Part 1

Engine

Special Tool(s):

Special Tool(s):

Special Tool(s):

Disassembly (Steps 1-32)





NOTE: For additional information, refer to the exploded view under the assembly procedure.

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 nut and position the fuel tube support bracket aside.





7. Remove the 2 stud bolts and thermostat housing.
^ Remove and discard the O-ring seal.





8. Remove the LH cylinder head banjo fitting and fuel tube.
^ Discard the sealing washers.





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





10. If equipped, remove the 2 bolts and serpentine belt tensioner.





11. Remove the 4 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.
^ Clean and inspect the sealing surfaces.





14. Remove bolts and the oil filter base.
^ 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 installed as an assembly.

Remove the bolts and the oil cooler assembly.
^ 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. If equipped, unsnap and remove the heat insulating wrap.





19. Using the special tool, remove the injection pressure regulator (IPR) valve.





20. Remove the 8 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. Remove 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.

Using the special tool, remove the glow plug harness.





28. Remove the 8 glow plugs.
29. Remove the protective covering from the LH cylinder head.





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

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





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





32. Remove the 4 bolts and the coolant pump pulley.