* Torque 3/4" 0-350 lb-ft

ISX / SIGNATURE ENGINE TORQUE VALUES

* 3/4" ratchet

* 24mm Socket P/N 3163484

* 3/4" impact wrench

* 3/4" handle

* Torque 1/2" 0-250 lb-ft Main Bearings (001-006)

* 1/2" ratchet

* 15mm Fluted Socket Tightening for the Blocks

Serial number 140000
* 1/2" handle
Identified by the "USA" mark just below the
water pump, behind the water filter.
Torque
110 LB-FT
* Torque 1/2" 0-250 lb-ft 180 Degrees

* 1/2" ratchet A CAUTION A

The alphabetic characters on the connecting rod cap must
correspond with the alphabetic characters on the connecting
* 15mm Hexagonal Socket rod, and must be installed with the characters aligned to
avoid damage to the connecting rods and crankshaft.
* 6" extension Install the connecting rod caps and bolts.
Connecting rod Torque Value:
* Torque 1/2" 0-250 lb-ft (001-014) Screws
1 and 2 Step 1 70 N*m [52 lb-ft]
Screws
* 1/2" ratchet 3 and 4 Step 1 70 Nm [52 lb-ft]
2 Turn each screw 60 degrees in the above sequence.
* 13mm
Hexagonal die

* Torque 1/2" 0-250 lb-ft

* 1/2" ratchet
Install (001-046-026)
A CAUTION A
* 13mm Hexagonal Socket Properly align the nozzles in the notch located on the hole
before tightening the screws. Engine damage may occur.
Piston Cooling Nozzle (001-046) Install the nozzle, washers, and screws.
Tighten the screws.
Torque Value: 65 N*m [48 Ib-ft]
* Torque 1/2" 0-250 lb-ft NOTE: The crankshaft must be rotated to allow access to
install all nozzles.

* 1/2" ratchet

* 13mm Hexagonal Socket

Install (007-031-026)
Lubricating Oil Pump (007-031) I aligned the dowel pins on the oil pump with the mounting -
holes in the cylinder block.
Install the oil pump, shims (if removed), and four bolts.
* Torque 1/2" 0-250 lb-ft Tighten the screws.
Torque Value: 56 N»m [40 Ib-ft]
* 1/2" ratchet

* 13mm Hexagonal Socket

* 17mm Hexagonal Socket

Install (001-089-026)
Install the block reinforcement plate and 10 screws.
Tighten the screws.
Block Reinforcement Plate (001-089) Torque Value: 137 Nm [102 Ib-ft]

Install the oil suction pipe to the lubricating oil pump.

Lubricating Oil Suction Tube (Block
Mounted) (007-035) Install the lubricating oil suction pipe screws. Tighten the
screws.
Torque Value: 47 N»m [35 Ib-ft]

Remove the guide studs and install two screws.

Tighten the screws in the sequence shown.
NOTE: Screw #1 has a final torque of 56 N•m [41 lb-ft]. All
Front Gear Housing (001-033) others have a final torque of 72 Nm [53 lb-ft],
Torque Value: Pasol 20 N» [15 Ib-ft] 2 72 Nm [53 Ib-ft]
 Torque 1/2" 0-250
lb-ft

1/2" Ratchet Front Gear Housing (001-033)

Crankshaft Position Sensor
13mm Hexagonal
Socket

10mm die
Hexagonal

Tighten screws 1-26 in k

Torque Value: 200 N*m [148 lb-ft]
405 N*m [300 lb-ft]
Cylinder Head (002-004) Rotate 90 degrees.
NOTE: It is recommended to use an air impact wrench and
socket, Tool No. 3163059 and 3163464, for

Torque 1/2" 0-250

lb-ft Upper Camshaft, Valve (002-024)
Tighten the screws.
1/2" Ratchet Torque Value: 4

13mm Hexagonal
Socket

Torque 1/2" 0-250

lb-ft Upper Camshaft. Injector (002-
025)
Tighten the screws.
1/2" Ratchet Torque Value: 4

13mm Hexagonal
Socket

Torque 1/2" 0-250

lb-ft Upper Camshaft, Valve (002-024)
Tighten the screws.
1/2" Ratchet
Torque Value: 4
Camshaft. Injector (002-
Upper Camshaft,
13mm Hexagonal 025)
Socket

Torque 1/2" 0-250 Install the retainer and screws. Remove the guide pin.
lb-ft Install the remaining screw and tighten all screws to a
star pattern.
torque of Torque
Basic Engine Timing (001-038) Value:

additional degrees in the same

Concept Lower Idler Gear - Install sequence as before.

10mm
combination
wrench
* Torque 1/2" 0-250 Adjustable Idler Gear - Final Installation
lb-ft While holding the adjustable idler gear in position, tighten
the adjustable idler gear mounting screws.

[22 lb-ft]
Basic Engine Timing (001-038) Turn each screw an
additional 60 degrees in the

* 0.010" shim

* 10mm Injector Camshaft I Concept Gear - Final Installation

combination
wrench Load the injector camshaft concept gear by tightening all
Basic Engine Timing (001-038) gear screws.
Injector Camshaft Concept Gear A CAUTION A
Be sure to tighten all concept gear bolts to the proper torque
so that they do not back out during engine operation. Severe
engine damage may occur.

Torque Value: 26 N«m [21 Ib-ft]

NOTE: The valve camshaft gear should rotate slightly on the
valve camshaft during this step.
 Torque 3/4" 0-350
lb-ft
3/4" Ratchet
24mm Socket P/N
3163484
3/4" Impact
Wrench 3/4"
Handle
1/2" Ratchet
Handle 1/2"
18mm Hex
Socket

* 1/2" ratchet
* 1/2" handle
* 18mm Hexagonal
Die
 4" extension
21mm Hex Slide the installation tool. No. Part 3162992, on the
Hta. Installation crankshaft seal. Make sure the weld nuts do not interfere
* Socket
31629921/2" Drive and the cover studs are visible.
Torque 1/2" 0-250 Tighten the injector camshaft concept gear mounting screw.
Tighten the three installation tool screws no more than 1/2
* lb-ft turn at a time, in a clockwise pattern, until the tool bottomsTorque Value: Pasol 216 Nm [160 Ib-ft]
Torque 3/8" 0-150 lb- out in the gear cover. Tighten the screws on the installation 2 Rotate 90 degrees
in Basic Engine Timing (001-088) tool.
1/2" Ratchet
* 1/2" Ratchet Injector Camshaft I Concept Gear - Final Installation
21mm Hexagonal Torque Value: 20 N*m [15 Ib-ft]
* Die Remove the installation tool and install the crankshaft seal
4" extension
18mm Socket 1/2" nuts onto the cover studs.
21mm
Drive Hex
Splined Tighten the eight crankshaft seal nuts.
1/2" Handle
Socket 1/2" Drive Torque Value: 8 N*m [71 lb-in.]
* Tighten the lower gear cover screws.
10mm Hexagonal
Torque Value: 28 Nm [21 Ib-ft]
Torque
Tubular1/2" 0-250
Socket A-, Valve Camshaft Gear - Final Installation 3
Tighten the valve camshaft gear screw.
lb-ft Torque Value: 148 [109 Ib-ft]
* Hta. Installation Basic Engine Timing (001-088) Finger tighten the three installation screws against the
installation tool. No, Part 3162994.
1/2" Ratchet Valve Camshaft Gear - Final Installation
3162994
The crankshaft rear seal must be pressed evenly into the
* 20mm Hexagonal bore. Misalignment of the seal rail can cause damage.
21mm Socket 1/2"
Socket Tighten the screws no more than 1/2 turn clockwise pattern,
21mm Socket
Drive P/N 3162813 until I. installation tool seats against the steering wheel
1/2" Drive P/N cover.
3162813
Use* clean
1/2" Ratchet
15W-40 oil
to lubricate the screw Tighten the screws.
* Torque
threads. 1/2" 0-250 A WARNING A
Torque 1/2" 0-250 lb-
lb-ft
Install the 10 screws. ThisTorque value: 20
component N*m 23 kg [50 lb] or more. To avoid
weighs
ft personal injury, use a crane or get help to lift the component.
Remove the two guide
studs, and install the Install the front gear cover using 16 screws. Tighten the remaining thirty-two 1 3-millimeter screws in the
* 1/2"
remaining Ratchet
Torque screws.
1/2" 0-250 lb- Upper Gear Cover (001-079) NOTE: Screws (7), (14), and (15) are longer than the othersequence shown.
Tighten screws.
ft the screws in Torque Value: 47 N«m [35 Ib-ft]
a star
13mmpattern.
Hexagonal Tighten the screws in the sequence shown.
* 1/2" Ratchet Install the oil drain plug.
Torque
SocketValue: 175 Nm Torque Value: 28 N»m [21 Ib-ft]
* Ib-ft]
[130
Tighten3" extension
the two
* 13mm
screws to theHexagonal
gear
housing.
Socket
Tighten the 15 screws.

KI
Torque
Torquevalue: 450-250
1/2" N»
* 19mm Hexagonal Die Torque value: 28 N
lb-ft
33 lb-ft]

1/2" Ratchet
Lower Gear Cover (001-080) Remove the device used to support the engine, install the
* Torque 1/2" 0-250 lb-
13mm Hexagonal three bolts on the rear of the oil pan and tighten.
ft Torque value: 47 N*m
Socket

* 1/2" Ratchet
*
16mm Hexagonal Die

* Torque 3/8" 0- Install (016-006-026)

3" extension
* 150 lb-in Steering Wheel Cover (016- Install the gasket, cover, and two screws. Tighten the
screws.
006) Torque Value: 11 N*m [97 Ib-in.]

* Torque 1/2" 0-250 lb- Install (016-002-026)

* 13mm Hex Socket
3/8"
Front Engine Support Bracket Install the mold support bracket and six mounting screws.
ft Drive
(016-002) Tighten the screws.
Torque value: 165 N*m
* 1/2" Ratchet
Install the rubber engine mounts inside the crossmember.
* 18mm Hexagonal Die

Install the flywheel cover over the guide studs.

Torque 3/8" 0-150
NOTE: Lubricate the threads and under the screw heads
lb-in Steering Wheel Cover (016- with clean 15W-40 lubricating oil.
006) Install the screws, and tighten in the sequence shown.
* Torque 1/2" 0-250 lb- Torque Value:

ft

Crankshaft Pulley (001-022)

* 1/2" Ratchet Pulley Mounting Bolts
Crankshaft
*
3/8"
18mmto 1/2"
Fluted Socket
reducer
* 3" extension
Torque 1/2" 0-250
two steps, using k
lb-ft Steering Wheel Cover (016- Torque Value:
006)
* Torque 1/2" 0-250 lb- Install (016-001-026) [74 lb-ft]
Engine Lift Stands (016-001) [145 lb-ft]
Install the front bracket and four screws.
ft
Install the rear bracket and four screws.
Tighten the screws.
* 1/2" Ratchet
Torque Value: 80 N*m [60 Ib-ft]
* 15mm Hexagonal
Socket

Install the ten screws.

Torque 1/2"
Remove the handles and guide studs.
0-250 lb-ft Steering wheel Install the remaining two screws into the holes from which
(016-005) the guide studs were removed.
* Torque 1/2" 0-250 lb- Tighten the screws in two steps, using the sequence
ft
[92 lb-ft]
Retaining Brace Bracket (001-081) [184 lb-ft]
* 1/2" Ratchet
* 13mm Hexagonal
4" extension
Socket

*
3" extension
* Torque 1/2" Tighten the two bolts to the cylinder head.
0-250 lb-ft Torque Value: 100 N*m [74 Ib-ft]

* 1/2" ratchet

Retaining Brace Bracket (001-081) * 15mm

Hexagonal die

* Extension of
3"

* Torque 1/2" 0-250 lb-ft

* Torque 1/2" 0-250 Tighten the mounting spacer screws.
* 1/2" ratchet Torque Value: 105 N*m [75 Ib-ft]
lb-ft
* 13mm
* 1/2" ratchet Retaining Brace Bracket (001-081) Hexagonal die
* 13mm
* Torque 1/2" 0-250
Hexagonal die lb-ft

* 1/2" ratchet

* 13mm
Hexagonal die

* Torque 1/2" 0-250 lb-ft Tighten the two screws to the gear housing. Torque
Value: 45 [33 Ib-ft]
* 1/2" ratchet

Accessory Holder (001-082) * 10mm

Hexagonal die

* Torque 1/2" 0-250 lb-ft

* 1/2" ratchet

* 10mm Fluted Socket

* 3" extension Tighten the two bolts and stud to the cylinder head. Torque
Value: 45 N*m [33 Ib-ft]

* Torque 1/2" 0-250 lb-ft

* 1/2" ratchet Accessory Holder (001-082)

* 15mm Hexagonal Socket

* 1/2" handle

Install the camshaft position sensor and screw.

Tighten the screw.
Torque Value: 25 N*m [18 Ib-ft]
* Torque 1/2" 0-250 lb-ft Connect the camshaft position sensor.
Accessory Holder (001-082)
* 1/2" ratchet

* 15mm Hexagonal Socket

* 1/2" handle

Install the injector into the cylinder head.

Injector (006-026) Install the injector clamp, and screw with washer.
Tighten the screw.
Torque Value: 80 N*m [59 Ib-ft]
Install the cross braces.

Lubricate the rocker shaft bolts with clean 15W-40 oil. Install
the remaining screws and washers.
Rocker Arm Assembly (003-009) Tighten the front mounting screw for each valve/brake rocker
shaft.
Torque Value: 68 Nm [50 Ib-ft]
Tighten the remaining screws.
Torque Value: 68 Nm [50 Ib-ft]
Loosen the screws one at a time 360 degrees and tighten again
using the torque plus angle method. Tighten the center screws
outward
Torque Value: Step 1 30 N•m [22 lb-ft] 2 Rotate 60 degrees.

Position the injector rocker assemblies onto the cylinder head.

Rocker Arm Assembly (003-009) Lubricate the injector rocker shaft bolts with clean 15W-40 oil.
Install the screws and washers.
Tighten all mounting screws.
Torque Value: 68 N*m [50 Ib-ft]
Loosen the screws one at a time 360 degrees and tighten -
again. using the torque plus angle method. Tighten the center
screws outward.
Torque Value: Step 1 30 Nem [22 lb-ft] 2 Turn 60 degrees.
* Torque 1/2"
0-250 lb-ft
 Torque 3/8"
0-150 lb-in Valve Train and Injector
Adjustment (003-004)
8mm ALLEN screwdriver tip.
1/4" bit adapter 3/8" to 1/4" reducer
Torque 6 lb-in 6mm ALLEN screwdriver tip.

Adapter for 1/4" tip 0.014" and 0.027" shim

Torque 1/2" 0-250 lb-ft
ALLEN KEY
6 mm
19mm Crow's Foot
Torque
ALLEN KEY1/2" 0-250
3 mmlb-ft Valve Train and Injector
8mm ALLEN key Adjustment (003-004)
7mm24mm
Shim Crow's
3163530 Foot

Torque 1/2" 0-250 lb-ft

13mm Crow's Foot

Torque 3/8" 0-150 lb-in

38mm Hexagonal Die

Reducers up to 3/8" Valve Train and Injector

Adjustment (003-004)

Valve Train and Injector

Adjustment (003-004)

Engine Brake Assembly (020-

004)

* Torque 1/2"
0-250 lb-ft Engine Brake Solenoid Valve
(020-012)
* 19mm
Hexagonal die

*
Safety pincers Engine Brake Control Valve (020-
017)

Install the engine receptacle into the cylinder head.

Engine Brake Harness (020-015)
Install the Deutsch connector retaining ring on the motor
receptacle and tighten the nut.
Internal Actuator Harness (01 9-
063) Torque Value: 11 N*m [97 lb-in.]
Install the Deutsch engine plug connector into the cylinder
head.
Connect the solenoid wires.
Install the rocker cover. See Procedure 003-011 in the
Signature, ISX. and QSX15 Troubleshooting and Repair
Manual Bulletin No. 3150971.
Torque 3/8"
0-150 lb-in
 Fuel Rail Pressure Sensor (019-115) Install (019-115-026) g THE— T QNV/-9
Wide flathead
* Tubular die
screwdriver
1 1/4" Hex tip
Install a new O-ring. Apply grease to the groove of the na ——L 9'90600 8.96 99062
o-ring to retain the o-ring during installation. -Fgg O EFgaEc
Screwdriver tip
adapter.1/2" 0-250
H Install a new Fuel Pressure Sensor. (6 jE
Install the rocker cover, eight bolts, and insulator
Torque
lb-ft Rocker Cover (003-011) Torque Value^ 14N-m [10 Ib-ft] assemblies. AE 16)
H Connect the engine harness to the Fuel Pressure Sensor. Tighten the screws.
Torque value: 25 N*m
1
H fuel. Run the engine and check for leaks. 5
10mm Hexagonal
Socket
* #25 Torx screwdriver H =a'nsM/2F9 — Lubricate the sensor O-ring.

Fuel Pump Inlet Restriction Sensor (019- H 12he—Aé

3"
bitextension ~ Install the Fuel Inlet Restriction sensor.
128) 1 H sT (1 tible.
* Screwdriver tip
adapter.
"KJ— U 4 Torque Value: 15 N*m [11 Ib-ft]
M 28 2 77p_A — Push the connectors together until they lock.
Torque 3/8" 0-150 NOTE: The primer bypass valve only exists on the following
integrated fuel system module part numbers:
lb-in Fuel Pump (005-016) • (12 VDG) No. from Part 4001840 or 4009811 HD-129
♦ (24 VDG) No. Part 4001843 or 4009813 HD-129
Torx screwdriver
Remove the priming bypass valve.
tip #25 H______________________________________ 19c00439
Inspect the priming bypass valve for damage or improper
sealing. Replace if necessary.
Screwdriver tip
___~Lubricate the sensor O-ring. Install the priming bypass valve and tighten.
adapter.
* 3/8" hex socket. Front Rail Pressure Sensor (019-170) ।HeInstall the Front Rail Pressure Sensor. Torque Value: 14N«m [120 Ib-in.]
3/8" inlet *—83sgTorque Value: 15 N*m [11 Ib-ft]
( ge-- 3-3e (2ej Push the connectors together until they lock.
85?—°02R3
* Torque 3/8" 0-150 lb- Install (005-016-026)
in Replace the damaged rings.
Install the pump and four torx head screws.
H____________________ Yo |________19000090 Torque Value: 13.5 N«m [120 lb-in.] Install the fuel
* #25 Torx screwdriver
control cover.
bit
_______________________________________Lubricate the sensor O-ring.

"
* Screwdriver tip Rear Rail Pressure Sensor (019-171)
adapter.
2Install the Rear Fuel Pressure Sensor.
"~Bless you Ae, Torque Value: 15 N»m [11 Ib-ft]
( ge-- '-—3Bea (2ej Push the connectors together until they lock.
Install (005-031-026)
Torque 3/8" 0-150
lb-in Fuel Pump Pulsation Damper (005- 855—°0,R23 Install the shock absorber, cover, and three torx screws.
031) Torque Value:
Two upper torx
screws Lower
torx screw [84 lb-in.]
__________________| |_________________19000090
48 lb-in.]
* Torque 1/2" 0-250 lb-
#30 Torx
ft
Screwdriver Bit Integrated Fuel System Module (IFSM) regulator.
TO. Remove the 1724-kPa/ 1aP E (9 1250-P6-!) fuel pressure
(005-073) / (96) \ 5===————
* Adapter for - Inspect for debris or damage. Replace the regulator-
screwdriver bit.
17mm Hexagonal Die í 9, 996==-== 4 dor, if necessary.
* Torque 3/8" 0-150
3" extension ——3583
Install 22 to the fuel shut-off valve.
the electrical connection Install the fuel pressure regulator and tighten.
lb-in Fuel Shut Off Valve (005-043) gNJ/B*ep4*,
Install the . Torque
nut onto the threaded post of the coil.
Value: 27 N»m [20 Ib-ft]
* 3" extension Use two wrenches to hold the nut post firmly, while
e- @=—-E—THE -
tightening the connecting nut.
Torque Value: 3 N«m [25 Ib-in.] A _0Ec0010e " *

#30 Torx
Screwdriver Bit
Adapter for -
* screwdriver
Torque 1/2"bit.
0-250 lb- Remove the 2206-kPa fuel pressure regulator D. ------to ' ‘
3"
ft extension Integrated Fuel System Module (IFSM)
*
* Torque 3/8" 0-150 lb-
(005-073) 20-! (AND /For
I aligned the actuator disc, spacer, and valve disc into the
electronic control valve body.
19mminHexagonal Die Fuel Shut Off Valve (005-043) Inspect for debris or damage. Replace the regulator- / yy
Install a new O-ring.
pain, if necessary. g[ -and ge=e= ==
Place the spring washer on the valve disc, with Eg-the cavity
* 3" extension
Install the fuel pressure regulator and tighten. and—4538) P82-/ "
side facing up.
NOTE: The coil must be oriented with the electrical
Shut-off Valve Solenoid
Fuel (FSOV) (019-050) Torque Value: 27 [20 Ib-ft] ‘
connection post at the bottom.
J4d-2e(
NOTE: Make sure the shut-off valve coil is the correct
voltage (12 VDC). The coil voltage and part number are
fused into the terminal connection end of the coil.
* Torque 3/8" 0-150 lb- Remove the two check valves placed at the inlet of A. 4-82-38 1 (6 1 fuel and fuel filter head. 1F9
Install the fuel shield and coil onto the front cover.
in Integrated Fuel System Module (IFSM) LJ==42Q2nw— Install a new O-ring and tighten the Allen head bolts.
Check that both seat properly and that they are HE--
(005-073) free of damage or debris. Replace if necessary. Torque Value: 3.39 N*m [30 Ib-in.]
*
Install both valves and check and tighten. \ week n**(
Screwdriver tip

*
12mm Allen
Screwdriver tip Torque Value: 17 N»m [150 lb-in.] G-/$
adapter.

Torque 3/8" 0-150 Install (019-110-026)

3" extension
* lb-in Fuel Metering Rail Actuator (019-110) Install a new O-ring. Apply grease to the O-ring groove to retain
the O-ring during installation.
* Torque 3/8" 0-150 lb- 52.a 574.a
Install a new fuel metering actuator. 4
Install (006-57-026)
in Fuel Pump Filter (006-057) ■Torque
PEBA 516545-
Value: 5.4 N»m [48 Ib-in.] '415 Install the fuel pump strainer, spring
E=#ralgg €5eg
HConnect the engine harness to the fuel metering actuator. Run compression, O-ring, and cap. Tighten the lid.
* 14mm Hexagonal B59ep3 ea*
Hthe engine and check for leaks. Torque Value: 17 N* 1150 lb-in.]
Socket
H /sh 5-50 __ /ioh i 5-5 Install the fuel supply line.
■ UT The

Torque 3/8" 0-150

lb-in Timing Rail Actuator (019-111)
“and I
____________________ _*06c00005
Install (019-111-026)
Install a new O-ring. Apply grease to the O-ring groove to retain
the O-ring during installation.

Torque Value: 5.4 N*rn [48 Ib-in.]

Connect the engine harness to the timing actuator. Run the
engine and check for leaks.
* Torque 1/2"
0-250 lb-ft

Integrated Fuel System Module

(IFSM) (005-073)
* Torque 1/2"
13mm die
0-250 lb-ft
Hexagonal
* 12mm Fluted Socket
16mm
Torque 1/2"die
0-250 lb-ft
Hexagonal
16mm die
3" extension
Hexagonal

3" extension
* 7/8" Return
Torque
Combination
1/2" 0-250 lb-ft Fuel Supply Pipes (006-
Wrench 024)
19mm Allen screwdriver bit
*1
Screwdriver tip adapter.
" or 1 1/16"
combination wrench
Torque 1/2" 0-250 lb-ft

10mm Hex Socket Torque,- 18 lb-ft

22mm Kickstand

Fuel Filter (Screw-On Type)

(006-015)

Lubricating Oil Cooler Element

(007-007)

Lubricating Oil Cooler (007-003)

Lubricating Oil Filter Bypass Valve

(007-014)

Install (007-015-026)
Lubricating Oil Filter Head Install the filter head adapter using service tool no. from part
(007-015) 3163624.
Torque Value; 203 N*m [150 Ib-ft]
Fill the new oil filter with clean lubricating oil.
Install the filter.

Install (007-011-026)
Lubricating Oil Bayonet Tube Install the bayonet tube and tighten the nut with your fingers.
(007-011)
Install the bayonet tube clamp, screw, and nut.
Tighten the bayonet tube nut.
Torque Value: 70 N*m [52 Ib-ft]
Tighten the clamp.
* Torque 1/2"
0-250 lb-ft
* It is squeezed by Install (007-013-026)
hand. Lubricating Oil Filter (Screw- Fill the filter with clean 15W-40 oil.
On) (007-013) Install the filter into the oil filter head. Tighten the filter until
the gasket contacts the surface of the filter head.

* Torque 1/2" 0-250 lb-

ft
* Screwdriver tip
6mm Allen

* Screwdriver tip
adapter.

*
11/16" Socket

*
19mm Allen key

Install and tighten the thermostat cap.

Install the alternator. See Procedure 013-001.
Install the water pump. See Procedure 008-062.

* Torque 1/2" 0-250 lb-

gr Install (008-014-026)
ft
*=5 NOTE: Use two thermostat housing cover screws to align the thermostat
housing.
*
13mm Hexagonal II I Lubricate the threads and under the heads of the screws |
Socket ____with engine oil.

etl9
Install the thermostat housing, gasket, and two bolts into the
* 3" extension cylinder head.
S— Tighten the two thermostat housing screws.
— Torque Value: 56 N»m [41 Ib-ft]
_7 vAa 08c000SO
1F39 Remove the two screws from the housing cover.
as guides.

* Torque 1/2" 0-250 lb-

ft

*
13mm Hexagonal
Socket

* 3" extension

* Torque 1/2" 0-250 lb-

ft

*
13mm Hexagonal
Socket

* 3" extension

* Torque 1/2" 0-250 lb-

ft

*
13mm Hexagonal
Socket

* 3" extension

* Torque 1/2" 0-250 lb-

ft

*
13mm Hexagonal
Socket

* 3" extension

A CAUTION A
 Mechanical overtightening can strip the threads or damage the filter
element seal.
Use the oil filter wrench, No. from Part 3375049, to tighten the filter an
additional 3/4 to 1 turn, or follow the instructions supplied with the
filter.

Remove the hose and oil supply connection from the plug on
the crankcase.

Torque Value: 34 N»m [25 Ib-ft]

Install (007-039-026)
Install the thermostat inside the lubricating oil cooler housing.
*52 Install the tapered retaining ring, with the tapered side facing away from
the lube oil cooler housing.
Lubricate the threads and under the screw heads with Chemtool Lubecote.
Install the thermostat housing cover, gasket, and four bolts to the cylinder head.
Tighten the screws.
Torque Value: 34 Nam [25 Ib-ft]

Install (006-082-026)
Replace the O-ring if damaged.
Install the gasket, water inlet connection, and four screws. Tighten the screws.
Torque Value: 60 N*m [45 Ib-ft]
Install the coolant hoses.

Install the water pump and three screws.

Remove the two guide studs, and install the remaining screws.
Tighten the screws.
Torque Value: 72 N*m [53 Ib-ft]

Install the belt tensioner and screw. See Procedure 008-080.

Torque Value: 34 N*m [25 Ib-ft]
Install the alternator. See Procedure 013-001.
 Install the upper radiator hose. Tighten the hose clamp.
* Torque
Torque1/2"
3/8"0-250
0-150 lb- NOTE: There are two different sized screws for mounting the
Torque Value: 5• ■<
Nem [40 Ib-in.]
belt tensioner bracket. The longer screw is for installation in
in
lb-ft Water Pump (008-062) position (1).
* 8mm Hexagonal Install the belt tensioner bracket and three screws.
tubular
13mm die.
Hexagonal Tighten the screws.
Socket Torque Value: 60 N* [45 Ib-ft]

3" extension
Industrial and Power Generation

* Torque 3/8" 0-150 lb- Fill (008-01 8-028)

Torque 1/2" 0-250 Close the
NOTE: radiator
Align drainpulley
the idler valves(1) and pilot adapter shaft (2)
in with the belt tensioner bracket (3), using the pilot adapter
lb-ft Water Pump (008-062) Install pin
guide the (4).
lower radiator hose.
* 8mm Hexagonal Tightenthe
Install the hose
belt clamps.
tensioner pulley and shaft to the belt
tubular
13mm die.
Hexagonal tensioner bracket,
Torque Value: using
5 N*m [40aIb-in.]
washer and screw.
Socket Tighten the screw.
Torque Value: 30 N«m
3" extension Install the dust seal.

* Torque 1/2" 0-250 lb- Install (010-080-026)

Torque 1/2" 0-250 Air Intake Connection (010-080) Install the
Tighten thefour
twomounting screws, air inlet connection, and a
bottom screws.
ft new gasket.
lb-ft Water Pump (008-062) Torque Value: 60 N«m [45 Ib-ft]
*
13mmHexagonal
13mm Hex Socket
Torque.- 41 lb-ft
Socket

3" extension
* 3" extension

* Torque 3/8" 0-150 lb- Check the coil assembly with a multimeter.
Torque 1/2" 0-250 Turbocharger Wastegate Control (010- Replace coil if not within specifications. Install (008-080-026)
in
lb-ft 109)
Automatic Belt Tensioner (Water Install the tensioner and 10 bolt
NOTE: If the coil assembly shows 0 ohms, there is an
* 3/8" hex socket. Pump) (008-080) electrical short in the coil. Tighten the screw.
3/8" inlet
10mm Hexagonal Tighten the nut holding the electrical connection post to the Torque value: 34 N'
Socket coil.
Torque Value: 3 Nam [25 Ib-in.]
3" extension

NOTE: The coil must be oriented with the electrical

* Torque 3/8" 0-150 lb- connection post at the bottom.
Torque 1/2" 0-250
Turbocharger Wastegate Control (010-
in
109) InstallMake
NOTE: (013-021-026)
sure the coil is the correct voltage (12 VDC).
lb-ft Automatic Belt Tensioner The coil voltage and part number are fused into the terminal
Automotiveend of the coil.
connection
* (013-021)
Screwdriver tip Install the tensioner and screw.
13mm
Torx #Hexagonal
25 Torque Value:
• Align the43 N*m [32
spacer andIb-ft]
valve disc in the control valve
Socket body.
• Install a new O-ring.
* Screwdriver tip • Place the spring washer on the valve disc, with the
Automotive
3"adapter.
extension
cavity side facing up.
• Install the guard and coil into the front cover.
• Install a new O-ring and tighten the screws.
Torque Value: 8 N*m [72 Ib-in.]

Torque 1/2" 0-250 Industrial and Power Generation

lb-ft
* Torque 3/8" 0-150 lb-
Automatic Belt Tensioner Install the automatic belt tensioner support bracket to the
front bracket using three screws.
(013-021)
Turbocharger Wastegate Control (010-
in Tighten the screws.
13mm Hexagonal 109)
Torque Value: 5
* Socket
3/8" hex socket. M
3/8" inlet
3" extension
Industrial and Power Generation

Torque 1/2" 0-250 Install the automatic belt tensioner onto the bracket using
two screws.
* lb-ft Automatic Belt Tensioner
Torque 1/2" 0-250 lb- (013-021)
Carbon Buildup in Air Compressor Tighten the screw (2).
ft
13mm Hexagonal (012-003) Torque Value: 40 N
Tighten the screw (1).
* Socket
13mm Hexagonal Torque Value: 55 N1
Socket
3" extension
* 3" extension

* It is squeezed by Install (008-006-026)

hand. Coolant Filter (008-006) Apply a thin film of clean engine oil, or equivalent, to the
sealing surface of the coolant filter gasket before installing
the coolant filter.

Mechanical overtightening can deform the thread or damage

the filter head.
N OTE: After installing the coolant filter, the ON mark on the
coolant filter collar must be properly aligned. If necessary,
manually rotate the collar to the appropriate position.

Tighten the coolant filter 1/2 to 3/4 turn after initial gasket
contact, or as specified by the manufacturer.

Install the electrical connection to the coil.

Install the nut onto the threaded post of the coil.
Use two wrenches to hold the nut post firmly, while tightening the connection nut.
Installing the Air Compressor Head
Assemble the air compressor using a new gasket.
Install the head and gasket.
Install the four 8-mm screws.

Torque Value: 3 N*m [25 Ib-in.]

Tighten the screws in the sequence shown. Use the torque

plus angle method.
Torque Value: Pasol 20 N»m [15 Ib-ft]
2 Rotate 90 degrees.
* Torque 1/2"
0-250 lb-ft

Air Compressor (012-014)

Torque 1/2" 0-250 lb-ft
13mm Hexagonal
15mmSocket
Hexagonal Socket

3" extension
3" extension

Torx1/2"
Torque screwdriver
0-250 lb-ft
tip #25
15mm Hexagonal Socket
Screwdriver tip
adapter.
3" extension

15mm curved wrench

* Torque 3/8"
0-150 lb-in

* 7/16" hex socket.

3/8" inlet

* 21mm kickstand

* Torque 1/2" 0-250 lb-ft

Dry Exhaust Manifold (011-007)
* 13mm Hexagonal Socket

* 3" extension

* Torque 3/8"
0-150 lb-in

* 7/16" hex socket.

3/8" inlet

Turbocharger (010-033)

A CAUTION A
Proper orientation of the turbocharger oil supply tube is
Turbocharger (010-033) critical to avoid failure. Avoid any contact between tube and
metal. (The inlet supply connection should be oriented
slightly off vertical to allow proper alignment.)

If installing a new turbocharger, be sure to locate the

turbocharger, loosen the turbocharger v-band clamps, and
adjust as necessary. Tighten the v-band clamps.

Torque Value: 9 N»m [75 Ib-in.]

If installing a new turbocharger, install the male ion elbow.

Torque Value: 30 N«m [22 Ib-ft]

Install the turbocharger oil supply pipe into the elbow.

Torque Value: 30 Nm [22 Ib-ft]

Turbocharger (010-033)

Turbocharger Discharge Elbow Clamp

* Torque 1/2"
0-250 lb-ft
* Torque 3/8"
0-150 lb-in Turbocharger (010-033)
* Torque 3/8"
* 7/16" hex socket.
0-150 lb-in
3/8" inlet
* 7/16" hex socket.
3/8" inlet
* Torque 3/8"
0-150 lb-in

* 7/16" hex socket.

3/8" inlet
* Torque 3/8"
Air Leaks from Air Intake and 0-150 lb-in
Exhaust Systems (010-024)
* 7/16" hex socket.
3/8" inlet
* Torque 3/8"
0-150 lb-in

* 7/16" hex socket.

3/8" inlet
* Torque 3/8"
0-150 lb-in
The noise may be caused by air leakage from the following:
* 7/16" hex socket.
3/8" inlet Air Leaks from Air Intake and Elbow connection between the turbocharger and the CAC.
Exhaust Systems (010-024) * Torque 1/2"
• Inspect the connection and O-ring for damage.
♦ Tighten the v-band clamps.
0-250 lb-ft
Torque Value: 14N«m [120 lb-in.]
* 14mm Hexagonal Socket

* 3" extension

Torque 1/2" 0-250 lb-ft

14mm Hexagonal Socket

Any CAC connection pipe or hose.
3" extension
Air Leaks from Air Intake and • Inspect the hose and tubing for damage.
Exhaust Systems (010-024) • Tighten the hose clamps.
Torque Value: 9 N*m [80 lb-in.]

Air leak from the turbine housing sealing surface.

Air Leaks from Air Intake and * Tighten the v-band clamp.
Exhaust Systems (010-024) Torque Value: 14 N*m [120 lb-in.]
* Check for an air leak.
* If an air leak is still present, remove and replace the
turbocharger.

Air leakage from the sealing surface of the compressor

housing.
Air Leaks from Air Intake and • Tighten the v-band clamp.
Exhaust Systems (010-024) Torque Value: 9 Nem [80 lb-in.]
• Check for an air leak.
• If an air leak is still present, remove and replace the
turbocharger.

x Install (008-036-026)
Belt Driven Fan Hub (008-036) 5 Automotive

This assembly weighs 23 kg [50 lb] or more. To avoid

personal injury, use a crane or get assistance to lift this
assembly.
Install the fan hub and screws.
Tighten the screws.
Torque Value: 115 N*m [85 Ib-ft]

NOTE: The fan hub must be installed before installing the

fan bracket.
Belt Driven Fan Hub (008-036) Install the fan hub to the fan bracket using four screws and
washers.
Tighten the screws.
Torque Value: 105 N»m [75 Ib-ft]

Industrial and Power Generation

* Torque 3/8"
0-150 lb-in

* Torque 1/2" 0-250 Use clean 1 5W-40 oil to lubricate the screw threads.
lb-ft Fan Bracket (008-088) Install six screws.
Remove the two guide studs, and install the two remaining
screws.
* 13mm Hexagonal
Socket
Tighten the eight screws in the sequence shown.
Torque Value: 55 Nam [41 Ib-ft]
* 3" extension

Industrial and Power Generation

* Torque 1/2" 0-250 Tighten screws Nos. 3,4,5, and 6.

lb-ft Fan Bracket (008-088) Torque Value: 115 Nem [85 Ib-ft]

* 13mm Hexagonal
Socket

* 3" extension
Industrial and Power Generation

* Torque 1/2" 0-250 Tighten screws Nos. 1, 2, 7, and ñ.

lb-ft Fan Bracket (008-088) Torque Value: 55 N*m [41 Ib-ft]

* 13mm Hexagonal
Socket

* 3" extension Industrial and Power Generation

* Torque 1/2" 0-250 Install (008-089-026)

lb-ft Fan Pulley (008-089) Industrial and Power Generation
Install the fan pulley using six screws.
* 13mm Hexagonal Tighten the screws in a star pattern.
Socket Torque Value: 95 N«m [70 Ib-ft]

* 3" extension

Install the fan cars

Tighten the mounting screws. Refer to OEM speci- "a}5/ cations.
Cooling Fan (008-040) Connect the batteries or the air starter motor supply line.

-08400027

* 1/2" handle Install (008-003-026)

60)
Water Pump Drive Belt (008-003) Using a 1/2-in. drive socket, lift and hold the belt tensioner.
Install the drive belt and release the tensioner

46 52)
NOTE: The belt tensioner is spring loaded and must be
pivoted away from the drive belt. If pivoted in the wrong
direction, damage to the belt tensioner may result.

Torque 1/2" 0-250 Install (013-001-026)

lb-ft Alternator (013-001) Install the alternator, bolt, washer, and nut to the alternator
mounting bracket. Tighten the nut.
Torque Value: 86 Nem [63 Ib-ft]
13mm Hexagonal Install the adjusting link and mounting screws.
Socket Tighten the screws.
Torque Value: 56 N»m [41 Ib-ft]
19mm Hexagonal
Die

3" extension

Torque 1/2" 0-250 Install (013-020-026)

lb-ft Starter Motor (013-020) A CAUTION A
Be sure to use the same thickness of starter motor spacer (if
used) as the one removed, to install the starter motor to
prevent damage to the engine.
16mm Fluted
Socket
Install the starter motor and three screws.
3" extension Tighten the screws.
Torque Value: 140 Nem [103 Ib-ft]
Install and tighten the electrical connections to the starter
motor.
* Torque 3/8"
0-150 lb-in
Torque 3/8" 0-150 lb-in
Ambient Air Pressure Sensor (019-004)
4mm Allen Screwdriver Tip Adapter for screwdriver tip.
3" extension

Coolant Level Sensor (019-017)

Coolant Temperature Sensor

(019-019)

* Torque 1/2"
0-250 lb-ft Electronic Control Module (ECM) (019-
031)
* 10mm
Hexagonal die

Connect the OEM actuator, sensor, and harness connectors to

the ECM. Tighten the screws connecting to the ECM
Engine Harness (019-043)
Torque Value:
NOTE: When replacing an ECM. The new ECM must be
calibrated. See Procedure 019-032.

Install (019-036-026)
Engine Position Sensor (EPS) (019- Install a new O-ring onto the engine position sensor.
038) Install the new sensor into the mounting hole.
Connect the sensor to the engine harness. Push the
connectors together until they snap into place.
Torque Value: 25 N*m [18 Ib-ft]

Vehicle Speed Sensor Magnetic

Pickup (019-091)

Tighten the lock nut against the transmission housing.

_ ___ _________ 1 1

1eee
Torque Value: 47 Nm [35 Ib-ft]
w

Install both connectors together until the connectors "snap" into

place. Connectors can be interchanged without changing
system performance.
• 6R 2

g(1
 Batteries can emit explosive gases. To avoid personal
injury, always ventilate the compartment before servicing
batteries. To avoid arcing, remove the negative (-) battery
cable first and connect the negative (-) battery cable to the

Install the cables and tighten the battery connections. Coat

the terminals with grease to prevent corrosion.

Oil Pressure/Temperature Sensor (019- Install (019-155-026) Install (019-159-026)

155) Install the oil pressure/temperature sensor. Make sure the new sensor has an O-ring. Install the new
Torque Value: 14N*m [10 Ib-ft]
sensor into the engine. Press the sensor.
Connect the sensor to the sensor harness. An audible click
will be heard when the connector locks into place. Torque Value: 14 Nam [10 Ib-ft]
Install (019-169-026)
△ CAUTION A
Drain the air compressor tank and all lines, before
removing or installing the air compressor governor.
Failure to drain the air compressor tank and pressure
lines could result in personal injury, mechanical damage,
electrical damage, or all of the above.
Make sure the new governor has an O-ring around the
Pressure/Temperature Sensor surface where it seals against the air compressor.
Intake Manifold (019-159) Install the governor on the air compressor.
Electronic Air Compressor Governor Torque Value: 14 Nm [10 Ib-ft]
(019-169)

Battery Cables and Connections (013-

009)