Part 1 of 2

Engine








Special Tool(s)

Disassembly





1. Remove the bolts and the flexplate.
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. Remove the high-pressure oil pump cover.
^ Remove the bolts.
^ Use a thin gasket scraper to separate the cover from the crankcase.
^ Clean and inspect the gaskets. Install a new gasket if necessary.
^ Clean and inspect the sealing surfaces.





19. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.





20. Remove the bolts from the high-pressure oil pump discharge pipe. Position the high-pressure discharge pipe aside.





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





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





23. Remove and discard the lower O-ring seal.





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

NOTE: Only one glow plug connector shown.

Remove the glow plug harness.





25. Remove the eight glow plugs.
26. Remove the protective covering from the LH cylinder head.





27. 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.





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





29. Remove the bolts and the coolant pump pulley.





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





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





32. 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.





33. 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.





34. Punch two holes in the seal.





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





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

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





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





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

Remove the inner and outer oil pump drive rotors.





39. Remove the engine front cover.
^ Remove the bolts.
^ Clean and inspect the gaskets. Install new gaskets if necessary.
^ Clean and inspect the sealing surfaces.





40. Remove the flywheel adapter.