Part 2

(Engine Disassembly Part 2)

45. Remove the bolts and engine front cover.





46. 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.
47. Remove the flywheel adapter.





48. 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 the following 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.





49. 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.





50. NOTE: Production engines will not have wear sleeve.

If equipped with a crankshaft wear sleeve, use the special tool to remove and discard the crankshaft rear wear sleeve.





51. Clean and inspect the crankshaft sealing surface.





52. CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the rear engine cover.

Remove the 11 bolts from the rear engine cover.





53. 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 crankcase and the lower crankcase meet.





54. 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 139.7 mm (5.5 inch) long thin-blade scraper is needed to correctly cut the sealant.

Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.





55. Remove the crankcase-to-head tube assembly.





56. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.

Remove the bolts and the high-pressure oil rail.





57. NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.

If the crankcase-to-head tube separated, using the special tool, remove the lower crankcase-to-head tube.
^ Remove and discard the D-ring seal.





58. Remove and discard the D-ring seals.





59. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.

Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.





60. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.

61. CAUTION: Failure to account for all snap rings or pieces of snap rings prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system causing severe engine damage.

CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.

NOTE: There is no need to drain the fuel rail.

NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve.

Remove the bolt, the fuel injector hold down and the fuel injector.





62. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.

Remove the shop towels.

63. NOTE: Left cylinder head shown, right cylinder head similar.

Remove and discard the 10 head bolts from each cylinder head.





64. Remove the 16 bolts and the rocker arm assemblies.





65. Remove the rocker arm carrier from the cylinder head.
^ Remove the bolts.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.





66. NOTE: Mark the location of the valve bridges before removing.

Remove the 16 valve bridges.





67. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.

Mark the location and remove the 16 push rods.





68. Remove the 5 outer bolts from each cylinder head.





69. Using the special tool, remove the cylinder heads.
1 Install the special tool.
2 Install the bolts.





70. Remove and discard the cylinder head gasket.





71. Remove and discard the 4 cylinder head dowel sleeves.





72. Remove the bolts and the rear engine tube assembly.





73. CAUTION: To prevent engine damage, keep the cam followers in the order in which they were removed. Install all cam followers back in their original positions.

Remove the bolts and the roller follower guides. Remove the hydraulic cam followers.





74. NOTE: The oil pan bolts must be installed in their original positions. Mark the locations of the longer bolts to aid in installation.

Remove the 16 bolts and oil pan.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.





75. Remove the oil pick-up tube and the screen.
^ Remove the bolts.
^ Remove and discard the O-ring.





76. Remove the bolts and upper oil pan.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.





77. NOTE: Prior to removing any piston and connecting rod assemblies, it is recommended that piston protrusion be evaluated. This will help identify bent or twisted connecting rods.

Check the piston protrusion above the crankcase as follows.
^ Zero the dial indicator gauge on the crankcase deck surface.
^ Position the dial indictor tip on the piston head at the 3 or 9 o'clock position.
^ Rotate the crankshaft to measure the maximum piston protrusion and record.
^ Reposition the dial indicator tip onto the piston head at the opposite position.
^ Rotate the crankshaft to measure the maximum piston protrusion and record. Average the 2 readings to see if the maximum piston protrusion is exceeded.





78. Using a feeler gauge, check for connecting rod side clearance.





79. Remove the bolts and the connecting rod caps.





80. CAUTION: To prevent engine damage, remove the ridge prior to removing the rod and piston assemblies if evident from the top of the cylinder bore. This reduces the chance of piston ring land damage during removal.

Use a razor knife or emery board to scrape the carbon ridge from the top of the cylinder bore.
81. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.





82. Remove the piston rings.
1 Remove the keystone ring.
2 Remove the intermediate compression ring.
3 Remove the oil control ring.





83. Remove and discard the connecting rod bearings.





84. Install the special tool and measure the camshaft gear backlash. Install a new gear if backlash is not within specification.





85. Install the special tool and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within specification.





86. 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.

Install the special tool and measure the crankshaft end play. Record the end play.





87. Remove the bolt and the crankshaft position (CKP) sensor.





88. Remove the bolt and the camshaft position (CMP) sensor.





89. Remove the block heater.





90. Remove the 20 lower case bolts. Remove the lower crankcase assembly.





91. Remove the lower crankcase seals and the lower bearings and discard.





92. Using the appropriate lifting device, remove the crankshaft assembly.





93. Remove and discard the crankshaft upper bearings and crankshaft upper thrust bearing.





94. CAUTION: Do not knick or scratch the camshaft bearings with the camshaft lobes or engine damage will occur.

Remove the thrust plate mounting bolts and remove the camshaft and gear.





95. CAUTION: This patch bolt is unique. Do not substitute or engine damage can occur.

Remove the bolts and the 8 piston cooling tubes.





96. Using the special tool, remove the camshaft bearings and discard.