Removal Procedure
- Engine - Remove - Engine Removal and Installation (F48 & RC1 - F47) , or Engine Removal and Installation (RWL & RC1 - F47) , or Engine Removal and Installation (F48 & RC1 & F47) , or Engine Removal and Installation (RWL & RC1 & F47) , or Engine Removal and Installation (F48 & WTX & F47) , or Engine Removal and Installation (RWL & WTX & F47) , or Engine Removal and Installation (F48 & WTX - F47) , or Engine Removal and Installation (RWL & WTX - 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]
Automatic Transmission Flex Plate Bolt (2) - Remove and DISCARD [8x]
- Automatic Transmission Flex Plate (1) - Remove
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).
Remove the 16 timing chain cover bolts (1, 2).
- NOTE:
Avoid prying close to the transmission pins.
Using a suitable tool at the locations indicated by the arrows to pry, loosen the timing chain lower cover carefully from the engine block.
Timing Chain Lower Cover (1) - Remove and DISCARD
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling 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.
Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Remove [2x]
- Fuel Injector Fuel Return Hose Bracket (2) Remove
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 seal rings (2) and 6 fuel injector washers (3).
- NOTE:
Some components not shown for graphic clarity.
Wiring Harness Retainer (3) @Engine Coolant Air Bleed Hose - Separate [2x]
- Remove the wiring harness.
- NOTE:
Some components not shown for graphic clarity.
Engine Coolant Air Bleed Pipe Bolt (1) - Remove [2x]
- Engine Coolant Air Bleed Hose Stud (2) - Remove
- Engine Coolant Air Bleed Hose (3) - Remove
Turbocharger Coolant Feed and Return Pipe Gasket (1) - Remove and DISCARD [2x]
Positive Crankcase Ventilation Hose Clamp (1) - Release [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Positive Crankcase Ventilation Hose (2) - Remove
Exhaust Gas Recirculation Valve Bracket Nut (1) - Remove
Exhaust Gas Recirculation Valve Bolt (1) - Remove [2x]
- Remove the exhaust gas recirculation valve (2) and exhaust gas recirculation cooler inlet pipe as an assembly.
- Exhaust Gas Recirculation Valve Inlet Gasket (3) - Remove and DISCARD
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
Exhaust Manifold Heat Shield Bolt (2) - Remove
- Exhaust Manifold Heat Shield (1) Remove
Exhaust Manifold Flange Bolt (3) - Remove [12x]
- Exhaust Manifold (2) - Remove
- Exhaust Manifold Gasket (1) - Remove and DISCARD
Intake Air Pressure and Temperature Sensor Bolt (1) - Remove
- Intake Air Pressure and Temperature Sensor (2) - Remove
Disconnect and remove the glow plug wiring harness (1).
- Detach the wiring harness retainers from the intake manifold.
Remove the 3 high pressure diesel fuel injection rail nuts (1).
Remove the high pressure diesel fuel injection rail (1).
- Charge Air Cooler Bracket - Remove
Fuel Injection Fuel Rail Stud (1) - Remove [3x]
Intake Manifold Cover Retainer (2) - Remove [2x]
- Intake Manifold Cover (1) - Remove
Intake Manifold Bolt (2) - Remove [9x]
- Intake Manifold (1) - Remove
- Intake Manifold Gasket (3) Remove and DISCARD [6x]
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]
- NOTE:
- Glow plugs must be discarded whenever removed, and replaced with NEW.
- If the cylinder head is removed, the accompanying glow plugs must be discarded and replaced with NEW.
- Handle with extreme care, do not allow glow plugs to touch each other.
Glow Plug (1) - Remove and DISCARD [6x]
- Inspect each glow plug tip and ensure the glow plug is not broken. If a broken tip is suspected, inspect the combustion chamber for the glow plug tip.
Timing Chain Cover Bolt (3) - Remove [4x]
- Timing Chain Cover Bolt (4) - Remove [2x]
- Timing Chain Upper Cover (1) @Cylinder Head - Remove
Camshaft Position Sensor Bolt (1) - Remove
- Camshaft Position Sensor (2) - Remove
Cylinder Head Temperature Sensor (1) - 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
Push the timing chain guide (1) in direction of the arrow to compress the tensioner piston.
- Install one EN-52234 Timing Chain Tensioner Retaining Pin (2) to lock the timing chain tensioner in position.
Timing Chain Guide Bolt (2) - Remove [2x]
- Timing Chain Guide (1) - Remove
Camshaft Sprocket Bolt (3) - Remove and DISCARD
- Camshaft Position Sensor Exciter Wheel (1) - Remove
- Camshaft Sprocket (2) - Remove
Secondary Timing Chain (1) - Remove
Camshaft Sprocket Bolt (1) - Remove and DISCARD
- Camshaft Sprocket (2) - Remove
Timing Chain Tensioner Shoe Bolt (2) - Remove
- Timing Chain Guide (1) - Remove
Camshaft Housing Bolt (1) - Loosen in sequence [16x] - Fastener Specifications
- Camshaft Housing Bolt (1) - Remove [16x]
Install the 2 J-43301 Coil Pack Pullers (1).
Loosen the 6 bolts (1) of the EN-52445-1 Camshaft Tool a half-turn each in sequence, until disengaged from the cylinder head.
Using the J-43301 Coil Pack Pullers (2), remove the camshaft housing (1).
- Camshaft Housing Gasket (3) - Remove and DISCARD [5x]
- Camshaft Housing Gasket (4) - Remove and DISCARD
Remove the EN-52445-2 Camshaft Tool (1) from the camshafts.
Remove the EN-52445-1 Camshaft Tool (3) from the camshaft housing.
Camshaft Bearing Cap Bolt (1) - Remove [16x]
- NOTE:
- Many internal engine components will develop specific wear patterns on their friction surfaces.
- Components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.
- Tag or mark each part immediately when removed. Indicate the location, direction, or orientation when necessary.
Camshaft Bearing Rear Cap (1) - Remove
- Camshaft Bearing Cap (2) - Remove [6x]
- Intake Camshaft (4) - Remove
Camshaft Bearing Cap Bolt (1) - Remove [12x]
Camshaft Bearing Cap (2) - Remove [6x]
- Exhaust Camshaft (3) - Remove
Loosen the 17 cylinder head bolts (1, 2) in sequence.
- Cylinder Head Bolt (1) - Remove and DISCARD [14x]
- Cylinder Head Bolt (2) - Remove [3x]
Cylinder Head (1) - Remove
- Cylinder Head Gasket (2) - Remove and DISCARD
- Using the appropriate tool, clean and prepare the applicable sealing surface.
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.
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling 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.