Part 2

Engine














46. 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. Remove the engine rear cover.

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

- Clean and inspect the sealing surfaces.





47. Prior to removing the exhaust manifolds, inspect the exhaust manifolds for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specification.

48. Remove the 8 bolts, 8 spacers and the RH exhaust manifold.
- Discard the bolts.





49. Remove the 8 bolts, 8 spacers and the LH exhaust manifold.
- Discard the bolts.





50. Disconnect the fuel injector electrical connectors.





51. Remove the crankcase-to-head tubes.





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

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

Remove the 18 bolts and the high-pressure oil rails.





53. 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 High Pressure Supply Tube Remover, remove the lower crankcase-to-head tube.





54. Inspect the D-ring seals for damage (nicks, cuts and gouges). If damaged, replace the crankcase-to-head tube.





55. Remove the port plug from the high-pressure oil rail.
- Inspect the port plug O-ring seals for damage (nicks, cuts and gouges). If damaged, replace the port plug.





56. NOTICE: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector may occur.

Using the Injector Connector Release Tool, push the fuel injector electrical connectors out of the rocker arm carrier.





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

58. NOTICE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.

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. For additional information, refer to Fuel Delivery and Air Induction.

NOTE: The bolt is part of the fuel injector hold-down assembly.

Loosen the bolt and remove the bolt and fuel injector hold-down assembly and the fuel injector.
- Remove and discard the O-ring seals and copper washer.





59. Remove the shop towels.

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

Remove and discard the 20 head bolts from both cylinder heads.





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





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

Remove the 4 bolts and the rocker arm carriers.

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

- Clean and inspect the sealing surfaces.





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

Remove the 16 valve bridges.





64. NOTICE: 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. The push rods are directional and the copper-coated end must be installed in the upward position where it will contact the rocker arm.

Mark and remove the 16 push rods.





65. Remove the 10 outer head bolts.





66. Using the Cylinder Head Lifting Bracket, remove the cylinder heads.





67. Check for cylinder head distortion. For additional information, refer to Cylinder Head Distortion Cylinder Head Distortion.

68. Remove and discard the cylinder head gaskets.





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





70. Check the cylinder block distortion. For additional information, refer to Cylinder Block Distortion Cylinder Block Distortion.

71. Remove the bolts and the high-pressure oil branch tube.





72. NOTICE: 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 2 bolts, the roller follower guides and the hydraulic cam followers.





73. Remove the 9 bolts and the upper oil pan.
- Remove and discard the press-in-place gasket.

- Clean and inspect the sealing surfaces.





74. 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:

- Position the Dial Indicator Gauge with Holding Fixture.

- Zero the Dial Indicator Gauge on the crankcase deck surface.

- Position the Dial Indicator Gauge tip on the piston head at the 3 o'clock or 9 o'clock position.

- Rotate the crankshaft to measure the maximum piston protrusion and record.

- Reposition the Dial Indicator Gauge tip onto the piston head at the opposite position.

- Rotate the crankshaft to measure the maximum piston protrusion and record.

- Average the 2 readings. If the average reading is lower than the specification, the piston is lower in the bore than it should be. This indicates a bent or twisted connecting rod.





75. Using a Feeler Gauge Set, check for the minimum connecting rod side clearance.





76. NOTE: Only one connecting rod cap shown.

Remove the 16 bolts and the connecting rod caps.





77. NOTICE: 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.

78. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.





79. Remove and discard the piston rings.

1. Remove the keystone ring.

2. Remove the intermediate compression ring.

3. Remove the oil control ring.





80. Remove and discard the connecting rod bearings.





81. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft gear backlash. Install a new gear if backlash is not within specification.





82. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within specification.





83. 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.

Install the Dial Indicator Gauge with Holding Fixture and measure the crankshaft end play. Record the end play.





84. Remove the bolt and the Crankshaft Position (CKP) sensor.





85. Remove the bolt and the Camshaft Position (CMP) sensor.





86. Remove the block heater.





87. Remove the 20 lower case bolts and the lower crankcase assembly.





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





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





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





91. NOTICE: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage may occur.

Remove the 2 thrust plate mounting bolts and remove the camshaft and gear.





92. NOTICE: This patch bolt is unique. Do not substitute or engine damage can occur.

Remove the 8 bolts and the 8 piston cooling tubes.





93. Using the Camshaft Service Set, remove the camshaft bearings and discard.