Steps 51-100
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".
51. Disconnect the ECT sensor electrical connector and wire retainer.
52. Disconnect the fuel pressure switch and the fuel temperature sensor electrical connectors. Disconnect the wire retainer.
53. Disconnect the Fuel Rail Pressure (FRP) sensor electrical connector and 2 wire harness retainers.
54. Disconnect the fuel pressure control valve electrical connector.
55. Remove the cylinder block opening cover.
56. NOTE: Only one wire retainer shown.
Disconnect the Crankshaft Position (CKP) sensor electrical connector and the 3 wire retainers.
57. NOTE: Only one fuel injector and glow plug electrical connector shown.
Disconnect the 8 fuel injector and 8 glow plug electrical connectors.
58. Disconnect the 3 wire retainers from the LH valve cover.
59. NOTE: Only one retainer shown.
Disconnect the 6 retainers from the fuel supply manifolds.
60. Remove the bolt and disconnect the 2 engine wire harness retainers.
- Pull forward to disconnect the engine wire harness retainer and then pull up to disconnect the other retainer. Remove the engine wire harness from the engine.
61. Remove the 4 bolts and the power steering mounting bracket.
62. Disconnect the fuel injection pump hose from the fuel rail.
63. Disconnect the fuel injector return hose and retainer from the secondary fuel filter. Disconnect the secondary outlet hose from the fuel injection pump supply tube.
64. Remove the 2 fuel injection pump supply tube assembly bolts.
65. Remove the fuel injection pump supply tube assembly stud bolt.
66. Remove the bolt and the fuel injection pump supply tube assembly.
- Remove and discard the O-ring seals.
67. NOTE: Only 2 bolts shown.
Remove the 4 bolts and crankcase vent oil separator.
- Remove and discard the gaskets.
68. Remove the 3 bolts and the secondary fuel filter assembly.
69. Remove the turbocharger coolant tube.
70. Remove the 2 bolts and heater supply tube.
- Remove and discard the O-ring seal.
71. NOTICE: The center lock of the fuel injector return hose connectors must be pulled completely out before the connector can be removed from the fuel injector or damage may occur to the connector.
Push down on the tabs and pull up on the center of the fuel injector return hose fitting to unlock the fitting.
- Disconnect the 8 fuel injector return hose fittings from the fuel injectors.
72. NOTE: RH valve cover shown, other connectors similar.
Disconnect and remove the fuel injector return hose and vacuum hose assembly from the retaining clips.
73. NOTE: Only one fuel injector supply tube shown.
Remove and discard the 8 fuel injector supply tubes.
74. NOTE: LH side shown, RH side similar.
Disconnect the 4 fuel rail supply tube assembly from the fuel rails.
75. Disconnect the 2 fuel rail supply tube assembly at the high-pressure fuel injection pump.
76. Remove the 5 bolts and fuel rail supply tube assembly.
- Discard the fuel rail supply tube assembly.
77. Remove the 2 bolts and LH fuel rail.
78. Remove the 2 bolts and RH fuel rail.
79. Remove the 3 bolts, thermostat housing and thermostat.
80. Remove the 5 bolts and the coolant crossover manifold assembly.
- Discard the gaskets.
81. WARNING: Support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft. Failure to follow this instruction may result in serious personal injury.
NOTICE: To prevent engine damage, always install 4 new bolts when installing the crankshaft pulley.
Remove the 4 bolts and the crankshaft pulley.
- Discard the bolts.
82. Remove the 4 bolts and the vacuum pump.
- Discard the gasket.
83. Remove the 10 bolts and flexplate.
- Discard the bolts.
84. Remove the crankshaft sensor pulse ring.
85. Remove the bolt and the CKP sensor.
86. Remove the 4 bolts and the LH exhaust manifold heat shield.
87. Remove the 5 bolts and the RH exhaust manifold heat shield.
88. Remove the 8 nuts, 8 spacers and the LH exhaust manifold.
- Remove and discard the LH exhaust manifold gasket and nuts.
- Replace any exhaust manifold stud(s) that is damaged or removed with the nut.
89. Remove the 8 nuts, 8 spacers and the RH exhaust manifold.
- Remove and discard the RH exhaust manifold gasket and nuts.
- Replace any exhaust manifold stud(s) that is damaged or removed with the nut.
90. NOTE: The fuel injector hold-down clamp bolts are torque-to-yield and cannot be reused.
Remove the 8 fuel injector bolts and fuel injector hold-downs.
- Discard the fuel injector bolts.
91. Using the Fuel Injector Remover tool, remove the 8 fuel injectors.
1. Install the Fuel Injector Remover tool to the fuel injector and fully hand-tighten the Fuel Injector Remover tool mounting bolt.
2. Install the allen head push bolt and tighten to remove the fuel injector.
3. Remove the Fuel Injector Remover tool mounting bolt and the lower portion of the Fuel Injector Remover tool.
4. Remove and discard the O-ring seal and the copper combustion gasket from the fuel injector.
5. Remove and discard the fuel injector return fuel O-ring.
- Position the fuel injector in the Fuel Injector Holding Rack and Injector Cups.
92. NOTE: Only one glow plug shown.
Remove the 8 glow plugs.
93. Remove the 15 bolts, 3 stud bolts and the LH valve cover.
- Discard the LH valve cover gasket.
94. Remove the 16 bolts, 2 stud bolts and the RH valve cover.
- Discard the RH valve cover gasket.
95. NOTICE: Failure to remove the oil spray bar in steps may result in damage to the oil spray bar.
NOTE: The nuts for the oil spray bar are captured nuts and remain on the oil spray bar.
Remove the LH oil spray bar. Loosen the nuts 2 revolutions at a time in the sequence shown until the LH oil spray bar can be removed.
- Inspect the O-ring seal, replace if necessary.
96. NOTICE: Failure to remove the oil spray bar in steps may result in damage to the oil spray bar.
NOTE: The nuts for the oil spray bar are captured nuts and remain on the oil spray bar.
Remove the RH oil spray bar. Loosen the nuts 2 revolutions at a time in the sequence shown until the RH oil spray bar can be removed.
- Inspect the O-ring seal, replace if necessary.
97. NOTE: Mark the location of the rocker arm assemblies prior to removing.
NOTE: On early build engines the bolts for the rocker arm assemblies are captured bolts and remain in the rocker arm assemblies.
NOTE: Only one cylinder shown.
Remove the 8 rocker arm assemblies.
98. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
NOTE: Only one cylinder shown.
Remove the 32 push rods.
99. NOTICE: Discard the M12 cylinder head bolts and install new bolts. They are torque-to-yield design and cannot be reused.
Remove the 18 M12 cylinder head bolts and 5 M8 cylinder head bolts for the LH cylinder head.
- Discard the 18 M12 cylinder head bolts.
100. NOTICE: Discard the M12 cylinder head bolts and install new bolts. They are torque-to-yield design and cannot be reused.
Remove the 18 M12 cylinder head bolts and 4 M8 cylinder head bolts for the RH cylinder head.
- Discard the 18 M12 cylinder head bolts.
