| : | Aug 6, 2007 |
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| . | Disconnect the battery ground cable. |
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Raise and support the vehicle. |
| . | Drain the engine oil. |
| . | Remove the engine. |
| . | Install the engine to a suitable engine stand. |
| . | Remove the power steering pump bracket.
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| . | Remove the air conditioning (A/C) compressor.
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| . | Remove the A/C compressor bracket.
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| . | Remove the LH engine mount bracket.
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Remove the oil level indicator and tube.
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| . | Remove the LH exhaust gas recirculation (EGR)
valve and cooler assembly.
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| . | Remove the LH exhaust manifold heat shield.
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| . | Remove the turbocharger heat shield.
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Remove the turbocharger oil return tube.
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| . | Release the turbocharger support bracket.
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Disconnect the turbocharger oil supply tube.
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| . | Release the exhaust cross-over pipe from the LH
exhaust manifold.
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| . | Remove the LH exhaust manifold and turbocharger
assembly.
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| . | Remove the cylinder block coolant inlet pipe.
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| . | Remove the crankshaft position (CKP) sensor.
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| . | Remove the RH EGR valve and cooler assembly.
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| . | Disconnect the generator electrical connectors.
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| . | Remove the generator.
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| . | Remove the RH exhaust manifold heat shield.
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| . | Remove the RH engine mount bracket.
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| . | Remove the generator bracket.
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| . | Remove the RH exhaust manifold and exhaust
cross-over pipe assembly.
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| . | Remove the EGR valve coolant pipe.
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| . | Remove the coolant pump.
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| . | Remove the accessory drive belt idler pulley.
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| . | Remove the cooling fan pulley.
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| . | Remove the crankshaft pulley.
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| . | Remove the timing belt cover.
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Remove the 2 low pressure fuel pipes.
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| . | Disconnect the engine oil pressure (EOP) sensor
electrical connector.
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Disconnect the 6 fuel injector electrical connectors.
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| . | Disconnect the camshaft position (CMP) sensor
electrical connector.
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| . | Disconnect the engine oil temperature sensor
electrical connector.
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| . |
:
Disconnect the 2 knock sensor (KS) electrical connectors. ![]() |
| . | Disconnect the fuel temperature sensor
electrical connector. ![]() |
| . | Remove the crankcase vent oil separator.
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| . | Disconnect the fuel rail pressure (FRP) sensor
electrical connector. |
| . | Disconnect the 2 fuel injection pump electrical
connectors. |
| . | Remove the engine wiring harness.
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:
Remove and discard the 2 high-pressure fuel rail supply lines.
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Remove and discard the high-pressure fuel diverter rail supply line. |
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Remove and discard the 2 high-pressure fuel rail supply lines.
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Remove and discard the 6 high-pressure fuel supply lines. ![]() |
| . | Disconnect the fuel return line from the fuel
injectors.
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| . | Remove the two fuel injector bolts. ![]() |
| . | Install the special tool studs. ![]() |
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Install the special tool remover legs to the studs. ![]() |
| . | Remove the fuel injector.
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| . | Remove the remaining fuel injectors. |
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Remove the 2 fuel rails.
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Remove the 2 fuel rail brackets.
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| . | Remove the fuel injection pump belt cover.
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| . | Remove and discard the fuel injection pump belt
tensioner.
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| . | Remove and discard the fuel injection pump belt. |
| . | Install the special tool to the camshaft rear
pulley.
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Using the special tool, remove the camshaft rear pulley bolt. |
| . | Remove the special tool.
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| . | Remove the camshaft rear pulley. ![]() |
| . | Remove the fuel injection pump belt rear cover.
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| . | Remove the LH engine cover locating studs.
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| . | Remove the LH valve cover.
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| . | Remove the RH engine cover locating studs.
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| . | Remove the RH valve cover.
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| . | Remove the brake vacuum pump.
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| . | Remove the breather line.
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| . | Remove the turbocharger oil supply line.
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| . | Remove the cylinder head coolant outlet
assembly.
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Disconnect the fuel pipe from the fuel cooler. |
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Remove and discard the fuel injector return line. |
| . | Rotate the crankshaft clockwise to align the
crankshaft alignment hole in the flywheel or flexplate with the cylinder
block aperture. ![]() |
| . | Check the camshaft pulley alignment holes are correctly aligned. If the alignment holes are not aligned, rotate the crankshaft one full turn clockwise. |
| . | Using the special tool, lock the flexplate.
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| . | Using the special tool, lock the flywheel.
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Loosen the 6 exhaust camshaft pulley bolts. ![]() |
| . | Remove and discard the timing belt tensioner.
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| . | Remove the 2 timing belt idler pulley's.
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| . | Remove and discard the timing belt. |
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Remove the 2 camshaft pulleys.
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| . | Using the special tool, remove the 2 camshaft
pulley hubs.
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| . | Remove the cooling fan drive hub bearing.
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| . | Retain the RH secondary timing chain tensioner
piston.
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Remove the RH bank camshaft bearing caps.
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| . | Remove the RH bank camshafts and secondary
timing chain tensioner assembly.
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| . | Remove the RH bank secondary timing chain
tensioner. ![]() |
| . | Remove the RH bank camshafts.
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Remove the RH cylinder head assembly.
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| . | Retain the LH secondary timing chain tensioner
piston.
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Remove the LH bank camshaft bearing caps.
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| . | Remove the LH bank camshafts and secondary
timing chain tensioner assembly.
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| . | Remove the LH bank secondary timing chain
tensioner. ![]() |
| . | Remove the LH bank camshafts.
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Remove the LH cylinder head assembly.
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| . | Remove the special tool from the flexplate.
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| . | Remove the flexplate.
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| . | Remove the special tool from the flexplate.
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| . | Install the special tool. ![]() |
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Remove the clutch disc and pressure plate.
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Remove the flywheel.
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| . | Remove the special tool. ![]() |
| . | Remove the oil cooler assembly.
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| . | Remove the fuel injection pump.
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| . | Remove the oil pan.
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| . | Remove the oil pump screen and pickup tube.
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| . | Remove the oil pan extension.
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