Engine

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Refer to exploded views in Description and Operation.

1. NOTICE: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

   Loosen the 6 clutch pressure plate-to-flywheel bolts evenly, by 2 turns at a time.
   

1. Remove Special Service Tool : 300-OTC1819E 2,200# Floor Crane, Fold Away

1. Remove Special Service Tool : 303-1502 Lifting Device Engine

1. If equipped with block heater.
   

1. NOTE: Discard the O-ring seals and gasket seals.

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. NOTE: Note the position of the component before removal.

1. NOTE: The O-ring seals are to be reused unless damaged.

1. NOTICE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

1. NOTE: Replace any damaged coil-on-plug assemblies.

1. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

   NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.

   NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract.

1. NOTE: Take extra care when handling the components.

   Remove any of the fuel injectors that remained in the fuel rail.
   

1. NOTE: Remove the fuel injectors that remained in the head.

   • Special Tool(s) : 307-005 (T59L-100-B) Slide Hammer
   • Special Tool(s) : 310-206 Remover, Fuel Injector

1. NOTICE: Do not set the valve cover sealing surface face down on a bench as the check valve and splitter leg is susceptible to breakage.

1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the fuel pump mounting bracket. Failure to follow these directions may result in damage to the fuel pump mounting bracket.

   General Equipment : Hot Air Gun

1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the brake vacuum pump mounting bracket. Failure to follow these directions may result in damage to the brake vacuum pump mounting bracket.

   General Equipment : Hot Air Gun

1. NOTE: Note the different lengths of the bolts.

1. NOTE: Note the position for installation.

1. Refer to: Exhaust Manifold Cleaning and Inspection (303-00 Engine System - General Information, General Procedures).
   

1. NOTE: Note the position for installation.

   If equipped with block heater.
   

1. NOTE: Note the different lengths of the bolts.

1. NOTE: Only rotate the crankshaft in a clockwise direction.

   11 o'clock position.
   

1. NOTE: The Crankshaft TDC Timing Pin will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.

   Install Special Service Tool : 303-748 Locking Tool, Crankshaft

1. NOTE: Only rotate the crankshaft clockwise direction.

   Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC .
   

1. Install Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

   Install a holding pin.
   

1. Special Tool(s) : 308-375 Remover, Input Shaft Seal , 100-001 (T50T-100-A) Slide Hammer

1. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

1. Remove Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

1. Special Tool(s) : 303-409 (T92C-6700-CH) Remover, Crankshaft Seal

1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the camshaft mega cap. Failure to follow these directions may result in damage to the camshaft mega cap.

   NOTICE: Do not pry on camshafts when removing or damage to the camshafts may occur.

   NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference.

   General Equipment : Hot Air Gun

1. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.

   NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.

1. Install new components as necessary.
   

1. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head bolts.

1. Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
   Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
   

1. Remove Special Service Tool : 303-748 Locking Tool, Crankshaft

1. Pry pads.
   

1. NOTE: The O-ring seal is to be reused unless damaged.

1. NOTE: Mark the location of the 3 different length bolts.

1. Clean the specified component with a abrasive pad.
   

1. NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.

   NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.

1. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

   Using a connecting rod installer, repeat until all the piston/rod assemblies are removed from the engine block.
   

1. NOTE: Mark the position of the parts, so they can be installed in their original positions.

   NOTE:

1. Refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures).
   

1. NOTE: The main bearing beam has 2 arrows pointing towards the front of engine for correct orientation for reassembly.

1. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

1. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

   NOTE: The center bulkhead has the thrust bearing.

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