General Information
Installations can vary from OEM to OEM. Use the following steps as a guideline. See the OEM service manual when
necessary.
Install
Install all accessories and brackets that were removed from the engine during engine removal.
For engine supplied components, see the corresponding procedure in this manual.
For vehicle installed components, see the corresponding OEM service manual.
Use a properly rated hoist and engine lifting fixture, Part Number 3162871 , attached to the engine-mounted lifting
brackets, to remove the engine.
If the engine was repaired, lift the engine and engine stand adapter plate from the engine rebuild stand.
Remove the engine stand adapter plate.
NOTE: The turbocharger will need to be installed after the engine stand adapter plate is removed.
If the engine was replaced, lift the engine from the shipping pallet.
NOTE: On applications in which the rear engine mounts are attached to the transmission, it is often necessary to
install the engine and transmission as an assembly. Refer to the OEM service manual for instructions.
Remove covers from all openings that were covered during removal.
Align the engine in the chassis, and tighten the engine mounting capscrews. Refer to the OEM torque specifications.
Connect all engine and chassis-mounted accessories that were removed.
NOTE: Make sure all lines, hoses, and tubes are properly routed and fastened to prevent damage. Make sure the air
intake and exhaust pipe connections are tight and free of leaks.
If not installed with the engine, connect the drive units to the flywheel housing. Refer to the OEM service manual for
instructions.
Fill the engine with clean 15W-40 engine oil. Refer to Procedure 007-037 in Section 7.
NOTE: The total coolant capacity of the engines varies.
Refer to the OEM service manual to determine the capacity of the entire cooling system.
Fill the cooling system with new coolant. Refer to Procedure 008-018 in Section 8.
Refer to Procedure 018-018 in Section V.
Perform a final inspection to make sure all hoses, wires, linkages, and components have been properly installed
and tightened.
Connect the batteries. Refer to the OEM service manual.
Disconnect the OEM connector from the electronic control module (ECM) to prevent the engine from starting.
Install a pressure gauge in the main oil rifle on the intake side of the engine to measure oil pressure.
If a port on the main oil rifle is not available, install a pressure gauge at the top of the oil filter head.
Crank the engine until the lubricating oil pressure gauge indicates a positive pressure.
After pressure is observed, connect the OEM connector to the electronic control module (ECM).
Remove the pressure gauge.
Prime the fuel system. Refer to Procedure 006-015 in Section 6.
Operate the engine at low idle for 2 to 3 minutes.
Shut off the engine and wait 5 to 7 minutes for the lubricating oil to drain to the lubricating oil pan.
Check the lubricating oil and coolant levels again.
Fill the engine to the correct lubricating oil and coolant levels, if necessary. Refer to Procedure 008-018 in
Section 8 and Refer to Procedure 007-037 in Section 7.
Operate the engine at 1000 to 1200 rpm for 8 to 10 minutes.
Check for proper operation, unusual noises, and coolant, fuel, or lubricating oil leaks.
Repair all leaks and component problems.
Refer to Procedure 014-006 in Section 14.
Check the lubricating oil and coolant levels again.
Use INSITE electronic service tool to read and clear any fault codes. Reference the Fault Code Troubleshooting
Manual, Bulletin 4022225.
