Part 1
EngineDisassembly (Steps 1-42)
General Equipment
CAUTION: If used as a leverage device, the fuel rail may be damaged. Care must be taken when working around the fuel rail.
1. Remove the flywheel or flexplate.
2. Remove the crankshaft spacer plate.
3. Remove the crankshaft spacer.
4. NOTE: The crankshaft rear seal may have a metal speedy sleeve. This sleeve must be removed before attempting to remove the seal.
If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.
5. Using the special tool, remove the crankshaft rear seal.
6. Install the engine on a suitable engine stand.
7. Remove the floor crane, Spreader Bar and the Engine Lifting Brackets.
8. Remove the generator mounting bracket.
1 Remove drive belt tensioner bolt.
2 Remove the generator mounting bracket bolts.
9. Remove the bolt and the engine ground strap. Detach the electrical connector.
10. Disconnect the PCV valve hose and electrical connector.
11. Disconnect the camshaft position (CMP) sensor and differential pressure feedback EGR system electrical connectors. Detach the wiring harness pin-type retainer. Remove the electrical connector bracket bolt.
12. Disconnect the 6 fuel injector electrical connectors and detach the 2 wiring harness retainers.
13. Disconnect the engine coolant temperature (ECT) sensor and knock sensor electrical connectors.
14. Remove the bracket bolt.
15. Disconnect the coolant hose.
16. Remove the coolant tube bracket retaining bolts.
17. Disconnect the coolant hose.
18. Detach the wiring harness retainer and remove the coolant tube and bracket, the PCV hose-to intake manifold fitting and the PCV hose as an assembly.
19. Disconnect the crankshaft position (CKP) sensor electrical connector.
20. Remove and discard the wiring anchors.
21. Remove the engine wiring harness.
22. Disconnect and remove the EGR tube from the exhaust manifold.
23. Remove the fuel rail bolts, fuel rail and the fuel injectors as an assembly.
24. Remove the bolts, the LH valve cover and the gasket.
25. Remove the bolts, the RH valve cover and the gasket.
26. Remove the thermostat housing.
1 Remove the bolts.
2 Release the bypass hose clamp and remove the housing.
27. Remove the bolt and the oil level indicator tube.
28. Remove the bolt and the knock sensor (KS).
29. Remove the nuts, LH exhaust manifold and the gasket.
^ Discard the nuts and gasket.
30. Remove and discard the 6 LH exhaust manifold studs.
31. Remove the nuts, RH exhaust manifold and the gasket.
^ Discard the nuts and gasket.
32. Remove and discard the 6 RH exhaust manifold studs.
33. Remove the bolts and the coolant pump.
34. NOTE: This bolt is a torque-to-yield design and cannot be reused.
Using the special tool, remove and discard the crankshaft pulley bolt.
35. NOTE: If the crankshaft pulley bolt is not installed, the special tool will bottom out before the pulley is off.
Install the crankshaft pulley bolt 2-3 turns. Using the special tools and the 8 mm x 1.25 x 100 mm bolts, remove the pulley.
36. Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the UP position.
37. NOTE: Mark each of the roller followers to make sure it is installed in its original position during reassembly.
Using the special tool, remove the camshaft roller followers.
38. Remove the RH hydraulic chain tensioner.
39. Remove the RH chain guide bolt.
40. NOTE: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
NOTE: Secure the chain to the camshaft drive cassette with a rubber band to aid in the removal of the cylinder head.
Remove the RH camshaft sprocket bolt and sprocket.
41. Remove the LH hydraulic chain tensioner.
42. Remove the LH chain guide bolt.
