Steps 1-50

Engine

















NOTICE: 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 8 bolts and the flywheel or the flexplate.
- Discard the bolts.





2. Remove the crankshaft spacer plate.

3. Remove the crankshaft spacer.

4. NOTE: The original crankshaft rear seal does not have a metal speedy sleeve. Replacement crankshaft rear seals come with a speedy sleeve. If present, 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 Oil Seal Remover, remove the crankshaft rear seal.





6. Install the engine on a suitable engine stand.

7. Remove the Heavy Duty Floor Crane, Spreader Bar and the Engine Lifting Brackets.

8. Remove the generator mounting bracket.

1. Remove the bolt and the drive belt tensioner.

2. Remove the 3 bolts and the generator mounting bracket.





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 (KS) electrical connectors.





14. Remove the bracket bolt.





15. Disconnect the coolant hose.





16. Remove the coolant tube bracket retaining bolt.





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 2 wiring anchors.





21. Remove the engine wiring harness.

22. Disconnect and remove the EGR tube from the exhaust manifold.





23. Remove the 4 fuel rail bolts, fuel rail and the fuel injectors as an assembly.





24. Remove the bolt and the KS.





25. Remove the thermostat housing.

1. Remove the 3 bolts.

2. Release the bypass hose clamp and remove the thermostat housing.





26. NOTE: RH shown, LH similar.

Loosen the 12 bolts and remove the valve covers.





27. Remove the bolt and the oil level indicator tube.





28. Remove the 6 nuts and the RH exhaust manifold and gasket.
- Discard the nuts and the gasket.





29. Remove and discard the 6 RH exhaust manifold studs.





30. Remove the 6 nuts and the LH exhaust manifold and gasket.
- Discard the nuts and the gasket.





31. Remove and discard the 6 LH exhaust manifold studs.





32. Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the up position.





33. NOTE: Mark each camshaft roller follower to make sure it is installed in its original position during reassembly.

Using the Valve Spring Compressor, remove the camshaft roller followers.





34. NOTE: Mark each hydraulic lash adjuster to make sure it is installed in its original position.

Remove the hydraulic lash adjuster.





35. Remove the RH hydraulic chain tensioner.





36. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the RH cylinder head and tighten the top 2 clamp bolts.
- Tighten to 10 Nm (89 lb-in).





37. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt.

Remove the RH camshaft sprocket bolt.





38. Remove the bolt.





39. NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.

NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.

Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.





40. Remove the LH hydraulic chain tensioner.





41. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the LH cylinder head.





42. Remove the LH camshaft sprocket bolt.





43. Remove the bolt.





44. NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.

NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.

Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.





45. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Remove the 10 bolts in the sequence shown and remove the cylinder heads.

- Discard the gaskets and the bolts.





46. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.

NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gaskets.

NOTE: Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.

1. Remove any large deposits of silicone gasket material with a plastic scraper.

2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.

3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

47. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to Engine System - General Information Cylinder Head Distortion and Cylinder Block Distortion.

48. Remove the 2 bolts and the CKP sensor.





49. Using the Strap Wrench to hold the crankshaft pulley, remove the bolt.





50. NOTE: If the pulley bolt is not installed, the tool will bottom out before the pulley is off.

Install the crankshaft pulley bolt 2 to 3 turns. Using the 2 Crankshaft Vibration Damper Removers and the two 8-mm bolts, remove the crankshaft pulley.

- Discard the crankshaft pulley bolt.