REMOVAL
1.
Connect the battery.
2.
Remove the battery.
3.
Remove the accessory drive belt.
4.
Remove the intake air housing.
5.
Fill the cooling system.
6.
Remove the crankshaft locking tool.
7.
Remove the charge air cooler outlet hose.
8.
Remove the charge air cooler inlet hose.
9.
Remove the high pressure fuel feed line (2).
10.
Remove the generator brace bolt (1).
11.
Disconnect the fuel return lines.
12.
Remove the EGR cooler.
13.
Remove the EGR cooler coolant lines.
14.
Remove the fuel block (1).
15.
Disconnect the coolant lines from the thermostat housing.
16.
Remove the thermostat housing.
17.
Disconnect the Baro sensor (1).
18.
Remove the Baro sensor.
19.
Remove the generator brace bolt (2).
20.
Remove the throttle plate assembly.
21.
Remove the generator bracket.
22.
Remove the generator.
23.
Connect the generator connectors (4).
24.
Connect the generator feed wire (3).
25.
Remove the fuel lines (3).
26.
Disconnect the fuel rail solenoid (2).
27.
Disconnect the fuel rail pressure sensor.
28.
Remove the fuel rail.
29.
Disconnect and position aside the glow plug harness.
30.
Remove the intake manifold.
31.
Remove the intake manifold bolts.
32.
Remove the intake manifold gasket.
33.
Disconnect the turbocharger module.
34.
Remove the turbocharger oil return line.
35.
Remove the turbocharger nuts.
36.
Remove the turbocharger oil feed line.
37.
Remove the turbocharge oil lines from the engine block.
38.
Remove the exhaust manifold.
39.
Remove the vacuum line from the vacuum pump.
40.
Remove the vacuum line (2) from the camshaft cover.
41.
Remove the exhaust manifold gasket (3).
42.
Disconnect the fuel injectors.
43.
Remove the fuel injectors.
44.
Disconnect the CMP.
45.
Remove the CMP.
46.
Remove the front engine lifting bracket.
47.
Remove the idler pulley bracket (1).
48.
Remove the upper front cover.
NOTE:
The crankshaft sprocket bolt is a L.H. thread.
49.
Remove the crankshaft damper (R.H thread).
50.
Remove the lower front cover.
51.
Make sure that the timing dimples on the back of the camshaft gears are lined up horizontally.
52.
Install the camshaft locking tool.
53.
Remove the timing belt.
54.
Remove the inner front cover.
55.
Remove the camshaft sprocket (2).
56.
Remove the exhaust camshaft oil seal (1).
57.
Remove the camshaft sprocket cover.
58.
Remove the intake camshaft oil seal (2).
59.
Using a circular pattern, loosen the camshaft cap bolts.
NOTE:
Observe the position marks on the cylinder head and camshaft cap. Always replace the camshaft cap to its original location.
60.
Remove the camshaft caps.
NOTE:
Observe the position of the rocker arms and lifters. Always return the rocker arms and lifters to their original location.
61.
Remove the rocker arms (1) and hydraulic lifters (2).
62.
Remove the cylinder head.