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 303-435 303-435-06 (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: Engine vacuum cleaner.
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.
CAUTION: Do not disassemble fuel injectors or clean their nozzles, even using ultrasonic cleaning.
1. Using a special tool, secure the engine to the stand.
- Install the support bracket.
- Place the engine on the stand.
2. Drain the engine oil. Allow the oil to drain into a suitable container.
3. Disconnect the oil feed line from the turbocharger. Discard the sealing washers as they are no longer needed.
4. Remove the turbocharger oil feed line. Discard the sealing washers as they are no longer needed.
5. Disconnect the oil return line from the turbocharger. Discard the O-ring as it is no longer needed.
6. Remove the oil filter. Discard the filter as it is no longer needed.
7. Remove the oil cooler. Discard the gasket as it is no longer needed.
8. Using the special tool, disconnect the positive crankcase ventilation (PCV) hoses from the lower PCV line.
9. Using the special tool, disconnect the PCV hoses from the cylinder head cover.
10. Disconnect the cylinder head temperature sensor connector.
- 1. Disconnect the plug connector from the PCV housing.
- 2. Disconnect the plug connector.
11. Remove the PCV housing.
12. Using the special tool, disconnect the PCV hose from the brake booster vacuum pump.
13. Remove the brake booster vacuum pump. Discard the O-ring as it is no longer needed.
14.
CAUTION: Before performing any repairs to fuel injection system components, perform the cleaning procedure for those components to prevent foreign material from entering the components.
Disconnect the fuel injector return line from the fuel injectors.
15. Remove the fuel injector return line.
16.
CAUTION: Before performing any repairs to fuel injection system components, perform the cleaning procedure for those components to prevent foreign material from entering the components.
Disconnect the fuel injector connectors.
17. Disconnect the camshaft position sensor (CMP) connector.
18. Disconnect the oil pressure switch connector.
19. Disconnect the oil level indicator tube bracket from the thermostat housing.
20. Disconnect the glow plug wiring harness bracket from the oil level indicator tube bracket.
21. Disconnect the knock sensor (KS) plug connector.
22. Disconnect the high fuel pressure sensor connector from the fuel rail.
23. Disconnect the fuel pump connectors.
24.
NOTE: Mark the orientation of the clamps to ensure they are installed in exactly the same position when installed.
Remove the high pressure fuel supply line clamps.
25.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel injectors until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Cover the fuel injectors to prevent dirt from entering.
Disconnect the high pressure fuel supply lines from the fuel injectors.
26.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel rail until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Cover the fuel manifold to prevent dirt from entering.
Disconnect the high pressure fuel supply lines from the fuel rail.
27. Using an engine vacuum cleaner, remove foreign material from the high pressure fuel supply lines and fuel rail.
28. Remove the high-pressure fuel supply lines. Discard the fuel lines as no longer needed.
29. Remove the high pressure fuel supply line clamp fastening nut.
30.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel pump and fuel rail until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
Disconnect the high pressure fuel supply line and clamp from the fuel pump and fuel rail.
31. Using an engine vacuum cleaner, remove foreign material from the high pressure fuel supply line, fuel pump and fuel rail.
32. Remove the high pressure fuel supply line.
33.
NOTE: Mark the orientation of the clamps to ensure they are installed in exactly the same position when installed.
Remove the clamp from the high-pressure fuel supply line. Discard the high-pressure fuel supply line as it is no longer needed.
34. Using an engine vacuum cleaner, remove foreign material from the fuel pump and fuel rail.
35. Install plugs into the open threaded holes on the fuel pump and fuel manifold.
36. Remove the fuel manifold.
37. Remove the fuel manifold mounting bracket.
38. Using the special tool, disconnect the coolant hose from the thermostat housing.
39. Remove the timing belt cover.
40. Loosen the timing belt tension. Loosen the timing belt tensioner bolt.
41. Remove the timing belt. Discard the timing belt as it is no longer needed.
42. Remove the timing belt tensioner.
43. Using a special tool, unscrew the camshaft pulley mounting bolt.
44. Using a special tool, remove the pulley from the camshaft.
45. Using the special tool, remove the fuel pump pulley.
46. Remove the fuel pump oil seal holder. Discard the seal as it is no longer needed.
47. Remove the rear timing belt cover.
48. Remove the cylinder head cover.
49. Remove the oil catch can.
50.
CAUTION: Remove the cylinder head bolts in the sequence shown
Remove the cylinder head. Discard the gasket and bolts as they are no longer needed.
51. Remove the front engine mount bracket.
52. Using the special tool, remove the water pump pulley (four bolts).
53. Remove the water pump. Discard the gasket as it is no longer needed.
54. Using a special tool, remove the crankshaft pulley. Discard the bolt as it is no longer needed.
55. Remove the accessory drive belt idler pulley.
56. Remove the timing chain housing cover. Discard the gasket as it is no longer needed.
57. Remove the timing chain tensioner.
58. Disconnect the fuel pump sprocket.
59. Remove the chain, sprockets and timing guides.
60. Remove the fuel pump bracket.
61. Remove the fuel pump. Discard the gasket as it is no longer needed.
62. Using the special tool, disconnect the upper coolant hose from the coolant distribution line.
63. Remove the coolant distribution pipe.
64. Remove the fuel pump bracket.
65.
CAUTION: Loosen the clutch pressure plate mounting bolts two turns at a time and in the sequence shown.
Remove the clutch slave and pressure plates.
66. Using the special tool, remove the dual flywheel. Discard the bolts as they are no longer needed.
67. Remove the crankshaft position sensor (CSP). Discard the sensor as it is no longer needed.
68. Remove the nuts and bolts securing the oil pan (16 bolts, two nuts).
69. Using special tools, remove the oil pan.
70. Remove the CKP sensor mounting bracket.
71. Remove the crankshaft rear oil seal holder. Discard the holder as it is no longer needed.
72. Remove the oil pump connecting pipe. Discard the O-rings as they are no longer needed.
73. Remove the oil pump intake pipe. Discard the O-ring as it is no longer needed.
74. Remove the air conditioning (A/C) compressor mounting bracket.
75. Remove the ladder frame (14 bolts). Discard the gasket as it is no longer needed.
76. Remove the rear timing chain housing. Discard the gasket as it is no longer needed.
77.
NOTE: Keep the connecting rod bearings and bearing caps in good condition for future installation.
Remove the pistons.
78.
NOTE: Keep the main bearings and main bearing caps in good condition for later installation.
Remove the crankshaft.
