Usage:
PREPARING TO REMOVE RADIATOR AND RADIATOR GUARD
1-Pre-cleaner. 2-Muffler and exhaust pipe extension. 3-Hood. 4-Safety lock. 5-Side guard.
1. Remove pre-cleaner (1), muffler and exhaust pipe extension (2), hood (3), and side guard (5).
2. Raise bucket and secure with safety lock (4).
3. Drain coolant from radiator.
4. Remove crankcase front guard (15).
PREPARING TO REMOVE RADIATOR AND RADIATOR GUARD
6-Bolts (elbow to top tank). 7-Water pressure sensing line. 8-Fan guard.
5. Disconnect water pressure sensing line (7).
6. Remove elbow-to-top tank bolts (6).
7. Remove fan guard (8).
8. Remove the three elbow-to-bottom tank bolts (10).
PREPARING TO REMOVE RADIATOR AND RADIATOR GUARD
9-Elbow. 10-Bolts (three). 11-Radiator bottom tank.
PREPARING TO REMOVE RADIATOR AND RADIATOR GUARD
12-Guard. 13-Bolts (six). 14-Bolts. 15-Crankcase front guard.
9. Remove the nine radiator guard-to-loader frame bolts (13) and (14).
LIFTING RADIATOR AND RADIATOR GUARD AS A UNIT
16-Forged eyebolts (3/8" - 16 NC).
10. Install forged eyebolts (16) in radiator top tank. Work radiator and guard assembly forward and lift out.
Remove Radiator
The radiator can be removed without removing the radiator guard assembly from the machine.
Separate the radiator-to-engine connections as for radiator guard assembly removal.
PREPARING TO REMOVE RADIATOR
1-Radiator top tank. 2-Shield retaining bolts.
Remove the shield retaining bolts (2).
Remove the bolt at each corner of the top tank (1).
PREPARING TO REMOVE RADIATOR
3-Bolts (four - two on each side).
Remove the four clamp bolts (3).
Remove the front guard (4) for access to remove the lower baffle assembly. Install two 3/8" - 16 NC forged eyebolts in top tank.
PREPARING TO REMOVE RADIATOR
4-Front guard.
Lift the radiator core from the guard assembly.
Remove Engine
preparatory steps:
a) Remove exhaust extension, precleaner, muffler and hood.
b) Remove radiator and radiator guard.
PREPARING TO REMOVE ENGINE
1-Junction box. 2-Fuel pressure line. 3-Governor control linkage. 4-Starter cable. 5-Starter ground cable. 6-Fuel supply line.
1. Remove junction box (1) cover and disconnect electrical wires.
2. Disconnect fuel pressure line (2).
3. Disconnect governor control linkage (3).
4. Disconnect starter cable (4) at solenoid and remove ground cable (5).
5. Disconnect fuel supply line (6) at accessory drive housing.
PREPARING TO REMOVE ENGINE
7-Water pressure sensing line. 8-Water temperature sensing unit. 9-Front support mounting bolt. 10-Torque converter oil cooler lines.
6. Remove water pressure sensing line (7) clamp bolts to separate line from engine.
7. Remove water temperature sensing unit (8) and separate line from engine.
8. Remove torque converter oil cooler lines (10).
9. Remove front support bolts (9), (one at each end of the front support.)
PREPARING TO REMOVE ENGINE
11-Air cleaner service indicator sensing line. 12-Rear support mounting bolt. 13-Flexible drive coupling to torque converter driving flange retaining bolts (eight).
10. Disconnect air cleaner service indicator sensing line (11).
11. Remove the two rear support mounting bolts (12) (one at each side of the flywheel housing).
12. Remove the coupling-to-converter flange retaining bolts (13).
LIFTING ENGINE FROM FRAME
13. Make sure all disconnections have been made.
14. Attach a lifting device to lifting eyes in top of cylinder head. Move engine upward and forward carefully - weight, 2400 lbs. (1089 kg).
Install Engine
Install and connect components removed or disconnected in Steps 1 thru 10.
Remove Water Pump
WATER PUMP REMOVAL
1-Water pump vent line. 2-Water bypass line. 3-Clamp. 4-Clamp. 5-Clamp. 6-Hose. 7 -Oil cooler bonnet. 8-Mounting bolts.
1. Drain the engine cooling system - capacity 12 U.S. Gal. (45 liters).
2. Remove the water pump vent line (1) and water bypass line (2).
3. Loosen hose clamp (3). Loosen water outlet hose clamps (4 and 5), and slide the hose (6) onto the engine oil cooler bonnet (7).
4. Remove the four water pump mounting bolts (8) and remove the water pump.
Install Water Pump
WATER PUMP INSTALLATION
1. Position the water pump on engine, and install the four mounting bolts.
2. Position the water outlet hose, and tighten the two hose clamps.
3. Tighten water pump water inlet hose clamp.
4. Install water pump water bypass line. Install vent line.
5. Fill the engine cooling system.
Disassemble Water Pump
WATER PUMP (EXPLODED VIEW)
1-Cover. 2-Bolt. 3-Washer. 4-Impeller. 5 -Seal assembly. 6-Housing. 7-Shaft. 8-Seal. 9 -Gear. 10-Bearings. 11-Washer. 12-Bolt. 13 -Cover. 14-Key 15-Spacer.
preparatory step:
a) Remove water pump
WATER PUMP
13-Bearing assembly cover.
1. Remove the cover (13).
REMOVING IMPELLER
2-Bolt. 4-Impeller.
2. Back the impeller retaining bolt (2) out approximately .25 in. (6,0 mm). Strike the retaining bolt with a soft hammer to separate the impeller (4) from the shaft (7). Remove the retaining bolt (2), washer (3), and impeller (4).
3. Remove the seal and ring from the impeller.
BEARING DISASSEMBLY
12-Bearing assembly retaining bolt.
4. Remove the bearing assembly retaining bolt (12) and washer (11).
5. Using a hammer and soft punch, drive the shaft (7) and seal assembly (5) out the impeller end of the water pump housing (6).
6. Remove the water pump drive gear (9) from housing (6).
BEARINGS REMOVED FROM WATER PUMP HOUSING
6-Housing. 8-Seal. 10-Bearings. 15 -Spacer.
7. Remove the bearings (10) and spacer (15) from the housing (6).
8. Remove the lip-type seal (8) from the housing (6).
Assemble Water Pump
1. Install the lip-type seal in water pump housing with the lip of seal toward bearing end of housing. Lubricate the lip of seal with clean SAE 30 engine oil.
2. Position the drive gear in housing, and install the shaft with key on shaft aligned with slot in drive gear.
3. Lubricate the bearing assemblies with clean SAE 30 engine oil. Install the bearing assemblies and spacer in the pump housing. Install the retaining bolt and washer.
4. Install the bearing assembly cover.
INSTALLING LIP-TYPE SEAL
A-8S8069 Seal Installer.
5. Using seal installer (A), install the seal assembly (4) in housing.
INSTALLING SEAL AND RING
2-Seal. 3-Ring. 4-Seal Assembly.
6. Install the seal (2) and ring (3) in the impeller (5) with the polished surface of ring toward the seal assembly (4).
INSTALLING IMPELLER
1-Bolt. 5-Impeller. 6-Cover.
7. Position the impeller (5) on shaft, and install retaining bolt (1) and washer. Tighten bolt (1) to 28 ± 1 lb. ft. (3,9 ± 0,14 mkg).
TIGHTENING IMPELLER
1-Impeller retaining bolt.
8. Install the water pump water inlet cover (6).
concluding step:
a) install water pump
Remove Fuel Transfer Pump
REMOVING FUEL TRANSFER PUMP
1-Bolt (two). 2-Bolt (two). 3-Service Meter.
1. Remove two mounting bolts (2) and remove Service Meter (3).
2. Remove 2 mounting bolts (1) and remove the fuel transfer pump.
Install Fuel Transfer Pump
1. Place a new gasket and seal on the fuel transfer pump and install the pump.
2. Install the Service Meter (3).
Disassemble Fuel Transfer Pump
FUEL TRANSFER PUMP (EXPLODED VIEW)
1-Bearing. 2-O-ring seal. 3-Ring. 4-O-ring seal. 5-Seal. 6-Seal. 7-Cage assembly. 8-Bearing. 9-Gear. 10-Nut. 11-Gasket. 12-Seal. 13-Screw. 14-Cover. 15-Dowel. 16-Shaft assembly. 17-Key. 18-Bolt. 19-Adapter. 20-O-ring seal. 21-Screw. 22-Gear. 23-Shaft. 24-Plunger. 25-Spring. 26-O-ring seal. 27-Bolt. 28-Body.
preparatory steps:
a) remove fuel transfer pump
FUEL TRANSFER PUMP DISASSEMBLY
2-O-ring seal. 4-O-ring seal. 7-Cage assembly. 9-Gear. 10-Nut. 16-Shaft assembly. 17-Key. 28-Pump body.
1. Remove the gear retaining nut (10), gear (9), and woodruff key (17).
2. Remove the cage assembly (7).
3. Remove the O-ring seals (2 and 4) from the cage assembly.
SEAL AND BEARING REMOVAL
7-Cage assembly. A-1P529 Handle, 1P528 Extension Tube, 1P457 Drive Plate and 1P454 Drive Plate.
4. Using tool (A), remove the bearing (1) and lip-type seals (5 and 6) from cage.
5. Separate the cover assembly (14) and pump body (28).
| NOTICE |
|---|
Be careful not to damage mating surfaces of cover assembly and pump body. |
6. Remove the lip-type seal (12) from the cover assembly.
7. Remove the gear (22) and gear and shaft assembly (16) from pump body.
BEARING REMOVAL
28-Pump body. B-1P529 Handle, 1P459 Drive Plate and 1P454 Drive Plate.
8. Using tool (B), remove the bearing (1) from pump body (28).
Assemble Fuel Transfer Pump
1. Clean all parts thoroughly before assembling pump.
2. Using tool (A), install the bearing (1) in pump body (28).
3. Position the gear (22) and gear and shaft assembly (16) in body (28).
4. Using the 1P529 Handle, 1P454 Drive Plate and 1P459 Drive Plate, install seal (12) in cover assembly (14) with the lip of the seal facing in.
5. Apply a thin film of 8S6747 Liquid Gasket Material to face of body assembly.
| NOTICE |
|---|
Do not allow gasket material to enter pump. |
BEARING INSTALLATION
28-Pump body. A-Tool (1P529 Handle, 1P459 Drive Plate and 1P454 Drive Plate).
6. Install the cover assembly on pump body.
NOTE: After tightening cover assembly retaining bolts, the gear and shaft assembly must rotate freely.
SEAL INSTALLATION
7-Cage assembly. B-Tool (1P529 Handle, 1P454 Drive Plate and 1P462 Drive Plate).
7. Using tool (B), install the seals (5 and 6) in the cage (7). Install the inner seal with lip of seal toward pump drive gear. Install the outer seal with lip toward pump body.
BEARING INSTALLATION
7-Cage assembly. 8-Bearing. A-Tool.
8. Using tool (A), install the bearing (8) in the cage assembly (7).
9. Install the O-ring seals (2 and 4) on cage assembly.
10. Lubricate the O-ring seals and lip-type seals with clean SAE 30 engine oil.
11. Position the cage assembly on the gear and shaft assembly (16).
12. Install the woodruff key (17), gear (9), and retaining nut (10). Tighten the retaining nut to 22 ± 5 lb. ft. (3, 0 ± 0,7 mkg).
concluding steps:
a) install fuel transfer pump
Remove Fuel Injection Pump Housing And Governor As A Unit
1. Disconnect governor control linkage (4) from the governor.
2. Remove the turbocharger oil supply line (2) and oil drain line (1).
3. Remove breather and fumes disposal tube (8).
4. Remove all the fuel injection lines (3). Plug or cap all fuel lines and openings.
5. Remove the fuel injection pump housing-to-accessory drive housing mounting bolts (5).
7. Loosen the bracket-to-block retaining bolts (7).
8. Move the fuel injection pump housing and governor forward off the dowels and lift.
PREPARING TO REMOVE FUEL INJECTION PUMP HOUSING AND GOVERNOR
1-Turbocharger oil drain line. 2-Turbocharger oil supply line. 3-Fuel injection lines (four). 4-Governor control linkage. 5-Fuel pump housing mounting bolts. 6-Bolts, fuel pump housing to bracket. 7-Bolts, bracket to block. 8-Fumes disposal tube.
Install Fuel Injection Pump Housing And Governor As A Unit
1. Locate top dead center compression stroke for No. 1 piston. (See LOCATING TOP DEAD CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING).
2. Position the fuel injection pump housing and governor on the engine, and install and tighten all mounting bolts. Tighten the bracket-to-block retaining bolts (7) last.
3. Remove all caps and plugs from lines and openings. Install the fuel injection lines. Tighten fuel injection line retaining nuts to 30 ± 5 lb. ft. (4,1 ± 0,7 mkg).
4. Install the turbocharger oil supply line (2) and the oil drain line (1). Connect control linkage (4) to the governor.
Disassemble Fuel Injection Pump Housing
FUEL INJECTION PUMP HOUSING COMPONENTS (EXPLODED VIEW)
1-Bonnet. 2-Nut. 3-Spring. 4-Washer. 5-Check valve. 6-Bushing. 7-Barrel. 8-Seal. 9-Ring. 10-Spring. 11-Plunger. 12-Plunger and barrel assembly. 13-Washer. 14-Spacer. 15-Lifter. 16-Fuel pump housing. 17-Rack. 18-Bearing. 19-Bearing. 20-Bearing. 21-Fuel pump camshaft. 22-Bolt. 23-Lock. 24-Plate. 25-Spring. 26-Gear. 27-Bearing.
1. Remove each fuel injection pump as follows:
a) Remove the felt washer (4).
REMOVING FUEL PUMP RETAINER
16-Fuel injection pump housing. 17-Rack. 26-Fuel pump camshaft gear. A-8S4613 Wrench.
b) Install wrench (A) and loosen retaining bushing (6) in housing.
REMOVING FUEL PUMP ASSEMBLY
12-Plunger and barrel assembly. B-8S2244 Extractor.
c) Install extractor (B) before removing wrench (A).
d) Lift the retainer (6) with wrench (A).
e) Remove the seal (8).
f) Lift the fuel injection pump out of the housing with extractor (B).
g) Remove the spacer (14). Keep the spacer and pump together, and identified as to location in the fuel injection pump housing.
2. Disassemble the fuel injection pumps as follows:
a) Remove the bonnet (1), ring (9), spring (3), and check valve (5) from the barrel (7).
b) Remove the plunger assembly (11), washer (13), and spring (10) from the barrel (7).
| NOTICE |
|---|
While disassembling and assembling fuel injection pumps, exercise considerable care to prevent damage to plunger surfaces. The barrel and plunger assemblies are matched, and the individual parts are not interchangeable with other barrels or plunger assemblies. |
3. Remove the rack (17) from housing (16).
4. Remove the lifters (15). Keep the lifters identified and together with their respective pumps and spacers.
REMOVING CAMSHAFT RETAINER
24-Plate. 25-Spring. 26-Gear.
5. Remove bolt (22), lock (23) and retaining plate (24).
6. Remove spring (25).
REMOVING CAMSHAFT GEAR
21-Fuel injection pump camshaft. 26-Gear assembly.
7. Remove gear assembly (26) from camshaft.
8. Remove the camshaft (21).
9. Using tool (C), remove the camshaft bearings (20 and 27) from the fuel injection pump housing.
10. Remove the two rack bearings (18 and 19) from the fuel injection pump housing.
REMOVING CAMSHAFT
21-Fuel injection pump camshaft.
REMOVING CAMSHAFT BEARINGS
18-Rack bearing. C-8S2241 Camshaft Bearing Installation and Removal Tool Group.
Assemble Fuel Injection Pump Housing
INSTALLING CAMSHAFT BEARINGS
C-8S2241 Camshaft Bearing Installation and Removal Group.
1. Using tool group (C), install the camshaft bearings (20 and 27) in the fuel injection pump housing. Install the bearing in governor end of housing so that the oil hole in bearing is aligned with oil hole in housing. Install the camshaft bearings flush with their respective ends of fuel injection pump housing.
INSTALLING RACK BEARINGS
D-Tool (1P529 Handle, 1P460 Drive Plate and 1P455 Drive Plate).
2. Using tool (D), install the two rack bearings in the fuel injection pump housing. Install the bearing (18) in governor end of housing, so it will be recessed .195 ± .005 in. (4,953 ± 0,127 mm) from face of housing. Install the rack bearing (19) in accessory drive end of housing so it will be flush with face of fuel injection pump housing.
3. Lubricate the camshaft (21) with clean SAE 30 engine oil. Install the camshaft in fuel injection pump housing (16).
INSTALLING CAMSHAFT
21-Fuel injection pump camshaft.
INSTALLING CAMSHAFT GEAR AND RETAINER
24-Plate. 25-Spring. 26-Gear.
4. Position the governor drive gear (26) and spring (25) on the camshaft (21). Install the camshaft retaining plate (24), bolt (22) and lock (23).
INSTALLING LIFTER
15-Lifter.
5. Install the lifters (15) in their respective positions in housing. Lubricate the rack generously with clean fuel oil. Install the rack (17) in fuel injection pump housing with the slot in rack toward the governor end of housing.
INSTALLING RACK
17-Rack.
6. Install the spacers (14) in their respective positions in housing. If new lifters and pumps are to be installed, it will be necessary to set the fuel pump timing dimension. See FUEL INJECTIONG PUMP TIMING DIMENSION SETTING - OFF ENGINE in TESTING AND ADJUSTING.
7. Assemble each fuel injection pump as follows:
a) Lubricate all parts generously with clean fuel oil.
b) Install the spring (10), washer (13), and plunger (11) in the barrel.
c) Install the spring (3), check valve (5), bonnet (1) and ring (9) on the barrel.
| NOTICE |
|---|
Do not attempt to install fuel injection pumps until the rack has been centered. |
8. Using tool (E), center the rack as follows:
a) Install locating fixture (28) on the fuel injection pump housing (16).
b) Install the rack setting gauge (29). Set the gauge at zero. Push the rack (17) against the gauge.
c) Install the clamp (30) on pump housing as illustrated. This will keep the rack centered while installing the fuel injection pumps.
CENTERING RACK
28-Locating fixture. 29-7S7113 Rack Setting Gauge.
CENTERING THE RACK
30-Clamp.
9. With the rack centered, install the fuel injection pumps as follows:
a) Rotate the camshaft until lobe of camshaft is down for pump to be installed.
b) Install the extractor (B) on the pump.
c) Sight down the pump, and align the notches in bonnet (1) and barrel (7) with the slot in pump gear segment (13). The slot should be in line with the center of these notches. Position the pump so the notches align with the guide pins in housing bore. Install the pump in its respective position in housing.
CHECKING FUEL PUMP INSTALLATION
7-Barrel. 11-Pump plunger gear segment. B-8S2244 Extractor.
INSTALLING FUEL PUMP RETAINER
6-Retaining bushing.
d) Install the seal (8) and retaining bushing (6). Apply a downward force to extractor (B), and tighten the bushing by hand (finger tight only) until the bushing is flush with top of housing. If the bushing cannot be installed this far by hand, remove it. Remove pump, realign components, and install again.
| NOTICE |
|---|
Do not force bushing flush with face of pump housing by using a wrench. If pump has been properly installed, bushing can be finger tightened flush with face of pump housing. |
CHECKING RACK TRAVEL
29-Rack setting gauge. 30-Clamp.
e) After each pump has been installed, check the rack travel in the following manner. Swing the clamp (30) away from the end of rack Using rack setting gauge (29), check rack travel. If the pump gear has been installed correctly with respect to the rack, total rack travel should be approximately .800 in. (20,32 mm). If total rack travel cannot be obtained, remove the pump, realign components, and re-install pump.
INSTALLING FUEL PUMP RETAINER
A-8S4613 Wrench.
f) Remove the extractor (B) and tool (E). Install wrench (A), and tighten retaining bushing (6) to 150 ± 10 lb. ft. (20,7 ± 1,4 mkg). Remove wrench (A). Install the felt washers and protective caps.
concluding steps:
a) connect governor to fuel injection pump housing
b) install fuel injection pump housing and governor as a unit
c) adjust governor and set rack (See GOVERNOR ADJUSTMENTS and FUEL RACK SETTING in TESTING AND ADJUSTING.
Separate Governor From Fuel Injection Pump Housing
GOVERNOR (TYPICAL EXAMPLE) (EXPLODED VIEW)
1-Cover assembly. 2-Low idle screw. 3-High idle screw. 4-Cover. 5-Plug. 6-Spring. 7-Plunger. 8-Bolt. 9-Guide. 10-Lever assembly. 11-Nut. 12-Screw. 13-Collar. 14-Screw. 15-Collar. 16-Spring. 17-Shaft. 18-Bearing. 19-Seal. 20-Pin. 21-Bearing races. 22-Weight assembly. 23-Seat assembly. 24-Spring. 25-Washer-type spring. 26-Seat. 27-Bolt. 28-Washer. 29-Spring. 30-Sleeve. 31-Bearing. 32-Retaining ring. 33-Retaining ring. 34-Bolt. 35-Cylinder. 36-Piston assembly. 37-Sleeve. 38-Seal.
preparatory step:
a) remove fuel injection pump housing and governor as a unit.
PREPARING TO DISASSEMBLE GOVERNOR
1-Idle screw cover. 4-Idle screw housing. 39-Decelerator return spring (not used on 955K).
1. Remove the idle screw cover.
2. Remove the idle screw housing.
REMOVING RACK STOP COLLAR
13-Rack stop collar. 14-Retaining screw. 15-Collar. 16-Spring. 40-Bolts.
4. Remove the rack stop collar retaining screw (14).
5. Remove the rack stop collar (13), collar (15), and spring (16).
6. Remove the governor-to-fuel injection pump housing mounting bolts (40).
PREPARING TO REMOVE GOVERNOR WEIGHT ASSEMBLY
22-Weight assembly. 23-Seat assembly. 24-Governor spring. 25-Washer-type spring. 34-Retaining bolts.
7. Remove the governor housing.
8. Remove the governor spring (24), seat assembly (23), and washer-type spring (25).
9. Remove the three mounting bolts (34) and lock that secure the cylinder and weight assemblies (22) to the fuel injection pump housing.
10. Pull the cylinder (35) and weight assemblies (22) straight out to clear locating dowels.
GOVERNOR WEIGHT ASSEMBLY REMOVED
41-Rack.
11. Slide the cylinder and weight assemblies sideways to disengage slot in piston from the rack (41).
Connect Governor To Fuel Injection Pump Housing
GOVERNOR WEIGHT ASSEMBLY REMOVED
22-Cylinder and weight assemblies. 41-Rack.
1. Position the cylinder (35) and weight assemblies (22) on the fuel injection pump housing so slot in piston is engaged with the rack (41).
2. Push the cylinder and weight assemblies onto the locating dowels.
INSTALLING GOVERNOR WEIGHT ASSEMBLY
23-Seat assembly. 24-Governor spring. 25-Washer-type spring. 27-Bolt. 34-Retaining bolts (three).
3. Install the three mounting bolts (34) and lock.
4. Install the washer-type spring (25), seat assembly (23), and governor spring (24) on the cylinder assembly (35). The washer-type spring (25) should be installed so the inside diameter of spring will contact the guide (9) in governor housing.
5. Position the governor housing on the fuel injection pump housing, and install the governor mounting bolts.
INSTALLING GOVERNOR STOP COLLAR
13-Rack stop collar. 14-Retaining screw. 15-Collar. 16-Spring. 40-Bolts.
6. Install the spring (16), collar (15), and rack stop collar (13) on bolt (27).
7. Install and tighten the rack stop collar retaining screw (14).
INSTALLING LOW IDLE SCREW HOUSING
4-Idle screw housing. 13-Rack stop collar.
8. Position the idle screw housing (4) on the governor so dowel in housing engages slot in rack stop collar (13).
concluding steps:
a) install fuel injection pump housing and governor as a unit
b) set the rack and adjust governor (See FUEL RACK SETTING AND GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING)
Disassemble Governor
preparatory step:
a) separate governor from fuel injection pump housing
GOVERNOR WEIGHT ASSEMBLY REMOVAL
20-Pin and ring.
1. Remove the seat (26) and, retaining ring and pin (20).
SEAT AND BEARING DISASSEMBLED
26-Seat. 27-Bolt. 28-Washers. 29-Spring.
2. Remove the seat (26), bolt (27), washers (28), and spring (29).
3. Remove the sleeve (30) and bearing (31) assembly from the cylinder and weight assemblies.
DISASSEMBLED BEARING ASSEMBLY
21-Bearing races. 30-Sleeve. 31-Bearing. 32-Retaining ring.
4. Remove the retaining ring (32) from sleeve.
5. Remove bearing (31) and races (21) from sleeve.
DISASSEMBLING GOVERNOR WEIGHT ASSEMBLY
22-Weight assembly. 33-Retaining ring. 35-Cylinder 36-Piston. 37-Sleeve. 42-Valve.
6. Remove the valve (42) from piston (36).
7. Remove the cylinder-to-weight assembly retaining ring (33).
8. Remove the weight assembly (22).
9. Remove piston (36) and sleeve (37) from the cylinder (35).
10. Remove the O-ring seal (38) from the sleeve (37).
REMOVING SPEED LIMITER VALVE
2-Low idle screw. 3-High idle screw. 5-Speed limiter plug. 6-Spring. 7-Plunger.
11. Remove the speed limiter plug (5), spring (6), and plunger (7) from the governor housing.
12. Remove the high idle screw (3) and low idle screw (2).
13. Remove the governor control lever and stop clamp.
14. Remove the ring (43).
15. Remove the plate assemblies (44 and 45) rollers (46) and spring from the ring (43).
REMOVING GOVERNOR CONTROL LEVER ASSEMBLY
17-Shaft. *43-Ring. *Plate assembly. *Plate assembly. *Rollers. *Not shown in exploded view.
16. Remove the lip-type seal (19) from ring (43).
17. Remove shaft assembly (17) from governor housing.
REMOVING LEVER ASSEMBLY
8-Retaining bolt and lock. 10-Lever assembly.
18. Remove the lever assembly-to-shaft assembly retaining bolt (8) and lock.
19. Remove the shaft assembly and lever assembly (10) from governor housing.
GOVERNOR (TYPICAL EXAMPLE) (EXPLODED VIEW)
1-Cover assembly. 2-Low idle screw. 3-High idle screw. 4-Cover. 5-Plug. 6-Spring. 7-Plunger. 8-Bolt. 9-Guide. 10-Lever assembly. 11-Nut. 12-Screw. 13-Collar. 14-Screw. 15-Collar. 16-Spring. 17-Shaft. 18-Bearing. 19-Seal. 20-Pin. 21-Bearing races. 22-Weight assembly. 23-Seat assembly. 24-Spring. 25-Washer-type spring. 26-Seat. 27-Bolt. 28-Washer. 29-Spring. 30-Sleeve. 31-Bearing. 32-Retaining ring. 33-Retaining ring. 34-Bolt. 35-Cylinder. 36-Piston assembly. 37-Sleeve. 38-Seal.
Assemble Governor
1. Position the lever assembly (10) and shaft assembly (17) in the governor housing. Install the retaining bolt and lock.
2. Using tool setup (A), install the seal in ring (43) with lip of seal toward the governor. Lubricate lip of seal with clean SAE 30 engine oil.
SEAL INSTALLATION
43-Ring. A-1P470 Drive Plate, 1P461 Drive Plate and 1P529 Handle.
GOVERNOR CONTROL RING ASSEMBLY
43-Ring. 44-Plate. 45-Plate. 46-Rollers. 47-Springs. 48-Spring.
3. Install spring (48) in slot in plate assembly (44). Install the plate assembly in ring (43). Install springs (47) in plate assembly (45). Position the plate assembly in ring on top of plate assembly (44) and install rollers (46).
INSTALLING GOVERNOR CONTROL RING ASSEMBLY
17-Shaft. 43-Ring.
4. Install shaft assembly (17) in governor. Install ring assembly (43).
SEAL INSTALLATION
B-1P529 Handle, 1P464 Drive Plate and 1P457 Drive Plate.
6. Using tool setup (B), install the seal (19) in governor control lever with spring side of seal toward governor. Lubricate lip of seal with clean SAE 30 engine oil.
7. Install the governor control lever on the shaft assembly (17).
CYLINDER ASSEMBLY
35-Cylinder. 36-Piston. 37-Sleeve.
8. Install the high (3) and low idle (2) screws in the governor housing.
9. Install the speed limiter plug (5), spring (6), and plunger (7) in the governor housing (4).
10. Install the O-ring seal (38) on sleeve (37).
11. Install piston (36) and sleeve (37) in the cylinder (35).
ASSEMBLY OF VALVE GROUP TO WEIGHT ASSEMBLY
22-Weight assembly. 33-Retaining ring. 35-Cylinder.
12. Position the weight assembly (22) on cylinder (35) and install retaining ring (33).
13. Install the valve (42) in piston (36).
14. Install the bearing (29) and races (28) on sleeve (30). Install retaining ring (32). Install the sleeve and bearing assembly on valve (42).
INSTALLING SLEEVE AND BEARING ASSEMBLY
30-Sleeve. 36-Piston. 42-Valve.
GOVERNOR ASSEMBLY
20-Pin and retaining ring. 27-Bolt.
15. Position the seat (26), bolt (27), washers (28) and spring (29) on the valve. Install the retaining pin and ring (20).
concluding steps:
a) connect governor to fuel injection pump housing.
b) install fuel injection pump housing and governor as a unit
c) set rack and adjust governor (See FUEL RACK SETTING and GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING)
d) adjust governor control (See GOVERNOR CONTROL LINKAGE ADJUSTMENTS in TESTING AND ADJUSTING)
Remove Timing Gear Cover
preparatory steps:
a) remove radiator and radiator guard
b) remove alternator
c) remove oil pan and oil pan plate
PREPARING TO REMOVE TIMING GEAR COVER
1-Fan drive. 2-Water pump. 3-Crankshaft pulley. 4-Front support mounting bolts.
1. Remove fan drive assembly (1), water pump (2), and crankshaft pulley (3).
2. Remove the two engine front support-to-frame mounting bolts (4) and nuts. Attach a hoist to the front of engine, and raise engine just enough to take weight of engine off front support.
3. Install blocks and jack under the front of cylinder block. Remove the front support-to-timing gear cover mounting bolts. Remove the engine front support.
4. Install two 3/8" - 16 NC forged eyebolts in the timing gear cover, and attach a hoist to the cover.
REMOVING TIMING GEAR COVER
1-Bolt.
5. Remove all of the timing gear cover mounting bolts and nuts except bolt (1).
6. Loosen bolt (1) while removing timing gear cover - weight 60 lbs. (27 kg).
Install Timing Gear Cover
1. Remove the old timing gear cover gasket, and install a new gasket.
INSTALLING TIMING GEAR COVER
1-Bolt.
2. Attach a hoist and install the timing gear cover while tightening mounting bolt (1).
3. Install the remaining timing gear cover mounting bolts and nuts.
4. Trim the timing gear cover gasket flush with oil pan face of cylinder block.
5. Position the engine front support on timing gear cover, and install mounting bolts.
6. Lower the front of engine until weight of engine is on front support. Remove the blocks and jack. Install the front support-to-frame mounting bolts.
7. Install the fan drive assembly.
concluding steps:
a) install crankshaft pulley
b) install water pump
c) install alternator
d) install oil pan plate and oil pan
Remove Timing Gears And Plate
1-Accessory drive gear. 2-Sleeve. 3-Bearing. 4-Accessory drive shaft. 5-Plate. 6-Block. 7-Retainer. 8-Bearing. 9-Idler gear. 10-Bolt. 11-Lock. 12-Retainer. 13-Nut. 14-Spring-type washer. 15-Bolt. 16-Bolt. 17-Lock. 18-Camshaft retainer. 19-Balancer shaft retainer. 20-Balancer shaft. 21-Camshaft bearing. 22-Balancer shaft bearing. 23-Bolt. 24-Camshaft drive gear. 25-Gasket.
preparatory steps:
a) remove timing gear cover
b) remove governor and fuel injection pump housing
REMOVING ACCESSORY DRIVE GEAR
1-Accessory drive gear. 7-Idler gear retainer. 9-Idler gear. 15-Bolts. A-Tool Set-up (8S2264 Puller Group, 8S8375 Sleeve, bolts and washers.
2. Using tool set-up (A) remove the accessory drive gear (1).
3. Remove the two idler gear retaining bolts (15) and retainer (7).
4. Remove idler gear (9).
5. Using tool (B) remove the idler gear bearing (8).
6. Remove retaining bolts (23) and remove the camshaft drive gear (24).
7. Remove plate retaining bolts (26), accessory drive bearing retainer (12), and timing gear plate (5).
REMOVING IDLER GEAR BEARING
9-Idler gear. B-Tool (1P529 Handle, 1P472 Drive Plate and 1P469 Drive Plate).
REMOVING TIMING GEAR PLATE
5-Plate. 10-Bolts (four). 12-Retainer. 23-Bolt (four). 24-Camshaft gear. 26-Bolts (ten).
Install Timing Gears And Plate
1. Install new accessory drive housing gasket and timing gear plate gasket (25).
2. Install the timing gear plate (5) accessory drive bearing retainer (12) and timing gear plate retaining bolts.
TIMING CAMSHAFT GEAR
24-Camshaft gear. 27-Crankshaft gear. 28-Timing marks.
3. Install the camshaft drive gear (24) with the mark (28) on the gear aligned with the mark on the crankshaft gear.
4. Install the camshaft gear retaining bolts and lock.
5. Using tool set-up (B), install bearing in idler gear (9).
6. Install the idler gear (9), retainer (7), and retaining bolts (15).
7. Install timing fixture (A) on the accessory drive housing.
8. Install accessory drive shaft (4). Position drive shaft tang in timing fixture slot.
9. Install the tapered sleeve (2) on the accessory drive shaft.
10. Install the accessory drive gear on the tapered sleeve.
11. Install washer (14) with concave (dished) face toward gear (1).
12. Install and tighten the retaining nut (13) to 100 ± 10 lb. ft. (13,9 ± 1,4 mkg).
TIMING ACCESSORY DRIVE GEAR
A-8S5417 Timing Fixture.
Remove Accessory Drive Shaft
PREPARING TO REMOVE ACCESSORY DRIVE SHAFT
29-Fuel transfer pump. 30-Timing gear cover. 31-Fuel injection pump housing. 32-Accessory drive housing. 33-Fuel drain line. 34-Fuel supply line. 35-Fumes disposal tube.
1. Remove timing gear cover (30).
2. Remove fuel injection pump housing (31) and governor.
3. Remove fuel transfer pump (29).
4. Disconnect the fuel supply line (34) and the fuel drain line (33). Remove breather and fumes disposal tube (35).
5. Remove the accessory drive shaft gear retaining nut (13) and washer (14).
1-Accessory drive gear. 7-Idler gear retainer. 9-Idler gear. 15-Bolt. A-Tool (8S2264 Puller Group, 8S8375 Sleeve, bolts and washers).
6. Using tool (A), remove the accessory drive gear and tapered sleeve.
7. Remove four retaining bolts (10), two locks (11) and retainer (12).
REMOVING ACCESSORY DRIVE HOUSING
4-Accessory drive shaft. 5-Timing gear plate. 9-Idler gear. 32-Accessory drive housing.
8. Remove the accessory drive housing (30).
9. Remove the accessory drive shaft (4) and bearing (3) as a unit.
REMOVING ACCESSORY DRIVE SHAFT
3-Bearing. 4-Shaft. 32-Housing.
PULLING ACCESSORY DRIVE SHAFT BEARING
3-Bearing. 4-Shaft. B-1B2320 Puller.
10. Using tool (B), remove bearing from shaft.
Install Accessory Drive Shaft
1. Heat the accessory drive shaft bearing (3) in 300°F oil and install the bearing on the shaft (4).
2. Install the drive shaft (4) and bearing (3) assembly in the accessory drive housing (32).
3. Install the accessory drive housing.
1-Accessory drive gear. 2-Sleeve. 3-Bearing. 4-Accessory drive shaft. 5-Plate. 6-Block. 7-Retainer. 8-Bearing. 9-Idler gear. 10-Bolt. 11-Lock. 12-Retainer. 13-Nut. 14-Spring-type washer. 15-Bolt. 16-Bolt. 17-Lock. 18-Camshaft retainer. 19-Balancer shaft retainer. 20-Balancer shaft. 21-Camshaft bearing. 22-Balancer shaft bearing. 23-Bolt. 24-Camshaft drive gear. 25-Gasket.
8S5417 TIMING FIXTURE
A-8S5417 Timing Fixture.
4. Rotate the accessory drive shaft until tool (A) can be installed.
5. Install the accessory drive shaft sleeve (2) drive gear (1), washer (14), and nut (13). Tighten the retaining nut (13) to 100 ± 10 lb. ft. (13,8 ± 1,4 mkg). Install washer (14) with concave (dished) face toward the gear (1).
6. Connect the fuel drain line and install the oil drain line.
TIMING GEARS
1-Accessory drive gear. 5-Plate. 13-Nut. 14-Washer. 23-Bolt. 24-Camshaft drive gear. 27-Crankshaft gear.
concluding steps:
a) install fuel transfer pump
b) install fuel injection pump housing and governor
c) install timing gear cover
Remove Camshaft
preparatory steps:
a) remove valve lifters
b) remove timing gear cover
PREPARING TO REMOVE CAMSHAFT
1-Accessory drive gear. 9-Idler gear. 16-Bolts. 18-Camshaft retainer. 24-Camshaft gear. 27-Crankshaft gear. 36-Reference timing marks. 37-Crankshaft gear timing mark.
1. Rotate the crankshaft until the "C" mark (37) on the crankshaft gear (27) is aligned with the "C" mark on the camshaft gear (24).
2. Mark the mating teeth of the accessory drive shaft gear (1) and idler gear (9). Mark the mating teeth of idler gear (9) and camshaft gear (24). This will insure proper fuel injection pump camshaft timing during installation of camshaft.
3. Remove the camshaft retaining bolts (16), lock (17), and retainer (18).
4. Slide the camshaft and gear (24) out of the cylinder block. Bearing (21) will stay in flywheel end of the block.
Install Camshaft
1. Thoroughly lubricate the lobes and bearing journals of the camshaft with clean SAE 30 engine oil.
INSTALLING CAMSHAFT
2. Install the camshaft in the cylinder block with timing marks aligned on the accessory drive shaft gear, idler gear, camshaft gear, and crankshaft gear.
3. Install the camshaft retaining bolts, lock and retainer.
NOTE: If any of the above four timing gears have been replaced, it will be necessary to time the accessory drive shaft. See REMOVE AND INSTALL FUEL INJECTION PUMP HOUSING AND GOVERNOR AS A UNIT.
concluding steps:
a) install timing gear cover
b) install valve lifters
Remove Balancer Shafts
preparatory steps:
a) remove oil pan plate
b) remove oil pump
c) remove timing gear cover
PREPARING TO REMOVE BALANCER SHAFT
19-Retainer. 20-Balancer shaft and gear assembly.
1. Remove two retaining bolts and retainer (19).
2. Remove balancer shaft assembly.
Install Balancer Shafts
INSTALLING BALANCER SHAFT
1. Lubricate and install balancer shafts.
2. Install thrust plate and two retaining bolts.
concluding steps:
a) install timing gear cover
b) install oil pump
c) install oil pan plate
Remove Oil Pump
preparatory step:
a) remove oil pan
REMOVING OIL PUMP
1-Elbow. 2 & 3-Bolts and locks.
1. Remove the oil pump suction tube elbow (1).
2. Remove the oil pump mounting bolts and locks (2 and 3). Remove the oil pump - weight 35 lbs. (16 kg).
Install Oil Pump
INSTALLING OIL PUMP
1. Position the oil pump on engine, and install the mounting bolts and locks.
2. Install the oil pump suction tube elbow.
concluding step:
a) install oil pan
Disassemble Oil Pump
preparatory step:
a) remove oil pump
OIL PUMP (EXPLODED VIEW)
1-Cover. 2-Spring. 3-Plunger. 4-Bolt. 5-Body. 6-Shaft and gear assemblies. 7-Body assembly. 8-Bearing. 9-Drive gear. 10-Idler gear. 11-Bearing. 12-Gears. 13-Spacer. 14-Shaft. 15-Bearing.
OIL PUMP DISASSEMBLY
9-Drive gear. 10-Idler gear. 15-Bearing. 16-Bell assembly.
1. Remove the oil pump idler gear. Using tool setup (A), remove the bearing (15) from idler gear (10).
2. Remove the suction bell assembly (16).
OIL PUMP DISASSEMBLY
1-Cover. 5-Body. C-8B7560 Step Plate and 1P2320 Puller Assembly.
3. Remove the oil pump drive gear retaining nut, washer, and cotter pin. Using tool setup (C), remove the pump drive gear (9) from shaft. Remove the woodruff key from shaft.
4. Remove the oil pump bypass valve cover plate (1), spring (2) and plunger (3).
5. Remove the oil pump body assembly (5).
OIL PUMP DISASSEMBLY
6-Shaft and gear assembly. 12-Gears. 13-Spacer.
6. Remove the oil pump gears (12).
7. Remove the spacer (13).
8. Remove the two shaft and gear assemblies (6).
REMOVING BEARING
B-1P529 Handle, 1P462 Drive Plate and 1P461 Drive Plate.
9. Using tool setup (B), remove the bearings from the two body assemblies.
Assemble Oil Pump
OIL PUMP (EXPLODED VIEW)
1-Cover. 2-Spring. 3-Plunger. 4-Bolt. 5-Body. 6-Shaft and gear assemblies. 7-Body assembly. 8-Bearing. 9-Drive gear. 10-Idler gear. 11-Bearing. 12-Gears. 13-Spacer. 14-Shaft. 15-Bearing.
OIL PUMP ASSEMBLY
6-Shaft and gear assembly. 13-Spacer.
1. Using tool setup (B), install the bearings (8 and 11) in the two body assemblies (5 and 7).
2. Lubricate the shaft and gear assemblies (6) with clean SAE 30 engine oil, and install them in oil pump body assembly (7).
3. Install the spacer (13).
4. Lubricate the oil pump gears (12) with clean SAE 30 engine oil. Install the key in the shaft and gear assembly. Install the oil pump gears.
OIL PUMP ASSEMBLY
5-Body.
5. Install the oil pump body assembly (5).
OIL PUMP ASSEMBLY
2-Spring. 3-Plunger.
6. Install the bypass valve plunger (3) and spring (2) in the body assembly (5). Install cover plate (1).
7. Position the oil pump drive gear (9) on the shaft, and install retaining nut and washer. Tighten nut to 60 lb. ft. (8,2 mkg) plus amount to align the cotter pin. Install the cotter pin.
8. Install the suction bell assembly.
INSTALLING IDLER GEAR BEARING
A-1P529 Handle, 1P465 Drive Plate and 1P468 Drive Plate.
9. Using tool set up (A), install the bearing in oil pump idler gear. Install the idler gear on the oil pump.
concluding step:
a) install oil pump
Remove Oil Pan Plate
preparatory step:
a) remove oil pan
REMOVING OIL PAN PLATE
1-Elbow. 2-Bell assembly. 3-Oil pan plate.
1. Remove the oil pump suction elbow (1) and bell assembly (2).
2. Remove the oil pan plate mounting bolts. Remove the oil pan plate (3).
Install Oil Pan Plate
1. Position the oil pan plate (3) on engine, and install the mounting bolts.
2. Install the oil pump suction bell assembly (2) and the elbow (1).
concluding step:
a) install oil pan
Remove Torque Converter Oil Cooler
REMOVING TORQUE CONVERTER OIL COOLER
1-Oil cooler-to-elbow assembly mounting bolts. 2-Oil inlet line. 3-Cooler. 4-Oil outlet line.
1. Drain the engine cooling system - capacity 12 U.S. Gal. (45 liters).
2. Disconnect oil inlet line (2) and oil outlet line (4) from the oil cooler.
3. Remove the oil cooler-to-elbow assembly mounting bolts (1).
4. Remove the torque converter oil cooler (3) - weight 25 lbs. (11 kg).
Install Torque Converter Oil Cooler
1. Position the transmission oil cooler on engine.
2. Install the oil cooler-to-elbow assembly mounting bolts.
3. Connect the oil inlet line and oil outlet line to the oil cooler.
4. Fill the engine cooling system.
Remove Rocker Shaft Assembly
CYLINDER HEAD AND VALVES
1-Bolt. 2-Rocker shaft assembly. 3-Rocker arm. 4-Valve rotators. 5-Spring. 6-Glow plug. 7-Bolt. 8- Seal. 9- Precombustion chamber. 10-Gasket. 11-Cylinder head. 12-Valve seat insert. 13-Pushrod. 14-Valve. 15-Gasket. 16-Lifter. 17-Cylinder block.
preparatory steps:
a) remove valve cover
REMOVING ROCKER SHAFT ASSEMBLY
1-Mounting bolts (four). 2-Rocker shaft assembly. 13-Push rods.
1. Remove the four rocker shaft assembly mounting bolts (1).
2. Remove the rocker shaft assembly (2).
3. Remove the push rods (13).
Install Rocker Shaft Assembly
1. Install the push rods.
2. Coat the rocker shaft assembly mounting bolt threads with 9M3710 Anti-Seize Compound.
INSTALLING ROCKER SHAFT ASSEMBLY
A,B,C,D-Tightening sequence.
3. Position the rocker shaft assembly on the engine, and install the mounting bolts and washers. Tighten the four bolts in alphabetical sequence to 115 lb. ft. (25,9 mkg). Retighten the four bolts in alphabetical sequence to 175 ± 5 lb. ft. (24,2 ± 0,7 mkg). Finally, retighten again (hand torque only) all the four bolts in alphabetical sequence to 175 ± 5 lb. ft. (24,2 ± 0,7 mkg).
4. Adjust the inlet valve clearance to .015 in. (0,38 mm) and exhaust valve clearance to .025 in. (0,64 mm).
concluding steps:
a) install valve cover
Remove Precombustion Chambers
preparatory steps:
a) remove fuel injection valves
1. Drain the cooling system - capacity 9 U.S. Gal. (34 liter).
REMOVING PRECOMBUSTION CHAMBER
9-Precombustion chamber. A-5F8353 Wrench.
2. Install wrench (A) in the precombustion chamber and remove the chamber (9) from the cylinder head.
3. Remove the precombustion chamber gasket (10). Remove the O-ring seal (8) from chamber.
Install Precombustion Chambers
1. Install new O-ring seal (8) on precombustion chamber (9).
2. Coat the precombustion chamber threads with 9M3710 Anti-Seize Compound.
3. Install the thinnest gasket (10) on the precombustion chamber.
4. Install the precombustion chamber in the cylinder head. Using wrench (A) tighten chamber to 150 ± 10 lb. ft. (20,7 ± 1,4 mkg).
LOCATING GLOW PLUG OPENING
5. If the glow plug opening is not positioned in the "go" range, remove precombustion chamber and replace gasket with the one called for in diagram.
6. Coat the threads of glow plug with 9M3710 Anti-Seize Compound.
7. Fill the cooling system.
concluding steps:
a) install fuel injection valves
Remove Cylinder Head Assembly
preparatory steps:
a) remove exhaust extension, muffler and hood
b) raise bucket and lock lift arms with lift arm support
c) drain coolant from engine
d) remove turbocharger and exhaust manifold as a unit
e) remove air cleaner and air pipes
PREPARING TO REMOVE CYLINDER HEAD
18-Water outlet elbow. 19-Breather and fumes disposal tube. 20-Valve cover. 21-Glow plug wiring harness. 22-Water pressure sensing line. 23-Water bypass line. 24-Vent line. 25-Temperature gauge sending unit.
1. Remove the glow plug wiring harness (21).
2. Remove the cylinder head water outlet elbow (18).
3. Remove the water temperature gauge sending unit (25) from the cylinder head.
4. Disconnect water pump water bypass line (23) from the cylinder head. Remove vent line (24).
5. Remove water pressure sensing line (22).
6. Remove breather and fumes disposal tube (19).
PREPARING TO REMOVE CYLINDER HEAD
26-Fuel lines. 27-Turbocharger oil drain line. 28-Turbocharger oil supply line.
7. Remove the turbocharger oil supply line (28) and oil drain line (27).
8. Remove the fuel injection lines (26) and install protective caps.
9. Remove the lifting eye from the rear of the cylinder head.
10. Remove valve cover (20).
11. Remove rocker shaft assembly.
12. Remove the cylinder head retaining bolts (1 and 7).
13. Install one 3/8" - 16 NC forged eyebolt, attach a hoist and strap. Remove the cylinder head assembly - weight 250 lbs. (113,40 kg).
To disassemble cylinder head, compress springs (5) to release locks of valves (14). Grind insert (12) seat and valve (14) face to specification or install new inserts and valves.
Install Cylinder Head Assembly
1. Install a new and dry cylinder head gasket (15).
2. Attach a hoist and position the cylinder head assembly on the engine. Install the push rods (13), and position the rocker shaft assembly (2) on the cylinder head.
3. Coat the threads of cylinder head mounting bolts (7) with 9M3710 Anti-Seize Compound. Install the bolts and washers, and tighten bolts in the following Step sequence:
1 Tighten all numbered bolts in numerical order to 115 lb. ft. (15,9 mkg).
2 Retighten all numbered bolts in numerical order to 175 ± 5 lb. ft. (24,2 ± 0,7 mkg).
3 Finally, retighten all numbered bolts (hand torque only) in numerical order to 175 ± 5 lb. ft. (24,2 ± 0,7 mkg).
4 Tighten all lettered bolts in alphabetical order to 22 lb. ft. (3,0 mkg).
5 Retighten all lettered bolts in alphabetical order to 32 ± 5 lb. ft. (4,4 ± 0,7 mkg).
6 Finally, retighten all lettered bolts (hand torque only) in alphabetical order to 32 ±5 lb. ft. (4,4 ± 0,7 mkg).
CYLINDER HEAD AND VALVES
1-Bolt. 2-Rocker shaft assembly. 3-Rocker arm. 4-Valve rotators. 5-Spring. 6-Glow plug. 7-Bolt. 8-Seal. 9-Precombustion chamber. 10-Gasket. 11-Cylinder head. 12-Valve seat insert. 13-Pushrod. 14-Valve. 15-Gasket. 16-Lifter. 17-Cylinder block.
4. Adjust the inlet valve clearance to .015 in. (0,38 mm) and the exhaust valve clearance to 0.25 in. (0,64 mm).
5. Install the lifting eye in the rear of the cylinder head.
6. Remove the protective caps and install the fuel injection lines.
8. Install the water pump vent line and bypass line.
9. Install the turbocharger oil supply and oil drain lines. Do not install the retaining bolts in the turbocharger ends of the lines.
11. Install the turbocharger oil drain line mounting bolts.
12. Install the turbocharger oil supply line mounting bolts.
13. Install or connect components removed or disconnected in Steps 1 through 6 for cylinder head removal.
Remove Pistons
CYLINDER BLOCK COMPONENTS
1-Liner. 2-Seal. 3-Rings. 4-Piston pin. 5-Piston. 6-Connecting rod. 7-Bearing. 8-Block. 9-Connecting rod bearing. 10-Thrust plates. 11-Connecting rod cap. 12-Gear. 13-Crankshaft. 14-Main bearing. 15-Main bearing. 16-Bolt. 17-Connecting rod nut and bolt.
preparatory steps:
a) remove cylinder head assembly
b) remove oil pump
c) remove oil pan plate
1. Remove the carbon ridge from the top inside surface of cylinder liners.
PREPARING TO REMOVE PISTON
11-Connecting rod cap.
2. Rotate the crankshaft (13) until two connecting rods (6) are at bottom dead center.
3. Remove the connecting rod caps (11) from these rods and push the pistons upward until the rings (3) clear the cylinder liner.
REMOVING PISTON (TYPICAL REMOVAL)
4. Remove the two pistons.
5. Repeat Step 2 through Step 4 for the remaining pistons.
Install Pistons
1. Thoroughly lubricate the crankshaft (13) bearing journals and cylinder liners (1) with clean SAE 30 engine oil.
2. Lubricate the piston rings (3) and connecting rod bearings (9) with clean SAE 30 engine oil.
INSTALLING PISTON (TYPICAL INSTALLATION)
A-7S9417 Piston Ring Compressor.
3. Using compressor (A), install the piston (5) with "V" mark on piston aligned with "V" mark on cylinder block. Guide the lower end of the rod over the crankshaft journal to prevent damage to the crankshaft.
4. Lubricate the threads of cap retaining bolts (17) with clean SAE 30 engine oil.
5. Position the caps (11) on the connecting rods, and install retaining nuts. Tighten nuts initially to 30 ± 3 lb. ft. (4,1 ± 0,4 mkg). Mark the nut and end of bolt, and tighten nut an additional 90° from mark.
| NOTICE |
|---|
When installing connecting rod cap, be sure that the number marked on side of cap is adjacent to and corresponds to the number marked on side of connecting rod. |
6. Rotate the crankshaft until the next two bearing journals are at bottom dead center.
7. Repeat Step 2 through Step 6 for the remaining pistons.
concluding steps:
a) install oil pan plate
b) install oil pump
c) install cylinder head assembly
Remove Cylinder Liners
preparatory step:
a) remove pistons
1. Check to make sure all coolant has been drained from the cylinder block.
2. Cover the crankshaft bearing journals before removing cylinder liners.
REMOVING CYLINDER LINER (TYPICAL REMOVAL)
A-1P2400 Cylinder Liner Puller Group
3. Using tool setup (A), remove the cylinder liners.
Install Cylinder Liners
1. Clean the cylinder liners (1) and liner bores in the cylinder block (8).
2. Install new O-ring seals (2) on the cylinder liners.
3. Coat O-ring seals and mating bore with liquid soap to ease installation of liners.
INSTALLING CYLINDER LINER (TYPICAL INSTALLATION)
A-1P2394 Plate.
4. Using plate (A), drive the cylinder liners into place.
CHECKING CYLINDER LINER PROJECTION (TYPICAL)
B-8B7548 Push-Puller Bar and two 3H465 Plates. C-1P5510 Liner Projection Tool Group.
5. Using tool setup (B) and two bolts, (5/8" - 11 NC X 4-1/2" long) clamp the liner in position. Tighten the two bolts evenly to 50 lb. ft. (6,9 mkg).
6. Check the cylinder liner projection using tool group (C). Liner projection must be .0020-.0056 in. (0,050-0,142 mm).
concluding step:
a) install pistons
Remove Crankshaft
CYLINDER BLOCK COMPONENTS
1-Liner. 2-Seal. 3-Rings. 4-Piston pin. 5-Piston. 6-Connecting rod. 7-Bearing. 8-Block. 9-Connecting rod bearing. 10-Thrust plates. 11-Connecting rod cap. 12-Gear. 13-Crankshaft. 14-Main bearing. 15-Main bearing cap. 16-Bolt. 17-Connecting rod nut and bolt.
preparatory steps:
a) remove engine
b) remove flywheel housing
c) remove timing gear cover
d) remove pistons
PREPARING TO REMOVE CRANKSHAFT
18-Camshaft gear. 19-Crankshaft gear. 20-Timing marks.
1. Rotate the crankshaft until the "V" mark on the crankshaft gear (19) is aligned with the "V" mark on the camshaft gear (18).
2. Mark the mating teeth of the accessory drive shaft gear and idler gear. Mark the mating teeth of idler gear and camshaft gear. This will insure proper fuel injection pump camshaft timing during installation of the crankshaft.
PREPARING TO REMOVE CRANKSHAFT
13-Crankshaft. 15-Main bearing cap.
3. Attach a hoist to the crankshaft (13).
4. Remove the crankshaft main bearing caps (15).
5. Remove the crankshaft - weight 145 lbs. (66 kg).
6. Remove the crankshaft main bearings from the cylinder block and from main bearing caps.
Install Crankshaft
1. Clean the bearing seating surfaces in the cylinder block. Install the upper halves of main bearings (14) in the block. Lubricate the bearings with clean SAE 30 engine oil.
2. Attach a hoist and position the crankshaft (13) in cylinder block with all timing marks aligned.
3. Clean the bearing seating surfaces of the main bearing caps (15). Install lower halves of main bearings in the caps.
CHECKING MAIN BEARING CLEARANCE
13-Crankshaft. 15-Main bearing cap. A-5B1161 Wire.
4. Using wire (A), check the main bearing clearance. Install the caps in their respective positions with the number stamped on cap facing the corresponding number stamped on pan face on left side of cylinder block.
5. Lubricate the threads of cap retaining bolts (16) and face of washers with clean SAE 30 engine oil. Install the cap retaining bolts and washers. Tighten both bolts to 30 ± 3 lb. ft. (4,1 ± 0,4 mkg) plus additional 90° and measure the thickness of wire (B). Main bearing clearance should be .0030-.0059 in. (0,076 - 0,150 mm).
6. Lubricate the lower halves of main bearings with clean SAE 30 engine oil. Install the main bearing caps in their respective positions. Install cap retaining bolts and washers. Tighten both bolts (16) to 30 ± 3 lb. ft. (4,1 ± 0,4 mkg) plus additional 90°.
CHECKING CRANKSHAFT END PLAY
B-8S2328 Dial Indicator Test Group.
7. Using tool (B), check the crankshaft end play as controlled by thrust bearings (10) on rear main.
CHECKING CRANKSHAFT END PLAY
10-Thrust bearing.
8. If the accessory drive shaft gear, idler gear, or camshaft gear has been removed of if the crankshaft gear has been replaced, it will be necessary to time the accessory drive shaft after assembling the engine. See REMOVE AND INSTALL FUEL INJECTION PUMP HOUSING AND GOVERNOR AS A UNIT.
concluding steps:
a) install pistons
b) install timing gear cover
c) install flywheel housing
Remove And Install Connecting Rod Bearings
preparatory steps:
a) remove oil pump
b) remove oil pan plate
REMOVING CONNECTING ROD BEARINGS
11-Connecting rod bearing caps. 17-Connecting rod bolts and nuts.
CYLINDER BLOCK COMPONENTS
1-Liner. 2-Seal. 3-Rings. 4-Piston pin. 5-Piston. 6-Connecting rod. 7-Bearing. 8-Block. 9-Connecting rod bearing. 10-Thrust plates. 11-Connecting rod bearing. 12-Gear. 13-Crankshaft. 14-Main bearing. 15-Main bearing cap. 16-Bolt. 17-Connecting rod nut and bolt.
1. Rotate the crankshaft (13) until two connecting rods (6) are at bottom dead center. Remove the connecting rod caps (11) from these rods. Remove the lower half of bearings (9) from the caps.
2. Push the connecting rods (6) away from the crankshaft, and remove upper half of bearings.
3. Clean the connecting rod bearing mounting surfaces, and install upper half of new bearings in rods. Lubricate the bearings and the crankshaft journals with clean SAE 30 engine oil. Pull the connecting rods into position on the crankshaft.
4. Clean the connecting rod cap bearing mounting surfaces, and install lower half of new bearings in the caps. Lubricate the bearings with clean SAE 30 engine oil.
5. Lubricate the threads of cap retaining bolts (17) with clean SAE 30 engine oil.
INSTALLING CONNECTING ROD BEARINGS
11-Connecting rod bearing cap. 17-Connecting rod bolt.
6. Position the caps (11) on the connecting rods (6), and install retaining nuts (17). Tighten the nuts initially to 30 ± 3 lb. ft. (4,1 ± 0,4 mkg). Mark the nut and end of bolt, and tighten nut an additional 90° from mark.
| NOTICE |
|---|
When installing connecting rod cap, be sure that the number marked on side of cap is adjacent to and corresponds to the number marked on side of connecting rod. |
7. Repeat the above steps for remaining connecting rod bearings.
concluding steps:
a) install oil pan plate
b) install oil pump
Remove Crankshaft Pulley
1-Pulley. 2-Washer. 3-Bolt.
1. Loosen the pulley retaining bolt (3) approximately 1/8" (0,31 cm).
REMOVING CRANKSHAFT PULLEY
1-Pulley. A-Tool Group.
2. Using tool (A) loosen the pulley (1) from the crankshaft.
3. Remove tool (A), pulley retaining bolt (3) and washer (2).
4. Remove crankshaft pulley (1).
Install Crankshaft Pulley
1. Install the crankshaft pulley, washer, and bolt.
2. Tighten the pulley retaining bolt to 230 ± 20 lb. ft. (31,8 ± 2,8 mkg). Tap the retaining bolt with a hammer and retighten to 230 ± 20 lb. ft. (31,8 ± 2,8 mkg).
Remove Crankshaft Front Seal
preparatory steps:
a) remove crankshaft pulley
REMOVING CRANKSHAFT FRONT SEAL
A-1P3075 Seal Puller Group.
1. Using tool (A) remove the crankshaft seal.
Install Crankshaft Front Seal
INSTALLING CRANKSHAFT FRONT SEAL
1-9S8878 Ring. 2-9S8879 Pusher Plate. 3-6B5310 Bolt. 4-4B4283 Washer.
1. Using tool setup (A), install the crankshaft front seal as follows:
2. Lubricate the lip of seal and outside diameter of crankshaft with clean SAE30 engine oil. Coat the outside diameter of seal with 8M8059 Loctite Sealant. Position the seal on crankshaft with lip of seal toward rear of engine.
CRANKSHAFT FRONT SEAL INSTALLATION TOOLS
1-9S8878 Seal Installer Ring. 2-9S8379 Pusher Plate. 3-6B5310 Bolt. 4-4B4283 Washer.
3. Position the seal installer ring (1) and pusher plate (2) on the crankshaft. Install the bolt (3) and washer (4).
4. Tighten the bolt (3) until seal bottoms in timing gear cover. Remove tool setup (A).
concluding step:
a) install crankshaft pulley.
Remove Balancer Shaft Bearings
preparatory steps:
a) remove oil pan plate
b) remove balancer shafts
c) remove flywheel housing
REMOVING BALANCER SHAFT BEARINGS
1-Balancer shaft front bearing location. 2-Balancer shaft center bearing location. 3-Balancer shaft rear bearing location. A-8S2241 Tool Group.
1. Using tool group (A), remove the balancer shaft bearings starting with the front bearing.
Install Balancer Shaft Bearings
1. Using tool group (A), install the camshaft bearings in the cylinder block starting with the front bearing. Install all bearings with oil hole in bearing aligned with oil hole in cylinder block.
2. At installation, the front and rear bearings are to be recessed .03 ± .02 in. (0,7 ± 0,5 mm) from their respective ends of the cylinder block.
concluding steps:
a) install flywheel housing
b) install camshaft
Flywheel And Flywheel Housing Components
FLYWHEEL HOUSING AND COMPONENTS (EXPLODED VIEW)
1-Bolt. 2-Seal. 3-Bolt. 4-Lock. 5-Bolt. 6-Lock. 7-Flywheel housing. 8-Gasket. 9-Cylinder block. 10-Mark. 11-Mark. 12-Crankshaft. 13-Lock. 14-Flywheel. 15-Gear. 16-Bolt. 17-Lock. 18-Bolt. 19-Lock.
Remove Flywheel
preparatory steps:
a) remove engine
b) remove flexible drive coupling
1. Remove all but one of the flywheel retaining bolts (1). Install a 5/8" - 18 NF guide pin in the crankshaft.
2. Install two 3/8" - 13 NC forged eyebolts in the flywheel (14). Use an FT797 Lifting Hook Bracket, hoist and chain to lift the flywheel from the housing (7).
3. Remove the flywheel - weight 85 lbs. (38,6 kg).
Install Flywheel
1. Install a 5/8" - 18 NF guide pin in the crankshaft.
2. Attach a hoist and position the flywheel on the crankshaft with mark (10) on flywheel aligned with mark (11) on the crankshaft.
3. Install all but one of the flywheel retaining bolts. Remove the eyebolt and guide pin, and install the remaining retaining bolt.
Remove Crankshaft Rear Seal
preparatory steps:
a) remove flywheel
REMOVING CRANKSHAFT REAR SEAL
2-Seal. A-1P3074 Seal Puller Group.
1. Using seal puller group (A), remove the crankshaft rear seal.
Install Crankshaft Rear Seal
INSTALLING CRANKSHAFT REAR SEAL
1-9S8548 Seal Pilot. 2-9S8890 Screw. 3-9S8871 Locator Assembly. 4-9S8858 Nut. 5-9S8864 Pusher Plate. 6-9S8543 Seal Installer Ring.
1. Using tool (A), install the crankshaft rear seal as follows:
a) Install the locator assembly (3) and retaining screws (2) on the crankshaft.
b) Lubricate the lip of seal and the seal pilot (1) with clean SAE 30 engine oil. Place the seal on the seal pilot (1) with the thickest portion of seal outer metal shell toward the flywheel. Coat the seal outer metal shell with 8M8059 Loctite Sealant. Slide the seal pilot (1) onto the locator assembly (3) and the crankshaft.
c) Place the seal installer ring (6) on the pusher plate (5), and slide the pusher plate onto the stud of the locator assembly (3).
d) Lubricate the nut (4) with clean SAE 30 engine oil, and install nut on side of locator assembly (3).
e) Tighten the nut (4) until the seal bottoms.
2. Remove tool set-up (A).
concluding step:
a) install flywheel
Remove Engine Oil Cooler
REMOVING ENGINE OIL COOLER
1-Hose. 2-Bonnet. 3-Mounting bolts. 4-Clamps. 5-Support mounting bolts. 6-Oil filter case. 7-Oil filter inlet line.
1. Drain the engine cooling system - capacity 12 U.S. Gal. (45 liters).
2. Loosen the water inlet bonnet hose clamps (4) and slide the hose (1) back on bonnet (2).
3. Remove oil filter case (6) and filter element.
4. Remove the oil cooler-to-elbow assembly mounting bolts (3).
5. Remove the two support bracket mounting bolts (5). Lift the engine oil cooler and oil filter base unit from the filter inlet and outlet oil lines.
6. Separate the oil filter base from oil cooler.
Install Engine Oil Cooler
INSTALLING ENGINE OIL COOLER
1-Hose, 2-Cooler. 3-Base-to-cooler mounting bolts. 4-Oil inlet line. 5-Oil outlet line 6-Filter base.
1. Position the oil filter base (6) on the oil cooler (2), and install mounting bolts (3).
2. Install new seals on filter base inlet and outlet oil lines (4 and 5).
3. Position the oil filter base and engine oil cooler on the engine, and install the four oil cooler-to-elbow assembly mounting bolts.
4. Install the two support bracket mounting bolts.
5. Position the water inlet hose (1) and tighten the hose clamps.
6. Install the oil filter element and case.
7. Fill the engine cooling system. Check the oil level in crankcase after starting engine.