Removal Procedure
- Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
- Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
- Remove the charged air cooler inlet duct to turbocharger charge air cooler outlet.
- Remove the water outlet tube.
- Remove the nut retaining the battery cable to the generator.
- If equipped, remove the battery cable to the auxiliary generator.
- Remove the battery cable harness clip from the bracket.
- Remove the bolt retaining the battery cable junction block from the power steering pump.
- Move and secure the battery cables out of the way.
- Disconnect the fuel hoses. Refer to Metal Collar Quick Connect Fitting Service .
- Remove the nut retaining the fuel hose bracket to the upper valve rocker arm cover.
- Disconnect the engine wiring harness connectors. Lift up on the latch in order to disconnect the connectors.
- Remove the bolts (1) retaining the engine wiring harness bulk connectors.
- Remove the bolts (2) retaining the engine wiring harness bracket.
- Remove the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.
- Remove the glow plug relay bracket. Refer to Glow Plug Relay Replacement .
- Remove the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement in Engine Electrical.
- Disconnect the PCV hose from the upper valve rocker arm cover.
- Remove the fuel injector line retainers.
- Remove the fuel injector feed lines.
Installation Procedure
- Install the fuel injector lines.
- Install the fuel injector line retainers.
- Connect the PCV hose to the upper valve rocker arm cover.
- Install the bolts (2) retaining the engine wiring harness bracket.
- Install the bolts (1) retaining the engine wiring harness bulk connectors.
- Connect the engine wiring harness bulk connectors.
- Install the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.
- Install the glow plug relay bracket. Refer to Glow Plug Relay Replacement .
- Install the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement in Engine Electrical.
- Connect the fuel hoses. Push in until locked.
- Install the nut retaining the fuel hose bracket to the valve rocker arm cover.
- Position the generator positive cable.
- Install the generator positive cable in the clip on the engine front cover.
- Install the generator positive cable and the retaining nut to the generator.
- Install the battery positive cable junction block bracket and bolt to the power steering pump.
- Install the charged air cooler inlet duct to turbocharger charge air cooler outlet.
- Align the marks on the hose and the intake manifold duct.
- Fill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
- Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten
Tighten the fuel injector lines to 41 N·m
(30 lb ft).
Tighten
Tighten the retainer screws to 4 N·m
(35 lb in).
Tighten
Tighten the wiring harness bracket bolts to 10 N·m
(89 lb in).
Tighten
Tighten the engine wiring harness bulk connector
bolts to 21 N·m (15 lb ft).
Tighten
Tighten the fuel hose bracket nut to 21 N·m
(15 lb ft).
Tighten
Tighten the generator positive cable nut to 9 N·m
(80 lb in).
Tighten
Tighten the junction block bracket bolt to 9 N·m
(80 lb in).
Tighten
Tighten the charge air cooler clamps to 6 N·m
(53 lb in).
