Removal Procedure
- Engine - Remove - Engine Removal and Installation (4WD, with RC1, without F47) , or Engine Removal and Installation (2WD, with RC1, without F47) Engine Removal and Installation (4WD, with RC1, with F47) , or Engine Removal and Installation (2WD, with RC1, with F47) , or Engine Removal and Installation (4WD, with WTX, with F47) , or Engine Removal and Installation (2WD, with WTX, with F47) , or Engine Removal and Installation (4WD, with WTX, without F47) , or Engine Removal and Installation (2WD, with WTX, without F47)
EN-52449 Engine Stand Adapter (2) @Engine Block - Install
- Engine@ EN-52449 Adapter (2) - Install the engine to a suitable engine stand.
- Remove the EN-52474 Engine Lift Bracket Set.
Install the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
- Crankshaft Pulley Bolt (2) - Loosen [4x]
Remove the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
Crankshaft Pulley Bolt (2) - Remove [4x]
- Crankshaft Pulley (1) - Remove
Engine Front Cover Bolt (1) - Remove [8x]
- Crankshaft Front Oil Seal (2) - Remove and DISCARD
Crankshaft Pulley Bolt (1) - Install and hand tighten [4x]
- Rotate the crankshaft with a suitable tool in the direction of the arrow at the crankshaft pulley bolts (1), until the following alignment is achieved:
- The crankshaft locking divot (2) aligns with the engine block (3)
- The crankshaft timing mark, dimension a, is at 40 degrees TDC
- Install the EN-52586 Crankshaft Fixing Pin (4).
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Camshaft Housing Cover Insulator (1) - Remove
Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).
- Unclip the fuel injector fuel return pipe retainer (2).
Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel injection rail.
Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel pump.
Fuel Feed Pipe Clip Bolt (1) - Remove
- Fuel Return Pipe Clip Bolt (2) - Remove
Diesel Fuel Separator Bracket Bolt (1) - Remove
- NOTE:
Do NOT reuse the high pressure diesel fuel feed pipes.
Remove the high pressure diesel fuel feed to rail pipe (2) and DISCARD.
Remove the fuel injection fuel feed pipe bracket bolt (1).
- Remove the fuel injection fuel feed pipe bracket (2).
Loosen the 12 high pressure diesel fuel feed pipe nuts (1) from the fuel injectors and the fuel injection rail.
- Remove and DISCARD the 6 high pressure diesel fuel feed to injector pipes (2).
Disconnect and reposition the fuel injector wiring harness, as needed.
- Retainer (3) - Disengage
- Fuel Injection Fuel Return Pipe Locking Spring (4) - Disengage [6x]
Fuel Injection Fuel Return Pipe (1) - Reposition
Disconnect the 6 high pressure diesel fuel injector electrical connectors (1).
- Disconnect the 8 fuel injector wiring harness retainers (2) and reposition the fuel injector wiring harness out of the way.
Fuel Injector Bolt (1) - Remove [6x]
- Multiport Fuel Injector Bracket (2) - Remove [6x]
- NOTE:
Mark the location of the high pressure diesel fuel injectors.
Using the EN-52451 Fuel Injector Remover (3) and EN-51146-1-3 Sliding Hammer (1), remove the 6 high pressure diesel fuel injectors (2).
Remove and DISCARD the 6 fuel injector seals (2) and 6 fuel injector washers (3).
Engine Coolant Air Bleed Hose Stud (2) - Remove
Positive Crankcase Ventilation Hose Clamp (1) - Release [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Positive Crankcase Ventilation Hose (2) - Remove
Turbocharger Oil Return Pipe Bolt (7) - Remove [2x]
- Lower Crankcase Extension Bolt (9) Remove
- Turbocharger Oil Return Pipe Bolt (8) - Remove [2x]
- Turbocharger Nut (2, 4) - Remove and DISCARD [3x]
- Turbocharger Assembly (1) - Remove
- Turbocharger Gasket (3) - Remove and DISCARD
- Turbocharger Oil Return Pipe Gasket (6) - Remove and DISCARD
- Turbocharger Oil Return Pipe Gasket (5) - Remove and DISCARD
Camshaft Housing Cover Bolt (1) - Loosen [7x]
- Camshaft Housing Cover Bolt (2) - Loosen [3x]
- Camshaft Housing Cover Bolt (3) - Loosen [9x]
- Camshaft Housing Cover Bolt (4) - Loosen [7x]
Camshaft Cover (1) - Remove
- Camshaft Housing Gasket (2) - Remove and DISCARD [2x]
- Camshaft Housing Cover Insulator (3) - Remove and DISCARD [26x]
Timing Chain Cover Bolt (3) - Remove [4x]
- Timing Chain Cover Bolt (4) - Remove [2x]
- Timing Chain Upper Cover (1) @Cylinder Head - Remove
Ensure that the camshaft notches (1) are in the 12 o'clock position.
If the camshaft notches are not in the 12 o'clock position, remove the EN-52586 Crankshaft Fixing Pin and rotate the crankshaft until the camshaft notch is in the 12 o'clock position, and the crankshaft aligns with the EN-52586 Crankshaft Fixing Pin locking location.
- Install the EN-52586 Crankshaft Fixing Pin (4).
Install the EN-52445-1 Camshaft Tool (3) to the camshaft housing.
- Check that the tab (1) of the EN-52445-1 Camshaft Tool sits correctly under the camshaft bearing rear cap (2).
- Check that the pins (6) of the EN-52445-1 Camshaft Tool sit correctly in the camshafts (5).
Install the EN-52445-2 Camshaft Tool (1) on the camshafts.
Timing Chain Tensioner (2) - Remove
- Timing Chain Tensioner Gasket (1) - Remove and DISCARD
Timing Chain Guide Bolt (2) - Remove [2x]
- Timing Chain Guide (1) - Remove
Use all components included with the service kit.
It is likely you will bend the crankshaft front oil seal during the removal. Use care to not damage the engine block.
Once the EN-52586 Crankshaft Fixing Pin is installed, do not remove until all timing components have been installed.
Do NOT reuse the high pressure diesel fuel feed pipes.