Part 1
EngineSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Special Tool(s) (Part 3):
Disassembly (Steps 1-47)
1. Remove the bolts and the flexplate.
^ Discard the bolts.
2. Mount the engine on an engine stand.
3. Remove the rear lifting eye.
4. Remove the special tools.
5. Remove the bolts and RH motor mount plate.
6. Remove the nut and position the fuel tube support bracket aside.
7. Remove the 2 stud bolts and thermostat housing.
^ Remove and discard the O-ring seal.
8. Remove the LH cylinder head banjo fitting and fuel tube.
^ Discard the sealing washers.
9. Remove the bolt and the accessory drive belt idler pulley.
10. If equipped, remove the 2 bolts and serpentine belt tensioner.
11. Remove the 4 bolts and oil filter adapter.
12. Remove and discard the O-ring seals from the oil filter base.
13. Remove the exhaust gas recirculation (EGR) cooler coolant supply port cover.
^ Remove the bolts.
^ Clean and inspect the gaskets.
^ Clean and inspect the sealing surfaces.
14. NOTE: Do not discard the oil cooler cover bolts. They are self-tapping bolts and will be needed to cut the threads in the new oil cooler cover.
Remove bolts and the oil cooler cover.
^ Clean and inspect the gaskets. Install new gaskets if necessary.
^ Clean and inspect the sealing surfaces.
15. 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 installed as an assembly.
Remove the bolts and the oil cooler assembly.
^ Clean and inspect the gaskets. Install a new gasket, if necessary.
^ Clean and inspect the sealing surfaces.
16. Remove the oil pump inlet strainer.
^ Clean and inspect for tears and other damage.
17. Remove the bolts and the turbocharger heat shield.
18. Using the special tool, remove the injection pressure regulator (IPR) valve.
19. Remove the 8 bolts from the high-pressure oil pump cover.
20. NOTE: 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.
21. Position the special tool and check the oil pump drive gear backlash.
22. Remove the bolts on the high-pressure tube assembly.
23. Remove the bolts and the high-pressure oil pump.
24. Remove and discard the lower O-ring seals.
25. Using the special tool, disconnect and remove the high-pressure tube assembly.
26. Remove and discard the high-pressure oil pump O-ring seal.
27. CAUTION: Do not pull on the wiring to remove the glow plug connector or damage may occur.
Using the special tool, remove the glow plug harness.
28. Remove the 8 glow plugs.
29. Remove the protective covering from the LH cylinder head.
30. NOTE: Mark the location of the stud bolts.
Remove the stud bolts, bolts and the RH valve cover.
^ Clean and inspect the gaskets. Install a new gasket, if necessary.
^ Clean and inspect the sealing surfaces.
31. Remove the high-pressure oil rail-to-valve cover gasket.
32. Remove the 4 bolts and the coolant pump pulley.
33. Remove the 4 bolts and the coolant pump.
^ Discard the O-ring seal.
34. If equipped, remove the 3 bolts and the dual generator pulley.
35. Check the crankshaft vibration damper runout.
^ Remove the paint from the face of the crankshaft vibration damper at 4 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.
36. CAUTION: To prevent engine damage, you must always install 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 4 bolts and the crankcase vibration damper.
^ Discard the bolts.
37. Punch 2 holes in the crankshaft front seal.
38. Using the special tool, remove the crankshaft front seal.
39. NOTE: Production engines will not have a wear sleeve.
If equipped, remove the crankshaft seal wear sleeve with the special tool.
40. Remove the bolts and the oil pump body.
^ Discard the O-ring seal.
41. NOTE: Mark the front of each drive rotor for correct reassembly orientation.
Remove the inner and outer oil pump drive rotors
42. Remove the bolts and engine front cover.
43. 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.
44. Remove the flywheel adapter.
45. 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.
NOTE: The drill bit used must be the appropriate size for the body dent puller used in this step.
Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal, as shown.
46. NOTE: It will be necessary to alternate between the 2 holes, drilled in the previous step, to walk the seal out of the engine rear cover.
Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.
47. NOTE: Production engines will not have a wear sleeve.
If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
