• Air Conditioning Compressor and Condenser Hose Seal-Large[3x]
• Air Conditioning Compressor and Condenser Hose Seal-Small[3x]
• Air Conditioning Evaporator Thermal Expansion Valve Seal-Large
• Air Conditioning Evaporator Thermal Expansion Valve Seal-Small
• Camshaft Housing Cover Insulator[26x]
• Camshaft Housing Gasket[2x]
• Catalytic Converter Clamp
• Catalytic Converter Gasket
• Crankshaft Front Oil Seal
• Emission Reduction Fluid Injector Clamp
• Engine Mount Frame Side Bolt[6x]
• Exhaust Gas Recirculation Cooler Inlet Pipe Gasket[2x]
• Exhaust Gas Recirculation Pipe Seal[2x]
• Exhaust Gas Recirculation Valve Cooler Gasket
• Exhaust Gas Recirculation Valve Inlet Gasket
• Exhaust System Front Gasket[2x]
• Fuel Injector Bolt[6x]
• Fuel Injector Seal[6x]
• Fuel Injector Washer[6x]
• High Pressure Diesel Fuel Feed to Rail Pipe[2x]
• High Pressure Diesel Fuel Feed to Injector Pipe[6x]
• Oil Filter
• Oil Level Indicator Seal
• Timing Chain Tensioner Gasket
• Transmission Fluid Cooler Seal[2x]
• Turbocharger Coolant Feed and Return Pipe Gasket[2x]
• Turbocharger Gasket
• Turbocharger Nut[3x]
• Turbocharger Oil Return Pipe Gasket[2x]

• EN-47909 Injector Bore and Sleeve Cleaning Kit
• EN-51146-1-3 Sliding Hammer
• EN-52451 Injector Remover

Equivalent regional tools:Special Tools

• EN-956-1 Extension
• EN-45059-A Angle Meter
• EN-49979 Crankshaft Holder
• EN-52445 Camshaft Tool
• EN-52449 Engine Stand Adapter
• EN-52452 Front Crankshaft Seal Installer
• EN-52474 Engine Lift Bracket Set
• EN-52586 Crankshaft Fixing Pin

Equivalent regional tools:Special Tools

Note: Use all components included with the service kit.

1. Engine»Remove—Engine Removal and Installation



2. EN-52449 Engine Stand Adapter (2) @Engine Block»Install
3. Engine@EN-52449 Adapter (2) »Install the engine to a suitable engine stand.
4. Remove the EN-52474 Engine Lift Bracket Set.



5. Install the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
6. Crankshaft Pulley Bolt(2)»Loosen[4x]



7. Remove the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).



8. Crankshaft Pulley Bolt(2)»Remove[4x]
9. Crankshaft Pulley(1)»Remove



10. Engine Front Cover Bolt(1)»Remove[8x]

Note: It is likely you will bend the crankshaft front oil seal during the removal. Use care to not damage the engine block.

11. Crankshaft Front Oil Seal(2)»Remove and DISCARD



12. Crankshaft Pulley Bolt(1)»Install and hand tighten[4x]
13. 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

Note: Once the EN-52586 Crankshaft Fixing Pin is installed, do not remove until all timing components have been installed.

14. Install the EN-52586 Crankshaft Fixing Pin (4).




Danger: 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.

15. Camshaft Housing Cover Insulator(1)»Remove



16. Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).
17. Unclip the fuel injector fuel return pipe retainer (2).



18. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel injection rail.



19. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel pump.



20. Fuel Feed Pipe Clip Bolt(1)»Remove
21. Fuel Return Pipe Clip Bolt(2)»Remove



22. Diesel Fuel Separator Bracket Bolt(1)»Remove




Note: Do NOT reuse the high pressure diesel fuel feed pipes.

23. Remove the high pressure diesel fuel feed to rail pipe (2) and DISCARD.



24. Remove the fuel injection fuel feed pipe bracket bolt (1).
25. Remove the fuel injection fuel feed pipe bracket (2).



26. Loosen the 12 high pressure diesel fuel feed pipe nuts (1) from the fuel injectors and the fuel injection rail.

Note: Do NOT reuse the high pressure diesel fuel feed pipes.

27. Remove and DISCARD the 6 high pressure diesel fuel feed to injector pipes (2).



28. Disconnect and reposition the fuel injector wiring harness, as needed.
29. Retainer(3)»Disengage
30. Fuel Injection Fuel Return Pipe Locking Spring (4)»Disengage[6x]



31. Fuel Injection Fuel Return Pipe (1)»Reposition



32. Disconnect the 6 high pressure diesel fuel injector electrical connectors (1).
33. Disconnect the 8 fuel injector wiring harness retainers (2) and reposition the fuel injector wiring harness out of the way.



34. Fuel Injector Bolt(1)»Remove and DISCARD[6x]
35. Multiport Fuel Injector Bracket(2)»Remove[6x]




Note: Mark the location of the high pressure diesel fuel injectors.

36. 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).



37. Remove and DISCARD the 6 fuel injector seals (2) and 6 fuel injector washers (3).



38. Engine Coolant Air Bleed Hose Stud(2)»Remove



39. Positive Crankcase Ventilation Hose Clamp(1)»Release[2x]—Hose Clamp Replacement Guidelines - Spring Type
40. Positive Crankcase Ventilation Hose(2)»Remove



41. Turbocharger Oil Return Pipe Bolt(7)»Remove[2x]
42. Lower Crankcase Extension Bolt(9)Remove
43. Turbocharger Oil Return Pipe Bolt(8)»Remove[2x]
44. Turbocharger Nut(2, 4)»Remove and DISCARD[3x]
45. Turbocharger Assembly(1)»Remove
46. Turbocharger Gasket(3)»Remove and DISCARD
47. Turbocharger Oil Return Pipe Gasket(6)»Remove and DISCARD
48. Turbocharger Oil Return Pipe Gasket(5)»Remove and DISCARD



49. Camshaft Housing Cover Bolt(1)»Loosen[7x]
50. Camshaft Housing Cover Bolt(2)»Loosen[3x]
51. Camshaft Housing Cover Bolt(3)»Loosen[9x]
52. Camshaft Housing Cover Bolt(4)»Loosen[7x]



53. Camshaft Cover(1)»Remove
54. Camshaft Housing Gasket(2)»Remove and DISCARD[2x]
55. Camshaft Housing Cover Insulator(3)»Remove and DISCARD[26x]



56. Timing Chain Cover Bolt(3)»Remove[4x]
57. Timing Chain Cover Bolt(4)»Remove[2x]
58. Timing Chain Upper Cover(1)@Cylinder Head»Remove



59. Ensure that the camshaft notches (1) are in the 12 o'clock position.



60. 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.
61. Install the EN-52586 Crankshaft Fixing Pin (4).



62. Install the EN-52445-1 Camshaft Tool (3) to the camshaft housing.
63. Check that the tab (1) of the EN-52445-1 Camshaft Tool sits correctly under the camshaft bearing rear cap (2).
64. Check that the pins (6) of the EN-52445-1 Camshaft Tool sit correctly in the camshafts (5).



65. Install the EN-52445-2 Camshaft Tool (1) on the camshafts.



66. Timing Chain Tensioner(2)»Remove
67. Timing Chain Tensioner Gasket(1)»Remove and DISCARD



68. Timing Chain Guide Bolt(2)»Remove[2x]
69. Timing Chain Guide(1)»Remove

1. Clean the crankshaft pulley (1).
2. Inspect the crankshaft pulley (1) for damage to belt drive surface and to crankshaft pulley hub.
3. Inspect the crankshaft pulley (1) hub groove for damage or wear.
4. Replace the crankshaft pulley (1) if any damage is found.



5. Clean the timing chain tensioner (1) surfaces.
6. Inspect the timing chain tensioner (1) for wear.
7. Replace the timing chain tensioner (1) if damaged.




Caution: The fuel injector must be cleaned with the proper cleaning equipment. DO NOT use abrasive cleaning methods, such as a metallic brush, to remove deposits. Cleaning an injector with improper tools will damage the fuel injector.

Note: The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation.

8. Using a soft bristle non-metallic brush and top engine cleaner, remove any deposits from the high pressure diesel fuel injector nozzle tip (1) and the copper washer sealing area before installation.
9. Inspect the high pressure diesel fuel injector nozzle tip (1) for cracks, dents, or other damage.
10. Inspect the high pressure diesel fuel injector nozzle tip (1) for any signs of discoloration.



11. Clean the camshaft housing (1) in solvent.
12. Inspect the camshaft housing (1) for damage or cracking. A cracked or damaged camshaft housing may:
1. Leak engine oil
2. Affect crankcase ventilation
3. Interfere with the camshafts
4. Allow water or condensation to enter the engine
13. Inspect the exterior of the camshaft housing (1) for the following conditions:
1. Damage to the camshaft housing bolt holes (2)
2. Damage to the camshaft housing injector bracket bolt holes (3)
3. Damage to the positive crankcase ventilation valve (4).



14. Inspect the interior of the camshaft housing for the following conditions:
1. Inspect the camshaft housing for cracks, casting imperfections, or damage.
2. Inspect the camshaft housing seal locations (2) for cracks or damage.
3. Inspect the crankcase ventilation oil separator cover (1) for cracks or damage.



15. Clean the timing chain upper cover (1).
16. Inspect the timing chain upper cover (1) mating surfaces for damage.
17. Replace the timing chain upper cover (1) if damaged.



18. Clean all threads on the compressor air intake turbocharger, if necessary.
19. Clean all sealing surfaces.
20. Inspect the wastegate regulator mechanism (1) for functionality.
21. Inspect the turbine blades for damage or foreign material.
22. Inspect the turbine blade shaft for excessive radial and axial end play.
23. Inspect the compressor air intake turbocharger for cracks or other damage.
24. Inspect the compressor air intake turbocharger mating surface for flatness.

1. Clean the secondary timing chain guide (1) surfaces.
2. Inspect the timing chain guide (1) for signs of cracking or wear.
3. Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in) of depth on the chain guide surface.

1. Timing Chain Guide(1)»Install
2. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
3. Apply thread locking adhesive to the external threads of the components.Adhesives, Fluids, Lubricants, and Sealers
4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Caution: Refer to Fastener Caution.

3. Timing Chain Guide Bolt(2)»Install and tighten[2x]—Fastener Specifications



4. Timing Chain Tensioner Gasket(1)»Install NEW

Caution: Refer to Component Fastener Tightening Caution.

5. Timing Chain Tensioner(2)»Install and tighten—Fastener Specifications



6. Remove EN-52445-2 Camshaft Tool Holder (3)



7. Remove the EN-52445-1 Camshaft Tool (3) from the camshaft housing.



8. EN-52586 Crankshaft Fixing Pin(4)»Remove
9. Rotate the engine by hand to ensure there is no interference.
10. Crankshaft Pulley Bolt(1)»Remove[4x]



11. Clean all sealing surfaces.
12. Ensure proper use of room temperature vulcanizing (RTV) sealant.Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
13. Apply a bead of sealant (1) to the crankshaft front oil seal sealing surface using the following procedure: Adhesives, Fluids, Lubricants, and Sealers
1. Begin applying a 4.0 mm (0.158 in) bead, dimension a.
2. Continue to apply the bead, increasing to a 6.0 mm  (0.236 in) bead, dimension b.
3. Continue to apply the bead, decreasing to a 4.0 mm (0.158 in) bead, dimension a.
4. At the end of the bead path, increase to a 6.0 mm (0.236 in) bead, dimension a.



14. Install the EN-52452 Front Crankshaft Seal Installer (1) to the crankshaft.
15. Install and hand tighten the 2 bolts (2) of the EN-52452 Front Crankshaft Seal Installer (1).



16. Crankshaft Front Oil Seal(1)»Install NEW
17. Check that the crankshaft front oil seal (1) sits correctly on the crankshaft and the 2 pins (2, 4).
18. Remove the 2 bolts (5) from the EN-52452 Front Crankshaft Seal Installer (3).
19. Remove the EN-52452 Front Crankshaft Seal Installer (3) from the crankshaft.



20. Engine Front Cover Bolt(1)»Install and tighten in sequence[8x]—Fastener Specifications



21. Crankshaft Pulley(1)»Install
22. Crankshaft Pulley Bolt(2)»Install and hand tighten[4x]



23. Install the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
24. Crankshaft Pulley Bolt(2)»Tighten[4x]—Fastener Specifications



25. Clean the camshaft housing gasket surface on the cylinder head.
26. Ensure proper use of room temperature vulcanizing (RTV) sealant.Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
27. Apply a bead of sealant (1) to the timing chain upper cover sealing surface using the following procedure: Adhesives, Fluids, Lubricants, and Sealers
1. Begin applying a 6.0 mm (0.236 in) bead, dimension a.
2. Continue to apply the bead, decreasing to a 4.0 mm  (0.158 in) bead, dimension b, for the remaining bead path, until near the end.
3. At the end of the bead path, increase to a 6.0 mm (0.236 in) bead, dimension a.



28. Timing Chain Upper Cover(1)@Cylinder Head»Install

Note: Take note that there are different bolt lengths.

29. Apply sealant to the front threads of the 2 timing chain cover bolts (4).
30. Timing Chain Cover Bolt(4)»Install and hand tighten[2x]
31. Timing Chain Cover Bolt(3)»Install and hand tighten[4x]
32. Timing Chain Cover Bolt(3, 4)»Tighten in sequence[6x]—Fastener Specifications
33. Clean the squeezed out sealant residues between the timing chain upper cover and the cylinder head.



34. Camshaft Housing Gasket(2)@Camshaft Housing»Install NEW[2x]
35. Camshaft Housing Cover Insulator(3)»Install NEW[26x]



36. Apply a 6.0 mm (0.236 in) bead of sealant (1) to the camshaft housing sealing locations where the timing chain upper cover joins the cylinder head. Adhesives, Fluids, Lubricants, and Sealers



37. Camshaft Housing(1)@Cylinder Head»Install
38. Camshaft Housing Bolt(2)»Hand tighten[26x]



39. Camshaft Housing Bolt(1, 2, 3, 4)»Tighten in sequence[26x]—Fastener Specifications



40. Turbocharger Oil Return Pipe Gasket(5)»Install NEW
41. Turbocharger Oil Return Pipe Gasket(6)»Install NEW
42. Turbocharger Gasket(3)»Install NEW
43. Turbocharger Assembly(1)»Install
44. Turbocharger Nut(2, 4)»Install NEW[3x]
45. Turbocharger Oil Return Pipe Bolt(8)»Install and tighten[2x]—Fastener Specifications
46. Turbocharger Oil Return Pipe Bolt(7)»Install and tighten[2x]—Fastener Specifications
47. Lower Crankcase Extension Bolt(9)Install and tighten—Fastener Specifications
48. Turbocharger Nut(2, 4)»Tighten[3x]—Fastener Specifications



49. Engine Coolant Air Bleed Hose Stud(2)»Install and tighten—Fastener Specifications



50. Positive Crankcase Ventilation Hose(2)»Install
51. Positive Crankcase Ventilation Hose Clamp(1)»Engage[2x]—Hose Clamp Replacement Guidelines - Spring Type



52. Using the EN-47909 Injector Bore and Sleeve Cleaning Kit (1) clean the 6 fuel injector bores in the cylinder head as needed.



53. Fuel Injector Seal(2)»Install NEW[6x]
54. Fuel Injector Washer(3)»Install NEW[6x]
55. High Pressure Diesel Fuel Injector(1)»Install[6x]




Note: Note the mounting position of the injector bracket.

56. Multiport Fuel Injector Bracket(2)»Install

Note: Do NOT tighten the fuel injector bolt until after the high pressure diesel fuel feed pipes are installed.

57. Fuel Injector Bolt(1)»Install NEW



58. Fuel Injection Fuel Return Pipe(1)»Install



59. Fuel Injection Fuel Return Pipe Locking Spring (4)»Engage[6x]
60. Retainer(3)»Install



61. Connect the fuel injector wiring harness using the 8 fuel injector wiring harness retainers (2).
62. Connect the 6 high pressure diesel fuel injector electrical connectors (1).



63. Install NEW high pressure diesel fuel feed to injector pipes (2).
64. Hand tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel rail.
65. Hand tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel injectors.
66. Tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel rail. Fastener Specifications
67. Tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel injectors. Fastener Specifications




Note: Tighten the fuel injector bolt only after installing the high pressure diesel fuel feed pipes.

68. Using the EN-45059-A Angle Meter, tighten the NEW fuel injector bolt (1). Fastener Specifications



69. Install the fuel injection fuel feed pipe bracket (2).
70. Install the fuel injection fuel feed pipe bracket bolt (1) and tighten. Fastener Specifications



71. Install a NEW high pressure diesel fuel feed to rail pipe (2).
72. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.



73. Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications
74. Attach the fuel injector fuel return pipe retainer (2).



75. Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1,2) and tighten. Fastener Specifications



76. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.
77. Tighten the high pressure diesel fuel feed to rail pipe fittings to both the high pressure diesel fuel pump and the high pressure diesel fuel injection rail. Fastener Specifications



78. Diesel Fuel Separator Bracket Bolt(1)»Install and tighten—Fastener Specifications




Danger: 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.

79. Camshaft Housing Cover Insulator(1)»Install



80. Remove the EN-49979 Holder (1) with EN-956-1 Extension (3).
81. Install the EN-52474 Engine Lift Bracket Set.
82. Using a suitable engine lifting device, remove the engine from the engine stand.



83. EN-52449 Engine Stand Adapter (2) @Engine Block»Remove
84. Engine»Install—Engine Removal and Installation