Steps 1-60

Part 1:

Part 2:

Part 3:

Special Tool(s)

Disassembly




1. Remove the bolts and the flexplate.
^ Discard the bolts.
2. Mount the engine on an engine stand.
3. Remove the rear lifting eye.





4. Remove the special tools.





5. Remove the bolts and RH motor mount plate.





6. Remove the retaining nut and position the fuel line bracket aside.





7. Remove the stud bolts and thermostat housing.
^ Remove and discard the O-ring seal.





8. Remove the left cylinder head banjo fitting and fuel line. Discard the sealing washers.





9. Remove the bolt and serpentine belt idler.





10. If equipped, remove the bolts and serpentine belt tensioner.





11. Remove the bolts and oil filter adapter.





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





13. Remove the Exhaust Gas Recirculation (EGR) cooler coolant supply port cover.
^ Remove the bolts.
^ Clean and inspect the gaskets. Install new gaskets if necessary.
^ Clean and inspect the sealing surfaces.





14. Remove the oil filter base.
^ Remove the bolts.
^ Clean and inspect the gaskets. Install new gaskets if necessary.
^ Clean and inspect the sealing surfaces.





15. CAUTION: In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.

NOTE: The oil cooler is replaced as an assembly.

Remove the oil cooler assembly.
^ Remove the bolts.
^ Clean and inspect the gaskets. Install a new gasket, if necessary.
^ Clean and inspect the sealing surfaces.





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





17. Remove the bolts and the turbocharger heat shield.





18. Unsnap and remove the heat insulating wrap.





19. Using the special tool, remove the Injection Pressure Regulator (IPR) valve.





20. Remove the eight bolts from the high-pressure oil pump cover.





21. 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.





22. NOTE: These are captured bolts and not removable.

Loosen the bolts on the high-pressure tube assembly.





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





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





25. Using the special tool, disconnect and remove the high-pressure tube assembly.





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





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

NOTE: Only one glow plug connector shown.

Using the special tool, remove the glow plug harness.





28. Remove the eight glow plugs.
29. Remove the protective covering from the LH cylinder head.





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

Remove the RH valve cover.
^ Remove the stud bolts, bolts and valve cover.
^ Clean and inspect the gaskets. Install a new gasket, if necessary.
^ Clean and inspect the sealing surfaces.





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





32. Remove the bolts and the coolant pump pulley.





33. Remove the coolant pump.
^ Remove the bolts.
^ Remove and discard the O-ring seal.





34. If equipped, remove the bolts and the dual generator pulley.





35. Check the crankshaft vibration damper runout.
^ Remove the paint from the face of the crankshaft vibration damper at four points, 90 degrees apart.
^ Attach the special tool to the cylinder block. Position the special tool 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.





36. CAUTION: To prevent engine damage, you must always install four new bolts when installing the vibration damper.

WARNING: To avoid personal injury, support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft very easily.

Remove the bolts and the crankcase vibration damper.
^ Discard the bolts.





37. Punch two holes in the seal.





38. Using the special tool, remove the crankshaft seal.





39. NOTE: The production engine will not have a wear sleeve.

If equipped, remove the crankshaft seal wear sleeve with the special tool.





40. Remove the oil pump body.
^ Remove the bolts.
^ Remove and discard the O-ring seal.





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

Remove the inner and outer oil pump drive rotors.





42. Remove the bolts and engine front cover.

43. CAUTION: Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out 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.





44. Remove the flywheel adapter.





45. CAUTION: 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.

Punch two holes across from each other in the rear main seal.





46. Using the special tool, remove the rear main seal.





47. NOTE: Production engines will not have wear sleeve.

If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.





48. Clean and inspect the crankshaft sealing surface.





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

Remove the 11 bolts from the rear engine cover.





50. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant can result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 5.5-inch 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.





51. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant can result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 5.5-inch 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.
52. Prior to removing the exhaust manifolds, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specification.





53. Remove the bolts and the RH exhaust manifold.





54. Remove the bolts and the LH exhaust manifold.





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

Remove the bolts and the high-pressure oil rail.





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

Using the special tool, push the fuel injector electrical connector 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. CAUTION: To prevent engine damage, do not use air tools when removing and installing the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall off.

CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system causing severe engine damage.

NOTE: If engine oil is found in the engine coolant or engine coolant is found in the combustion chambers, new injector sleeves may need to be installed.

Remove the bolt, the fuel injector hold down and the fuel injector.

59. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.

Remove the shop towels.





60. NOTE: The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.

Remove the crankcase-to-head tube assembly.
^ Remove and discard the O-ring seals.