:	Aug 6, 2007

Timing Pin - Automatic Transmission
303-1117




Timing Pin - Manual Transmission
303-1116




Camshaft pulley holding tool
303-1145/1




Holder - Camshaft Pulleys Front
303-1124




Flex plate locking tool
303-947




Locking Tool - Flywheel
303-1123

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Disconnect the battery ground cable.

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: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle.

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Drain the engine oil.

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Remove the engine.

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Install the engine to a suitable engine stand.

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Remove the power steering pump bracket.   Remove the 3 bolts.

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Remove the air conditioning (A/C) compressor.   Disconnect the electrical connector.   Remove the 3 bolts.

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Remove the A/C compressor bracket.   Remove the 2 bolts.

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Remove the LH engine mount bracket.   Remove the 4 bolts.

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: Make sure that all openings are sealed. Use new blanking caps. Remove the oil level indicator and tube.   Release the wiring harness clip.   Remove the bolt.   Remove and discard the O-ring seal.

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Remove the LH exhaust gas recirculation (EGR) valve and cooler assembly.   Disconnect the electrical connector.   Remove and discard the clip.   Release the clip and disconnect the coolant hose.   Remove the 5 bolts.   Collect the bracket.

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Remove the LH exhaust manifold heat shield.   Remove the 2 bolts.

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Remove the turbocharger heat shield.   Remove the 2 bolts.

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: Make sure that all openings are sealed. Use new blanking caps. Remove the turbocharger oil return tube.   Release the wiring harness clip.   Remove the 3 bolts.   Remove and discard the gasket.   Remove and discard the O-ring seal.

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Release the turbocharger support bracket.   Remove the 4 bolts.

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: Make sure that all openings are sealed. Use new blanking caps. Disconnect the turbocharger oil supply tube.   Remove the banjo bolt.   Remove and discard the 2 sealing washers.

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Release the exhaust cross-over pipe from the LH exhaust manifold.   Remove and discard the 3 nuts.   Remove and discard the gasket.

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Remove the LH exhaust manifold and turbocharger assembly.   Remove and discard the 6 nuts.   Remove and discard the gasket.

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Remove the cylinder block coolant inlet pipe.   Remove the 2 bolts.   Remove and discard the O-ring seal.

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Remove the crankshaft position (CKP) sensor.   Disconnect the electrical connector.   Reposition the access cover.   Remove the bolt.

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Remove the RH EGR valve and cooler assembly.   Disconnect the electrical connector.   Remove and discard the clip.   Release the clip and disconnect the coolant hose.   Remove the 4 bolts.

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Disconnect the generator electrical connectors.   Reposition the rubber insulator.   Remove the nut.

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Remove the generator.   Remove the 3 bolts.

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Remove the RH exhaust manifold heat shield.   Remove the 3 bolts.

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Remove the RH engine mount bracket.   Remove the 4 bolts.

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Remove the generator bracket.   Remove the 5 bolts.

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Remove the RH exhaust manifold and exhaust cross-over pipe assembly.   Remove and discard the 6 nuts.   Remove and discard the gasket.

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Remove the EGR valve coolant pipe.   Remove the bolt.   Disconnect the electrical connector.   Release from the 2 clips.   Release the clip.

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Remove the coolant pump.   Remove the 3 bolts.   Remove and discard the O-ring seal.

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Remove the accessory drive belt idler pulley.   Remove the bolt.

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Remove the cooling fan pulley.   Remove the 3 bolts.

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Remove the crankshaft pulley.   Remove the 6 bolts.

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Remove the timing belt cover.   Fully loosen the 16 bolts.

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:   Note the fitted position. Remove the 2 low pressure fuel pipes.   Disconnect the 2 quick release connectors.

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Disconnect the engine oil pressure (EOP) sensor electrical connector.   Release the wiring harness clip.

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:   LH shown, RH is similar Disconnect the 6 fuel injector electrical connectors.   Release the 4 wiring harness clips.

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Disconnect the camshaft position (CMP) sensor electrical connector.   Release the wiring harness clip.

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Disconnect the engine oil temperature sensor electrical connector.   Release the wiring harness clip.

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:   LH shown, RH is similar. Disconnect the 2 knock sensor (KS) electrical connectors.

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Disconnect the fuel temperature sensor electrical connector.

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Remove the crankcase vent oil separator.   Disconnect and release the 2 breather hoses.

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Disconnect the fuel rail pressure (FRP) sensor electrical connector.

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Disconnect the 2 fuel injection pump electrical connectors.

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Remove the engine wiring harness.   Remove the nut.   Release the 2 clips.

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: Make sure that all openings are sealed. Use new blanking caps. :   RH shown, LH is similar Remove and discard the 2 high-pressure fuel rail supply lines.   Release the 2 clips.

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: Make sure that all openings are sealed. Use new blanking caps. Remove and discard the high-pressure fuel diverter rail supply line.

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: Make sure that all openings are sealed. Use new blanking caps. :   LH shown, RH is similar Remove and discard the 2 high-pressure fuel rail supply lines.   Release the clip.

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: Make sure the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.   : Make sure that the fuel injector adaptor union does not move when loosening the high-pressure fuel supply lines. Failure to follow this instruction may result in damage to the fuel injector or the fuel injector adaptor union.   : Make sure that all openings are sealed. Use new blanking caps. Remove and discard the 6 high-pressure fuel supply lines.

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Disconnect the fuel return line from the fuel injectors.   Remove and discard the 6 clips.

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Remove the two fuel injector bolts.

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Install the special tool studs.

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: Make sure the fuel injector remover legs are correctly engaged to the fuel injector. Failure to follow this instruction may result in damage to the component. Install the special tool remover legs to the studs.

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Remove the fuel injector.   Rotate the special tool bolts evenly, in a clockwise direction.   Remove the special tool.   Remove and discard the fuel injector clamp.   Remove and discard the sealing washer.

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Remove the remaining fuel injectors.

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:   LH shown, RH is similar. Remove the 2 fuel rails.   Remove the 4 bolts.

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:   RH shown, LH is similar Remove the 2 fuel rail brackets.   Remove the 4 bolts.

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Remove the fuel injection pump belt cover.   Release the 2 clips.

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Remove and discard the fuel injection pump belt tensioner.   Remove the bolt.

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Remove and discard the fuel injection pump belt.

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Install the special tool to the camshaft rear pulley.   Rotate the crankshaft to align the special tool to the engine lifting bracket.   Install and tighten the bolt.

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:   Discard the bolt. Using the special tool, remove the camshaft rear pulley bolt.

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Remove the special tool.   Remove the bolt.

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Remove the camshaft rear pulley.

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Remove the fuel injection pump belt rear cover.   Fully loosen the 2 bolts.

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Remove the LH engine cover locating studs.

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Remove the LH valve cover.   Release the KS electrical connector from the valve cover.   Fully loosen the 13 bolts.   Remove the fuel line support bracket.   Remove and discard the gasket.

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Remove the RH engine cover locating studs.   Remove the nut.   Remove the bolt.   Remove the bracket.

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Remove the RH valve cover.   Release the glow plug electrical connector from the valve cover.   Release the KS electrical connector from the valve cover.   Fully loosen the 13 bolts.   Remove and discard the gasket.

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Remove the brake vacuum pump.   Remove the 3 bolts.   Remove the bracket.   Remove and discard the gasket.

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Remove the breather line.   Remove the bolt.   Release the clip.

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Remove the turbocharger oil supply line.   Remove the bolt.   Remove and discard the 2 O-ring seals.

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Remove the cylinder head coolant outlet assembly.   Remove the 4 bolts.   Remove and discard the O-ring seal.

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: Make sure that all openings are sealed. Use new blanking caps. Disconnect the fuel pipe from the fuel cooler.

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: Make sure that all openings are sealed. Use new blanking caps. Remove and discard the fuel injector return line.

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Rotate the crankshaft clockwise to align the crankshaft alignment hole in the flywheel or flexplate with the cylinder block aperture.

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Check the camshaft pulley alignment holes are correctly aligned. If the alignment holes are not aligned, rotate the crankshaft one full turn clockwise.

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Using the special tool, lock the flexplate.   Install a starter motor bolt to retain the special tool.

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Using the special tool, lock the flywheel.   Install a starter motor bolt to retain the special tool.

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: Do not use the special tools to lock the camshafts. Failure to follow this instruction may result in damage to the engine or the special tools. Loosen the 6 exhaust camshaft pulley bolts.

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Remove and discard the timing belt tensioner.   Remove the bolt.

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Remove the 2 timing belt idler pulley's.   Remove the 2 bolts.   Collect the plastic shield from behind the upper idler pulley.

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Remove and discard the timing belt.

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:   LH shown, RH is similar. Remove the 2 camshaft pulleys.   Remove the 6 bolts.

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Using the special tool, remove the 2 camshaft pulley hubs.   Remove and discard the 2 bolts.

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Remove the cooling fan drive hub bearing.   Remove the 3 bolts.

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Retain the RH secondary timing chain tensioner piston.   Reposition the secondary timing chain tensioner.   Install a 1.5 mm (0.060 in.) diameter pin into the secondary timing chain tensioner piston.

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: Evenly and progressively, release the camshaft bearing caps. Remove the RH bank camshaft bearing caps.   Remove the 18 bolts.

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Remove the RH bank camshafts and secondary timing chain tensioner assembly.   Remove the 2 bolts.   Release the RH secondary timing chain tensioner.

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Remove the RH bank secondary timing chain tensioner.

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Remove the RH bank camshafts.   Release the secondary timing chain from the RH camshafts.   Remove and discard the seal.

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: The cylinder head must not be placed mating face down. Failure to follow this instruction may result in damage to the vehicle.   : Only use a plastic scraper to clean off the old gasket. Remove the RH cylinder head assembly.   Remove and discard the 8 bolts.   Remove and discard the gasket.

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Retain the LH secondary timing chain tensioner piston.   Reposition the secondary timing chain tensioner.   Install a 1.5 mm (0.060 in.) diameter pin into the secondary timing chain tensioner piston.

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: Evenly and progressively, release the camshaft bearing caps. Remove the LH bank camshaft bearing caps.   Remove the 18 bolts.

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Remove the LH bank camshafts and secondary timing chain tensioner assembly.   Release the LH secondary timing chain tensioner.   Remove the 2 bolts.

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Remove the LH bank secondary timing chain tensioner.

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Remove the LH bank camshafts.   Release the secondary timing chain from the LH camshafts.   Remove and discard the 2 seals.

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: The cylinder head must not be placed mating face down. Failure to follow this instruction may result in damage to the vehicle.   : Only use a plastic scraper to clean off the old gasket. Remove the LH cylinder head assembly.   Remove and discard the 8 bolts.   Remove and discard the gasket.

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Remove the special tool from the flexplate.

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Remove the flexplate.   Using the special tool, lock the flexplate.   Remove the 8 bolts.

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Remove the special tool from the flexplate.

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Install the special tool.

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: Working in a diagonal sequence, progressively loosen the bolts. :   Restrain the flywheel. Remove the clutch disc and pressure plate.   Remove the 6 bolts.

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:   Restrain the flywheel. Remove the flywheel.   Remove the 8 bolts.

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Remove the special tool.

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Remove the oil cooler assembly.   Remove the 8 bolts.   Remove and discard the gasket.

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Remove the fuel injection pump.   Remove the 4 bolts.

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Remove the oil pan.   Remove the 14 bolts.   Remove and discard the gasket.

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Remove the oil pump screen and pickup tube.   Remove the bolt.   Remove and discard the 2 O-ring seals.

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Remove the oil pan extension.   Remove the 18 bolts.   Remove and discard the gasket.