Part 3

Engine















Upper End Components and Front End Accessory Drive (FEAD) Components











Lower End Components and Coolant Pump











Oil Filter Adapter Assembly











Timing Drive Components and Cylinder Heads











Flywheel and Exhaust Manifolds









NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play. For additional information, refer to Engine.


101. Install the wiring harness retaining bracket and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





102. Connect the KS electrical connector.





103. Connect the bubbler tube from the Supercharger (SC).





104. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector and pin-type retainer.





105. Attach the 2 wiring harness pin-type retainers (1 shown) to the coolant tube assembly bracket.





106. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.





107. Install a new gasket, the Throttle Body (TB) and spacer assembly and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





108. Connect the electronic throttle control electrical connector.





109. Connect the Throttle Position (TP) sensor electrical connector.





110. Install and connect the crankcase ventilation tube.





111. Install the EGR tube.
- Tighten to 40 Nm (30 lb-ft).





112. Install the 3 SC drive belt idler pulleys and the 3 bolts.
- Tighten the heavy load idler pulley (closest to centerline of engine) to 48 Nm (35 lb-ft).
- Tighten the smooth idler pulley and the grooved idler pulley to 25 Nm (18 lb-ft).





113. Install the coolant pump pulley and install the 4 bolts hand-tight.





114. Install the accessory drive belt idler pulley (grooved) and the bolt.
- Tighten to 25 Nm (18 lb-ft).





115. Install the accessory drive belt idler pulley (smooth) and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).





116. Install the accessory drive belt tensioner and the bolt.
- Tighten to 25 Nm (18 lb-ft).





117. Install the generator, 2 bolts and the stud bolt.
- Tighten to 50 Nm (37 lb-ft).





118. Connect the generator electrical connector.





119. Install the power steering pump and reservoir assembly and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





120. Install the power steering reservoir bracket bolts.
- Tighten to 25 Nm (18 lb-ft).





121. Install the power steering tube bracket bolt.
- Tighten to 10 Nm (89 lb-in).





122. Install the power steering tube bracket nut.
- Tighten to 10 Nm (89 lb-in).





123. Position the SC drive belt and install the SC drive belt tensioner and bolt.
- Tighten to 48 Nm (35 lb-ft).





124. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.





125. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).





126. Connect the coolant hose from the Charge Air Cooler (CAC).





127. Install the thermostat housing assembly and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).





128. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.





129. Connect the 2 upper radiator hoses to the intake manifold.





130. Connect the 2 coolant vent hoses to the intake manifold.





131. Install the coolant tube bracket nut.
- Tighten to 9 Nm (80 lb-in).





132. Connect the coolant hose to the thermostat housing.





133. Install the Engine Lifting Bracket.





134. Install the Engine Lifting Bracket.





135. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, remove the engine from the work stand.





136. Apply a 4 mm (0.15 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer mating surface on the engine block.





137. NOTICE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Install the crankshaft rear seal retainer plate and the 6 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





138. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Using the Crankshaft Rear Oil Seal Installers, install the crankshaft rear seal.





139. Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear seal.





140. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

141. NOTICE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing joints and the crankshaft rear seal retainer plate-to-cylinder block sealing joints.





142. Using a new gasket, install the oil pan, 14 bolts and 2 stud bolts.
- Tighten in the sequence shown to 25 Nm (18 lb-ft).





143. Install the engine/transmission spacer plate.





144. Position the flywheel on the crankshaft pilot and start the 8 flywheel bolts.

145. Tighten the flywheel bolts evenly in the sequence shown to fully seat the flywheel on the crankshaft pilot.
- Tighten to 80 Nm (59 lb-ft).