Part 2

Engine

Special Tool(s):

Disassembly (Steps 33-64)

33. Remove the 4 bolts and the coolant pump.
^ Discard the O-ring seal.

34. If equipped, remove the 3 bolts and the dual generator pulley.

35. Check the crankshaft vibration damper runout.
^ Remove the paint from the face of the crankshaft vibration damper at 4 points, 90 degrees apart.
^ Attach the special tool to the cylinder block. Position the special tool on one of the unpainted surfaces.
^ Using a suitable tool, pry the crankshaft forward. Zero the dial indicator.

^ NOTE: Pry the crankshaft forward at the same point to eliminate possible error caused by crankshaft end play.

Rotate the crankshaft 90 degrees. Pry the crankshaft forward. Record the measurement. Repeat at each unpainted surface.
- If the runout exceeds specification, install a new crankshaft vibration damper.

36. CAUTION: To prevent engine damage, you must always install new bolts when installing the vibration damper.

WARNING: To avoid personal injury, support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft very easily.

Remove the 4 bolts and the crankcase vibration damper.
^ Discard the bolts.

37. Punch 2 holes in the crankshaft front seal.

38. Using the special tool, remove the crankshaft front seal.

39. NOTE: Production engines will not have a wear sleeve.

If equipped, remove the crankshaft seal wear sleeve with the special tool.

40. Remove the bolts and the oil pump body.
^ Discard the O-ring seal.

41. NOTE: Mark the front of each drive rotor for correct reassembly orientation.

Remove the inner and outer oil pump drive rotors.

42. Remove the bolts and engine front cover.

43. CAUTION: Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the front cover gasket.

Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.

44. Remove the flywheel adapter.

45. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.

NOTE: The drill bit used must be the appropriate size for the body dent puller used in the next step.

Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal, as shown.

46. NOTE: It will be necessary to alternate between the 2 holes, drilled in the previous step, to walk the seal out of the engine rear cover.

Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.

47. NOTE: Production engines will not have a wear sleeve.

If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.

48. Clean and inspect the crankshaft sealing surface.

49. CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the rear engine cover.

Remove the bolts from the rear engine cover.

50. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant can result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 139.7 mm (5.5 inch) long thin-blade scraper is needed to properly cut the sealant.

Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet.

51. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant can result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 139.7 mm (5.5 inch) long thin-blade scraper is needed to properly cut the sealant.

Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet.
52. Prior to removing the exhaust manifolds, inspect the exhaust manifolds for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specification.

53. Remove the bolts and the RH exhaust manifold.

54. Remove the bolts and the LH exhaust manifold.

55. Disconnect the fuel injector electrical connector.

56. Remove the crankcase-to-head tube.

57. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.

Remove the bolts and the high-pressure oil rail.

58. CAUTION: Use care not to deform the lower crankcase-to-head tube during removal. If the tube is damaged, a new tube must be installed.

NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.

If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube.
^ Remove and discard the D-ring seal.

59. Remove and discard the D-ring seals.

60. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.

Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
61. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.

62. CAUTION: To prevent engine damage, do not use air tools when removing and installing the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall off.

CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system, causing severe engine damage.

NOTE: There is no need to drain the fuel rail.

NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve. For additional information, refer to Fuel Delivery and Air Induction.

Remove the bolt, the fuel injector hold-down and the fuel injector.

63. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.

Remove the shop towels.

64. NOTE: Left cylinder head shown, right cylinder head similar.

Remove and discard the 20 head bolts from both cylinder heads.