Disassembly
Fig. 1 Cylinder head exploded view:
Fig. 2 Cylinder block exploded view:
Fig. 3 TDC inspection plug location:
Fig. 4 Cylinder head removal:
1. Remove drive belts, alternator, starter and A/C compressor, if equipped.
2. Remove oil supply line and oil return hose from turbocharger.
3. Remove turbocharger attaching bolts, then the turbocharger.
4. Remove valve cover attaching bolts, then the cover and gasket.
5. Remove TDC inspection plug. Rotate the crankshaft into position and insert TDC rod Mot. 861 into TDC slot in crankshaft countershaft. Ensure rod is not inserted into crankshaft counterweight balance hole.
6. Remove fan and water pump pulley assembly.
7. Drain cooling system and engine oil.
8. Remove timing belt cover attaching screws, then the cover.
9. Install sprocket holding tool Mot. 854 or equivalent, then remove the camshaft sprocket retaining bolt.
10. Loosen belt tensioner bolts and position tensioner away from belt. Tighten tensioner bolts, then remove belt.
11. Disconnect fuel pipe fittings from injectors and injection pump. Cap all openings.
12. Disconnect and cap all hoses from fuel injection pump.
13. Remove mounting brackets and attaching bolts, then the injection pump assembly.
14. Remove cylinder head attaching nuts and bolts, then loosen pivot bolt.
15. Remove the remaining cylinder head attaching bolts. Place a block of wood against the cylinder head and tap it lightly with a hammer to loosen cylinder head gasket.
16. Remove the pivot bolt and rocker arm shaft attaching bolts, then the rocker arm shaft assembly. Do not lift cylinder head from the cylinder block until gasket is completely loosened from the cylinder liners, since liner seals could be damaged.
17. Remove the cylinder head and gasket, then install cylinder liner clamps, Mot. 521-01 or equivalent, onto cylinder block.
18. Remove camshaft sprocket attaching bolt.
19. Install tool B.Vi 28-01 or equivalent, onto camshaft sprocket, then remove sprocket.
20. Disconnect fuel return hose fittings from injectors, then remove holders and injectors. Cap all openings. Mark each injector with the corresponding cylinder number to facilitate installation.
21. Remove copper washers and heat shields. Copper washers and heat shields must be replaced when injectors are installed.
22. Remove wire harness and glow plugs.
23. Remove intake and exhaust manifolds, then gaskets from the cylinder head.
24. Remove camshaft oil seal using a suitable puller, then remove camshaft from cylinder head.
25. Remove thermostat housing and gasket.
Fig. 5 Vacuum pump with oil pump drive gear:
Fig. 6 Intermediate shaft assembly:
Fig. 7 Water pump removal:
26. Remove vacuum pump along with pump drive gear.
27. Loosen intermediate shaft drive sprocket bolt using sprocket holding tool Mot. 855 or equivalent, and suitable wrench.
28. Remove intermediate shaft bolt, sprocket, cover attaching screws, cover, clamp plate and intermediate shaft.
29. Remove oil pan attaching screws, then the oil pan.
30. Remove oil pump assembly attaching screws, then the oil pump.
31. Using a long strap and clip, retain timing belt tensioner plunger, then remove water pump attaching screws, water pump, inlet housing and gasket.
32. Remove crankshaft pulley attaching bolt, washer and pulley. Remove pins from the crankshaft pulley.
33. Using a suitable puller, remove the crankshaft sprocket and washer as follows:
a. Position sprocket removal tool B.Vi 28-01 (with shaft end protector tool 15-01), with jaws inserted behind sprocket washer.
b. Force sprocket washer and sprocket away from crankshaft until washer stops against Woodruff key. Do not force washer beyond this position.
c. Remove tools installed in step (a), then install tools with jaws inserted between the sprocket washer and sprocket assembly.
d. Force sprocket from crankshaft assembly.
e. If there is not enough clearance between the washer and sprocket to insert sprocket removal tool jaws, insert two .078 inch metal strips between the washer and sprocket.
f. Insert the removal tool jaws behind the washer and force the washer and sprocket assembly from crankshaft until the washer stops at the Woodruff key. Then repeat step (c).
34. Remove connecting rod bearing cap bolts, connecting rod bearing caps and bearing inserts.
35. Remove cylinder liner clamps.
36. Remove connecting rods, cylinder liners and pistons as an assembly. Each piston and cylinder liner are a matched set. Mark each piston and liner to ensure installation in their original positions.
37. Install holding plate Mot. 582 or equivalent to prevent the crankshaft from turning, then remove flywheel or drive plate from crankshaft.
38. Remove the crankshaft main bearing caps. Mark the crankshaft main bearing caps according to their position, to facilitate installation in their original positions.
39. Remove bearing inserts from the caps, then crankshaft and bearing upper inserts.
40. Using a suitable puller, remove clutch pilot bearing from the crankshaft, if equipped.
Fig. 8 Rocker arm shaft assembly:
ROCKER ARM SHAFT DISASSEMBLY
1. Remove camshaft thrust plate.
2. Remove end plug and filter.
3. Remove No. 1 shaft bearing.
4. Remove set bolt and No. 5 shaft bearing.
5. Remove springs, rocker arms and remaining shaft bearings.
6. Retain all components in order removed to facilitate installation.
CYLINDER HEAD DISASSEMBLY
1. Compress valve spring, then remove valve collets.
2. Release valve spring compressor, then remove spring retainer, spring, oil seal, spring seat and valve.
3. Place valve train components in their original order to facilitate installation.
PISTON & ROD DISASSEMBLY
1. Remove piston rings.
2. Remove piston pin retaining clips, then the piston pin.
3. Keep disassembled parts in their original order to facilitate installation.