Part 3

Cylinder Head














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





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





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





84. Connect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.





85. Connect the EVAP Evaporative Emission (EVAP) canister purge valve electrical connector.





86. Install and connect the crankcase ventilation tube.





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





88. 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).





89. Install the coolant pump pulley and the 4 bolts.
- Do not tighten the bolts at this time.





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





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





92. Install the accessory drive belt idler pulley and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





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





94. Connect the Crankshaft Position (CKP) sensor electrical connector.





95. Attach the wiring harness retainer and install the 2 wiring harness brackets and the 2 nuts to the oil pan stud bolts.
- Tighten to 10 Nm (89 lb-in).





96. Install the alternator and the 3 bolts.
- Tighten to 50 Nm (37 lb-ft).





97. Connect the B+ wire to the generator and install the nut.
- Tighten to 8 Nm (71 lb-in).





98. Connect the generator electrical connector.





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





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





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





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





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





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





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





106. Install the coolant tube bracket nut.





107. Connect the coolant hose to the thermostat housing.





108. Install the Engine Lifting Bracket.





109. Install the Engine Lifting Bracket.





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





111. Install the engine/transmission spacer plate.





112. 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).





113. Install the engine into the vehicle. For additional information, refer to Engine Engine - Removal.