Steps 1-60
Special Tool(s)
Disassembly
All vehicles
1. Remove the bolts and the flexplate.
^ Discard the bolts.
2. NOTE: LH side shown, RH side similar. Remove the bolts and the LH and RH motor mounts.
3. Mount the engine on an engine stand.
4. Remove the rear lifting eye.
5. Remove the front lifting brackets.
6. Remove the three bolts and the starter.
7. NOTE: LH shown, RH similar.
Remove the cylinder block drain plugs.
8. Disconnect the wire retainer. Remove the nut, oil level indicator and tube.
9. Remove the bolt and the fuel lines and bracket.
10. Disconnect the exhaust pressure tube at the exhaust manifold.
11. Remove the retaining nuts and the exhaust pressure bracket assembly.
12. Remove the stud bolts and thermostat housing.
^ Remove and discard the O-ring.
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. Install new gaskets if necessary.
^ Clean and inspect the sealing surfaces.
18. Remove the oil filter base.
^ Remove the bolts.
^ Clean and inspect the gaskets. Install new gaskets if necessary.
^ Clean and inspect the sealing surfaces.
19. CAUTION: In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.
NOTE: The oil cooler is replaced as an assembly.
Remove the oil cooler assembly.
^ Remove the bolts.
^ Clean and inspect the gaskets. install a new gasket 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.
Early build vehicles
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. Install a new gasket if necessary.
^ Clean and inspect the sealing surfaces.
23. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
24. Remove the bolts from the high-pressure oil pump discharge pipe. Position the high-pressure discharge pipe aside.
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.
Late build vehicles
28. Unsnap and remove the heat shield.
29. Remove the IPR valve.
30. Remove the bolts from the high-pressure pump cover.
31. CAUTION: To prevent engine damage, do not pry the high-pressure pump cover from the pump or damage to the cover can occur.
Use a thin gasket scraper to separate the cover from the crankcase at the rear cover seam.
32. NOTE: These are captured bolts and not removable.
Loosen the bolts on the high-pressure tube assembly.
33. Remove the bolts and the high-pressure oil pump.
34. Remove and discard the lower O-ring seals.
35. Using the special tool, disconnect and remove the high-pressure tube assembly.
36. Remove and discard the high-pressure oil pump O-ring seal.
All vehicles
37. CAUTION: Do not pull on the wiring to remove the glow plug connector or damage may occur.
NOTE: Only one glow plug connector shown.
Using the special tool, remove the glow plug harness.
38. Remove the eight glow plugs.
39. Remove the Injection Control Pressure (ICP) sensor.
40. NOTE: RH side shown, LH side similar.
NOTE: Mark the location of the stud bolts.
Remove the valve covers.
^ Remove the stud bolts and bolts.
^ Clean and inspect the gaskets. Install a new gasket if necessary.
^ Clean and inspect the sealing surfaces.
41. Remove the RH high-pressure oil rail to valve cover gasket.
42. Remove the bolts and the coolant pump pulley.
43. Remove the coolant pump.
^ Remove the bolts.
^ Remove and discard the O-ring.
44. If equipped, remove the bolts and dual generator pulley.
45. 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.
46. CAUTION: To prevent engine damage, you must always install four new bolts when installing the vibration damper.
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.
47. Punch two holes in the seal.
48. Using the special tool, remove the crankshaft seal.
49. NOTE: The production engine will not have a wear sleeve.
If equipped, remove the crankshaft seal wear sleeve with the special tool.
50. Remove the oil pump body.
^ Remove the bolts.
^ Remove and discard the O-ring seal.
51. NOTE: Mark the front of each drive rotor for correct reassembly orientation.
Remove the inner and outer oil pump drive rotors.
52. Remove the bolts and engine front cover.
53. CAUTION: Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the front cover gasket.
Use a thin blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.
^ Clean and inspect the sealing surfaces.
54. Remove the flywheel adapter.
55. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.
Punch two holes across from each other in the rear main seal.
56. Using the special tool, remove the rear main seal.
57. NOTE: Production engines will not have wear sleeve.
If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
58. Clean and inspect the crankshaft sealing surface.
59. CAUTION: To prevent engine damage, damaged or missing dowel pins should be installed before installing the rear engine cover.
Remove the 11 bolts from the rear engine cover.
60. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.
NOTE: A 5-1/2-inch long thin-blade scraper is needed to correctly cut the sealant.
Use a thin-blade scraper to cut the sealant where the LH crankcase and the lower crankcase meet.