Part 1

Engine













Disassembly

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

1. Remove the 10 bolts and the flexplate.
- Discard the bolts.





2. Mount the engine on an engine stand.

3. Remove the 4 bolts and RH motor mount plate.





4. Remove the nut and position the fuel tube support bracket aside.





5. Remove the 2 stud bolts and thermostat housing.
- Remove and discard the O-ring seal.





6. Remove the LH cylinder head banjo bolt and fuel tube.
- Discard the sealing washers.





7. Remove the bolt and the accessory drive belt idler pulley.





8. If equipped, remove the 2 bolts and serpentine belt tensioner.





9. Remove the 4 bolts and oil filter adapter.





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





11. NOTICE: In the event of a catastrophic engine failure, always install a new oil cooler. Foreign material cannot be removed from the oil cooler and engine damage may occur.

Remove the 10 bolts and the oil cooler assembly.





12. If necessary, replace the oil cooler. For additional information, refer to Oil Cooler Service and Repair in the disassembly and assembly of subassemblies.

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





14. Remove the 3 bolts and the turbocharger heat shield.





15. Using the Injection Pressure Regulator Socket, remove the Injection Pressure Regulator (IPR) valve.





16. Remove the 8 bolts from the high-pressure oil pump cover.





17. 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. Remove the high-pressure oil pump cover.

- Remove and discard the press-in-place gasket.





18. Position the Dial Indicator Gauge with Holding Fixture and check the oil pump drive gear backlash.





19. Remove the bolts on the high-pressure oil branch tube adapter.





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





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





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





23. NOTICE: Do not pull on the wiring to remove the glow plug connector or damage may occur.

Using the Glow Plug Connector Remover/Installer, remove the glow plug harness.





24. Remove the 8 glow plugs.





25. Remove the protective covering from the LH cylinder head.

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

Remove the 6 stud bolts, 5 bolts and the RH valve cover.

- Clean and inspect the gaskets. Install a new gasket, if necessary.

- Clean and inspect the sealing surfaces.





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





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





29. Remove the 4 bolts and the coolant pump.
- Discard the O-ring seal.





30. If equipped, remove the 3 bolts and the dual generator pulley.





31. 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 Dial Indicator Gauge with Holding Fixture to the cylinder block. Position the Dial Indicator Gauge with Holding Fixture 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.





32. WARNING: Support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft. Failure to follow this instruction may result in serious personal injury.

NOTICE: To prevent engine damage, always install new bolts when installing the vibration damper.

Remove the 4 bolts and the crankcase vibration damper.
- Discard the bolts.





33. Punch 2 holes in the crankshaft front seal.





34. Using the Oil Seal Remover, remove the crankshaft front seal.
- Discard the seal.





35. NOTE: Production seals will not have a wear sleeve. If a service part has been installed, it will have a wear sleeve.

If equipped, remove and discard the crankshaft seal wear sleeve with the Crankshaft Front Wear Ring Remover.





36. Remove the 5 bolts and the oil pump body.
- Discard the O-ring seal.





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

Remove the inner and outer oil pump drive rotors.





38. Remove the 17 bolts and engine front cover.





39. NOTICE: Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out and damaging it 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.

40. NOTICE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin.

Remove the flywheel front adapter.





41. NOTICE: 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.

NOTICE: Drill only deep enough to penetrate the seal. Engine damage will occur if the seal is drilled too deep.

Using a center punch, mark a location for 2 holes 180 degrees apart, 9.53 mm (0.37 in) from the outer diameter of the crankshaft flange. Using a drill bit of the appropriate size for the Slide Hammer being used, drill a hole on each side of the crankshaft rear seal as shown. Drill the holes to a depth of 8.76 mm (0.34 in) to capture the metal case of the crankshaft seal as well as the wear ring.





42. Using the 2 drilled holes, the Slide Hammer and a commercially available body dent puller attachment, walk the seal out of the rear cover by alternating from side to side to remove the crankshaft rear seal.
- Discard the crankshaft rear seal.





43. Clean and inspect the crankshaft sealing surface.





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

Remove the 8 bolts from the engine rear cover.





45. NOTICE: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out and damaging it while removing the rear cover.

NOTE: A 139.7 mm (5.5 in) long thin-blade scraper is needed to properly cut the sealant.

Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet.