Engine Disassembly

1. Separate engine and transmission and remove clutch cover and disc.
2. Drain engine oil and coolant into suitable containers.
3. Remove accessories and mounting brackets.
4. Remove engine mounts.
5. Remove intake manifold with venturi and air duct.
6. Remove exhaust manifold and engine sling.
7. Remove front engine components: fan, temp-coupling, fan pulley, alternator adjusting bar, crank pulley, thermostat housing, and water pump.

Fig. 2 Timer assembly removal:

8. Remove timing cover and using a suitable puller, remove timer assembly, Fig. 2.
9. Remove front cover and vacuum tube assembly.
10. Disconnect fuel pipes from injectors and injection pump assembly and remove fuel pipes.
11. Remove spill tube, injectors and injector washers. Plug injector nozzle holes to prevent entry of dirt.
12. Remove oil filter, oil cooler, and oil filter bracket.
13. Remove injection pump and diesel pump controller assemblies.
14. Disconnect and remove glow plug harness and oil cooler hose.
15. Remove rocker cover and rocker shaft assembly.
16. Remove pushrods and keep them in correct order.

Fig. 3 Cylinder head bolt loosening sequence:

17. Remove cylinder head bolts in proper sequence, Fig. 3, and remove cylinder head.
18. To remove oil pump:

Fig. 4 Oil pump drive spindle support:

a. Remove spindle support and drive spindle, Fig. 4.
b. Invert engine and remove oil pan. Then remove oil pump.
19. Straighten lock tabs and remove flywheel.

Fig. 5 Camshaft removal:

20. Remove camshaft locking plate, bring crankshaft to upper side, Fig. 5, and remove camshaft.
21. Remove valve lifters and keep in correct order.
22. Remove crankshaft gear using a suitable puller, then remove front plate.

Fig. 6 Oil jet removal:

23. Remove oil jet bolts and oil jets, Fig. 6.
24. Remove connecting rod caps and bearings.
25. Using a suitable drift, drive connecting rod/piston combinations out through cylinder head side taking care not to damage assemblies or crankshaft.

Fig. 7 Rear main bearing cap removal:

26. Remove main bearing caps with bearings using tool, Fig. 7, to remove rear cap.
27. Remove crankshaft and bearings. Keep bearings and caps in order.
28. Remove oil seal from crankshaft and rear bearing cap.

PISTON & ROD DISASSEMBLY

1. Remove piston rings with piston rings expander.
2. Remove piston pin retainer, immerse piston in oil of 176°F and push out piston pin.

CYLINDER HEAD DISASSEMBLY

1. Remove glow plugs.
2. Remove valves, springs and related components using a suitable spring compressor, keeping all components in correct order.
3. Remove valve stem seals from valve guide bosses.

Fig. 8 Rocker shaft assembly:

ROCKER SHAFT DISASSEMBLY

1. Remove cotter pin, washer, and outer spring, Fig. 8.
2. Remove valve rockers, inner springs, and rocker shaft brackets, making sure to keep all components in correct order. If rocker shaft brackets are difficult to remove, immerse rocker shaft assembly in oil of 158°F for a few minutes and remove brackets.
3. To assemble rocker shaft, reverse disassembly procedure.