Special tool
 | Hammer with movable striker 205-047 (15-011) |
 | Universal Flange Holding Wrench 205-072 (15-030A) |
 | Flywheel Locking Tool 303-393 (21-168) |
 | Clamp removal/installation tool 303-397 (24-003) |
 | Booth 303-435 (21-187) |
 | Support bracket for 303-435 (21-187) 303-435-06 (21-031B) |
 | Adapter for 205-047 303-633 (21-227) |
 | Camshaft Sprocket Puller 303-651 (21-229) |
 | High Pressure Fuel Pump Pulley Puller 310-095 (23-067) |
General equipment: Scraper.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, absolute cleanliness is especially important when working with these components. Always plug any open ports or lines.
All cars
1. Using a special tool, secure the engine to the stand.
- Attach the support bracket.
- Place the engine on the stand.
2. Drain the oil from the engine. Allow the oil to drain into a suitable container.
3. Disconnect the positive crankcase ventilation (PCV) housing. Disconnect the ventilation hoses.
4. Remove the high-pressure fuel supply lines. Discard the high-pressure fuel supply lines as they are no longer needed.
5. Remove the lower power steering pump mounting bolts.
6. Remove the power steering pump.
7. Remove the generator with the drive shaft.
8. Disconnect the turbocharger feed and return oil lines. Discard the sealing washers as they are no longer needed.
9. Remove the oil filter. Discard the filter as it is no longer needed.
10. Remove the oil cooler. Discard the gasket as it is no longer needed.
11. Remove the generator bracket.
12. Remove the cylinder head cover.
- 1.Remove the PCV hoses.
- 2. Remove the cylinder head cover bolts.
Cars without charge air cooler
13. Remove the lower timing belt cover.
14. Remove the front engine mount bracket.
Cars with charge air cooler.
15. Remove the timing belt cover.
16. Remove the front engine mount bracket.
All cars
17. Loosen the timing belt tension. Loosen the timing belt tensioner bolt.
18. Remove the timing belt. Discard the timing belt as it is no longer needed.
19. Remove the timing belt tensioner.
Engines with mechanical timing belt tensioner
20. Discard the timing belt tensioner as it is no longer needed.
All cars
21. Using a special tool, unscrew the camshaft pulley mounting bolt.
22. Using a special tool, remove the pulley from the camshaft.
23. Remove the high pressure fuel pump pulley bolts.
24. Using the special tool, remove the high pressure fuel pump pulley.
25. Remove the high pressure fuel pump oil seal holder. Discard the seal as it is no longer needed.
26. Remove the rear timing belt cover.
27. Remove the oil catch can.
28.
CAUTION: Remove the cylinder head bolts in the sequence shown.
Remove the cylinder head. Discard the gasket as it is no longer needed.
29. Using the special tool, remove the water pump pulley.
30. Remove the water pump. Discard the gasket as it is no longer needed.
31. Using a special tool, remove the crankshaft pulley. Discard the bolt as it is no longer needed.
32. Remove the accessory drive belt pulley.
33. Remove the timing chain housing cover. Discard the gasket as it is no longer needed.
34. Remove the timing chain tensioner.
35. Disconnect the high pressure fuel pump sprocket
36. Remove the chain, sprockets and timing guides.
37. Remove the high pressure fuel pump bracket.
38. Remove the high pressure fuel pump. Discard the gasket as it is no longer needed.
39. Using the special tool, disconnect the upper coolant hose from the coolant distribution pipe.
40. Remove the coolant distribution pipe.
41.
CAUTION: The clutch pressure plate mounting bolts should be loosened two turns at a time and in the sequence shown.
Remove the clutch slave and pressure plates.
42. Using a special tool, remove the flywheel. Discard the bolts as they are no longer needed.
43. Remove the crankshaft position sensor (CSP).
44. Remove the CKP sensor support bracket.
45. Remove the crankshaft rear oil seal holder. Discard the holder as it is no longer needed.
46. Remove the oil pan mounting nuts and bolts (sixteen bolts, two nuts).
47. Using special tools, remove the oil pan.
48. Remove the oil pump connecting pipe. Discard the O-rings as they are no longer needed.
49. Remove the oil pump intake pipe. Discard the O-ring as it is no longer needed.
Cars with air conditioning system
50. Remove the air conditioning (A/C) compressor support bracket.
All cars
51. Remove the ladder frame (14 bolts). Discard the gasket as it is no longer needed.
52. Remove the rear timing chain housing. Discard the gasket as it is no longer needed.
53.
CAUTION: Keep the connecting rod bearing caps in good condition for future installation.
CAUTION: Keep the connecting rod bearing shells and connecting rod bearing cap shells in good condition for future installation.
Remove the pistons.
54.
CAUTION: Keep the lower and upper main bearing shells in good condition for later installation.
Remove the crankshaft.
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