Part 1

Engine













Disassembly

All vehicles

NOTE: This procedure assumes that the engine was removed using the recommended body off engine removal procedure. If it was necessary to remove the engine using the alternate body on engine removal procedure, some of the components in this procedure will have already been removed.

1. Remove the 3 bolts and the starter.





2. Disconnect the electrical connector for the engine cooling fan. Carefully squeeze the locking tabs and remove the cooling fan electrical connector from the stator.





3. NOTE: The cooling fan has a LH thread.

Using the Fan Clutch Nut Wrench and Fan Hub Nut Wrench, remove the engine cooling fan.





4. Remove the 2 nuts, 2 bolts and engine cooling fan stator.





5. Remove the accessory drive belt.





Vehicles with A/C

6. Remove the A/C drive belt.
- Remove the belt from the bottom of the A/C clutch pulley, then remove it from crankshaft pulley.





All vehicles

7. Remove the retaining nut for the power steering hoses.





8. NOTE: When removing the pump, raise the supply tube up to clear the Engine Coolant Temperature (ECT) sensor connector.

Disconnect the power steering hose from the engine. Remove the 3 bolts and the power steering pump.





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





10. Disconnect the wire retainer and the plug for the generator. Position back the wiring boot and remove the nut from the generator wiring. Position aside the wiring.





11. Remove the 2 nuts, 2 bolts and the Front End Accessory Drive (FEAD) assembly.





Vehicles with A/C

12. Disconnect the A/C pressure switch electrical connector.





13. Disconnect the A/C compressor clutch electrical connector and wire retainer.





14. Remove the 3 bolts and the A/C compressor.





All vehicles

15. Remove and discard the center bolt and the RH engine mount.





16. NOTICE: The engine mount bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.

Remove the 4 bolts and the RH engine mount bracket.

- Discard the bolts.





17. Remove the 2 stator stand offs.





18. Remove the engine fill hose.





19. NOTE: Lower radiator hose shown, upper radiator hose similar.

Remove the clips. Remove the upper and lower radiator hoses.





20. NOTICE: The engine mount bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.

Remove the 4 bolts and the LH engine mount bracket.

- Discard the bolts.





21. NOTICE: Use a suitable engine stand with 6 mounting arms to support the engine. Failure to correctly support the engine may result in engine damage.

Mount the engine on the Car/Truck Engine Stand.





22. NOTE: LH shown, RH similar.

Remove the 2 cylinder block coolant drain plugs.





23. Disconnect the Exhaust Pressure (EP) sensor tube.





24. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector.





25. Remove the bolt and washer for the EGR-Oxidation Catalytic Converter (OC) pipe bracket.
- Discard the bolt.





26. Remove the bolt and washers for the EGR-OC pipe bracket.
- Discard the bolt.





27. NOTE: Turbocharger side shown, exhaust manifold side similar.

Remove the 4 bolts for the turbocharger inlet pipe-to-EGR-OC pipe.

- Discard the bolts.

- Remove and discard the gaskets.





28. Remove the 2 bolts and the EGR-OC pipe.
- Discard the bolts.





29. NOTE: LH side shown, RH side similar.

Remove and discard the 6 retaining nuts for the turbocharger inlet pipes.





30. Remove the 6 bolts, bracket and the turbocharger inlet pipes.
- Discard the bolts and gaskets.





31. Disconnect the crankcase vent oil separator drain tube.





32. Remove the 4 bolts and the crankcase vent oil separator.
- Remove and discard the press-in-place gasket.





33. NOTICE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.

NOTE: Use a back-up wrench to prevent the fittings from turning.

Remove the turbocharger oil feed tube banjo bolts and sealing washers.

- Discard the sealing washers.





34. Remove the bolt and the turbocharger oil feed tube.
- Remove and discard the O-ring seal.





35. Disconnect the turbocharger actuator electrical connector and pushpin retainer.





36. NOTE: Rear bolts shown, front bolts similar.

Remove the 4 bolts for the turbocharger crossover tube.





37. Remove the 5 bolts and the turbocharger heat shield.





38. Remove the 2 bolts and 2 hold downs for the turbocharger.





39. Install the Turbocharger Lifting Bracket.
- Tighten to 20 Nm (177 lb-in).





40. NOTICE: Failure to use the turbocharger lifting bracket during removal, handling or installation of the turbocharger may result in damage to the low pressure-to-high pressure turbocharger seal.

NOTICE: Make sure the turbocharger assembly is kept level to the engine during removal or installation. Failure to follow these instructions may result in damage to the high-pressure oil drain tube.

NOTE: Use care when removing the turbocharger. The crossover tube should not be removed, it has one-time-use seals.

Using the Heavy Duty Floor Crane, remove the turbocharger assembly.

41. Remove the turbocharger drain tubes.

1. Remove and discard the low-pressure drain tube.

2. Remove the high-pressure drain tube.

- Remove and discard the O-ring seals.





42. NOTICE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.

Loosen the clamp and disconnect the EGR cooler hose.

- Discard the EGR cooler clamp.





43. Remove the 2 retaining nuts for the vertical EGR cooler.





44. NOTE: RH heater supply tube removed for clarity.

Remove the bolt and the EGR cooler coolant tube.

- Remove and discard the O-ring seal.





45. Disconnect the EGRT sensor electrical connector.





46. Disconnect the coolant hose from the vertical EGR cooler.





47. Remove the nut and bolt for the vertical EGR cooler.





48. Remove the vertical EGR cooler stud.
- Remove and discard the gasket.





49. Remove the 5 bolts and the vertical EGR cooler assembly.
- Remove and discard the gasket.





50. Disconnect the EGR valve and Throttle Body (TB) electrical connectors.





51. Remove the 4 bolts and the intake throttle adapter.
- Remove and discard the press-in-place gasket.





52. Disconnect the EP sensor electrical connector and retaining clip.





53. Disconnect the glow plug electrical connector and pushpin retainers.





54. Disconnect the Camshaft Position (CMP) sensor electrical connector and pushpin retainer.





55. Disconnect the LH fuel charging harness electrical connector. Disconnect the pushpin retainers and remove the harness from the retaining clip.





56. Disconnect the fuel temperature sensor electrical connector.





57. Disconnect the ECT sensor electrical connector and wire retainer.





58. Disconnect the Engine Oil Temperature (EOT) sensor and Engine Oil Pressure (EOP) switch electrical connectors. Remove the bolt for the engine wiring harness retainer.





59. Disconnect the pushpin retainers from the oil drain back tube brackets.





60. Disconnect the Crankshaft Position (CKP) sensor electrical connector and pushpin retainer.