Special tool
 | Hammer with moving hammer 205-047 (15-011) |
 | Universal wrench for holding flanges 205-072 (15-030A) |
 | Flywheel locking tool 303-393 (21-168) |
 | Clamp remover/installer 303-397 (24-003) |
 | Stand 303-435 (21-187) |
 | Support bracket for 303-435 303-435-06 (21-031V) |
 | 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: Vacuum cleaner for engine.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, when working with these elements, it is especially important to observe absolute cleanliness. Always insert plugs into any open holes or lines.
CAUTION: Do not disassemble fuel injectors or clean their nozzles, even with ultrasonication.
1. Using the special tool, fix the engine on the stand.
- Install the support bracket.
- Install the engine on the stand.
2. Drain the engine oil. Allow the oil to drain into a suitable container.
3. Disconnect the oil supply line from the turbocharger. Discard the sealing washers as they are no longer needed.
4. Remove the turbocharger oil supply 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 hoses (PCV) from the lower PCV pipeline.
9. Using the special tool, disconnect the PCV hoses from the cylinder head cover.
10. Disconnect the plug connector of the cylinder head temperature sensor.
- 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 vacuum pump of the vacuum amplifier of brakes. Discard the O-ring as it is no longer needed.
14.
CAUTION: Before making any repairs to the fuel injection system components, follow the cleaning procedure for these components to prevent foreign material from entering the components.
Disconnect the fuel injector fuel return line from the fuel injectors.
15. Remove the fuel injector return line.
16.
CAUTION: Before making any repairs to the fuel injection system components, follow the cleaning procedure for these components to prevent foreign material from entering the components.
Disconnect the fuel injector connectors.
17. Disconnect the plug connector of the camshaft position sensor (SMR).
18. Disconnect the plug connector of the oil pressure switch.
19. Disconnect the oil dipstick tube bracket from the thermostat housing.
20. Disconnect the glow plug harness bracket from the oil dipstick tube bracket.
21. Disconnect the knock sensor connector (KS).
22. Disconnect the fuel high pressure sensor connector from the fuel manifold.
23. Disunite the plug connectors of the fuel pump.
24.
NOTE: Mark the orientation of the clips to ensure they are in exactly the same position when installing.
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: Close fuel injectors to prevent dirt from entering.
Disconnect the high pressure fuel lines from the fuel injectors.
26.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel manifold until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Close the fuel rail to prevent dirt from entering.
Disconnect the high pressure fuel lines from the fuel rail.
27. Using an engine vacuum cleaner, remove foreign matter from the high pressure fuel supply lines and fuel manifold.
28. Remove the high pressure fuel lines. Discard fuel lines as no longer needed.
29. Remove the high pressure fuel line clamp nut.
30.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel pump and fuel manifold 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 manifold.
31. Using an engine vacuum cleaner, remove foreign material from the high pressure fuel supply line, fuel pump and fuel manifold.
32. Remove the high pressure fuel supply line.
33.
NOTE: Mark the orientation of the clips to ensure they are in exactly the same position when installing.
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 a vacuum cleaner for the engine, remove foreign matter from the fuel pump and fuel manifold.
35. Install the plugs in 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 the special tool, remove the camshaft pulley bolt.
44. Using the 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 retainer. 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 separator.
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 the 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 case 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 pipe.
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 in the sequence shown.
Remove the driven and pressure plates of the clutch.
66. Using the special tool, remove the dual flywheel. Discard the bolts as they are no longer needed.
67. Remove the crankshaft position sensor (TFR). Discard the sensor as it is no longer needed.
68. Remove the nuts and bolts of the oil pan (16 bolts, two nuts).
69. Using the special tools, remove the oil pan.
70. Remove the CKP sensor mounting bracket.
71. Remove the crankshaft rear oil seal retainer. Discard the holder as it is no longer needed.
72. Remove the oil pump connecting pipe. Discard 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 compressor mounting bracket (A/C).
75. Remove ladder frame (14 bolts). Discard the gasket as it is no longer needed.
76. Remove the rear timing chain case. Discard the gasket as it is no longer needed.
77.
NOTE: Keep the connecting rod bearings and bearing caps in order for later installation.
Remove the pistons.
78.
NOTE: Keep the main bearings and main bearing caps in order for later installation.
Remove the crankshaft.
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