- Remove the engine from the stand.
- Install the engine to the vehicle.
Notice: Refer to Fastener Notice in the Preface section.
- Install the right engine mount bracket to frame bolts.
Tighten
Tighten the bolts to 65 N·m (48 lb ft).
- Install the right engine mount to engine bolts.
Tighten
Tighten the bolts to 58 N·m (43 lb ft).
- Install the right engine mount to engine mount bracket bolts.
Tighten
Tighten the bolts to 65 N·m (48 lb ft).
- Install the left engine mount bracket to frame bolts.
Tighten
Tighten the bolts to 65 N·m (48 lb ft).
- Install the left engine mount to engine bolts.
Tighten
Tighten the bolts to 58 N·m (43 lb ft).
- Install the left engine mount to engine mount bracket bolts.
Tighten
Tighten the bolts to 65 N·m (48 lb ft).
- Lower the engine onto the engine mounts.
- Remove the lifting device and the
J 36857
- Install the G102, G103 and G108.
Tighten
Tighten the ground bolts to 34 N·m (25 lb ft).
- Install the right exhaust manifold. Refer to
Exhaust Manifold Replacement - Right Side
.
- Install the left exhaust manifold. Refer to
Exhaust Manifold Replacement - Left Side
.
- Install the oil filter adapter and oil cooler assembly replacement. Refer to
Oil Filter Adapter and Oil Cooler Assembly Replacement
.
- Install the oil pump pickup tube. Refer to
Oil Pump Suction Pipe and Screen Assembly Removal
- Install the engine flywheel housing. Refer to
Engine Flywheel Housing Replacement
.
- Install the upper oil pan. Refer to
Upper Oil Pan Replacement
.
- Install the engine flywheel. Refer to
Engine Flywheel Replacement
.
- Install the transmission. Refer to
Transmission Replacement
.
- Install the engine oil indicator tube. Refer to
Oil Level Indicator and Tube Replacement
.
- Install the transmission fill tube.
- Position the fuel injection pump and install the 4 bolts.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
- Connect the fuel pump electrical connector.
- Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148
sealant on the right intake manifold mating surface.
- Install the right intake manifold.
- Install the intake manifold bolts/nuts.
- Tighten the right intake manifold bolts/nuts.
Tighten
Tighten the bolts/nuts in sequence to 25 N·m (18 lb ft).
- Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148
sealant on the left intake manifold mating surface.
- Install the left intake manifold.
- Tighten the left intake manifold bolts/nuts.
Tighten
Tighten the bolts/nuts in sequence to 25 N·m (18 lb ft).
- Position the turbocharger cooling outlet pipe and install the 2 bolts.
Tighten
Tighten the bolts to 9 N·m (80 lb in).
- Position the RH fuel rail and install the 2 bolts.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
- Install the RH fuel injector feed pipes.
Tighten
Tighten the fittings to 41 N·m (30 lb in).
- After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.
- Connect the fuel rail pressure (FRP) sensor electrical connector (1).
- Position the LH fuel rail and install the 2 bolts.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
- Install the LH fuel injector feed pipes.
Tighten
Tighten the fittings to 41 N·m (30 lb ft).
- After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.
- Install the LH to RH fuel rail pipe.
Tighten
Tighten the fittings to 41 N·m (30 lb ft).
- After installing the fuel pipes, clean the pipes and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.
- Position the fuel pipe/hose assembly and connect the hose (1) at the fuel pump.
- Install the fuel pipe bracket bolt (2).
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Compress the clamp and install the fuel system pressure relief hose.
- Install the fuel pump to the LH fuel rail pipe.
Tighten
Tighten the fittings to 41 N·m (30 lb ft).
- After installing the fuel pipe, clean the pipe and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.
- Install NEW center intake manifold gaskets to the center intake.
- Install the center intake manifold.
Important: The center intake manifold lower nuts MUST be installed and tightened first.
- Install the center intake manifold lower 4 nuts (2).
Tighten
Tighten the nuts to 10 N·m (89 lb in).
- Install the center intake manifold upper 4 nuts (1).
Tighten
Tighten the nuts to 10 N·m (89 lb in).
- Install the fuel pipe clamp bolt (2) and turbocharger coolant inlet pipe bracket bolt (3).
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Install the fuel pipe.
- Connect the fuel pump hose to the fuel pipe.
- Install the fuel line bracket bolt.
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Connect the fuel hoses to the fuel pipe.
- Install the fuel feed/return bracket bolt.
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Position the bracket, and install the nut and the 2 bolts.
- Position the engine wiring harness over from the RH side of the engine.
- Connect the ECT wiring harness electrical connector (1) and the oil pressure sensor electrical wiring harness electrical connector (2).
- Connect the intake air temperature sensor No. 2 and the fuel rail temperature sensor electrical connector.
- Connect the fuel injector electrical connectors.
- Install the LH glow plug nuts (2) and the routing bolts (1).
Tighten
Tighten the glow plug nut to 1.7 N·m (15 lb in).
- Connect the LH main engine wiring harness connector and install the bracket bolts (1).
Important: Lubricate the NEW washer with diesel fuel before installing.
- Position the oil fed pipe and a NEW washer into place.
- Install the oil feed pipe bolt.
Tighten
Tighten the bolt to 34 N·m (25 lb ft).
- Position the turbocharger lower heat shield.
- Install a new turbocharger oil return pipe gasket at the flywheel housing.
- Install the turbocharger (with the oil return pipe).
- Install the turbocharger bolts.
Tighten
Tighten the bolts to 108 N·m (80 lb ft).
- Install the turbocharger oil return pipe nuts at the top of the flywheel housing.
Tighten
Tighten the nuts to 21 N·m (15 lb ft).
- Install the turbocharger oil feed pipe banjo bolt and a NEW washer.
Tighten
Tighten the bolt to 34 N·m (25 lb ft).
Important: Use care not to damage this hose during the procedure.
- Position the turbocharger coolant inlet pipe hose to the turbocharger and install the bolt with NEW washers.
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Install the fuel line to the bracket bolt.
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Position the glow plug control module bracket.
- Install the glow plug control module bracket bolts (2).
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Install the fuel line bracket bolt (1).
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Position the glow plug control module and install the glow plug control module bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Connect the positive battery cable to the glow plug control module.
- Connect the fuel feed and return plugs.
Important: Use care not to damage this hose during the procedure.
- Position the turbocharger coolant outlet pipe clamp (1) and install the hose to the turbocharger pipe.
- Install the turbocharger upper heat shield.
- Install the turbocharger upper heat shield bolts.
Tighten
Tighten the bolts to 9 N·m (80 lb in).
- Connect the engine wiring harness electrical connector to the turbocharger vane control solenoid valve.
- Connect the engine wiring harness electrical connector to the turbocharger vane position sensor.
- Install the EGR cooler tube bracket and the 2 bolts.
Tighten
Tighten the 2 bolts to 25 N·m (18 lb ft).
- If necessary, remove the EGR bracket, nut, and the EGR bracket bolt.
Tighten
Tighten the EGR bracket bolt and nut to 25 N·m (18 lb ft).
- Install the EGR valve and EGR cooler tube assembly.
- Install the EGR nut (1) and bolt (2).
Tighten
Tighten the EGR nut and bolt to 50 N·m (37 lb ft).
- Connect the EGR solenoid electrical connector.
- Install the crankcase ventilation hose/pipe. Refer to
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
- Install the EGR cooler tube bracket bolt.
Tighten
Tighten the EGR cooler tube bracket bolt to 25 N·m (18 lb ft).
- Compress the clamp and connect the EGR heater inlet hose/pipe to the EGR cooler
tube.
- Install the EGR coolant hose. Refer to
Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement
.
- Install the left exhaust pipe. Refer to
Exhaust Pipe Replacement - Left Side
.
- Install the right exhaust pipe. Refer to
Exhaust Pipe Replacement - Right Side
.
- Install the air intake pipe. Refer to
Air Intake Pipe Replacement
.
- Install a NEW O-ring seal to the center intake manifold.
- Install 2 NEW metal EGR gaskets to the EGR valve.
- Install the intake manifold tube with the stud.
Tighten
Tighten the stud to 25 N·m (18 lb ft).
- Install the intake manifold tube bolts (2, 4) and nut (1).
Tighten
Tighten the bolt/nut to 25 N·m (18 lb ft).
- Install the EGR cooler water pipe bracket bolt (5).
Tighten
Tighten the bolt to 15 N·m (11 lb ft).
- Install the engine wiring harness clip to the intake manifold tube.
Tighten
Tighten the bolt to 15 N·m (11 lb ft).
- Install the engine wiring harness clip to the intake manifold tube.
- Install the rear intake manifold tube nut (2).
Tighten
Tighten the nut to 25 N·m (18 lb ft).
- Install the 2 rear intake manifold tube bolts (3).
Tighten
Tighten the nut to 25 N·m (18 lb ft).
- Install the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.
- Connect the positive cable to the IAH by performing the following:
106.1. | Position the positive battery cable to the IAH stud. |
106.2. | Install the positive battery cable nut to the IAH. |
Tighten
Tighten the nut to 10 N·m (89 lb in).
- Reposition the positive battery cable boot.
- Connect the engine harness electrical connector to the MAP sensor.
- Connect the IAH electrical connector.
- Install the thermostat bypass pipe. Refer to
Thermostat Bypass Pipes Replacement
.
- Position the thermostat housing crossover with the NEW gaskets.
- Install the 8 thermostat housing crossover bolts.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
- Connect the coolant temperature sensor electrical connector.
- Install the fuel pipe bracket bolt.
Tighten
Tighten the fuel pipe bracket bolt to 25 N·m (18 lb ft).
- Install the EGR valve coolant pipe to the thermostat housing bolt.
- Install the oil fill tube and the oil fill tube bolts.
Tighten
Tighten the oil fill tube bolts to 25 N·m (18 lb ft).
- Compress the clamp and connect the turbocharger inlet cooling hose/pipe.
- Position the fuel line and install the fuel line bolt.
- Position the A/C compressor and power steering pump bracket.
- Install the A/C compressor and power steering pump bracket bolts.
Tighten
Tighten the bolts to 46 N·m (34 lb ft).
- Position the power steering pump and loosely install the front bracket bolts.
Important: Tighten the front bracket bolts before the rear bracket bolts, to ensure pulley alignment.
- Loosely install the rear power steering pump bracket bolts.
Tighten
• | Tighten the front bolts to 50 N·m (37 lb ft). |
• | Tighten the rear bolts to 50 N·m (37 lb ft). |
- Install the A/C compressor.
- Install the A/C compressor bolts.
Tighten
Tighten the bolts to 50 N·m (37 lb ft).
- Connect the A/C cut out switch electrical connector.
- Connect the A/C compressor clutch electrical connector.
- If equipped with dual generator system, install the idler pulley and the bolt.
Tighten
Tighten the bolt to 50 N·m (37 lb ft).
- Install the auxiliary generator bracket and bolt, if equipped.
Tighten
Tighten the bolt to 50 N·m (37 lb ft).
- If equipped, install the auxiliary generator. Refer to
Auxiliary Generator Replacement
.
- Install the generator mounting bracket and bolts.
Tighten
Tighten the generator mounting bracket bolts to 50 N·m (37 lb ft).
- Install the drive belt tensioner and tensioner belt.
Tighten
Tighten the bolt to 50 N·m (37 lb ft).
- Install the oil indicator tube bracket bolt.
Tighten
Tighten the oil indicator tube bracket bolt to 21 N·m (15 lb ft).
- Install the 2 wiring harness routing bolts.
Tighten
Tighten the wiring harness routing bolts to 10 N·m (89 lb in).
- Install the 2 RH engine wiring harness bracket bolts.
- Connect the RH engine wiring main harness connector.
- Install the generator (2) and the generator bolts (1).
Tighten
Tighten the generator bolts to 50 N·m (37 lb ft).
- Install the positive battery cable to the generator, perform the following:
137.1. | Install the positive cable. |
137.2. | Install the positive cable nut. |
Tighten
Tighten the positive cable nut to 9 N·m (80 lb in).
- Position the boot to cover the terminal stud.
- Connect the generator electrical connector.
- Install the drive belt. Refer to
Drive Belt Replacement
.
- Install the cooling fan. Refer to
Fan Replacement
.
- Install the cooling layer. Refer to
Cooling Layer Installation
.
- Run the vehicle to verify correct engine operation and inspect for engine fluid leaks.
- Install the engine cover. Refer to
Engine Cover Replacement
.