Engine Disassemble

NOTE: With the engine removed.





1. Remove Engine Flywheel
a. Remove the flywheel bolt.
b. Remove the flywheel.





2. Remove Oil Level Indicator and Tube
a. Remove the oil level indicator tube bracket bolt.
b. Remove the oil level indicator tube. Pull the tube outward.





c. Remove the o-ring seal from the oil level indicator tube





3. Remove Intake Manifold
a. Remove the bolts for the center intake manifold.
b. Remove the center section of the intake manifold from the turbocharger and the left and right intake manifolds.
c. Remove the gaskets from the left and right intake manifolds.
d. Remove the O ring from the turbocharger inlet housing.





e. Remove the nuts for the fuel line. brackets and fuel lines.
f. Remove the nuts for the miscellaneous brackets and the brackets.
g. Remove the Crankcase Depression Regulator (CDR) valve from the right valve rocker arm cover.
h. Remove the intake manifold bolts.
i. Remove the intake manifolds.
j. Remove the gaskets.





4. Remove POE Wiring Harness
- Tools Required
- J 39083 Glow Plug Connector Tool, Or Equivalent
a. Unplug or disconnect the wiring harness connectors from devices or attaching points.
b. Remove the harness.





5. Remove Turbocharger
a. Remove the clamps from the right hand side exhaust pipes.
b. Remove the right hand side exhaust pipe.





c. Remove the clamps to the left hand side exhaust pipes.
d. Remove the left hand side exhaust pipes.





e. Remove the wastegate bracket mounting bolt from the right hand side cylinder head.
f. Remove the mounting bolt from the Engine block.
g. Remove the turbocharger assembly.
h. Remove the O-ring seal from the engine block.
i. Inspect the turbocharger. Refer to Turbocharger.





6. Remove Oil Pump Drive
a. Remove the hold down clamp and the bolt.





b. Remove the oil pump drive, by pulling the oil pump drive outwards.
c. Remove the gasket.





7. Remove Thermostat Housing/Thermostat
a. Remove the bolts from the thermostat housing.
b. Remove the thermostat housing.





c. Remove the thermostats with the seals.





8. Remove Coolant Crossover
a. Remove the nut holding the fuel air bleed (shredder) valve.
b. Remove the engine coolant temperature (ECT) sensor.
c. Remove the clamps from the bypass hose.
d. Remove the bolts from the coolant crossover.
e. Remove the coolant crossover.
f. Remove the bypass hose.
g. Remove the gaskets.





9. Remove Accessory/Engine Lift Brackets
a. Remove the three bolts.
b. Remove the lift bracket.





10. Remove Fuel Injection Line
a. Remove the injection line clips at the brackets.
b. Remove the injection lines at the nozzles using a 22 mm (0.87 inch) open end wrench to hold the nozzle body while opening the injection line. Wear safety glasses in order to protect against fuel spray.
- Cap the lines and the nozzles immediately Do not bend the injection lines.
c. Remove the injection lines at the pump Cap the lines and the pump fittings immediately tag the lines for installation.
d. Remove the injection line brackets.





11. Remove Fuel Inlet and Return Line
a. Remove the clamps from the return hoses at the injection nozzles.
b. Remove the fuel return hoses at the injection nozzles
c. Remove the fuel return crossover line brackets at the front of both valve rocker arm covers.
d. Remove the clamps and the fuel inlet hose from the fuel injection pump.
e. Remove the clamps and the fuel return hose from the fuel injection pumps
f. Remove the fuel return crossover lines.





12. Remove Fuel Injection Nozzle
- Tools Required
- J 29873 Nozzle Socket, Or Equivalent

CAUTION: In order to remove or install an injection nozzle, use the nozzle socket on the 3 mm portion of the nozzle. Failure to use the 3 mm hex portion will result in damage to the injection nozzle.

a. Remove the injection nozzle using the nozzle socket.Store the nozzles in a clean place.
b. Remove the gaskets.





13. Remove Glow Plug
- Tools Required
- J 41515 A Glow Plug Socket, Or Equivalent

a. Remove all of the left side glow plugs using the glow plug socket.





b. Remove all of the right side glow plugs using the glow plug socket.





14. Remove Exhaust Manifold
a. Remove the left side exhaust manifold bolts.
b. Remove the left side exhaust manifold.





c. Remove the right side exhaust manifold bolts.
d. Remove the right side exhaust manifold.





15. Remove Oil Fill Neck
a. Remove the nut holding the bracket to the thermostat housing.





b. Remove the nuts from the oil fill neck bracket to the front of the engine.





c. Remove the oil fill neck





d. Remove the seal.





16. Remove Water Pump

NOTE: The water pump bolts to the backing plate from the back.Remove the water pump and the backing plate together.

a. Remove the bolts and the stud nuts which hold the water pump and the water pump backing plate to the front crankcase cover.
b. Remove the water pump backing plate and the water pump together.





c. Remove the bolts which hold the water pump to the water pump backing plate.
d. Remove the water pump.
e. Remove the gasket.





17. Remove Fuel Injection Pump

CAUTION: The fuel injection pump is an electronically controlled device. Handle carefully in order to prevent damage to internal and external components.

a. Remove the three bolts from the fuel injection pump timing gear.
b. Remove the fuel injection pump timing gear.





c. Remove the three fuel injection pump mounting nuts.

CAUTION: Never rotate the engine with the starter, the starter location engine rotation fixture, or with the wrench from the front of the engine with the fuel injection pump removed. The loose fuel pump drive gear could become lodged in the front cover and cause gear tooth distress and shear the camshaft drive gear. Align the camshaft gear timing marks before installing the fuel injection pump drive gear.





d. Remove the fuel injection pump.
e. Remove the fuel injection pump gasket.





18. Remove Crankshaft Balancer
- Tools Required
- J 39046 Crankshaft Balancer Remover, Or Equivalent

a. Remove the bolt for the front crankshaft pulley.
b. Remove the front crankshaft pulley.





c. Remove the bolt and washer for the crankshaft balancer.





d. Remove the crankshaft balancer using the crankshaft balancer remover.
19. Remove Engine Front Covers

NOTE: In order to prevent damage, take care when removing the crankshaft position sensor. Prying up the mounting bracket may break the bracket loose from the sensor. If the mounting bracket separates from the sensor, replace the crankshaft position sensor.





a. Remove the bolt in the crankshaft position sensor mounting bracket.





b. Twist and pull the crankshaft position sensor straight out from the front cover.





c. Remove the oil pan to front cover bolts.
d. Remove the front cover to block bolts.
e. Remove the front cover

CAUTION: Perform TDC Offset Recovery procedure if the timing chain, timing gears, engine front cover, crankshaft position sensor, crankshaft or other components affecting the timing are replaced.

f. Remove the front crankshaft seal using a large screwdriver. Do not reuse the seal.

20. Check Timing Chain Wear





21. Remove Timing Chain and Camshaft Sprocket
a. Remove the camshaft sprocket bolt and the washer.





b. Remove the injection pump camshaft gears





c. Remove the camshaft sprocket with the timing chain.





d. Remove the crankshaft sprocket. Do not damage the square bosses of the crankshaft sprocket during removal.
e. Remove the keyways from the camshaft and the crankshaft.





22. Remove Valve Rocker Arm Cover
a. Remove the valve rocker arm cover bolts and stud/nuts.

CAUTION: Prying on the valve rocker arm cover may cause damage to the sealing surfaces. Use a block of wood against the side of the valve rocker arm cover and strike with a hammer in a sideways direction to shear the RTV sealant.

b. Remove the valve rocker arm covers.





23. Remove Valve Rocker Armed Push Rod
a. Remove the bolts from the valve rocker arm shaft assemblies.

NOTE: Mark the valve rocker arm assemblies, in order to return each assembly to the original location.





b. Remove the valve rocker arm shaft assemblies.

NOTE: Install tine valve pushrods in the original position end in the same direction at assembly. Each end of the valve pushrods have a different degree of hardness. The upper end of the valve pushrod is copper colored. A paint stripe also identifies the upper end of the valve pushrod.

c. Remove the valve pushrods.





24. Remove Cylinder Head
a. Remove the cylinder head bolts.
b. Remove the cylinder heads.





c. Remove the cylinder head gaskets.
25. Remove Valve Lifter

NOTE: When removing the valve lifters, place the lifters in an organizer rack. The lifters must be installed in the same bore from which these were removed.





a. Remove the bolts and the valve lifter retaining clamps.





b. Remove the valve lifter guide plates





c. Remove the valve lifters.





26. Remove Camshaft
a. Remove the bolts.
b. Remove the camshaft thrust bearing.





c. Remove the camshaft sprocket spacer.





d. Remove the camshaft. Pull the camshaft from the block carefully to avoid damage to the camshaft bearings.





27. Remove Oil Pan
a. Remove the oil pan bolts.
b. Remove the oil pan.





c. Remove the oil pan rear seal.





28. Remove Oil Pump
a. Remove the oil pump bolts.
b. Remove the oil pump and drive shaft assembly.





29. Remove Piston, Connecting Rod, and Bearing


- Tools Required
- J 24270 Ridge Reamer, Or Equivalent

a. Use the ridge reamer in order to remove the ridge or the deposits from the upper end of the cylinder bores.
1) Turn the crankshaft until the piston is at the bottom of the stroke.
2) Place a cloth on top of the piston.
3) Perform the cutting operation with the ridge reamer.
4) Turn the crankshaft until the piston is at the top dead center (TDC).
5) Remove the cloth and the cuttings.
6) Repeat this procedure for each cylinder.
b. Before removing the pistons and the rods, check the pistons and the rods for cylinder identification numbers
c. If the pistons are not numbered, use a metal number stamp in order to mark the piston, the rod and the cap using the following procedure
- Mark the cylinder number, on the bottom of the front section of the piston boss, of each piston.
- Mark the cylinder number on the bearing tang slot side of both the rod and the cap.
- Mark the components from the front to the rear, with the engine in an upright position and viewed from the front.
- The left bank is numbered 1, 3, 5, 7, while the right bank is number 28.
- Be sure to mark both, the rod and the cap with the correct cylinder number.
- Keep the connecting rod and cap together as mating parts.





d. Remove the connecting rod nuts.
e. Remove the connecting rod cap.





f. Remove the bearing inserts from the connecting rod.





g. Attach two short pieces of 10 mm (3/8 inch) hose to the connecting rod bolts, in order to protect the crankshaft journal during removal.
h. Push the connecting rod and the piston out of the bore.
i. After removal, assemble the connecting rod, the cap and the bearings. If reusing the bearing inserts, keep the inserts in the rods and cap from which they were removed.





30. Remove Rear Crankshaft Oil Seal
- Remove the rear oil seal using a small screw driver. Do not reuse the Old seal.
31. Remove Crankshaft, Bearings, and Bearing Cap

NOTE: Check the crankshaft bearing caps for location markings. Mark the caps, if necessary. Return the crankshaft bearing caps to their original locations during assembly.





a. Remove the crankshaft bearing cap bolts.
b. Remove the crankshaft bearing caps.





c. Remove the crankshaft by lifting the crankshaft straight up, in order to avoid damage to the crankshaft journals and the thrust flange surfaces.





d. Remove the crankshaft bearing inserts. If reusing the bearing inserts, place them in a rack in order to return the bearing inserts to the original location during assembly.