If a torque value is not specified, use the chart listed in the specifications section, Group 18, to determine the correct torque value. Many of the gaskets and o-rings are manufactured from a material designed to absorb oil. These gaskets will enlarge and provide a tight seal after coming in contact with oil. Use ONLY a recommended contact adhesive or a vegetable based oil to install these parts.
Always use a capscrew of the same system, metric or U. Customary, the same dimension and the same grade as the capscrew removed. The use of a longer capscrew than the capscrew that is listed can result in damage to the engine. Engine Lifting Brackets Warning: The engine lifting equipment must be designed to safely lift the engine as an assembly. Use a properly rated hoist and engine lifting fixture, Part No. Refer to Section E for the weight of the engine you are working on.
Engine Disassembly Engine - Preparation for Cleaning Install caps or tape on all engine openings to prevent moisture and dirt from entering the engine: Protect all electrical components and wiring from the full force of the cleaner spray nozzle. Engine - Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Steam clean and dry with compressed air.
Lubricating Oil - Draining Warning: Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. The oil pan capacity is 34 Liters [9. Remove the oil drain plug from the bottom of the oil pan. Drain the oil into a suitable container. Use fuel and water filter wrench, Part No. Fan Drive Belt - Removal Loosen the idler pulley shaft locknut. Turn the adjusting screw counterclockwise to release tension, and remove the belt.
Fan and Fan Hub - Removal If an electric fan clutch is used, disconnect the fan clutch connector from the base wiring harness. Remove the six capscrews and the fan. NOTE: The six capscrews also hold the fan drive pulley in position. Do not allow the pulley to fall. Loosen the adjusting link capscrew 2.
Loosen the pivot capscrew and nut 3. Turn the adjusting screw 4 to release tension, and remove the belt. Rotate the tensioner away from the belt until it stops. Remove the alternator belt while holding the tensioner back. Remove the capscrew 2 from the thermostat housing and the adjusting link. Remove the pivot bolt and alternator.
Alternator and Brackets Bus Applications Loosen the alternator pivot mounting capscrew. Remove the alternator brace link. Remove the alternator pivot capscrew and the alternator. Remove the mounting nut from the rear of the gear housing and the four cylinder block mounting capscrews from the lower alternator mounting bracket.
Remove the lower alternator mounting bracket. Remove the belt tensioner from the front of the engine. Remove the three mounting capscrews and the tensioner bracket from the gear cover.
Turbocharger - Removal Remove the oil supply line and gasket from the top of the turbocharger. Remove the other end of the supply line from the lubricating oil filter head. Remove the oil drain line and gasket from the bottom of the turbocharger. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the v-band clamp, discharge elbow and o-ring from the turbocharger compressor discharge outlet. Remove the four turbocharger mounting nuts. Remove the turbocharger and gasket.
Plug the supply and drain holes in the turbocharger. Exhaust Manifold - Removal Caution: The exhaust manifold assembly has three sections which can separate and fall causing personal injury during removal. Hold the assembly on each end to remove it. Remove one capscrew from each end section of the exhaust manifold and install two guide pins, Part No.
Remove the remaining capscrews. Remove the exhaust manifold, gaskets and the two guide pins. Air Intake Manifold - Removal Remove the intake manifold pressure sensor and the intake manifold temperature sensor wire connectors from the top rear end of the intake manifold.
Tag the wires as they are removed for future identification. Remove the boost pressure sensor 1 and the intake manifold temperature sensor 2 from the manifold. Remove the wire clamps holding the harness to the manifold. Remove the air intake connection and gasket from the top of the manifold. Remove two of the mounting capscrews and install two guide pins, Part No. Remove the remaining capscrews, beginning at the ends and moving toward the center, intake manifold and gasket.
Remove the guide pins. Use four M10 x 25 capscrews and install the front lifting bracket on the rocker lever housing. Thermostat Housing - Removal Loosen the bottom coolant bypass hose clamp.
NOTE: If the housing is stuck, hit the housing with a mallet to loosen it. Remove the four capscrews, the housing, and the thermostat. Torque Converter Cooler Disc - Removal The torque converter cooler disc 2 restricts the water flow through the thermostat housing 1 to water pump bypass hose 2. This allows coolant to be circulated through a remote mounted torque converter oil cooler. Remove the disc 2 from the thermostat housing to water pump bypass hose connection.
Lubricating Oil Cooler - Removal Remove the four oil cooler to thermostat housing support flange mounting capscrews. Remove the four oil cooler to lubricating oil filter head mounting capscrews, oil cooler and gaskets. Remove the oil cooler water inlet and outlet tubes and the mounting flange.
Remove the capscrew from the turbocharger drain line bracket. Remove the turbocharger oil drain line from the cylinder block drain connection. Use standard puller, Part No. Water Pump - Removal Remove the two water transfer connection capscrews.
Remove the three water pump mounting capscrews. Rotate the water pump outward so the water transfer connection can be removed from the water pump. Remove the water transfer connection from the water pump. Twist the water pump outward from the top and angle the rear of the pump downward as it is being removed to allow the pump to pass the thermostat housing support while being removed.
Thermostat Housing Support - Removal Remove the wiring harness from the coolant temperature sensor. Tag the harness connection for future identification. Loosen the air compressor water return tube connection 1. NOTE: If the support is stuck, hit the support with a mallet to loosen it. Remove the four capscrews 2 and the support.
Remove the remaining capscrews beginning at the ends and moving toward the center of the plate. Caution: Care must be taken to ensure no surface scratches occur on the water header plate or cylinder block mounting surfaces. Scratches on these surfaces will cause future leak paths. Remove the water header plate, gasket and guide pins. Remove the four capscrews 2 , the hand hole cover and gasket. Turbocharger Oil Drain Connection - Removal Remove the turbocharger oil drain tube connection fitting from the side of the cylinder block.
Install two guide pins, Part No. Warning: To avoid personal injury, use a properly rated hoist to lift the engine. The engine weighs approximately kg [ lb]. Use the engine lifting fixture, Part No. Install the exhaust side of the engine to the adapter plate of the rebuild stand. Align the top of the adapter plate 3 to the top row of the water header plate mounting capscrews holes 4.
The cylinder block must be positioned so two capscrew holes 5 and 6 in the bottom row will show on each side of the adapter plate.
Align the guide pins with the bottom row of holes in the adapter plate at points 7 and 8. Use eight capscrews, Part No. Remove the fuel filter head. Electronic Control Module - Removal Remove the ambient air pressure sensor wire connector and the ambient air pressure sensor 1 , if equipped, from the front electronic control module ECM mounting bracket.
Remove the harness wire clamps from the support bracket at points 1 and 2. Loosen the AMP connector mounting capscrews from the actuator harness and the sensor harness.
Remove the actuator and sensor harness connectors from the ECM. NOTE: The actuator harness is the top connector nearest the engine, and the sensor harness is the bottom connector.
Tag the connectors as they are removed for future identification. Electronic Control Cooling Plate - Removal Remove the four mounting capscrews, the electronic control cooling plate and the mounting brackets.
Starting Motor - Removal The component weighs 23 kg [50 lb] or more. The starter mounting capscrews can be one of several different sizes. These sizes could be in metric or U. Use the correct wrench size to avoid damage to the capscrews.
Remove the three capscrews and the starting motor. Fuel Lines - Removal Remove the fuel supply tube 1 and the fuel drain tube 2 from the cylinder head. Remove the fuel pump gear pump cooling tube 3. Fuel Pump - Removal Remove the actuator harness wire from the fuel shutoff valve.
Tag the wire for future identification. Remove the two support bracket capscrews. Remove the four fuel pump mounting capscrews, fuel pump and gasket. Remove the coupling spider. Air Compressor - Removal Remove the coolant inlet tube 1 and coolant outlet tube 2 from the air compressor. Remove the nuts 3 from the two top mounting capscrews. Remove the four air compressor mounting capscrews 4 , air compressor and splined coupling.
Remove the outlet tube clamp capscrew 3 and the tube. Hydraulic Pump Drive - Removal Remove the three pump drive adapter mounting capscrews. Install a slide hammer and the engine barring tool, Part No. Use two M Section 0 - Engine Disassembly and Assembly - Group 00 M11 Caution: Do not allow the hydraulic drive gear to slide out of the adapter or the gear housing during removal.
Damage to the gear will result. Remove the hydraulic drive adapter, o-ring, and hydraulic drive gear. Sensor Harness and Sensors - Removal Tag all connections as they are removed for future identification. Disconnect the connector 1 that connects the sensor and actuator harnesses.
Remove all the sensor wiring harness clamps from the engine and the sensor wiring harness. Remove the harness bracket from the cylinder block. Remove the oil temperature sensor 1 and oil pressure sensor 2 from the cylinder block. Remove the engine position sensor 3 from the rear of the gear housing. Rocker Lever Cover - Removal Remove the breather tube and the tube retaining clip 1 from the side of the cylinder block. Remove the 16 capscrews, isolators and spacers from the cover. Remove the cover and gasket.
Rocker Lever Housing Spacer - Removal If the engine is equipped with a JacobsW Engine Brake, disconnect the two electrical connections from the terminals on the inside and outside of the spacer. Disconnect the oil supply hose connection. Remove the oil supply hose. JacobsW Engine Brake - Removal If the engine is equipped with a JacobsW Engine Brake, press the connector into the front housing to allow clearance for housing removal. Internal Actuator Harness - Removal Use a Torx screwdriver T25 to loosen the screw which secures the two sections of the actuator harness together at the rear of the rocker lever housing.
The screw head is accessible from inside the rocker lever housing. Disconnect the two sections of the actuator harness. Disconnect the ground wire connection of the actuator harness 1 from the engine. Tag the end for future identification. Remove the external section of the actuator harness. Use care not to damage the plug as it is being removed from the rocker housing. Disconnect the wire connectors from the injectors. Tag the connectors for future identification. The connectors must be connected to the same injector as they were removed from when the engine is reassembled.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the internal section of the actuator wiring harness. Push Rods - Removal Mark the location of the valve push tubes and injector push rods as they are removed. The push tubes and push rods must be installed in the same location when the engine is assembled.
Loosen the adjusting screws and remove the valve push tubes and injector push rods. Hold the push tubes and push rods while loosening the adjusting screws. Do not let them fall into the engine while rotating the accessory drive pulley. NOTE: Some push tubes and rods are under compression due to the valves being open.
Rotate the crankshaft clockwise with the accessory drive pulley to relieve the spring tension. Rocker Lever Assemblies - Removal Install a piece of one-quarter inch key stock 18 inches long on top of the four front rocker lever assembly supports. Use four M The two capscrews on the end supports will fasten on one side of the bar stock to the engine brake mounting holes.
The two capscrews on the center supports will fasten on the opposite side of the bar stock to the engine brake mounting holes. Loosen, but do not remove, the eight rocker shaft capscrews. The capscrews hold the rocker lever assemblies together. Grasp hold of the bar stock and lift the front rocker lever assembly from the engine. Repeat the process to remove the rear rocker lever assembly. Crossheads - Removal Remove the crossheads. Number each crosshead with the cylinder number and position as it is removed.
NOTE: Each crosshead must be installed in the same position as it was removed from when the engine is assembled. Injectors - Removal Remove the injector hold down capscrews and hold down clamps. Use injector puller, Part No. Insert the pin of the tool into the hole provided in the body of the injector.
Number each injector with the cylinder number as it is removed. Remove the capscrews, washers, rocker lever housing, and gasket. Cylinder Head - Removal Remove the seven 12 point capscrews from the camshaft side of the cylinder head. Remove the three capscrews inside the intake ports.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the remaining 32 capscrews starting from the ends and moving toward the center. NOTE: The illustration shown is for torquing the cylinder head during installation.
Reverse the order for removal. Install cylinder head lifting bracket, Part No. NOTE: If the capscrews are not available from the kit, install two rocker lever support capscrews M14—2. To prevent damage to the cylinder head, lift it straight up. The cylinder head is doweled to the cylinder block.
To prevent damage to the combustion face of the cylinder head, place it on wooden blocks after removal. Use a hoist or hydraulic arm to remove the cylinder head. Remove the gasket. Cam Follower Assemblies - Removal Remove the nuts and washers from the seven supports. Do not allow the nuts or washers to fall into the engine.
NOTE: The cam follower assembly consists of two shaft assemblies with a common center support. Slide the cam follower removal and installation tool, Part No. If necessary, bump the dowel supports to loosen. Slide the tool forward until the adjusting screws on the top of the tool can be finger tightened in to the socket of the injector cam followers.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Lift the cam follower assemblies to remove them from the engine. Remove the tool from the cam follower assemblies. Lubricating Oil Pan - Removal Rotate the engine on the rebuild stand to position the engine on its side. Remove two capscrews at points 1 and 2 and install two guide pins, Part No. Remove the remaining 32 capscrews and oil pan. Use a mallet to loosen the oil pan if it is stuck.
Lubricating Oil Transfer Tube - Removal Remove the oil transfer tube from the oil pan on rear sump lubricating oil pans. NOTE: The straight transfer tube is used on some aluminum front sump oil pan applications. Remove and discard the two o-rings from the transfer tube. Block Mounted Front Sump Suction Tube Removal If the engine is equipped with a block mounted front sump suction tube, remove the suction tube retaining capscrew from the cylinder block.
Remove the suction tube from the cylinder block. Remove and discard the o-ring from the suction tube. Flywheel - Removal Install two capscrews M Remove two mounting capscrews 3 and install two guide pins, Part No. The clutch pressure plate capscrew holes are U.
Customary threads. Remove the remaining seven mounting capscrews from the flywheel. Install the nylon lifting sling, Part No. Tighten capscrews 1 and 2 in alternating sequence to loosen the flywheel. Use a hoist to remove the flywheel. Crankshaft Rear Oil Seal - Removal Remove the 12 capscrews and clamping ring 1 , Use a heal bar to remove the oil seal 3 and dust seal 2 together.
Remove the gasket 4. Flywheel Housing - Removal Remove the capscrews and both rear engine mounts. Remove capscrews 1 and 2 and install two flywheel housing guide pins, Part No. Remove the remaining 12 capscrews and the flywheel housing. Use a mallet to loosen the housing if it is stuck. Remove the two guide pins from the crankshaft.
Remove the idler shaft retaining capscrew. Use idler shaft puller, Part No. Manufacture a sleeve from Caution: Do not drop the idler gear bearings as the idler gear is removed.
Damage to the bearings can result. Install the tool into the idler gear bore through the idler shaft bore to hold the idler gear and bearings together while they are removed.
Remove the idler gear to gain access to the rest of the housing capscrews. The cup plug bore will be damaged and oil leakage will occur. To gain access to the housing capscrews, use a drift to drive the cup plugs straight through into the housing. Retrieve the plugs from inside of the housing. NOTE: Do not reuse the cup plugs that are removed. The cup plugs must be replaced with new ones. Use offset wrench, Part No.
Use a rubber hammer to loosen the housing. Remove the housing and the guide pins. Accessory Drive Pulley - Removal Remove the pulley retaining capscrew. The crankshaft must be held in position to allow the capscrew to be removed. NOTE: This is a slip fit pulley and does not require the use of a puller. Remove the pulley. If a dust seal is installed, remove the dust seal from the pulley. The dust seal can be slipped off the hub by hand. Accessory Drive Oil Seal - Removal Remove the five capscrews, clamping ring 1 , seal 2 , and gasket 3.
Accessory Drive Assembly - Removal Remove the six mounting capscrews, accessory drive assembly, and gasket. Remove the remaining capscrews, pulley, and damper.
Do not use a hammer or a screwdriver to remove the viscous damper. These tools can damage the damper. Crankshaft Front Oil Seal - Removal Remove the six capscrews, the clamping ring 1 , the oil seal 3 and dust seal 2 together, and the gasket 4.
Gear Cover - Removal Six of the gear cover capscrews were removed with the front support bracket. Remove the remaining 14 capscrews and the gear cover.
Remove the rectangular seals from the grooves around the mounting surfaces of the gear housing. Each shaft must be installed in the same position it was removed from. Lubricating Oil Pump - Removal Caution: Do not pry on the gear pump flange when removing the oil pump. This can result in damage to the pump.
Remove the three mounting capscrews, and two spacers if applicable. Use both hands to pull, or insert two capscrews M Camshaft - Removal Rotate the camshaft to align the holes in the camshaft gear with the thrust support capscrews. Remove the two capscrews. Remove the three capscrews, the rear cover plate and gasket. Install the expander 1 , Part No. Turn the screw inside the expander clockwise to expand the swell plug. Install the arbor sleeve 2 over the expander.
Install the locating pilot extensions 3 to the expander. Use one hand to slowly rotate and pull the camshaft from the cylinder block and the other hand to balance the camshaft as it is removed. Remove the camshaft pilot tool. Gear Housing - Removal Remove the gear housing mounting capscrews and the housing. Remove the rectangular seal from the back side of the housing.
Piston Cooling Nozzles - Removal Caution: The nozzles must be removed before the piston and rod assemblies to avoid damage to the nozzles. The crankshaft must be rotated to allow access to remove all the nozzles. Remove each retaining capscrew and nozzle. Pistons and Connecting Rods - Removal Caution: Do not use emery cloth or sandpaper to remove carbon from the cylinder liners and cylinder block top deck surface.
Aluminum oxide or silicon particles from emery cloth or sandpaper can cause serious engine damage. Rotate the crankshaft to expose the carbon ridge above the ring travel area in the cylinder liner.
Loosen the connecting rod capscrews. Do not remove the capscrews from the rods until the caps have been loosened. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Hit the heads of connecting rod capscrews with a mallet to loosen the caps from the dowel rings.
Do not drop the bottom bearing shell when the cap is removed. Remove the connecting rod capscrews and caps. Caution: Do not mark on the bearing to crankshaft mating surface. Damage to the engine can occur if bearings are used again. Install two connecting rod guide pins, Part No. Use a wooden dowel, hammer handle or equivalent to push the rod away from the crankshaft. Push the rod until the piston rings are outside of the block. Use both hands to remove the piston and rod assembly.
The piston and connecting rod assemblies must be installed in the same cylinder number they were removed from to insure proper fit of worn mating surfaces if parts are used again. Use a tag to mark the cylinder number each piston and rod assembly was removed from.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Place the rod and piston assemblies into a container to protect them from damage. A unique number, not cylinder number, is stamped on the connecting rod and matching cap. When the rods and caps are installed in the engine, the numbers on the rods and caps must match and be installed on the same side of the engine.
Remove the upper rod bearing. Damage to the engine can occur if the bearings are used again. The main bearing caps are marked for position as shown. The caps must be installed with the number on the cap matching the number on the oil pan flange of the cylinder block.
The caps must be oriented so they are lock tang to lock tang. Use a steel stamp to mark any caps without a number before the cap is removed. To avoid damage to the cylinder block, do not rock the cap to remove, pull straight up.
Remove the main bearing cap capscrews. Use main bearing cap puller, Part No. ST, to remove the main bearing caps. The tool must be centered on the cap. Pull straight up to remove the cap. Remove the lower main bearing shells from the caps. Damage to the engine can result if the bearings are used again. Mark the bearing shells with the journal number they were removed from in the flat surface of the bearing tang.
Caution: Do not damage the crankshaft when removing the thrust bearings. Lift the crankshaft straight up to avoid damage to the crankshaft or cylinder block. Install nylon lifting sling, Part No. Attach the sling to a hoist and remove the crankshaft. Use both thumbs to remove the upper bearing shells. Mark these bearing shells with the journal number they were removed from in the flat surface of the bearing tang.
Do not mark on the bearing to crankshaft mating surface. The pressure regulator spring 2 is under compression. Wear face and eye protection. Remove the retainer plug 1 , the pressure regulator spring 2 and plunger 3. Use light duty puller kit, Part No. Remove the pressure regulator spring 2 , washer 3 , and valve disc 4.
NOTE: The high oil pressure regulator seat will remain in the cylinder block. Cylinder Liners - Removal Rotate the engine on the rebuild stand so the head deck is facing up. Use universal liner puller, Part No. Caution: The liner puller must be installed and used as described to avoid damage to the cylinder block. The puller plate must be parallel to the main bearing saddles and must not overlap the liner outside diameter.
Remove the liners with universal liner puller, Part No. The liner puller must be centered on the top of the cylinder block to prevent damage to the cylinder block. Turn the puller jackscrew clockwise to loosen the liner from the cylinder block.
Use both hands to remove the liners. Section 0 - Engine Disassembly and Assembly - Group 00 M11 When the liner is removed from the cylinder block, use DykemW or equivalent, to place a mark on the camshaft side of the liner to show liner orientation.
Pistons and Connecting Rods - Disassembly Caution: The piston pin can fall from the piston assembly when the retainer snap rings are removed. The piston and pin can be damaged.
Use internal snap ring pliers to remove the retainer snap rings from both sides of the piston. Caution: Do not use a hammer to remove the piston pins. The piston can be distorted and damaged. Use care to prevent damage to the piston. Mark the cylinder number the piston, crown, skirt, and pin was removed from on the parts to make sure they are installed in the correct cylinder if they are used again.
Use a hoist and engine lifting sling, Part No. Install the exhaust side of the cylinder block to the adapter plate of the rebuild stand.
Align the top of the adapter plate 3 with the top row of water header plate mounting capscrew holes 4. Remove the guide pins and install two capscrews, Part No. Cylinder Liners - Installation The current o-ring has been produced by two distinctly different manufacturing processes. Following are those two methods and the installation procedures.
The edges are rounded. It does not require specific care in orientation of the o-ring other than normal prevention of rolling the o-ring. This o-ring must be installed with the straight side facing the block, and the chamfered side next to the liner. If the o-ring is not installed this way, liner bore distortion can occur. Make sure the cylinder block and all parts are clean before assembly.
Caution: The liners must be installed within 30 seconds after being lubricated with oil. If the liners are not installed within this time limit, the o-rings will swell and be damaged when the liner is installed.
Use clean 15W oil to coat the liner o-ring seals. Install the o-ring seal on the liner. Install the liner into the cylinder block. When acceptable reused liners are installed, rotate the liner 90 degrees from their original position in the engine. The thrust and anti-thrust surfaces must face the front and back of the cylinder block.
Use the cylinder liner driver, Part No. If the liner does not seat properly, remove the liner. Inspect the counterbore seat and liner for nicks, burrs, or dirt. Install the liner again. Use cylinder liner clamping tool, Part No. Place the force plate 3 across the top of the liner with the step inside the liner bore. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Put the installation tool bridge 1 across the liner and install the two cylinder head capscrews finger tight to hold the bridge down.
Rotate the force plate until the areas where the protrusion measurements will be taken are exposed. Caution: Do not use an impact wrench to tighten the liner force plate screw. Excessive torque will cause damage to the liner installation tool. Tighten the forcing screw 2. Use a depth gauge, Part No. If the liner protrusion still does not meet the specifications, use counterbore ledge tool, Part No.
Use a feeler gauge to measure the liner to block clearance at the four block casting points. Cylinder Liner to Block Clearance mm in 0. The bore must not be more than 0. NOTE: The cylinder block can be distorted when mounted on the engine rebuild stand. If the liner bore does not meet the specifications, remove the engine from the engine rebuild stand and set it on a clean flat surface. Measure the liner bore out-of-roundness again. If the liner bore is more than 0.
NOTE: The block counterbore diameters above and below the cylinder block counterbore area are not critical dimensions and do not need to be measured. A mm in. B mm in. Measure the liner outside diameter C. C mm in. Inspect the liner bore A and measure the protrusion B again. Replace the liner if it does not meet the specifications.
Each must be installed in the correct location to prevent engine damage. If used bearing shells are to be installed, each must be installed in its original location in the engine. The bearing journal numbers should have been marked in the bearing tangs during disassembly. Caution: The tang 1 on the bearing shell must be in the slot 2 of the bearing saddle to correctly position the bearing and prevent engine damage.
Install the upper main bearing shells. Crankshaft - Installation The component weighs 23 kg [50 lb] or more. Use a hoist and nylon lifting sling, Part No. Do not damage or move the bearing shells when the crankshaft is installed. Install the crankshaft. NOTE: 0. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Push the crankshaft toward the rear of the engine to install the rear thrust bearing, and to the front to install the front thrust bearing.
The grooves in the thrust bearings must be installed toward the crankshaft to prevent damage to the crankshaft and cylinder block during engine operation. Install the lower main bearing shells with the tang 1 in the slot 2 of the main bearing cap. Use LubriplateW , or equivalent, to coat the inside diameter of the bearing shells. Use LubriplateW , or equivalent, to coat the lower thrust bearings. Caution: The grooves of the thrust bearing must be facing out from the bearing cap to prevent damage to the crankshaft and cylinder block during engine operation.
The locating dowels must not protrude above the thrust bearing surface. Use clean 15W oil to coat the main bearing capscrew threads and on both sides of the washers. Drain the excess oil from the capscrews before installing them in the cylinder block to prevent hydraulic lock and possible engine damage during engine operation. Install the main bearing caps, capscrews and washers. Caution: Do not hit the main bearing caps with a hammer. The main bearing cap and bearings can be damaged.
If the dowel pins and main bearing cap are not in alignment, the cylinder block and main bearing cap will be damaged when the capscrews are tightened. Caution: Do not use an impact wrench to tighten the capscrews; the capscrews must be tightened alternately and evenly in specific steps to the correct torque values to prevent damage to the cylinder block, main bearing caps and crankshaft. Use your hands to turn the crankshaft. If it does not turn freely, loosen the main bearing capscrews one at a time to locate the bearing that is too tight.
If a tight bearing is found, remove the cap and bearing. Check for dirt, dings and proper fit. Replace the bearing if necessary. Use dial indicator, Part No. If nicks or burrs cannot be removed with fine crocus cloth, the cap and bearings must be replaced. Measure the thrust bearing thickness and replace the bearings if they are not within specifications.
Crankshaft Thrust Bearing Thickness mm in 4. Compress the spring to Install the valve disc 4 , washer 3 and regulator spring 2.
Use plug driver, Part No. Measure the retainer plug depth in the cylinder block. Relief Valve Retainer Installed Depth mm in 8. Viscosity Sensor - Installation Install the viscosity sensor in the cylinder block. Regulator Spring Free Length mm in Use a spring compression tester to determine if the spring is defective. Replace the spring with a new spring if it is defective. Warning: The regulator spring must be compressed to install the retainer plug 1.
NOTE: A counterbore plunger and orifice is unique to engines with a viscosity sensor. Low oil pressure will result if a solid plunger is used with a viscosity sensor. Install the plunger 3 and spring 2. Install and tighten the retainer plug 1.
Flywheel Housing - Installation Measure the inside diameter of the housing bore to determine the SAE number and size of the housing being used. Flywheel Housing Maximum Bore I. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rotate the engine on the rebuild stand to position the cylinder head mounting surface facing up. Install the flywheel housing over the guide pins. Install the ten capscrews M Remove the guide pins and install the remaining two capscrews M NOTE: This is not the final torque value.
The flywheel housing bore must be aligned with the crankshaft. The capscrews will be tightened to the final torque value after the flywheel housing is aligned. This component weighs 23 kg [50 lb] or more.
Install the five of the seven long capscrews M Remove the two guide pins and install the two remaining M Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the four alignment plate capscrews and the alignment plate.
ST, must be spaced out from the flywheel and longer mounting capscrews used. An alternative method is to use a magnetic base with the dial indicator gauge. Use dial indicator gauge, Part No. ST, 2 to measure the bore alignment. Install the attachment and gauge as shown. Install the engine barring tool, Part No. Rotate the crankshaft one complete revolution degrees and record the TIR.
If the maximum bore alignment does not meet the specifications, use a mallet to move the housing in the necessary direction. NOTE: If the bore alignment is not within specifications and the bore is not round, the housing must be replaced.
Flywheel Housing Face Alignment - Measurement Caution: If the tip of the gauge enters the capscrew holes, the gauge will be damaged. Position the contact tip of the gauge against the flywheel housing face. Push the crankshaft toward the front of the engine. Rotate the crankshaft one complete revolution degrees while keeping the crankshaft end thrust pushed forward, and record the TIR. If the maximum face alignment does not meet the specifications, check for nicks, burrs and foreign material between the cylinder block mounting face and the flywheel housing mounting surface.
If none is found, the housing must be replaced. If it does not meet these specifications, the bore and face must be realigned. Measure the bore and face alignment again. NOTE: If the bore and face alignment does not meet the specification, loosen the housing capscrews, tighten the capscrews again, and measure the bore and face alignment again.
Remove the barring tool and flywheel housing alignment measuring tool from the crankshaft. Apply LubriplateW , or equivalent, on the outer races and the bearings. NOTE: The outer bearing races of new replacement gears are already pressed into the gear. Install the bearing and spacer into the idler gear.
Use the manufactured sleeve to hold the bearing assembly together when installing the idler gear assembly. Apply a thin film of LubriplateW , or equivalent, into the idler shaft bore of the housing and on the idler shaft. Install the idler gear assembly into the flywheel housing. Hold the idler gear and bearings in place and remove the plastic sleeve. Caution: Do not use a hammer when installing the idler shaft and capscrew, or the part can be damaged.
Hold the gear assembly in place and insert the idler shaft through the housing and idler gear bearings. If the gear does not turn freely, it can indicate misalignment between the bore and the shaft.
Remove the idler shaft and install it again. Apply LubriplateW under the head of the idler shaft capscrew. Insert the capscrew through the idler shaft.
Tighten the installation capscrew to draw the shaft into the bore. After the idler shaft has been seated, remove the capscrew. Apply pipe sealant, Part No. Apply LubriplateW under the head of the capscrew. Install the capscrew and tighten to its final torque value. NOTE: New cup plugs must be used. Do not use the cup plugs that were removed from the housing.
Apply a film of cup plug sealant, Part No. Use driver, Part No. Make sure the crankshaft and crankshaft gear are clean. Install the crankshaft gear on the guide pins. Use flat washers as a spacer and install the gear with two capscrews M Mount the gauge so the tip of the gauge is reading at the outmost edge of the output shaft. The oil seal must be installed with the lip of the seal and the crankshaft clean and dry to provide a proper oil sealing surface.
Use the installation sleeve provided with the seal to install the seal and gasket on the crankshaft. Install clamping ring using the 12 capscrews M Tighten in a star pattern. Torque Value:. Place a light film of oil or anti-freeze on the inside diameter of the dust seal. Install the dust seal on the crankshaft with the larger outside diameter facing toward the engine.
Push the dust seal back by hand on the crankshaft until the entire dust seal contacts the oil seal case. Flywheel - Installation Install one guide pin, Part No. The crankshaft flange must be clean and free of damage. Install the flywheel on the guide pin. Caution: Capscrew length is critical. Capscrews of different length can result in loss of flywheel integrity that can cause engine damager and personal injury. Tighten the capscrews in a star pattern.
ST, to check the flywheel bore 3 and face 4 runout. Install the attachment to the flywheel housing. Install the gauge on the attachment. Install the contact tip of the indicator against the inside diameter of the flywheel bore. The maximum TIR must not exceed 0.
We'll assume you're ok with this, but you can opt-out if you wish. Accept Reject Read More. Close Privacy Overview This website uses cookies to improve your experience while you navigate through the website.
Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent.
You also have the option to opt-out of these cookies. But opting out of some of these cookies may affect your browsing experience. Necessary Necessary. Necessary cookies are absolutely essential for the website to function properly. This category only includes cookies that ensures basic functionalities and security features of the website. These cookies do not store any personal information.
Non-necessary Non-necessary. Any cookies that may not be particularly necessary for the website to function and is used specifically to collect user personal data via analytics, ads, other embedded contents are termed as non-necessary cookies.
0コメント