Engine - 3.5L GTDI: Assembly: Engine
Special Tool(s)
| Compressor, Piston Ring 303-D032 (D81L-6002-C) | |
| Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) | |
| Bar, Engine Spreader 303-1454 | |
| Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent | |
| Handle 205-153 (T80T-4000-W) | |
| Hold Down, Secondary Chain 303-1530 | |
| Installer, Differential Bearing Cone 205-142 (T80T-4000-J) | |
| Installer, Spindle Bearing 205-149 (T80T-4000-R) | |
| 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent | |
| Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) | |
| Installer, Front Cover Oil Seal 303-335 | |
| Installer, Front Crankshaft Seal 303-1251 | |
| Installer, VCT Spark Plug Tube Seal 303-1247/2 | |
| Lift Eye, Right Front 303-1529 | |
| Seal Installer, Fuel Injector 310-207 | |
| Sizer, Teflon ® Seal 303-1567 | |
| Strap Wrench 303-D055 (D85L-6000-A) | |
| Tool, Camshaft Holding 303-1248 |
Material
| Item | Specification |
| Motorcraft ® Metal Surface Prep ZC-31-B | - |
| Motorcraft ® Silicone Gasket Remover ZC-30-A | - |
| Motorcraft ® High Performance Engine RTV Silicone TA-357 | WSE-M4G323-A6 |
| Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft ® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada) | WSS-M2C946-A |
| Motorcraft ® Orange Concentrated Antifreeze/Coolant VC-3-B (US); CVC-3-B2 (Canada) | WSS-M97B44-D |
| Motorcraft ® Thread Sealant with PTFE TA-24-B | WSK-M2G350-A2 |
NOTE:
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, may cause engine failure.
NOTE:
Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. Refer to: Engine System General Information
.
NOTE:
If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed. Refer to: VCT unit .
- 2.
- Select the crankshaft main bearings for each crankshaft journal.
- Record the code that is on the cylinder block face.
- Record the code that is on the crankshaft flange.
- The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.
NOTE:
The #1 main bearing is at the front of the engine block.
NOTE:
This step is for selecting the correct main bearings.
- 3.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4.- Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
- Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing.
- As an example, if the engine block code letter is "M" and the crankshaft code letter is "M", the correct bearing grade for this main bearing is a "2" for the upper bearing and a "2" for the lower bearing.
- Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.
NOTE:
This chart is for selecting main bearings 1 and 4 only.
NOTE:
This chart is continued in the next step.
- 5.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3.- Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code.
- Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 2 crankshaft main bearing.
- As an example, if the engine block code letter is "N" and the crankshaft code letter is "H", the correct bearing grade for this main bearing is "2".
- Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
NOTE:
This chart is for selecting main bearings 2 and 3 only.
NOTE:
This chart is continued in the next step.
- 7.
Using the original connecting rod cap bolts, install the connecting rod caps and bolts.- Stage 1: Tighten to 17 lb.ft (23 Nm)
- Stage 2: Tighten to 32 lb.ft (43 Nm)
- Stage 3: Tighten an additional 90 °
NOTE:
The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
- 10.
Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
- 11.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
- 12.
Lubricate the upper crankshaft main bearings with clean engine oil and install in the cylinder block.
NOTE:
Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
- 13.
Install the crankshaft.
NOTE:
Lubricate the thrust surfaces of the crankshaft with clean engine oil.
NOTE:
Do not install the upper thrust bearings until the crankshaft is installed.
- 14.
Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.
NOTE:
Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
- 15.
Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.
NOTE:
Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
- 16.
Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Check seating and squareness of the bearings to make sure of proper seating in caps.
- 17.
Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.
- 18.
Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.
NOTE:
To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
NOTE:
Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
- 19.
Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
- 20.
Tighten the main bearing bolts.- Stage 1: Tighten to 24 lb.ft (33 Nm)
- Stage 2: Tighten an additional 135 °
NOTE:
While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.
- 21.
Install the new main bearing cap side bolts.- Stage 1: Tighten to 33 lb.ft (45 Nm)
- Stage 2: Tighten an additional 90 °
- 22.
- 1.
Position the crankshaft to the rear of the cylinder block.
- 2.
Using the Holding Fixture with Dial Indicator Gauge, zero the Dial Indicator Gauge.
- 3.
Move the crankshaft to the front of the cylinder block. Measure and record the crankshaft end play.
- 1.
- 23.
- Prepare the connecting rod and cap
- Insert the new bolts in the rod cap.
- Insert the upper and lower rod bearings into the rod and cap.
NOTE:
The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
- 24.
- 1.
Center line of the piston parallel to the wrist pin bore.
- 2.
Upper compression ring gap location.
- 3.
Upper oil control segment ring gap location.
- 4.
Lower oil control segment ring gap location.
- 5.
Expander ring and lower compression ring gap location.
- 1.
NOTE:
The arrow on the top of the piston indicates the front of the engine.
NOTE:
The piston compression upper and lower ring should be installed with the "O" mark on the ring face pointing up toward the top of the piston.
- 25.
Using the Piston Ring Compressor, install the piston and connecting rod assemblies. Repeat until all 6 piston assemblies are installed.
NOTE:
If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.
NOTE:
If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.
NOTE:
Make sure the piston rings are positioned to specifications for installation. Refer to: Piston .
NOTE:
Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
NOTE:
Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
- 26.
Install the connecting rod cap and the new bolts.- Stage 1: Tighten to 17 lb.ft (23 Nm)
- Stage 2: Tighten to 32 lb.ft (43 Nm)
- Stage 3: Tighten an additional 90 °
NOTE:
After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation.
NOTE:
The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
- 27.
Install the main bearing cap support brace and the new bolts.- Stage 2: Tighten to 18 lb.ft (24 Nm)
- Stage 3: Tighten an additional 180 °
- 28.
Apply a 3 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
NOTE:
The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.
NOTE:
Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
- 34.
Apply a 3 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the oil pan.
NOTE:
Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
- 35.
Apply a 5.5 mm (0.21 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
NOTE:
Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
- 37.
Using a straight edge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.
- 39.
Install the remaining oil pan bolts.- Stage 1: Tighten bolts 1 through 14 to 18 lb.ft (24 Nm)
- Stage 2: Tighten bolt 10 an additional 90 °
- Stage 2: Tighten bolts 15 and 16 to 89 lb.in (10 Nm)
- 40.
Install the channel cover plate and the bolts.- Stage 1: Tighten to 89 lb.in (10 Nm)
- Stage 2: Tighten an additional 45 °
- 43.
Install the cylinder head and the new bolts.- Stage 1: Tighten to 177 lb.in (20 Nm)
- Stage 2: Tighten to 26 lb.ft (35 Nm)
- Stage 3: Tighten an additional 90 °
- Stage 4: Tighten an additional 90 °
- Stage 5: Tighten an additional 45 °
NOTE:
If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.
- 46.
Install the cylinder head and the new bolts.- Stage 1: Tighten to 177 lb.in (20 Nm)
- Stage 2: Tighten to 26 lb.ft (35 Nm)
- Stage 3: Tighten an additional 90 °
- Stage 4: Tighten an additional 90 °
- Stage 5: Tighten an additional 45 °
NOTE:
If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.
- 48.
Install the valve tappets.
NOTE:
RH shown, LH similar.
NOTE:
Coat the valve tappets with clean engine oil prior to installation.
NOTE:
The valve tappets must be installed in their original positions.
- 50.
Position the crankshaft dowel pin in the 9 o'clock position.
NOTE:
The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.
- 51.
Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral position as shown
NOTE:
Coat the camshafts with clean engine oil prior to installation.
- 52.
Position the RH camshaft seals gaps as shown.
NOTE:
The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
- 53.
Install the camshaft caps, oil tube and the bolts.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 45 °
NOTE:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- 55.
Tighten the camshaft cap bolts.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 45 °
- 56.
Using a feeler gauge confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Check .
NOTE:
Use a camshaft sprocket bolt to turn the camshafts.
NOTE:
If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
- 58.
Install the camshaft bearing cap and bolts.- Stage 1: Tighten to 89 lb.in (10 Nm)
- Stage 2: Tighten an additional 45 °
- 61.
Install the Camshaft Holding Tool.
NOTE:
The Camshaft Holding Tool will hold the camshafts in the TDC position.
- 62.
Install the Chain Tensioner Hold Down Tool.
NOTE:
The VCT oil control solenoids are removed for clarity.
- 64.
Position the RH VCT units and secondary timing chain onto the camshafts by aligning the holes in the VCT units with the dowel pins in the camshafts.
NOTE:
It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.
- 65.
Install the new RH VCT unit bolts.- Stage 1: Tighten to 30 lb.ft (40 Nm)
- Stage 2: Loosen: 1 turn(s)
- Stage 3: Tighten to 18 lb.ft (25 Nm)
- Stage 4: Tighten an additional 180 °
- 66.
Remove the Chain Tensioner Hold Down Tool.
NOTE:
The VCT oil control solenoids are removed for clarity.
NOTE:
Make sure the secondary timing chain is centered on the timing chain tensioner guides.
- 67.
Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral position as shown.
NOTE:
Coat the camshafts with clean engine oil prior to installation.
- 68.
Position the LH camshaft seals gaps as shown.
NOTE:
The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
- 69.
Install the camshaft caps, oil tube and the bolts.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 45 °
NOTE:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- 71.
Tighten the camshaft cap bolts.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 45 °
- 72.
Using a feeler gauge confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Check .
NOTE:
Use a camshaft sprocket bolt to turn the camshafts.
NOTE:
If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
- 75.
Install the Camshaft Holding Tool.
NOTE:
The Camshaft Holding Tool will hold the camshafts in the TDC position.
- 76.
Install the Chain Tensioner Hold Down Tool.
NOTE:
The VCT oil control solenoids are removed for clarity.
- 78.
Position the LH VCT units and secondary timing chain onto the camshafts by aligning the holes in the VCT units with the dowel pins in the camshafts.
NOTE:
It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.
- 79.
Install the new LH VCT unit bolts.- Stage 1: Tighten to 30 lb.ft (40 Nm)
- Stage 2: Loosen: 1 turn(s)
- Stage 3: Tighten to 18 lb.ft (25 Nm)
- Stage 4: Tighten an additional 180 °
- 80.
Remove the Chain Tensioner Hold Down Tool.
NOTE:
The VCT oil control solenoids are removed for clarity.
NOTE:
Make sure the secondary timing chain is centered on the timing chain tensioner guides.
- 82.
Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
- 84.
Install the timing chain with the colored links aligned with the timing marks on the VCT units and the crankshaft sprocket.
NOTE:
It may be necessary to rotate the camshafts slightly, to align the timing marks.
- 87.
- 1.
Release the ratchet detent.
- 2.
Using a soft-jawed vise, compress the ratchet plunger.
- 3.
Align the hole in the ratchet plunger with the hole in the tensioner housing and install a lockpin.
- 1.
- 88.
- Install the timing chain tensioner and the bolts.
- Tighten to 89 lb.in (10 Nm)
- Remove the lockpin.
- Install the timing chain tensioner and the bolts.
NOTE:
It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.
- 89.
- As a post-check, verify correct alignment of all timing marks.
- There are 48 links in between the RH intake VCT unit colored link (1) and the LH intake VCT unit colored link (2).
- There are 35 links in between LH intake VCT unit colored link (2) and the 2 crankshaft sprocket links (3).
- 90.
Install the VCT oil control solenoids and the bolts.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 20 °
NOTE:
Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
- 92.
Install the RH oil tube and the bolts.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 45 °
- 97.
- Apply a 3.0 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.
- Apply a 5.5 mm (0.21 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in places as indicated.
NOTE:
The engine front cover and 6 bolts must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
NOTE:
Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
- 98.
Install the engine front cover and the bolts.- Tighten to 27 lb.in (3 Nm)
NOTE:
Make sure the locating dowel pins are seated correctly in the cylinder block.
- 100.
Install the remaining engine front cover bolts.- Stage 1: Tighten bolts 1 thru 21 to 89 lb.in (10 Nm)
- Stage 2: Tighten bolts 1 thru 20 to 18 lb.ft (24 Nm)
- Stage 3: Tighten bolt 21 to 177 lb.in (20 Nm)
- Stage 4: Tighten bolt 21 an additional 90 °
- Stage 5: Tighten bolt 22 to 89 lb.in (10 Nm)
- Stage 6: Tighten bolt 22 an additional 45 °
- 102.
Install the coolant pump and the bolts.- Stage 1: Tighten to 89 lb.in (10 Nm)
- Stage 2: Tighten an additional 45 °
- 103.
Install the CMP sensors and the bolts.- Tighten to 89 lb.in (10 Nm)
NOTE:
Apply clean engine oil to the CMP sensor O-ring seals.
- 104.
If removed, using the special tools, install the spark plug tube seals.
NOTE:
RH shown, LH similar.
NOTE:
Installation of new seals is only required if damaged seals were removed.
- 105.
If removed, using the special tools, install the VCT oil control solenoid seals.
NOTE:
RH shown, LH similar.
NOTE:
Installation of new seals is only required if damaged seals were removed.
- 107.
Apply an 8 mm (0.31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to- RH cylinder head joints.
NOTE:
If the valve cover is not installed and the fasteners tightened 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. Failure to follow this procedure can cause future oil leakage.
- 109.
Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
- 111.
Apply an 8 mm (0.31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
NOTE:
If the valve cover is not installed and the fasteners tightened 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. Failure to follow this procedure can cause future oil leakage.
- 112.
Install the LH valve cover and tighten the 4 bolts and 7 stud bolts.- Tighten to 89 lb.in (10 Nm)
- 113.
Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
- 114.
Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before installing.
- 115.
- Install the CMP sensors and the bolts.
- Tighten to 89 lb.in (10 Nm)
- Install all of the coil-on-plugs and the bolts.
- Tighten to 62 lb.in (7 Nm)
- Install the CMP sensors and the bolts.
NOTE:
Apply clean engine oil to the CMP sensor O-ring seals.
- 116.
- Install the engine wiring harness attach all of the wiring harness retainers.
- Connect the coil-on-plug electrical connectors.
- Connect the CMP sensor electrical connectors.
- Connect the VCT sensor electrical connectors.
- 117.
- Attach the wiring harness retainers.
- Connect the coil-on-plug electrical connectors.
- Connect the VCT sensor electrical connectors.
- Install the oil level indicator.
- 118.
- Install the CKP sensor and bolt.
- Tighten to 89 lb.in (10 Nm)
- Connect the CKP sensor electrical connector.
- Install the CKP sensor and bolt.
- 119.
- Attach the wiring harness grommet to the cylinder block.
- Install the stud bolt.
- Tighten to 89 lb.in (10 Nm)
- 121.
- Install the ground wire and stud bolt.
- Stage 1: Tighten to 89 lb.in (10 Nm)
- Stage 2: Tighten an additional 20 °
- Attach the wiring harness retainer and if equipped, install the nut.
- Tighten to 89 lb.in (10 Nm)
- Connect the CMP sensor electrical connectors.
- Install the ground wire and stud bolt.
- 122.
- Connect the RH and LH fuel charge harness electrical connectors.
- Connect the fuel pressure sensor electrical connector.
- Connect the KS electrical connector.
- 123.
- Install the ground wire and stud bolt.
- Connect the CHT sensor electrical connector and wiring harness retainer.
- 124.
Clean the surface and apply an 8mm bead of sealer.
NOTE:
Make sure that the mating faces are clean and free of foreign material.
- 125.
Install the vacuum pump and the bolts.- Stage 1: Tighten to 89 lb.in (10 Nm)
- Stage 2: Tighten to 33 lb.ft (45 Nm)
NOTE:
Manually align the brake vacuum pump drive key with the camshaft slot before installation.
- 127.
Install the RH block coolant drain plug.- Stage 1: Tighten to 142 lb.in (16 Nm)
- Stage 2: Tighten an additional 180 °
- 132.
Install the new oil cooler and the bolt.- Tighten to 43 lb.ft (58 Nm)
NOTE:
A new oil cooler must be installed or severe damage to the engine can occur.
- 134.
- Install a new O-ring seal.
NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.- Install a new gasket.
- 135.
- 1.
Install the LH turbocharger and the bolts.- Tighten to 24 lb.ft (32 Nm)
- 2.
Install the oil return tube bolt.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 30 °
- 3.
Install the coolant/oil tube assembly bolt.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 30 °
- 1.
- 136.
Install the LH turbocharger coolant supply tube and fitting into the cylinder head.- Tighten to 159 lb.in (18 Nm)
- 137.
Install a new O-ring seal.- Install a new O-ring seal.
NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.- Install a new gasket.
- 138.
- 1.
Install the RH turbocharger and the bolts.- Tighten to 24 lb.ft (32 Nm)
- 2.
Install the oil return tube bolt.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 30 °
- 3.
Install the coolant/oil tube assembly bolt.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 30 °
- 1.
- 139.
Install the RH turbocharger coolant supply tube and fitting into the cylinder head.- Tighten to 159 lb.in (18 Nm)
- 140.
- 1.
Install the high-pressure fuel tube then tighten the flare nuts.- Stage 1: Tighten to 133 lb.in (15 Nm)
- Stage 2: Tighten an additional 45 degrees or 50 Nm (37 lb-ft), whichever comes first.
- 2.
Install the high pressure fuel tube bracket bolt.- Stage 1: Tighten to 89 lb.in (10 Nm)
- Stage 2: Tighten an additional 45 degrees.
- 1.
- 142.
Install the coolant outlet and the bolts.- Stage 1: Tighten to 89 lb.in (10 Nm)
- Stage 2: Tighten an additional 45 °
- 145.
Install the thermostat housing and the bolts.- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Tighten an additional 45 °
- 146.
- 1.
Install the coolant pump pulley and the bolts.- Tighten to 18 lb.ft (24 Nm)
- 2.
Install the accessory drive belt tensioner and the bolts.- Tighten to 18 lb.ft (25 Nm)
- 1.
- 151.
Using a strap wrench install the new crankshaft bolt and the washer.- Stage 1: Tighten to 89 lb.ft (120 Nm)
- Stage 2: Loosen: 1 turn(s)
- Stage 3: Tighten to 37 lb.ft (50 Nm)
- Stage 4: Tighten an additional 90 °
- 152.
- Attach the vacuum hose retainers to the valve covers.
- Connect the electrical connector to the vacuum solenoid.
- Connect the vacuum hoses to the turbochargers.
- 154.
Install the LH engine support insulator-to-cylinder block bracket and the 4 new bolts.- Tighten to 63 Nm (46 lb-ft).
- 156.
Install the Right Front Lift Eye and the bolts.
NOTE:
This lift eye may have been installed on engines that did not come equipped with a factory lift eye.