PROCEDURE

1 Drain the oil (if provided)

2 Drain the water (if provided)

3 Remove the radiator (if provided)

4 Disconnect electrical connections

5 Disconnect the fuel pressure pipes (5) (Fig 1)

6 Remove the air cleaner (4) and keep it in a vertical position.

7 Disconnect the accelerator linkages.

8 Remove the FIP (2) and injectors (3)

9 Remove the fuel filter assembly (8)

10 Remove the flywheel (6)

11 Remove the fan belt (9)

12 Remove the dynamo/alternator (10)

13 Remove the self-starter (11). (Fig 3)

14 Remove the water pump assembly (12)

15 Remove the inlet (4) and exhaust (15) manifold

16 Remove the valve cover (16). (Fig 2)

17 Remove the rocker assembly (17) from the cylinder head.

18 Remove the push-rods (18).

19 Remove the tappet side covers.

20 Remove the tappets (19).

21 Remove the cylinder head mounting bolts and remove the cylinder head (20).

22 Remove the cylinder head gasket

23 Remove the crankshaft pulley using the special puller.

24 Remove the timing cover.

25 Remove the timing gear and chain (22). (Note down the timing marks)

26 Remove the crankshaft.

27 Remove the oil sump (23).

28 Disconnect the oil pipes from the oil pump

29 Remove the oil pump and strainer (24).

30 Remove the oil filter.

31 Remove the connecting rod caps. (Note down marks/ No’s on the caps.)

32 Remove the piston (21) and connecting rod (27) from the engine. (Note down the marks/Nos. on
the pistons.)

33 Remove the main bearing caps. (Note down the marks/Nos. On the caps.)

34 Remove the flywheel housing (25).

35 Remove the crankshaft (28).