Engine Disassembly

PRELIMINARY COMPONENTS

1. Remove starter.
2. Remove vacuum sensing tube.
3. Remove alternator.
4. Remove fan and pulley.
5. Remove thermostat housing.
6. Remove water pump.

INJECTION PUMP

1. Remove fuel cut solenoid coupler.
2. Disconnect injection pipes and fuel hoses.
3. Remove drive gear cover retaining nuts, then the cover.
4. Remove drive gear locknut, spring washer and lock plate.

Fig. 1 Removing injection pump:

5. Remove injection pump to case attaching nuts and bolts, then using extractor tool 49 SE01 157 or equivalent, Fig. 1, remove injection pump from engine.

INTAKE MANIFOLD

1. Disconnect vacuum sensing tube at manifold.
2. Remove intake manifold to cylinder head attaching bolts, then the intake manifold.

REMOVING CYLINDER HEAD

1. Remove injectors and glow plugs from cylinder head.
2. Remove valve cover to cylinder head attaching bolts and the valve cover.

Fig. 2 Cylinder head bolt tightening sequence:

3. Remove rocker shaft and cylinder head bolts in reverse order of sequence shown in Fig. 2.
4. Remove rocker shaft, valve caps and pushrods, then the cylinder head and gasket.

VALVE & VALVE SPRING

1. Using a suitable spring compressor, compress valve spring.
2. Remove the taper sleeves, upper spring seat, valve springs and lower spring seat.
3. Remove valve from cylinder head.

CRANKSHAFT PULLEY

1. Install flywheel brake 49 E301 060 or equivalent, onto flywheel ring gear.
2. Remove pulley retaining bolt and washer, then pull crankshaft pulley off the front end of the crankshaft.

CLUTCH ASSEMBLY

1. Install flywheel brake as described previously.
2. Remove clutch cover to flywheel retaining bolts, then the clutch cover, pressure plate and disc.
3. Remove flywheel to crankshaft retaining bolts, then the flywheel brake and flywheel.
4. Remove end plate.

OIL PAN

1. Invert cylinder block.
2. Remove oil pan to cylinder block attaching bolts.
3. Remove oil pan and gasket.

OIL PUMP & STRAINER

1. Remove setscrew from side of cylinder block.
2. Remove oil pipe attaching bolts.
3. Remove oil pump and strainer.

TIMING GEAR COVER

1. Remove timing gear cover to case attaching bolts.
2. Remove timing gear cover and gasket.

CAMSHAFT, CRANKSHAFT, IDLER & INJECTION PUMP GEARS

1. Remove oil slinger and washers from crankshaft snout.

Fig. 3 Removing timing gears:

2. Using puller set 49 0839 425C or equivalent, remove crankshaft timing gear, Fig. 3.
3. Position a clean rag between camshaft and idler gears, then remove cam gear lock bolt and washers.
4. Using puller set 49 0839 425C or equivalent, remove cam gear from camshaft, Fig. 3.
5. Remove idler gear to spindle retaining nuts and washers, then remove idler gear and spindle assemblies.
6. Remove injection pump drive gear.
7. Remove timing gear case to cylinder block attaching bolts, then the timing case.

CAMSHAFT

1. Remove tappets from cylinder block.
2. Remove camshaft thrust plate to cylinder block retaining bolts and washers, then pull camshaft from block.

PISTON & CONNECTING ROD

1. Remove connecting rod bearing cap retaining nuts and bolts, then separate bearing cap from connecting rod.
2. Using the wooden handle end of a hammer, push the piston and connecting rod assembly outward until piston rings clear cylinder bore. Remove piston and connecting rod assembly through top of cylinder block.
3. To separate piston from connecting rod, remove piston pin retaining clips, then press pin from piston using a suitable driver.

CRANKSHAFT

1. Remove rear oil seal cap retaining bolts, then the cap and seal.
2. Remove main bearing cap to cylinder block retaining bolts, then the main bearing caps and thrust washers.
3. Lift crankshaft from cylinder block.