| Assembly Special Tool(s) | | Remover, O-Ring Seal 100-010 | | | Adapter for 205-044 205-044-01 | | | Universal Flange Holding Wrench 205-072 | | | Installer, Wheel Speed Sensor Ring 205-307 | | | Lifting Bracket, Engine 303-122 | | | Gauge, Bolt Angle 303-174 | | | Locking Tool, Flywheel 303-254 | | | Installer, Timing Cover Seal 303-255 | | | Installer Crankshaft Seal 303-395 | | | Remover/Installer, Hose Clamp 303-397 | | | Mounting Stand 303-435 | | | Mounting Bracket for 303-435 303-435-04 | | | Mounting Plate for 303-435-04 303-435-12A | | | Installer, Crankshaft Front Seal 303-684 | | | Alignment Peg, Camshaft 303-735 | | | Installer, Main Bearing Cup 303-1057 | | | Alignment Peg, Crankshaft 303-1059 | | | Aligner, Clutch Disc 308-204 | General Equipment Materials Name Specification Engine Oil - 5W-30 WSS-M2C913-B Cleaner WSK-M5B401-A1 Silicone Sealant WSE-M4G323-A4 WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign material entering the components. 3 - Oil pump drive sprocket O-ring seal 4 - Oil pump drive sprocket woodruff key 16 - Crankshaft position (CKP) sensor 20 - Left-hand clutch cover clip 21 - Right-hand clutch cover 28 - Fuel injector to cylinder head sealing washer 33 - Fuel injector high-pressure fuel supply line support grommets 38 - Oil level indicator and tube 39 - Intake manifold assembly seals 42 - Oil cooler supply hose clamp 43 - Generator retaining bracket 45 - Generator retaining clamp 51 - Timing belt idler pulley 52 - Engine front mount bracket 56 - Timing belt lower cover 59 - Timing belt upper cover 60 - Engine coolant bypass pipe O-ring seal 61 - Engine coolant bypass pipe 64 - Fuel filter crash protection shield 67 - Brake vacuum pump vacuum hose 68 - Positive crankcase ventilation (PCV) hose 69 - Thermostat housing O-ring seal 71 - Thermostat housing retaining nuts 72 - Turbocharger variable vain vacuum regulator 73 - Turbocharger variable vain vacuum regulator retaining nuts 74 - Turbocharger variable vain vacuum regulator hose 75 - Engine wiring harness bracket 76 - Engine wiring harness bracket retaining nut 80 - High pressure fuel line 83 - Exhaust manifold gasket 85 - Exhaust manifold heat shield 86 - Exhaust manifold bushers 87 - Exhaust manifold retaining nuts 92 - EGR pipe retaining clamp 93 - EGR pipe retaining stud 94 - Engine wiring harness bracket 95 - Glow plug wiring harness retaining bolt 98 - Intermediate shaft retaining bracket 100 - Turbocharger oil return hose gasket 101 - Turbocharger oil return hose 102 - Turbocharger retaining bolts 103 - Turbocharger retaining nut 104 - Turbocharger oil supply tube to turbocharger banjo bolt seal 105 - Turbocharger oil supply tube to turbocharger banjo bolt 106 - Turbocharger oil supply tube to cylinder block banjo bolt seal 108 - Turbocharger variable vain solenoid vacuum supply tube 109 - Turbocharger intake pipe O-ring seal 110 - Turbocharger intake pipe 112 - Fuel pump fuel temperature sensor electrical connector 113 - Engine coolant temperature (ECT) sensor electrical connect 114 - Turbocharger variable vain solenoid electrical connector 115 - EGR valve electrical connector 116 - Fuel pump fuel pressure regulator electrical connector 117 - EGR vacuum regulator electrical connector 118 - Oil pressure switch electrical connector 119 - Turbocharger variable vain vacuum regulator electrical connector 120 - Engine coolant shutoff valve electrical connector 121 - Wiring harness retaining clip 122 - Fuel pressure sensor electrical connector 123 - Water in fuel sensor electrical connector 124 - Generator electrical connector 125 - Crankshaft position (CKP) sensor electrical connector 126 - Fuel filter heater electrical connector 127 - Fuel temperature sensor electrical connector 128 - Manifold absolute pressure (MAP) sensor electrical connector 129 - Intake air temperature (IAT) sensor electrical connector 130 - Fuel injector electrical connectors 131 - Glow plug wiring harness electrical connector 132 - Camshaft position (CMP) sensor electrical connector Assembly Details Item 1 : Crankshaft bearing caps | | -
Install the piston cooling jets. | | | -
CAUTION:Install the crankshaft main bearing upper shells in the correct order. Install the crankshaft main bearing upper shells. | | | -
CAUTION:Install the crankshaft main bearing lower shells in the correct order. Install the crankshaft main bearing lower shells. | | | -
Using the special tool, install the crankshaft rear main bearing cap. | | | -
Install the crankshaft half thrust washers into the fourth crankshaft main bearing with the oil grooves facing outwards. | | | -
CAUTION:Install the crankshaft main bearing caps in the correct order. Install the crankshaft main bearing caps and tighten the bolts in two stages. | Item 2 : Connecting rod bearing caps | | -
CAUTION:Install the connecting rods bearing caps shells in the correct order. Install the connecting rod bearing shells. | | | -
NOTE:Install the pistons with the arrows pointing to the front of the engine. NOTE:The piston ring gaps and oil supply ring elements must be distributed evenly around the circumference. | | | -
CAUTION:Install the connecting rods bearing caps in the correct order. Install the connecting rods and tighten the nuts in two stages. | Item 5 : Oil pump | | -
Install the oil pump together with the oil pump chain and the oil pump drive sprocket. | | | -
Install the oil level indicator tube retaining bolt. | | | -
Install the oil pan baffle. | Item 6 : Cylinder head gasket | | -
Clean the mating faces of the cylinder head and the cylinder block with cleaner. | | | -
CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole marked). Install a new cylinder head gasket. | Item 7 : Cylinder head | | -
NOTE:Only rotate the crankshaft in the normal direction of rotation. Rotate the crankshaft until piston No. 1 is approximately 90 degrees before top dead center (TDC). | | | -
Using the special tool, install the cylinder head bolts. - Tighten the bolts in the sequence shown in two stages.
| Item 8 : Timing chain | | -
Lubricate the camshaft bearings with clean engine oil | | | -
CAUTION:The copper links of the timing chain must align with the timing marks on the camshaft sprockets. Position the camshafts together with the timing chain on to the cylinder head. | Item 9 : Camshaft housing | | -
Clean the upper mating face of the cylinder head and the camshaft housing with cleaner. | | | -
Apply a 4 mm diameter bead of sealant to the cylinder head. | | | -
Tighten the camshaft housing retaining bolts in the sequence shown in two stages. | Item 10 : Fuel injector retaining studs | | -
Install the fuel injector retaining stud in the sequence shown. | Item 11 : Timing chain tensioner | | -
Using the special tool, install the chain tensioner. | Item 12 : Camshaft seal | | -
NOTE:Install a new camshaft seal. Using the special tool, install the camshaft seal. | Item 13 : Crankshaft front seal retainer | | -
Clean the mating faces of the crankshaft front seal retainer and the cylinder block with cleaner. | | | -
CAUTION:Install the crankshaft front seal retainer within four minutes of applying the sealer. Apply a 3 mm bead of sealant to the mating face of the crankshaft front seal retainer. | Item 15 : Coolant pump | | -
Tighten the coolant pump retaining bolts in the sequence shown. | Item 17 : Crankshaft front seal | | -
Using the special tool, install the crankshaft front seal. | Item 18 : Oil pan | | -
Clean the mating face of the oil pan and the cylinder block with cleaner. | | | -
CAUTION:Install the oil pan within four minutes of applying the sealant. Apply a 3mm bead of sealant to the mating face of the oil pan. | Item 22 : Crankshaft rear seal | | -
NOTE:A new crankshaft rear seal is supplied with an alignment and protection sleeve that must be removed following installation. Using the special tool, install the crankshaft rear seal. - Remove and discard the alignment and protection sleeve.
| Item 23 : Flywheel | | -
Inspect the flywheel.
For additional information, refer to: Flywheel Inspection (303-00 Engine System - General Information, General Procedures).
| | | -
NOTE:Do not fully tighten the flywheel retaining bolts at this stage. Install the flywheel. - Tighten the flywheel retaining bolts finger tight.
| Item 24 : Flywheel retaining bolts | | -
CAUTION:Make sure that the special tool engages correctly. NOTE:Only rotate the crankshaft in the normal direction of rotation. Using the special tool, lock the flywheel. | | | -
Tighten the flywheel retaining bolts in the sequence shown. | Item 27 : Pressure plate retaining bolt | | -
Using the special tool, centralize the clutch disc on the pressure plate. | | | -
Using the special tool, install the clutch disc and pressure plate. | | | -
CAUTION:Make sure that the special tool engages correctly. NOTE:Only rotate the crankshaft in the normal direction of rotation. Using the special tool, lock the flywheel. | | | -
NOTE:Install new clutch pressure plate retaining bolts. Tighten the clutch pressure plate retaining bolts finger tight and then by two turns at a time in the sequence shown to the specified torque. | | | -
Remove the special tools. | Item 29 : Fuel injector seals | | -
Press the new fuel injector seal into the cylinder head. | Item 30 : Fuel injectors | | -
Make sure the fuel injector retaining bracket retaining clip is correctly installed. | | | -
Remove and discard the blanking cap from the injector nozzle. | Item 31 : Fuel injectors retaining bracket nuts | | -
Install the fuel injector retaining bracket nuts finger tight. | Item 32 : Fuel injector fuel return line connections | | -
Remove and discard the blanking plugs from the fuel injectors and the fuel injector return pipe connections. | Item 34 : Fuel injector high-pressure fuel supply line CAUTION:Remove the blanking plugs from the high-pressure fuel supply line, the fuel injector and the fuel injection supply manifold at the last possible moment. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system. CAUTION:Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system. CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions. NOTE: Maintain pressure on the high-pressure fuel supply line to keep the line in contact with the fuel injector cone and fuel injection supply manifold while installing the unions. NOTE:If it is not possible to correctly install the new high-pressure fuel supply line, it will be necessary to remove the remaining high-pressure fuel supply lines and to loosen the fuel injection supply manifold to allow correct alignment. | | -
Using the pneumatic vacuum gun, vacuum foreign material from the area around the fuel injectors and the fuel injection supply manifold. | | | -
Remove and discard the blanking plugs from the high-pressure fuel supply lines, the fuel injection supply manifold and the fuel injectors. | | | -
Install the fuel injector high-pressure fuel supply lines. - Finger tighten the high-pressure fuel supply line unions.
| | | -
NOTE:Tighten the fuel injector retaining bracket nuts so that the fuel injector retaining bracket remains level. Using the special tool, tighten the fuel injector retaining bracket nuts in two stages. - Stage 1: 4 Nm
- Stage 2: 45 degrees
| | | -
CAUTION:Individual high-pressure fuel supply lines must have both unions tightened before continuing on to the next high-pressure fuel supply line. Failure to follow this instruction may result in damage to the high-pressure fuel supply lines. Tighten the high-pressure fuel supply line unions. | Item 40 : Intake manifold assembly | | -
Tighten the intake manifold retaining bolts in two stages in the sequence shown. | Item 46 : Exhaust gas recirculation (EGR) vacuum regulator | | -
Install the EGR vacuum regulator vacuum lines. | Item 49 : Camshaft pulley | | -
NOTE:Only rotate the camshaft in the normal direction of rotation. Using the special tool, align the camshaft. - Turn the camshaft until the alignment hole of the camshaft pulley is at the 4 o´clock position.
| Item 50 : Camshaft pulley retaining bolt | | -
Using the special tool, tighten the camshaft pulley bolt in two stages. | Item 53 : Timing belt tensioner NOTE:A new timing belt tensioner is supplied locked to aid installation. NOTE:Do not tighten the timing belt tensioner retaining bolt at this stage. Item 54 : Timing belt | | -
NOTE:Only rotate the camshaft in the normal direction of rotation. Install the special tool. - Turn the camshaft until the alignment hole of the camshaft pulley is at the 4 o´clock position.
| | | -
NOTE:Only rotate the crankshaft in the normal direction of rotation. Rotate the crankshaft until piston No. one is at TDC. | | | -
Install the special tool. | | | -
CAUTION:Make sure that the special tool engages correctly. NOTE:Only rotate the crankshaft in the normal direction of rotation. Using the special tool, lock the flywheel. | | | -
CAUTION:Install the timing belt with the direction arrows in the direction of crankshaft rotation. NOTE:Install a new timing belt. Install the timing belt. | | | -
NOTE:Use an Allen key to maintain tension on the timing belt tensioner until the retaining bolt is tightened. Unlock the timing belt tensioner and tension the timing belt. - Using an Allen key, turn the timing belt tensioner counterclockwise to increase the tension on the timing belt.
- Check that the pointer is positioned on the left-hand side of the window, if necessary increase the tension of the timing belt by turning the Allen key.
- Tighten the timing belt tensioner retaining bolt.
| | | -
CAUTION:Do not touch the outer sensor ring. Using the old crankshaft pulley retaining bolt, install the timing pulley and the crankshaft pulley. | | | -
NOTE:Only rotate the crankshaft in the normal direction of rotation. Rotate the crankshaft four times. | | | -
Install the special tool. | | | -
Using the special tool, check the valve timing. - If its not possible to install the special tool, repeat the previous steps.
| | | -
NOTE:Use an Allen key, maintain tension until the timing belt tensioner bolt is tightened. Use an Allen key, adjust the correct timing belt tension. - Use an Allen key, keep the timing belt tensioner adjustment arm in position.
- Loosen the timing belt tensioner retaining bolt.
- Tighten the timing belt tensioner retaining bolt when the pointer is positioned centrally in the window.
| | | -
CAUTION:Do not touch the outer sensor ring. Remove the crankshaft pulley and the crankshaft timing pulley. | Item 55 : Crankshaft timing pulley CAUTION:Do not touch the outer sensor ring. Item 58 : Crankshaft pulley bolt | | -
Install the special tool. | | | -
NOTE:Install a new crankshaft pulley retaining bolt. Install the crankshaft timing pulley and the crankshaft pulley. - Tighten the crankshaft pulley retaining bolt in two stages.
| Item 65 : Brake vacuum pump O-ring seals | | -
CAUTION:Make sure the drive coupling is aligned with the camshaft coupling. Install new brake vacuum pump seals. | Item 82 : Thermostat housing coolant hose retaining clamp | | -
Using the special tool, connect the coolant bypass to thermostat housing coolant house. | Item 84 : Exhaust manifold | | -
Install the special tool. | | | -
Remove the special tools. | Item 107 : Turbocharger oil supply tube to cylinder block banjo bolt | | -
Install the turbocharger oil supply tube in line filter into the turbocharger oil supply tube to cylinder block banjo bolt. | |
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