Part 1

Engine

Special Tool(s):

Special Tool(s):

Special Tool(s):

Material:

Disassembly
1. Remove the bolts and the flexplate/flywheel.
^ Discard the bolts.





2. Mount the engine on an engine stand.
3. Remove the rear lifting eye.
4. Remove the front lifting brackets.





5. Remove the 3 bolts and the starter.





6. NOTE: LH shown, RH similar.

Remove the cylinder block coolant drain plugs.





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

Remove the bolts and the LH and RH motor mounts.





8. Remove the 4 nuts and the glow plug control module and mounting bracket.





9. Disconnect the wire harness retainer, the nut and the oil level indicator and tube.
^ Discard the oil level indicator tube O-ring seal.





10. Remove the 2 bolts and the thermostat housing.
^ Discard the O-ring seal.





11. Remove the bolt, the fuel tubes and the bracket.





12. Remove the LH cylinder head banjo fitting and fuel tube.
^ Discard the sealing washers.





13. Remove the bolt and accessory drive belt idlers.





14. If equipped, remove the bolts and accessory drive belt tensioner.





15. Remove and discard the O-ring seals from the oil filter base.





16. Remove the exhaust gas recirculation (EGR) cooler coolant supply port cover.
^ Remove the bolts.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.





17. 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 the oil filter base.
^ Remove the bolts.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.





18. 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.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.





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





20. If equipped, unsnap and remove the heat shield.





21. Using the special tool, remove the injection pressure regulator (IPR) valve.





22. Remove the bolts from the high-pressure pump cover.





23. 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.





24. Position the special tool and check the oil pump drive gear backlash.





25. Loosen the bolts on the high-pressure tube assembly.





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





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





28. Using the special tool, disconnect and remove the high-pressure tube assembly.





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





30. 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.





31. Remove the 8 glow plugs.





32. Remove the injection control pressure (ICP) sensor.





33. NOTE: RH shown, LH 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.





34. Remove the RH high-pressure oil rail-to-valve cover gasket.





35. Remove the 4 bolts and the coolant pump pulley.





36. Remove the bolts and the coolant pump.
^ Discard the O-ring seal.





37. If equipped, remove the bolts and dual generator pulley.





38. 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.





39. CAUTION: To prevent engine damage, you must always install 4 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.





40. Punch 2 holes in the crankshaft seal.





41. Using the special tool, remove and discard the crankshaft seal.





42. NOTE: The production engine will not have a wear sleeve.

If equipped, remove the crankshaft seal wear sleeve with the special tool.
^ Discard the crankshaft seal wear sleeve.





43. Remove the bolts and the oil pump body.
^ Remove and discard the O-ring seal.





44. NOTE: Mark the front of each drive rotor for correct reassembly orientation.

Remove the inner and outer oil pump drive rotors.