Installation Procedure
Timing Chain Guide (1) - Install
Install the timing chain (1) to the fuel injection pump driven sprocket (2).
- Lubricate the high pressure diesel fuel pump shaft. Adhesives, Fluids, Lubricants, and Sealers
Install the timing chain (1) and the fuel injection pump driven sprocket (2) as an assembly.
Timing Chain Guide (1) - Install
- If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Timing Chain Guide Bolt (2) - Install and tighten [2x] - Fastener Specifications
Observe the alignment of the timing links on the timing chain for installation:
- Timing link (1) will align with the fuel injection pump driven sprocket
- Timing link (2) will align with the primary timing chain fixed guide
- Timing link (3) will align at the lower position at the crankshaft sprocket
- If the 3 color links are not aligned, rotate the fuel injection pump shaft until alignment is achieved.
If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Install a NEW fuel injection pump bolt (1) and hand tighten.
Timing Chain Guide (1) - Install
- If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Timing Chain Guide Bolt (2) - Install and tighten - Fastener Specifications
Camshaft Sprocket (2) - Install
- Camshaft Sprocket Bolt (1) - Install NEW and hand tighten
Secondary Timing Chain (1) - Install
- Ensure that the timing chain slack is on the secondary timing chain tensioner side.
Camshaft Sprocket (2) - Install
- Camshaft Position Sensor Exciter Wheel (1) - Install
- Camshaft Sprocket Bolt (3) - Install NEW and hand tighten
Timing Chain Guide (1) - Install
- If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Timing Chain Guide Bolt (2) - Install and tighten [2x] - Fastener Specifications
- NOTE:
Check that the nose of the EN-52445-3 Camshaft Tool (1) sits correct in the gap (2) of the camshaft position sensor exciter wheel (3).
Install the EN-52445-3 Camshaft Tool (1) to both camshafts.
Timing Chain Tensioner Gasket (1) - Install NEW
- Timing Chain Tensioner (2) - Install and tighten - Fastener Specifications
Camshaft Sprocket Bolt (1) - Tighten [2x] - Fastener Specifications
Timing Chain Tensioner (4) - Install
- Timing Chain Tensioner Bolt (3) - Install and tighten [2x] - Fastener Specifications
- Remove the EN-52234 Timing Chain Tensioner Retaining Pin (2).
Tighten the fuel injection pump bolt (1). Fastener Specifications
Timing Belt (1) @Oil Pump Sprocket (2) - Install
- Timing Belt (1) @Crankshaft - Install
- Oil Pump Sprocket (2) - Install
Install the EN-47634 Holder (1) to the oil pump sprocket (2).
- Oil Pump Drive Bolt (3) - Install and tighten - Fastener Specifications
- Remove the EN-47634 Holder (1) and the EN-956 Extension (4).
Remove EN-52445-3 Camshaft Tool Holder (2).
- Remove EN-52445-2 Camshaft Tool Holder (3)
Remove the EN-52445-1 Camshaft Tool (3) from the camshaft housing.
Crankshaft Position Sensor Seal (1) - Install NEW
- Crankshaft Position Sensor (2) - Install
- Crankshaft Position Sensor Bolt (3) - Install and tighten - Fastener Specifications
EN-52586 Crankshaft Fixing Pin (4) - Remove
- Rotate the engine by hand to ensure there is no interference.
- Crankshaft Pulley Bolt (1) - Remove [4x]
Clean all sealing surfaces.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Apply a bead of sealant (1) to the crankshaft front oil seal sealing surface using the following procedure: Adhesives, Fluids, Lubricants, and Sealers
- Begin applying a 4.0 mm (0.158 in) bead, dimension a.
- Continue to apply the bead, increasing to a 6.0 mm (0.236 in) bead, dimension b.
- Continue to apply the bead, decreasing to a 4.0 mm (0.158 in) bead, dimension a.
- At the end of the bead path, increase to a 6.0 mm (0.236 in) bead, dimension a.
Install the EN-52452 Front Crankshaft Seal Installer (1) to the crankshaft.
- Install and hand tighten the 2 bolts (2) of the EN-52452 Front Crankshaft Seal Installer (1).
Crankshaft Front Oil Seal (1) - Install NEW
- Check that the crankshaft front oil seal (1) sits correctly on the crankshaft and the 2 pins (2, 4).
- Remove the 2 bolts (5) from the EN-52452 Front Crankshaft Seal Installer (3).
- Remove the EN-52452 Front Crankshaft Seal Installer (3) from the crankshaft.
Engine Front Cover Bolt (1) - Install and tighten in sequence [8x] - Fastener Specifications
Crankshaft Pulley (1) - Install
- Crankshaft Pulley Bolt (2) - Install and hand tighten [4x]
Install the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
- Crankshaft Pulley Bolt (2) - Tighten [4x] - Fastener Specifications
Clean the camshaft housing gasket surface on the cylinder head.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Apply a bead of sealant (1) to the timing chain upper cover sealing surface using the following procedure: Adhesives, Fluids, Lubricants, and Sealers
- Begin applying a 6.0 mm (0.236 in) bead, dimension a.
- Continue to apply the bead, decreasing to a 4.0 mm (0.158 in) bead, dimension b, for the remaining bead path, until near the end.
- At the end of the bead path, increase to a 6.0 mm (0.236 in) bead, dimension a.
Timing Chain Upper Cover (1) @Cylinder Head - Install
- Apply sealant to the front threads of the 2 timing chain cover bolts (4).
- Timing Chain Cover Bolt (4) - Install and hand tighten [2x]
- Timing Chain Cover Bolt (3) - Install and hand tighten [4x]
- Timing Chain Cover Bolt (3, 4) - Tighten in sequence [6x] - Fastener Specifications
- Clean the squeezed out sealant residues between the timing chain upper cover and the cylinder head.
Camshaft Housing Gasket (2) @Camshaft Housing - Install NEW [2x]
- Camshaft Housing Cover Insulator (3) - Install NEW [26x]
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) @Cylinder Head - Install
- Camshaft Housing Bolt (2) - Hand tighten [26x]
Camshaft Housing Bolt (1, 2, 3, 4) - Tighten in sequence [26x] - Fastener Specifications
Turbocharger Oil Return Pipe Gasket (5) - Install NEW
- Turbocharger Oil Return Pipe Gasket (6) - Install NEW
- Turbocharger Gasket (3) - Install NEW
- Turbocharger Assembly (1) - Install
- Turbocharger Nut (2, 4) - Install NEW [3x]
- Turbocharger Oil Return Pipe Bolt (8) - Install and tighten [2x] - Fastener Specifications
- Turbocharger Oil Return Pipe Bolt (7) - Install and tighten [2x] - Fastener Specifications
- Lower Crankcase Extension Bolt (9) Install and tighten - Fastener Specifications
- Turbocharger Nut (2, 4) - Tighten [3x] - Fastener Specifications
Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
Positive Crankcase Ventilation Hose (2) - Install
- Positive Crankcase Ventilation Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- NOTE:
If service part comes with seal protector then use inner seal protector ring to slip the seal lip over the crankshaft snout, instead of EN-52446-2 Seal Protector.
Install the EN-52446-2 Seal Protector (1) to the crankshaft.
- Install the 4 EN-52446-4 Studs (2).
- Install the 4 EN-52446-5 Nuts (3) and hand tighten.
- NOTE:
- Observe the locations for additional sealer (2) while applying the sealant path.
- The bolts must be installed and fastened to final torque specification immediately after the component is installed.
Clean all sealing surfaces.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Apply a 4.0 mm (0.158 in) bead of sealer along the timing chain lower cover sealing path (1), dimension a. Increase the bead to 6.0 mm (0.236 in) at the two locations (2), dimension b. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
If service part comes with seal protector then use inner seal protector ring to slip the seal lip over the crankshaft snout, instead of EN-52446-2 Seal Protector.
Align the timing chain lower cover (1) with the two transmission locating pins (2).
- Timing Chain Lower Cover (1) - Install NEW
- Check that the crankshaft rear oil seal sits correct on the crankshaft.
- Remove the EN-52446-2 Seal Protector (3).
Timing Chain Cover Bolt (1) - Install and hand tighten
- Timing Chain Cover Bolt (2) - Install and hand tighten [15x]
- Timing Chain Cover Bolt (1, 2) - Tighten in sequence [16x] - 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 6 NEW fuel injector seal rings (2) and 6 fuel injector washers (3) to the high pressure diesel fuel injectors (1).
- Install the 6 high pressure diesel fuel injectors (1) to the cylinder head.
- NOTE:
Note the mounting position of the fuel injector bracket.
Multiport Fuel Injector Bracket (2) - Install [6x]
- Fuel Injector Bolt (1) - Install [6x]
- Using the EN-45059-A Angle Meter, tighten the 6 fuel injector bolts (1). Fastener Specifications
Fuel Injection Fuel Return Pipe (1) - Install
Fuel Injection Fuel Return Pipe Locking Spring (4) - Engage [6x]
- Retainer (3) - Install
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 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 the fuel injection fuel feed pipe bracket bolt (1) and tighten. Fastener Specifications
Install a NEW high pressure diesel fuel feed to rail pipe (2).
- Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.
Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications
- Attach the fuel injector fuel return pipe retainer (2).
Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications
Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.
- 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
Diesel Fuel Separator Bracket Bolt (1) - Install and tighten - Fastener Specifications
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling 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
Automatic Transmission Flex Plate (1) - Install
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Automatic Transmission Flex Plate Bolt (2) - Install NEW and hand tighten [8x]
- Automatic Transmission Flex Plate Bolt (2) - Tighten in sequence [8x] - Fastener Specifications
Remove the EN-49979 Holder (1) with EN-956-1 Extension (3).
- Install the EN-52474 Engine Lift Bracket Set.
- Using a suitable engine lifting device, remove the engine from the engine stand.
EN-52449 Engine Stand Adapter (2) @Engine Block - Remove
- Engine - Install - Engine Removal and Installation (F48 & RC1 - F47) , or Engine Removal and Installation (RWL & RC1 - F47) , or Engine Removal and Installation (F48 & RC1 & F47) , or Engine Removal and Installation (RWL & RC1 & F47) , or Engine Removal and Installation (F48 & WTX & F47) , or Engine Removal and Installation (RWL & WTX & F47) , or Engine Removal and Installation (F48 & WTX - F47) , or Engine Removal and Installation (RWL & WTX - F47)
Refer to Fastener Caution .
The link at the crankshaft is difficult to see.
Final torque for camshaft sprockets is completed after secondary timing chain and exhaust camshaft sprocket is installed.
Refer to Component Fastener Tightening Caution .
Take note that there are different bolt lengths.
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.