Disassembly

When disassembling the engine or when removing components from the engine, never use a lead pencil to place alignment marks on cylinder head assemblies or use a sharp tool to pry off engine components as damage may result. Keep disassembled components in order and on a clean workbench to facilitate assembly.
1. Install engine in suitable working fixture.
2. Remove air filter cover and filter.
3. Remove air injection pump with filter, bracket and hoses, if equipped.
4. Remove EGR valve, connecting pipe and bracket from air distribution/filter housing, if equipped.
5. Disconnect injection system electrical connectors and position connectors clear of intake pipes.
6. Remove throttle control rod and return spring from throttle housing.
7. Remove auxiliary air regulator and auxiliary air valve from right side of engine.
8. Remove all hose clamps and tie wraps.
9. Remove nuts attaching intake manifold and carefully lift manifold off together with air distribution/filter housing fuel distributor, fuel lines and injectors.
10. Mark distributor cap, housing and rotor alignment for assembly, then remove distributor cap, ignition wires and ignition coil.
11. Remove distributor from engine.
12. Disconnect air ducts connecting air blower outlets and heat exchanger inlets and remove together with cover shrouds.
13. Remove all retaining screws for cooling air ducts and cover shrouds.
14. Loosen two screws of band strap on alternator/blower housing.
15. Pull blower housing rearward and remove air guide from alternator.
16. Disconnect electrical connectors at alternator and remove alternator with blower housing and fan.
17. Remove upper air guide with wiring harness.
18. Remove rear engine mount crossmember from engine mount.
19. Remove muffler flange attaching bolts and nuts.
20. Loosen muffler straps at rear center mount and remove muffler.
21. Remove engine mount attaching bolts.
22. Remove heat exchangers, removing thermal reactors, catalytic converter, EGR filter with lines and air injection lines as equipped.
23. On models equipped with air conditioning, remove compressor bracket from right chain housing cover.
24. On all models, disconnect camshaft oil supply lines, then remove both chain housing covers.
25. Remove chain tensioner attaching nuts and pull tensioner out with idler pulley.
26. Using tool P9191 or equivalent, remove camshaft sprocket attaching nuts.
27. Using tool P212 or equivalent, withdraw aligning dowels from chain housing.
28. Remove chain guides from chain housing. Ensure that pistons do not collide with valves when rotating crankshaft or camshafts.
29. Remove sprocket wheels and wheel flanges.
30. Remove woodruff keys from camshafts.
31. Remove three sealing flange retaining bolts and push out flange with suitable tool.
32. Remove nuts attaching chain housings to crankcase.
33. Remove stud bolts, then the chain guides, from inside of crankcase.
34. Remove oil cooler attaching nuts and the oil cooler.
35. Remove oil pressure relief valve and safety valve.
36. Remove intermediate shaft cover, then the intake and exhaust valve covers.
37. To remove cylinder heads individually, proceed as follows: When reusing original parts, mark relationship for assembly in original position. The design of the engine allows individual cylinder heads to be removed. Do not place marks of any kind on cylinder head such as lead pencil marks or use a screwdriver to pry off cylinder head or serious engine damage will result. If no work is to be performed on either the cylinder heads or camshaft housings, the entire cylinder head bank can be removed as an assembly.
a. Disconnect battery ground cable.
b. Remove cover plates and heat exchanger only from the side from which it is desired to remove the cylinder head.
c. Remove rear engine support and exhaust muffler assembly.
d. Carefully remove camshaft drive only from desired side.
e. Loosen camshaft housing attaching nuts, then remove spring washers and lift off camshaft housing. There are three (3) .315 inch (3 X 8 mm) internal hexagon attaching nuts on the camshaft housing.
f. Loosen cylinder head attaching nuts and lift cylinder head from engine.
38. To remove camshaft housing and cylinder heads as an assembly, proceed as follows:
a. Loosen evenly, then remove cylinder head attaching nuts.
b. Remove cylinder heads with camshaft housing, then cooling air shrouds and cylinders.
39. Remove piston pin retaining clips and drive out piston pin with suitable tool.
40. Remove engine crankcase breather cover, oil pressure sensor, thermostat and oil drain cover with screen.
41. Remove M8 nuts and washers attaching crankcase halves together.
42. Using suitable tools, remove flywheel.

Fig. 1 Bearing No. 1 Cap Nuts Location:

Fig. 2 Removing Nut In Left Chain Housing:

43. Remove nuts from studs at bearing No. 1, Fig. 1, then the nuts inside the oil cooler flange on right crankcase half. Crankcase must be turned so left crankcase half faces upward and right crankcase half can support crankshaft and intermediate shaft.
44. Remove nut on stud inside left chain housing, Fig. 2.
45. Remove attaching bolts, then separate crankcase halves.
46. Remove crankshaft and mount in tool P209a or equivalent. Label connecting rods according to cylinder, then remove connecting rods.
47. Remove oil pump attaching nuts, then remove oil pump, connecting shaft, intermediate shaft and chains as an assembly.