Installation Procedure
Clean the camshaft housing gasket surface on the cylinder head.
- Camshaft Housing Gasket (2) - Install NEW [2x]
- 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 6.0 mm (0.236 in) 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) - Install
- CAUTION:
Refer to Fastener Caution .
Camshaft Housing Bolt (1, 2, 3, 4) - Hand tighten [26x]
- Camshaft Housing Bolt (1, 2, 3, 4) - Tighten in sequence [26x] - Fastener Specifications
Oil Filler Tube (3) - Install
Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
Using the EN-47909 Injector Bore and Sleeve Cleaning Kit (1), clean the 6 fuel injector bores in the cylinder head as needed.
Install the 6 NEW fuel injector seals (2) to the 6 high pressure diesel fuel injectors (1).
- Install the 6 NEW fuel injector washers (3) to the 6 high pressure diesel fuel injectors (1).
- Install the 6 high pressure diesel fuel injectors (1) into their original positions.
- NOTE:
Note the mounting position of the injector bracket.
Multiport Fuel Injector Bracket (2) - Install [6x]
- Fuel Injector Bolt (1) - Install and hand tighten [6x]
- Using the EN-45059-A Angle Meter, tighten the 6 fuel injector bolts (1). Fastener Specifications
Connect the fuel injector wiring harness using the 8 fuel injector wiring harness retainers (2).
- Connect the 6 high pressure diesel fuel injector electrical connectors (1).
Install the charge air cooler bracket (1).
- Install the high pressure diesel fuel injection rail (2).
- Install and tighten the 3 fuel injection fuel rail nuts (3). Fastener Specifications
Fuel Injector Fuel Return Pipe (1) - Reposition
Engage the 6 fuel injection fuel return pipe locking springs (4).
- Retainer (3) - Install
Install and connect the glow plug wiring harness (1).
Intake Air Pressure and Temperature Sensor (2) - Install
- Intake Air Pressure and Temperature Sensor Bolt (1) - Install and tighten - Fastener Specifications
- Connect the intake air pressure and temperature sensor electrical connector.
Connect the high pressure diesel fuel sensor (1) and fuel pressure regulator (2) electrical connectors.
Throttle Body Gasket (3) - Install NEW
- Throttle Body (2) - Install
- Throttle Body Bolt (1) Install and tighten [3x] - Fastener Specifications
- Connect the throttle body electrical connector.
Install 6 NEW high pressure diesel fuel feed to injector pipes (2)
- Hand tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel rail.
- Hand tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel injectors.
- Tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel rail. Fastener Specifications
- Tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel injectors. Fastener Specifications
Install the fuel injection fuel feed pipe bracket (2).
- Install and tighten the fuel injection fuel feed pipe bracket bolt (1). Fastener Specifications
Install the NEW high pressure diesel fuel feed to rail pipe (2).
Fuel Feed Pipe Clip Bolt (2) - Install and tighten - Fastener Specifications
- Fuel Feed Pipe Clip Bolt (1) - Install and tighten - Fastener Specifications
Install and hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.
Install and hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.
- Tighten the high pressure diesel fuel feed to rail pipe fittings to both the high pressure diesel fuel pump and the high pressure diesel fuel injection rail. Fastener Specifications
Attach the fuel injector fuel return pipe retainer (2).
- Install and tighten the 2 fuel injection fuel feed pipe bolts (1). Fastener Specifications
Diesel Fuel Separator (1) - Reposition
Diesel Fuel Separator Bracket Bolt (1) - Install and tighten - Fastener Specifications
Fuel Pump Fuel Feed Hose (1) - Reposition
Fuel Feed Pipe Clip Bolt (1) - Install and tighten - Fastener Specifications
- Front Wheelhouse Liner- Left Side - Install - Front Wheelhouse Liner Replacement
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling 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.
Camshaft Housing Cover Insulator (1) - Install
Exhaust Gas Recirculation Pipe Bracket (5) - Install
- Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
Connect electrical connectors, reposition the harness and hoses as needed.
- Turbocharger Gasket (2) - Install NEW
- Compressor Air Intake Turbocharger (1) - Install
Catalytic Converter Gasket (1) - Install NEW
Turbocharger Oil Feed Pipe Gasket (3) - Install NEW
- Turbocharger Oil Feed Pipe (2) - Install
- Turbocharger Oil Feed Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
Turbocharger Stud (3) - Install and tighten [3x] - Fastener Specifications
Turbocharger Nut (1) - Install NEW and tighten [3x] - Fastener Specifications
Exhaust Gas Recirculation Valve Cooler Gasket (2) - Install NEW
- Exhaust Gas Recirculation Valve (1) - Install
Exhaust Gas Recirculation Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
Exhaust Gas Recirculation Pipe Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Electrical Connector (1) - Connect
Exhaust Gas Recirculation Outlet Pipe Gasket (2) - Install NEW
- Exhaust Gas Recirculation Pipe (1) - Install
Exhaust Gas Recirculation Pipe Nut (1) - Install and tighten - Fastener Specifications
Exhaust Gas Recirculation Pipe Nut (1) - Install and tighten - Fastener Specifications
Connect the exhaust pressure differential sensor hose to the exhaust gas recirculation pipe.
- Exhaust Pressure Sensor Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Heater Inlet Hose Bracket (2) - Install
- Exhaust Gas Recirculation Valve Bracket Nut (1) - Install and tighten - Fastener Specifications
- Reposition and attach the wiring harness retainers to the heater inlet hose bracket (2).
Turbocharger Coolant Feed Hose (2) @ Water Outlet - Install
- Turbocharger Coolant Feed Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Exhaust Pressure Differential Sensor Bracket (2) - Reposition
- Exhaust Pressure Differential Sensor Bracket Stud (1) Install and tighten [2x] - Fastener Specifications
Positive Crankcase Ventilation Hose (2) - Install
- Positive Crankcase Ventilation Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Catalytic Converter Clamp (1) - Install NEW
Catalytic Converter Brace Bracket Nut (1) - Tighten [2x] - Fastener Specifications
Catalytic Converter Brace Bracket Nut (1) - Tighten [2x] - Fastener Specifications
- NOTE:
Quantity of fasteners may vary based on option content.
Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
{If equipped} Battery Negative Cable Extension Cable Strap (1) @ Catalytic Converter Brace Bracket - Install
- {If equipped} Catalytic Converter Brace Bracket Nut (2) - Install and tighten - Fastener Specifications
Catalytic Converter Clamp (1) - Tighten - Fastener Specifications
- Front Wheelhouse Liner- Right Side - Install - Front Wheelhouse Liner Replacement
Charge Air Cooler Bracket (2) - Install
- Charge Air Cooler Bolt (1) - Install and tighten [5x] - Fastener Specifications
Engine Coolant Air Bleed Hose Clip (1) - Install
Oil Filler Tube Support Stud (1) - Install and tighten - Fastener Specifications
Engine Wiring Harness Bracket (3) - Install
- Engine Wiring Harness Bracket Bolt (2) Install and tighten - Fastener Specifications
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
Turbocharger Bracket Bolt (1) - Install and tighten - Fastener Specifications
Intake Manifold Resonator (2) - Install
- Engage the retaining spring (1).
Turbocharger Heat Shield (1) - Reposition
Turbocharger Heat Shield Nut (2) - Install and tighten - Fastener Specifications
- Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
- CAUTION:
Refer to Component Fastener Tightening Caution .
Exhaust Gas Recirculation Cooler Temperature Sensor (2) - Install and tighten - Fastener Specifications
- Retainer (1) - Install
Reposition the upper intake manifold bracket (2) with the nitrogen oxides sensor attached.
- Upper Intake Manifold Brace Nut (1) - Install and tighten [3x] - Fastener Specifications
Charge Air Cooler (1) - Install
Charge Air Cooler Bolt (1) - Install and tighten [4x] - Fastener Specifications
Charge Air Cooler Inlet Air Hose (2) - Install
- Charge Air Cooler Inlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Charge Air Cooler Outlet Air Hose (2) - Install
- Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Charge Air Cooler Coolant Hose (3) @ Charge Air Cooler - Install
- Charge Air Cooler Coolant Pump Hose (2) @ Charge Air Cooler - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Wiring Harness Retainer (4) @ Charge Air Cooler - Install
Wiring Harness Retainer (2) @ Charge Air Cooler - Install [3x]
- Electrical Connector (1) - Connect [3x]
Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) - Install NEW
- Exhaust Gas Recirculation Pipe Seal (2) - Install NEW
- Exhaust Gas Recirculation Pipe (1) - Install
Install and tighten the 2 exhaust gas recirculation outlet pipe bolts (1). Fastener Specifications
Install and tighten the exhaust gas recirculation outlet pipe bolt (2). Fastener Specifications
- Reposition the turbocharger coolant return hose, and install the turbocharger coolant return hose clip (1).
Reposition the turbocharger coolant feed pipe (2).
- Install and tighten the turbocharger coolant feed and return pipe bolt (3). Fastener Specifications
- NOTE:
Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Install and tighten the 2 exhaust gas recirculation cooler bolts (1). Fastener Specifications
Engine Coolant Air Bleed Hose (2) - Reposition
Engine Coolant Outlet Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
Engine Wiring Harness (3) - Reposition
- Connect the electrical connectors and attach retainers as necessary.
- Engine Wiring Harness Bracket Nut (2) - Install and tighten [3x] - Fastener Specifications
Air Cleaner Outlet Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten - Fastener Specifications
- Oil Filler Cap - Remove
Intake Manifold Cover (2) - Install
- Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
- Oil Filler Cap - Install
Air Cleaner Outlet Front Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] - Fastener Specifications
- Plenum Front Panel Outer Reinforcement - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
- Fill the charge air cooling system. Charge Air Cooling System Draining and Filling (GE 47716 LM2) , or Charge Air Cooling System Draining and Filling (Static LM2) , or Charge Air Cooling System Draining and Filling (GE 47716 LM2 with RC1) , or Charge Air Cooling System Draining and Filling (Static LM2 with RC1)
- Fill the cooling system to the proper level. Cooling System Draining and Filling (Static LM2) , or Cooling System Draining and Filling (GE 47716 LM2)