)»Install and tighten[26x]—Fastener Specifications

Clean the 6 fuel injector bores in the cylinder head.
If the fuel injector is reused, clean the fuel injectors.
Fuel Injector Seal(2)»Install NEW[6x]
Fuel Injector Washer(3)»Install NEW[6x]
High Pressure Diesel Fuel Injector(1)»Install[6x]

Note: Pay attention to the mounting position of the injector brackets.

Multiport Fuel Injector Bracket(2)»Install[6x]

Note: Tighten the fuel injector bracket bolt only when installing the high pressure diesel fuel feed pipes.

Fuel Injector Bolt(1)»Install NEW and hand tighten[6x]

Charge Air Cooler Bracket(1)»Install
High Pressure Diesel Fuel Injection Rail(2)»Install

Note: Tighten the fuel injection fuel rail nuts only when installing the high pressure diesel fuel feed pipes.

Fuel Injection Fuel Rail Nut(3)»Install, but do NOT tighten[3x]

Diesel Glow Plug Wiring Harness(3)»Install
Electrical Connector(2)@Glow Plug»Connect[6x]
Clip(1)@Diesel Glow Plug Wiring Harness»Install[3x]

High Pressure Diesel Fuel Feed to Injector Pipe(2)»Install[3x]

Hand tighten the NEW 3 gray coded high pressure diesel fuel feed pipes nuts (3) at the fuel rail.
Hand tighten the NEW 3 black coded high pressure diesel fuel feed pipes nuts (5) at the fuel injector.

High Pressure Diesel Fuel Feed to Injector Pipe(1)»Install[3x]

Hand tighten the NEW 3 gray coded high pressure diesel fuel feed pipes nuts (3) at the fuel rail.
Hand tighten the NEW 3 black coded high pressure diesel fuel feed pipes nuts (5) at the fuel injector.

Fuel Injector Bolt(4)@Multiport Fuel Injector Bracket»Tighten[6x]—Fastener Specifications
Tighten the 6 gray coded high pressure diesel fuel feed pipes nuts (3) at the fuel rail. Fastener Specifications
Tighten the 6 black coded high pressure diesel fuel feed pipes nuts (5) at the fuel injector. Fastener Specifications

Fuel Injection Fuel Feed Pipe Bracket(1)»Install
Fuel Injection Fuel Feed and Return Pipe Retainer Bolt(2)»Install and tighten—Fastener Specifications

Fuel Injector Fuel Return Hose Bracket(2)»Install
Fuel Return Pipe Clip Bolt(1)»Install and tighten[2x]—Fastener Specifications

High Pressure Diesel Fuel Feed to Rail Pipe(1)»Install NEW[2x]

Hand tighten the 2 high pressure diesel fuel feed to rail pipes to the fuel injection fuel rail (5).
Hand tighten the 2 high pressure diesel fuel feed to rail pipes to the fuel injection fuel pump (4).

Fuel Feed Pipe Clip Bolt(2, 3)»Install and tighten[4x]—Fastener Specifications
High Pressure Diesel Fuel Feed to Rail Pipe(1)»Install and tighten[4x]—Fastener Specifications

Fuel Injection Fuel Rail Nut(1)»Tighten[3x]—Fastener Specifications

Fuel Pump Fuel Feed Hose(2)»Install
Fuel Feed Hose Connector(4)»Connect—Metal Collar Quick Connect Fitting Service
Fuel Feed Hose Connector Retainer(3)Engage
Heater Outlet Pipe Bolt(1)@Fuel Pump Fuel Feed Hose»Install and tighten—Fastener Specifications

Seal Ring(6)»Install NEW[6x]
Fuel Injection Fuel Return Pipe(2)»Install
Clip the fuel injection fuel pipe retainer (3) to the high pressure diesel fuel feed to rail pipe.
Push the 6 fuel injection fuel return pipe locking springs (1) in the direction shown and install the fuel injection fuel return pipe on the fuel injectors.
Fuel Injection Fuel Return Pipe Clip(4)@High Pressure Diesel Fuel Injection Rail»Install
Unlock the fuel injection fuel return pipe clip (5) by pressing the spring notch in direction of the arrow, and install the hose to the diesel fuel separator.

Fuel Injector Wiring Harness(3)»Install
Retaining Clip(2)@Fuel Injector Wiring Harness»Install[8x]
Wiring Harness Connector(1)@Fuel Injector Wiring Harness»Connect[6x]

Crankshaft Pulley Bolt(1)»Install[4x]
Rotate the crankshaft with a suitable tool in the direction of the arrow at the crankshaft pulley bolts (1), until the crankshaft locking divot (2) aligns with the engine block (3).
EN-52586 Crankshaft Fixing Pin(4)»Install

Clean the 8 flex plate bolt threads in the crankshaft.

Note: The flex plate and the bolts fits only in one position.

Position the flex plate (1) to align the flex plate alignment bore (2) to the crankshaft alignment bore.

Automatic Transmission Flex Plate(1)»Install
Due to the unknown shelf life of the adhesive patch, prepare the 8 NEW automatic transmission flex plate bolts (2) as follows:

Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
Apply thread locking adhesive to the external threads of the components.Adhesives, Fluids, Lubricants, and Sealers
Ensure there are no gaps in the thread locking adhesive once applied to the component.

Automatic Transmission Flex Plate Bolt(2)»Install NEW and hand tighten[8x]
EN-52586 Crankshaft Fixing Pin»Remove
Clean all sealing surfaces.
Ensure proper use of room temperature vulcanizing (RTV) sealant.Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

Note:

Observe the locations for additional sealer while applying the sealant path.
Install and align the crankshaft front oil seal to the block within 8 minutes after applying the sealer.
The bolts must be installed and fastened to final torque specification immediately after the component is installed.

Apply a 4.0 mm (0.158 in) bead of sealer along the timing chain lower cover sealing path (1), dimension a. Increase the bead to 6.0 mm (0.236 in) at the two locations (2), dimension b.Adhesives, Fluids, Lubricants, and Sealers

Install the EN-52452 Front Crankshaft Seal Installer (1).
Install and hand tighten 2 bolts EN-52452 Front Crankshaft Seal Installer (2).

Crankshaft Front Oil Seal(1)»Install NEW
Check that the crankshaft front oil seal sits correct on the crankshaft and on the engine front cover locating pins (2, 4)
Remove the 2 bolts from the EN-52452 Front Crankshaft Seal Installer (5)
Remove the EN-52452 Front Crankshaft Seal Installer (3).

Engine Front Cover Bolt(1)»Install and tighten[8x]—Fastener Specifications

Radiator Outlet Pipe Seal(2)@Water Pump Inlet Pipe(1)»Install NEW
Water Pump Inlet Pipe(1)@Engine Block»Install
Water Pump Gasket(3)@Water Pump(4)»Install NEW
Water Pump(4)»Install
Water Pump Bolt(5, 6)»Install and tighten[6x]—Fastener Specifications

Crankshaft Pulley(1)»Install
Crankshaft Pulley Bolt(2)»Install, but do NOT tighten[4x]

Note: Have an additional technician hold the special tool EN-956-1 Extension in place while torquing takes place.

Install the EN-49979 Holder (1) with EN-956-1 Extension (3).
Crankshaft Pulley Bolt(2)»Tighten—Fastener Specifications
Remove the EN-49979 Holder (1) with EN-956-1 Extension (3).

Engine Coolant Thermostat Housing Gasket(1)»Install NEW
Engine Coolant Flow Control Valve(2)»Install
Engine Coolant Flow Control Valve Bolt(3)Install and tighten[6x]—Fastener Specifications

Engine Oil Cooler Gasket(3)»Install NEW
Engine Oil Cooler Gasket(2)»Install NEW
Engine Oil Cooler(1)»Install

Engine Oil Cooler Bolt(1)»Install and tighten[5x]—Fastener Specifications

Intake Manifold Runner Control Valve Gasket(3)»Install NEW
Intake Manifold(1)»Install
Intake Manifold Bolt(2)»Install[9x]—Fastener Specifications

Intake Manifold Cover(1)»Install
Intake Manifold Cover Retainer(2)»Install[2x]

Diesel Glow Plug Wiring Harness(1)@Intake Manifold»Install

Clean the exhaust manifold flange bolt threads in the cylinder head.
Exhaust Manifold Gasket(3)»Install NEW
Exhaust Manifold(2)»Install
Exhaust Manifold Flange Bolt(1)»Install and tighten[12x]—Fastener Specifications

Exhaust Manifold Heat ShieldInstall
Exhaust Manifold Heat Shield Bolt(1)»Install—Fastener Specifications

Turbocharger Oil Return Pipe Gasket(5)»Install NEW
Turbocharger Oil Return Pipe Gasket(6)»Install NEW
Turbocharger Gasket(3)»Install NEW
Turbocharger Assembly(1)»Install
Turbocharger Nut(2, 4)»Install NEW[3x]
Turbocharger Oil Return Pipe Bolt(8)»Install and tighten[2x]—Fastener Specifications
Turbocharger Oil Feed Pipe Bolt(7)»Install and tighten[2x]—Fastener Specifications
Turbocharger Oil Feed Pipe Bracket Bolt(9)»Install and tighten—Fastener Specifications
Turbocharger Nut(2, 4)»Tighten[3x]—Fastener Specifications

Exhaust Gas Recirculation Valve Cooling Feed Hose Clamp(1)»Release—Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Valve Cooling Feed Hose(2)»Install

Positive Crankcase Ventilation Hose Clamp(1)»Release[2x]—Hose Clamp Replacement Guidelines - Spring Type
Positive Crankcase Ventilation Hose(2)»Install

Oil Level Indicator Seal(2)@Oil Level Indicator Tube»Install NEW
Oil Level Indicator Tube(1)»Install

Oil Level Indicator Tube Bolt(3)»Install and tighten[2x]—Fastener Specifications
Clip(4)@Oil Level Indicator Tube»Install
Engine Oil Level Indicator(2)»Install

Exhaust Gas Recirculation Cooler Inlet Pipe Gasket(3)@Exhaust Gas Recirculation Cooler Inlet Pipe»Install NEW
Exhaust Gas Recirculation Cooler Inlet Pipe(2)»Install

Note: Support the exhaust gas recirculation cooler inlet pipe when applying torque to the bolts.

Note: Considering the reduced clearance, carefully install the bolts to ensure the tool does not contact the pipe.

Exhaust Gas Recirculation Cooler Bolt(1)»Install and tighten[2x]—Fastener Specifications

Engine Coolant Air Bleed Hose(1)»Install
Engine Coolant Outlet Pipe Bracket Bolt(2)»Install and tighten—Fastener Specifications

Turbocharger Coolant Feed and Return Pipe Gasket(1)»Install NEW[2x]

Note: Some components not shown for graphic clarity.

Engine Coolant Air Bleed Hose(3)»Install
Engine Coolant Air Bleed Hose Stud(2)»Install and tighten—Fastener Specifications
Engine Coolant Air Bleed Pipe Bolt(1)»Install and tighten[2x]—Fastener Specifications

Note: Some components not shown for graphic clarity.

Wiring Harness Retainer(3)@Engine Coolant Air Bleed Hose»Install[2x]
Engine Coolant Air Bleed Hose(2)@Engine Coolant Air Bleed Hose»Install
Engine Coolant Air Bleed Hose Clamp(1)»Engage—Hose Clamp Replacement Guidelines - Spring Type

Note: Some components not shown for graphic clarity.

Position the engine wiring harness channel (3) to the front of the engine.
Engine Wiring Harness Bracket Bolt(2)»Install and tighten—Fastener Specifications
Engine Wiring Harness Bracket Nut(1)»Install and tighten[2x]—Fastener Specifications

Engine Coolant Air Bleed Hose Clamp(1)»Release—Hose Clamp Replacement Guidelines - Spring Type
Engine Coolant Air Bleed Pipe(2)»Install
Clip(3)@Exhaust Gas Recirculation Cooler Outlet Pipe»Engage

Engine Coolant Thermostat Gasket(1, 6)@Thermostat Bypass Hose»Install NEW[2x]
Thermostat Bypass Hose(3)»Install
Thermostat Bypass Pipe Bolt(2, 5)»Install and tighten[4x]—Fastener Specifications
Thermostat Bypass Pipe Bolt(4)»Install and tighten—Fastener Specifications

Engine Coolant Thermostat Gasket(4)@Thermostat Bypass Hose»Install NEW
Thermostat Bypass Hose Clamp(1)»Release—Hose Clamp Replacement Guidelines - Spring Type
Thermostat Bypass Hose(2)»Install
Thermostat Bypass Pipe Bolt(3)»Install and tighten[2x]—Fastener Specifications

Thermostat Bypass Hose Clamp(3)»Release—Hose Clamp Replacement Guidelines - Spring Type
Thermostat Bypass Hose(1)»Install
Water Outlet Stud (2)»Install and tighten—Fastener Specifications

Note: Coat the oil filter seal with a thin film of fresh engine oil.

Oil Filter(3)»Install and tighten—3/4 to 1 full turn after gasket makes contact with the sealing surface on the filter mounting flange
Clean and inspect the oil pan drain plug (1) and seal (2). Replace as necessary.
Oil Pan Drain Plug Seal(2)»Install
Oil Pan Drain Plug(1)»Install and tighten—Fastener Specifications

Note: Engine prelubing is necessary by using a NEW engine block.

If equipped, remove the engine oil pressure sensor thread hole closure plug instead of the engine oil pressure sensor (1).
Engine Oil Pressure Sensor»Remove and DISCARD
Install the M12x1.75 adapter P/N 509376.

Note: A constant and continuous flow of clean engine oil is required in order to properly prime the engine. Ensure an approved engine oil is used, as specified in the owners manual.

Install the flexible hose to the adapter and open the valve.
Pump the handle on the EN-45299 Engine Preluber in order to flow a minimum of 1–1.9 liters (1–2 quarts) of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
Close the valve and remove the flexible hose and adapter from the engine.
Engine Oil Pressure Sensor»Install NEW and hand tighten—Fastener Specifications
Fill the engine oil to the proper level with NEW engine oil.
Install the EN-52474 Engine Lift Hook Set.
Engine»Install—Engine Removal and Installation