Part 1 of 2

Engine














Special Tool(s)

Disassembly





1. Remove the bolts and the flexplate/flywheel.
2. Mount the engine on an engine stand.
3. Remove the rear lifting eye.





4. Remove the front lifting brackets.





5. Remove the three bolts and the starter.





6. NOTE: Left side shown, right side similar.

Remove the bolts and the LH and RH motor mounts.





7. Remove the retaining nuts and the glow plug control module and mounting bracket.





8. Remove the oil level indicator and tube.
^ Remove the nut.
^ Remove and discard the O-ring.





9. Disconnect the exhaust backpressure tube at the exhaust manifold.





10. Remove the retaining nut and the exhaust backpressure tube assembly.





11. Remove the thermostat.
^ Remove the stud bolt and bolt.
^ Remove and discard the O-ring.





12. Remove the bolt and the fuel lines and bracket.





13. Remove the left cylinder head banjo fitting and fuel line. Discard the sealing washers.





14. Remove the bolt and serpentine belt idler.





15. Remove the bolts and serpentine belt tensioner.





16. Remove and discard the O-rings from the oil filter base.





17. Remove the Exhaust Gas Recirculation (EGR) cooler coolant supply port cover.
^ Remove the bolts.
^ Clean and inspect the gaskets. Replace if necessary.
^ Clean and inspect the sealing surfaces.





18. Remove the oil filter base.
^ Remove the bolts.
^ Clean and inspect the gaskets. Replace if necessary.
^ Clean and inspect the sealing surfaces.





19. NOTE: The oil cooler is replaced as an assembly.

Remove the oil cooler assembly.
^ Remove the bolts.
^ Clean and inspect the gaskets. Replace if necessary.
^ Clean and inspect the sealing surfaces.





20. Remove the oil pump inlet strainer. Clean and inspect for tears and other damage.





21. Remove bolts and the turbocharger heat shield.





22. Remove the high-pressure oil pump cover.
^ Remove the bolts.
^ Use a thin gasket scraper to separate the cover from the crankcase.
^ Clean and inspect the gaskets. Replace if necessary.
^ Clean and inspect the sealing surfaces.





23. Remove the bolts from the high-pressure oil pump discharge pipe.





24. Using the special tool, disconnect and remove the high-pressure oil pump discharge pipe.
^ Remove and discard the D-ring seal.





25. Remove and discard the high-pressure pump O-ring seal.





26. Remove the bolts and the high-pressure oil pump.





27. Remove and discard the lower O-ring seal.





28. NOTE: Left side shown, right side similar.

Remove the glow plug buss bar.





29. Remove the eight glow plugs.





30. NOTE: Mark the location of the stud bolts.

Remove the valve covers.
^ Remove the stud bolts and bolts.
^ Clean and inspect the gaskets. Replace if necessary.
^ Clean and inspect the sealing surfaces.





31. Remove the bolts and the coolant pump pulley.





32. Remove the coolant pump.
^ Remove the bolts.
^ Remove and discard the O-ring.





33. Check the crankshaft vibration damper runout.
^ Remove the paint from the face of the crankshaft vibration damper at four points 90 degrees apart.
^ Attach the special tool to the cylinder block. Position the special tool on one of the unpainted surfaces.
^ Using a suitable tool, pry the crankshaft forward. Zero the dial indicator.

^ NOTE: Pry the crankshaft forward at the same point to eliminate possible error caused by crankshaft end play.

Rotate the crankshaft 90 degrees. Pry the crankshaft forward. Record the measurement. Repeat at each unpainted surface.
^ If the runout exceeds specification, install a new crankshaft vibration damper.





34. WARNING: To avoid personal injury, support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft very easily.

Remove the bolts and the crankcase vibration damper.
^ Discard the bolts.





35. Punch two holes in the seal.





36. Using the special tool, remove the crankshaft seal.





37. NOTE: Production engine will not have a wear sleeve.

If equipped, remove the crankshaft damper wear sleeve with the special tool.





38. Remove the gerotor oil pump cover.
^ Remove the bolts.
^ Remove and discard the O-ring seal.





39. NOTE: Mark the front of each gerotor for proper reassembly orientation.

Remove the inner and outer gerotors.





40. Remove the engine front cover.
^ Remove the bolts.
^ Clean and inspect the gaskets. Replace if necessary.
^ Clean and inspect the sealing surfaces.





41. Remove the flywheel adapter.