Steps 101-148

Engine









Disassembly

NOTE: This procedure assumes that the engine was removed using the recommended body off engine removal procedure. If it was necessary to remove the engine using the alternate body on engine removal procedure, some of the components in this procedure will have already been removed.

NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US EPA or CARB Regulations".

101. NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: RH side shown, LH side similar.

Remove the cylinder heads.





102. Check for cylinder head distortion. For additional information, refer to Cylinder Head Distortion Cylinder Head Distortion.

103. NOTE: LH side shown, RH side similar.

Remove and discard the 2 cylinder head gaskets from the cylinder block.





104. NOTE: Only one cylinder head dowel shown.

Remove and discard the 4 cylinder head dowels from the cylinder block.





105. Check for cylinder block distortion. For additional information, refer to Cylinder Block Distortion Cylinder Block Distortion.

106. NOTICE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original positions or engine damage may occur.

NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.

NOTE: Only one valve tappet guide shown.

NOTE: Some valve tappets will be removed with the valve tappet guides.

Remove the 8 valve tappet guides.

- Remove the 16 valve tappets from the valve tappet guides.





107. NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.

Remove the remaining valve tappets from the engine.





108. Remove the 15 bolts and lower oil pan.
- Remove and discard the lower oil pan gasket.





109. NOTE: Use care when removing the hose from the oil cooler, damage to the oil cooler may occur during removal.

Disconnect the hose retainer. Remove the oil cooler outlet hose assembly.





110. NOTICE: Failure to remove the oil cooler nut may result in damage to the oil cooler.

Remove the oil cooler nut.





111. NOTICE: In the event of a catastrophic engine failure, always install a new oil cooler. Foreign material cannot be removed from the oil cooler and engine damage may occur.

Remove the 7 bolts and the oil cooler assembly.

- Remove and discard the oil cooler gaskets.





112. Remove the 4 bolts, stud bolt and the oil filter adapter.
- Remove and discard the oil filter adapter gasket.





113. NOTE: Do not remove the zero leak plug from the oil pan.

Remove the 25 bolts and the upper oil pan.

- Remove and discard the upper oil pan gasket.





114. NOTICE: Use extreme care when removing the slinger or damage to the engine front cover may occur.

Using 2 pocket screwdrivers, carefully remove and discard the front crankshaft slinger.

- It will be necessary to remove the slinger from the sides as well as the top and bottom.





115. NOTE: Do not scratch or damage the crankshaft during removal or installation of the front crankshaft seal.

Using the Front Crank Seal Remover, remove and discard the front crankshaft seal from the engine front cover.





116. NOTICE: Use care when removing the engine front cover to not scratch the crankshaft sealing surface.

Remove the 14 bolts and the engine front cover.

- Remove and discard the engine front cover and gaskets.





117. NOTE: Do not scratch or damage the crankshaft during removal or installation of the rear crankshaft seal.

Using the Rear Crank Seal Remover, remove and discard the rear crankshaft seal.





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

Remove the 10 bolts and the engine rear cover.

- Remove and discard the engine rear cover gasket.





119. NOTE: Prior to removing any piston and rod assemblies, it is recommended that piston protrusion be evaluated. This will help identify bent or twisted connecting rods.

Install the Dial Indicator Gauge with Holding Fixture. Check the piston protrusion above the crankcase as follows.

- Zero the Dial Indicator Gauge with Holding Fixture on the crankcase deck surface.

- Position the Dial Indicator Gauge tip on the piston head at the 3 or 9 o'clock position.

- Rotate the crankshaft to measure the maximum piston protrusion and record.

- Reposition the Dial Indicator Gauge tip onto the piston head at the opposite position.

- Rotate the crankshaft to measure the maximum piston protrusion and record.

- Average the readings. If the average is lower than specification, the piston is lower in the bore than it should be. This indicates a bent or twisted connecting rod.





120. NOTICE: If evident from the top of the cylinder bore, remove the carbon ridge prior to removing the rod and piston assemblies. This reduces the chance of piston ring land damage during removal.

Using a knife or emery board, scrape the carbon ridge from the top of the cylinder bore.

121. Using a Feeler Gauge Set, check the connecting rod side clearance. Compare to Specifications.





122. NOTICE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage may occur.

NOTE: Mark the location of connecting rod cap prior to removal.

NOTE: Only one connecting rod cap shown.

Remove the 2 connecting rod bolts and connecting rod cap.





123. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.





124. Remove and discard the piston rings.

1. Remove the top compression ring.

2. Remove the intermediate ring.

3. Remove the oil control ring.





125. Remove and discard the connecting rod bearings.





126. Using the Dial Indicator Gauge with Holding fixture, check the high-pressure fuel injection pump drive gear backlash. For additional information, refer to Specifications.





127. NOTE: The crankshaft gear contains a single timing mark. The camshaft contains a single timing mark. The high-pressure fuel injection pump drive gear contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft drive gear is aligned with the double mark on the camshaft gear, and the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear. Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.

Rotate the crankshaft clockwise, as viewed from the front, until the single mark on the camshaft drive gear and the double mark on the high-pressure fuel injection pump drive gear are aligned.





128. Remove the high-pressure fuel injection pump drive gear nut.





129. Using a Universal Puller, remove the high-pressure fuel injection pump drive gear.





130. Remove the 2 bolts and the fuel rail supply tube bracket.





131. NOTICE: Do not pry against the mating surface of the high-pressure fuel injection pump or damage to the high-pressure fuel injection pump may occur.

Remove the 3 high-pressure fuel injection pump spacers and high-pressure fuel injection pump.

- Discard the O-ring seal.





132. Install the Dial Indicator Gauge with Holding Fixture, measure the camshaft gear backlash. For additional information, refer to Specifications





133. Install the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play. For additional information, refer to Specifications





134. Install the Dial Indicator Gauge with Holding Fixture, measure the crankshaft end play. For additional information, refer to Specifications





135. NOTE: RH side shown, LH side similar.

Remove the 10 crankshaft main bearing cap side bolts.





136. Remove the 20 crankshaft main bearing cap bolts.





137. Remove the 5 crankshaft main bearing caps from the cylinder block.
- Remove and discard the lower crankshaft main bearing thrust washer.

- Remove and discard the 5 lower crankshaft main bearings from the crankshaft main bearing caps.





138. Remove the crankshaft from the cylinder block.





139. NOTE: Only one upper bearing shown.

Remove and discard the 2 upper crankshaft main bearing thrust washers. Remove and discard the 5 upper crankshaft main bearings from the cylinder block.





140. Remove the bolt and camshaft gear.
- Using 2 suitable pry tools, carefully walk the camshaft gear off the camshaft.





141. Remove the 2 bolts and the camshaft thrust plate.





142. NOTICE: If the camshaft is being replaced, the camshaft bearings have to be replaced and machined by a machine shop. Failure to follow this may result in engine damage.

NOTICE: Use care when removing the camshaft from the engine or damage to the camshaft and the bearings may occur.

NOTICE: Use the slide hammer as a handle for the camshaft. Using the slide hammer as intended may result in engine damage.

NOTE: Use care when removing the camshaft, the camshaft will slide out the other end of the cylinder block.

Using the Camshaft Remover/Installer and the Slide Hammer, remove the camshaft.





143. Remove the 8 bolts and the 8 piston cooling tubes.





144. Remove the high-pressure fuel injection pump mounting bolts. Inspect the front cover roll pin for wear or damage, replace if necessary.





145. NOTE: Only one pipe plug shown.

If necessary, remove the pipe plugs.





146. If equipped, remove the block heater.





147. If damaged, remove and discard the turbocharger alignment dowels.





148. If damaged, remove and discard the cylinder block zero clearance patch from the engine.