: | Aug 6, 2007 |
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Apply an 8 mm bead of sealant to the cylinder block in the areas shown.
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Install the oil pan extension.
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Secure the oil pan extension.
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Install the oil pump screen and pickup tube.
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Install the oil pan.
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. | Install the fuel injection pump.
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Install the oil cooler assembly.
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. | Install the crankshaft position (CKP) sensor.
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Install the flexplate.
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. | Using the special tool, lock the flexplate.
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. | Install the special tool. ![]() |
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Install the flywheel.
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Using the special tool, install the clutch disc and pressure plate.
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. | Remove the special tool. ![]() |
. | Using the special tool, lock the flywheel.
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. | Check the LH cylinder head face for distortion, across the center and from corner to corner. |
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Install a new LH cylinder head gasket. |
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Install the LH cylinder head assembly.
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. | Check the RH cylinder head face for distortion, across the center and from corner to corner. |
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Install a new RH cylinder head gasket. |
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Install the RH cylinder head assembly.
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. | Install the secondary timing chain to the RH bank camshafts. |
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Install the RH bank secondary timing chain tensioner.
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Install the RH bank camshafts and secondary timing chain tensioner assembly.
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. | Secure the RH bank secondary timing chain
tensioner.
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Install the RH bank camshaft bearing caps.
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. | Apply sealant to the RH exhaust camshaft end
bearing cap at the positions shown. ![]() |
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Install the RH bank exhaust camshaft end bearing caps.
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. | Release the RH bank secondary timing chain
tensioner piston.
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. | Install the secondary timing chain to the LH bank camshafts. |
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Install the LH bank secondary timing chain tensioner.
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Install the LH bank camshafts and secondary timing chain tensioner assembly.
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. | Secure the LH bank secondary timing chain
tensioner.
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Install the LH bank camshaft bearing caps.
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. | Apply sealant to the 2 LH exhaust camshaft end
bearing caps at the positions shown. ![]() |
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Install the LH bank exhaust camshaft end bearing caps.
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. | Release the LH bank secondary timing chain
tensioner piston.
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. | Install the fuel injection pump belt rear cover.
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. | Install the camshaft rear pulley.
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. | Install the special tool to the camshaft rear
pulley.
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Secure the camshaft rear pulley.
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. | Remove the special tools.
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Install the new fuel injection pump belt. |
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Install a new fuel injection pump belt tensioner.
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. | Install the fuel injection pump belt cover.
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. | Install the cooling fan drive hub bearing.
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Using the special tool, install the 2 camshaft pulley hubs.
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. | Install the 2 exhaust camshaft pulleys.
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. | Install the special tools.
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. | Install the 2 timing belt idler pulleys.
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. | Rotate both camshaft pulleys clockwise. ![]() |
. | Install a new timing belt tensioner.
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Install the new timing belt.
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Tension the timing belt.
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Secure the camshaft pulleys.
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. | Remove the special tools. ![]() |
. | Remove the special tool.
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. | Remove the special tool.
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. | Rotate the engine two complete turns clockwise. |
. | Using the special tool, lock the flexplate.
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. | Using the special tool, lock the flywheel.
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. | Install the special tools to the exhaust
camshaft pulleys.
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. | Remove the special tool.
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. | Remove the special tool.
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Install a new fuel injector return line. |
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Connect the fuel pipe to the fuel cooler. |
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Install the cylinder head coolant outlet assembly.
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Install the turbocharger oil supply line.
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. | Install the breather line.
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Install the brake vacuum pump.
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Install the RH valve cover.
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. | Install the RH engine cover locating studs.
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Install the LH valve cover.
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. | Install the LH engine cover locating studs.
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. | Install the fuel rail brackets.
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. | Install the fuel rails.
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Install the new RH fuel rail high-pressure supply line.
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Install the new LH fuel rail high-pressure supply line.
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Install the new fuel diverter rail high-pressure supply line.
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Install the new RH fuel rail high-pressure supply line.
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Install the new LH fuel rail high-pressure supply line.
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Install a new fuel injector clamp.
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. | Install the fuel injector.
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. | Install the remaining fuel injectors. |
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Install the new high-pressure fuel injector supply lines.
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Connect the fuel return line to the fuel injectors.
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. | Install the engine wiring harness.
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. | Connect the fuel injection pump electrical
connectors. |
. | Connect the fuel rail pressure (FRP) sensor
electrical connector. |
. | Install the crankcase vent oil separator.
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. | Connect the fuel temperature sensor electrical
connector. ![]() |
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Connect the 2 KS electrical connectors. ![]() |
. | Connect the engine oil temperature sensor
electrical connector.
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. | Connect the camshaft position (CMP) sensor
electrical connector.
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Connect the 6 fuel injector electrical connectors.
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. | Connect the engine oil pressure (EOP) sensor
electrical connector.
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. | Install the 2 low pressure fuel pipes. |
. | Install the timing belt cover.
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. | Install the crankshaft pulley.
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. | Install the cooling fan pulley.
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. | Install the accessory drive belt idler.
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Install the coolant pump.
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. | Install the exhaust gas recirculation (EGR)
valve coolant pipe.
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Install the RH exhaust manifold and exhaust cross-over pipe assembly.
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. | Install the generator bracket.
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. | Install the RH engine mount bracket.
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. | Install the RH exhaust manifold heat shield.
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Install the generator.
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. | Connect the generator electrical connectors.
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. | Install the RH EGR valve and cooler assembly.
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Install the cylinder block coolant inlet pipe.
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Install the LH exhaust manifold and turbocharger assembly.
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Secure the exhaust cross-over pipe to the LH exhaust manifold.
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Connect the turbocharger oil supply tube.
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. | Secure the turbocharger support bracket.
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Install the turbocharger oil return tube.
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. | Install the turbocharger heat shield.
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. | Install the LH exhaust manifold heat shield.
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Install the LH EGR valve and cooler assembly.
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Install the oil level indicator and tube.
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. | Install the LH engine mount bracket.
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. | Install the air conditioning (A/C) compressor
bracket.
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. | Install the A/C compressor.
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. | Install the power steering pump bracket.
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. | Remove the engine from the engine stand. |
. | Install the engine. |
. | Fill the engine with the recommended oil to the
correct level. |