Installation of New Cylinder Heads and Camshafts on Certain 3512E Petroleum Tier 4 Final Engines {0703, 1100, 1209, 1210} Caterpillar

Engine

3512E (S/N: SK31-UP; SK51-UP)

Pumper

SPF743 (S/N: MLX1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, including human factors that can affect safety. This person should also have the necessary training, skills, and tools to perform these functions properly.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates.

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Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.

General Information

Graphic Color Description

Color-coding of targeted components, or sections of a part, is used to communicate a required action.

The descriptions below illustrate the different colors and what is represented when used in a graphic.

(Blue) The primary component of focus for a particular step. Target or primary component to be installed or removed. Installation implied unless otherwise noted with a symbol.

(Yellow) Components disconnected, connected, or placed aside for access, but not removed. Highlighted areas of adjustment, inspection, or special attention.

(Cyan) Special tools or other equipment required for use in a particular step.

(Light Gray) Components used for reference.

(Magenta) Any fastener, retainer, or electrical connector used to install or remove the primary component.

Graphic Symbol Description

This section includes all the symbol graphics used throughout the Visual Service Procedure (VSP), along with a brief description of what the symbol represents.

Attach - To connect together or to fasten on something.

Clean - To remove foreign or undesired material.

Compress, Load - To press together, to squeeze. To transfer weight or force to an object. The weight or force carried by an object.

Connect - To place in an electrical circuit. To join or fasten together.

Cut - To divide or terminate. To reduce the length of an object.

Disconnect - To remove from an electrical circuit. To separate.

Finger Tighten - To apply tension or torque with one digits and unaided by a tool or lever.

Inspect - To confirm, inspect, look, or observe to confirm or assure accuracy, conformance.

Lubricate, Oil - To apply a material to a surface to reduce

Remove - To take off.

Rotate - Clockwise - To turn on an axis. To alternate position or orientation, for the purpose of achieving even wear.

Slide - To pass along a surface with a smooth, slipping movement. To move along in continuous contact with a surface.

Special Tool - To work with a nonstandard device.

Tighten - To make nearer to fully stretched, without slack, to apply tension or torque.

Unload - To take off force or discharge energy.

Torque Specifications

English (SAE) Fasteners

The following table has the recommended standard torque values.

Table 1

Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 5 N·m (18 ± 5 lb ft)
3/8	47 ± 10 N·m (35 ± 5 lb ft)
7/16	70 ± 15 N·m (50 ± 10 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 20 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Table 2

Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	30 ± 5 N·m (20 ± 5 lb ft)
M10	55 ± 10 N·m (40 ± 5 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 20 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 45 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Removal Procedure

1. Obtain a PSR from the engine ECM.

Exhaust Removal

Removal Procedure

Table 3

Required Tools
Tool	Part Name	Qty
A	Suitable Lifting Device	2

Illustration 1	g06185548

Illustration 2	g06185600

Illustration 3	g06185928

Illustration 4	g06185963

Illustration 5	g06185972

Support Assembly Removal

Removal Procedure

Table 4

Required Tools
Tool	Part Name	Qty
A	Suitable Lifting Device	4

Illustration 6	g06186007

Illustration 7	g06186048

Illustration 8	g06186081

Engine Harness Removal

Removal Procedure

Illustration 9	g06186327

Illustration 10	g06186355

Illustration 11	g06186379

Illustration 12	g06186400

Illustration 13	g06186442

Illustration 14	g06186829

Illustration 15	g06186838

Illustration 16	g06186911

Illustration 17	g06186929

Illustration 18	g06186936

Illustration 19	g06186949

Illustration 20	g06186960

Air Inlet Tube Assembly Removal

Removal Procedure

Illustration 21	g06186975

Illustration 22	g06186987

Oil Filter and Tube Removal

Removal Procedure

Illustration 23	g06192062

Illustration 24	g06192066

Exhaust Cooler (NRS) Removal

Removal Procedure

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

Illustration 25	g06187029

Illustration 26	g06187036

Note: Clamps are one time use only, discard and replace with new clamps.

Illustration 27	g06187043

Illustration 28	g06187051

Illustration 29	g06187062

Accumulator (Fuel Injection) Removal

Removal Procedure

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

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This fuel system may contain high-pressure fuel for extended periods after engine shutdown. Do not open the high-pressure fuel system without first releasing the high-pressure fuel from the system. Refer to the Operation and Maintenance Manual, "High-Pressure Fuel System - Pressure Release" to properly release fuel pressure. Exposure to high-pressure fuel may result in personal injury.

Table 5

Required Tools
Tool	Part Number	Part Name	Qty
A	276-7018	Plug Cap Kit	1
B	1U-5512	Abrasive Material	1
	8T-7765	Surface Reconditioning Pad	1
C	9U-7078	Cap / Plug-Tapered	50

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NOTICE
Use Tooling (A) and (C) to cap fuel lines, fittings, ports. and any other openings on the fuel system to prevent contamination. Use clean latex gloves before handling cleaned components.

Note: Prior to loosening any high-pressure joints, use compressed air to remove any external debris around the accumulator bore in the cylinder head just behind the accumulator clamp.

Illustration 30	g06069726

Loosen plug (1) one full turn, do not remove plug (1). After 30 seconds, use CATET to verify that the fuel rail pressure is below 2.0 MPa (290 psi). Refer to Operation and Maintenance Manual, "High-Pressure Fuel System - Pressure Release" for more information.

Illustration 31	g06187127

Illustration 32	g06187135

Note: Use Tooling (A) on the tube assemblies and place the tube assemblies in a clean new resealable bag.

Illustration 33	g06187139

Note: Do not remove the studs from the cylinder head.

Illustration 34	g06187147

Note: Remove accumulator slowly out of the cylinder head. If prying is required to remove accumulator, ensure that a pry-bar or similar device only makes contact with the surface underneath the accumulator clamp.

Illustration 35	g06187149

Cap the bottom of accumulator and place in a clean new resealable bag.

If necessary, use Tooling (B) to remove any rust scale from the outer rim of the accumulator bore.

Note: Surface does not have to be polished.

Carefully remove any remaining debris from the outer edge of the accumulator bore using a new lint-free towel moistened with brake cleaner.

Use Tooling (A) to plug the open accumulator bore in the cylinder head.

Note: If replacing accumulator at either cylinder #11 or #12, ensure that a new end plug and ball is available. Reuse of the end plug and ball in the accumulator is not recommended.

Note: If removing accumulator at either cylinder #11 or #12 for inspection only, do not remove the end plug.

Valve Cover Removal

Removal Procedure

Illustration 36	g06187161

Illustration 37	g06187172

Illustration 38	g06187182

Intake Manifold Removal

Removal Procedure

Illustration 39	g06187430

Illustration 40	g06187441

Exhaust Manifold Bolts Removal

Removal Procedure

Illustration 41	g06187500

Illustration 42	g06187520

Fuel Manifold, Fuel Supply and Return Lines Removal

Removal Procedure

Illustration 43	g06187533

Illustration 44	g06187542

Illustration 45	g06187545

Jacket Water Manifold Removal

Removal Procedure

Table 6

Required Tools
Tool	Part Name	Qty
A	Suitable Lifting Device	2

Illustration 46	g06187615

Illustration 47	g06187645

Fuel Injector Removal

Removal Procedure

Table 7

Required Tools
Tool	Part Number	Part Name	Qty
A	5F-4764	Pry Bar	1

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 48	g06187649

Illustration 49	g06187654

Illustration 50	g06187888

Illustration 51	g06187906

Note: Only pry on the underside of the injector clamp.

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NOTICE
Remove fuel/fluids from the cylinder. Turning over (cranking) an engine with a fuel injector removed could result in personal injury or death from fluids escaping at high velocity.

Rocker Shaft Assembly Removal

Removal Procedure

Illustration 52	g06187944

Illustration 53	g06187971

Cylinder Head Removal

Removal Procedure

Table 8

Required Tools
Tool	Part Name	Qty
A	Eye Bolts	2
B	Suitable Lifting Devices	2

Illustration 54	g06187985

Illustration 55	g06188024

Illustration 56	g06188081

Illustration 57	g06188108

Illustration 58	g06188118

Illustration 59	g06188127

Illustration 60	g06188171

Illustration 61	g06188180

Camshaft Removal

Removal Procedure

Table 9

Required Tools
Tool	Part Number	Part Name	Qty
A	238-9586	Camshaft Drive Group	1
B	1P-0820	Hydraulic Puller	1
	8B-7548	Push-Puller Tool Group	1
	8B-7559	Adapter	2
	5H-1504	Hard Washer	3
	9U-6600	Hand Hydraulic Pump	1
C	125-0200	Camshaft Pilot As.	2
D	125-0201	Camshaft Guide As	1
E	8T-3169	Crank Assembly	1
F	-	Suitable Lifting Device	1

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened.

Illustration 62	g06188211

Illustration 63	g06188217

Illustration 64	g06188220

Illustration 65	g06188534

Illustration 66	g06058772

Place three washers from Tooling (B) behind plate (10) and install bolt (7).

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NOTICE
Do not apply more than 51675 kPa (7500 psi) pressure to the hydraulic puller. The adapters are rated at 6 1/2 tons each and the hydraulic puller is rated at 17 tons at 68900 kPa (10,000 psi). If too much pressure is applied, the gear may be damaged.

Install Tooling (B) on camshaft drive gear (6). Apply 51675 kPa (7500 psi) to Tooling (B). Strike the screw on Tooling (B) with a hammer until camshaft drive gear (6) is free from the camshaft. Remove Tooling (B) and camshaft drive gear (6).

Repeat steps for camshaft drive gear (9).

Illustration 67	g06058988

Install Tooling (C) on the end of the camshaft.

Install Tooling (D) on the flywheel housing.

Install Tooling (E) on the end of Tooling (C).

The combined weight of camshaft (13) and camshaft (14) is 70 kg (154 lb).

Illustration 68	g06188651

Illustration 69	g06188669

Rotate the camshaft with Tooling (E). Pull the camshaft out of the engine until a suitable lifting device can be attached.

Illustration 70	g06188680

Remove the dowel from the front of the camshaft if necessary.

Oil Discharge Elbow Removal

Removal Procedure

Illustration 71	g06192003

Illustration 72	g06192004

Illustration 73	g06192008

Installation Procedure

Camshaft Install

Parts Required

Table 10

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	2	7N-4320	Gasket	Illustration 98 (1)
2	1	513-4774	Camshaft-As Front	Illustration 77 (2)
3	1	513-4775	Camshaft-As Rear	Illustration 79 (1)
4	1	513-4776	Camshaft-As Rear	Illustration 85 (1)
5	1	513-4777	Camshaft-As Front	Illustration 83 (2)

Installation Procedure

Table 11

Required Tools
Tool	Part Number	Part Name	Qty
A	238-9586	Camshaft Drive Group	1
B	1P-0820	Hydraulic Puller	1
	8B-7548	Push-Puller Tool Group	1
	8B-7559	Adapter	2
	5H-1504	Hard Washer	3
	9U-6600	Hand Hydraulic Pump	1
C	125-0200	Camshaft Pilot As.	2
D	125-0201	Camshaft Guide As	1
E	8T-3169	Crank Assembly	1
F	-	Suitable Lifting Device	1

Illustration 74	g06189065

Note: Do not tighten the bolts on Tooling (D).

Illustration 75	g06189070

Illustration 76	g06189085

Illustration 77	g06189107

If the dowel was removed from the front half of the camshaft, install the dowel. Install the dowel to 55 ± 0.5 mm (0.9 ± 0.02 inch) from the surface of the camshaft.

Illustration 78	g06189131

Illustration 79	g06189184

Illustration 80	g06189189

Note: Do not tighten the bolts on Tooling (D).

Illustration 81	g06189191

Illustration 82	g06189250

Illustration 83	g06189274

If the dowel was removed from the front half of the camshaft, install the dowel. Install the dowel to 55 ± 0.5 mm (0.9 ± 0.02 inch) from the surface of the camshaft.

Illustration 84	g06189285

Illustration 85	g06189293

Illustration 86	g06189298

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NOTICE
If the camshaft is out of time more than 18 degrees (approximate 1/2 of the timing pin is out of the groove), the valves can make contact with the pistons. This will cause damage to the engine. Refer to Testing and Adjusting, Camshaft Timing for more information.

Illustration 87	g06189305

Illustration 88	g06189312

Illustration 89	g06189317

Illustration 90	g06189323

Illustration 91	g06189329

Illustration 92	g06189540

Use Tooling (A) and a rachet to turn the flywheel until bolt can be installed through the hole and into the flywheel. doing so will position the No. 1 cylinder at the top center. Refer to Testing and Adjusting, Finding the Top center Position for the No. 1 Piston for more information.

Illustration 93	g06058772

Note: Use the following procedure to install camshaft drive gear (9) and camshaft drive gear (6).

Clean the taper of the camshaft and the tapered bore of the camshaft drive gear with a lint free cloth saturated with solvent to remove oil. Clean the parts again with a lint free alcohol wipe to remove any residue. The alcohol wipe will dirty after cleaning the parts. Clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe.

Note: The taper of the camshaft gear must be clean, dry, and free of residue before assembly.

Ensure that the camshaft timing pins and the timing pin for the flywheel are installed.

Place camshaft drive gear (9) and camshaft drive gear (6) in position. Remove the backlash by rotating the gears in the opposite direction of camshaft rotation.

Note: For "Standard Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears CLOCKWISE.

Illustration 94	g06189575

Illustration 95	g06189580

Ensure that the hole in the camshaft ring gear is properly seated on the locating pin.

Illustration 96	g06189587

Place a Mark on bolt (8) (7).

Place a driver against the retaining plate of the camshaft gear drive. Strike the driver solidly with a hammer 3 to 4 times.

Illustration 97	g06189594

Repeat steps until the Mark on bolts (7) and (8) have turned at least 90°.

Illustration 98	g06189604

Illustration 99	g06189614

Valve Lifter Installation

Parts Required

Table 12

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	24	7N-4782	Spring-Lft Gde	Illustration 100 (1)
2	24	416-8319	Lifter As-Valve	Illustration 101 (1)

Installation Procedure

Illustration 100	g06189721

Illustration 101	g06189743

Note: Install valve lifter in cylinder head with stamped word left on end of bronze pin always oriented to the left as viewed from the side of the engine regardless of left or right bank.

Cylinder Head Installation

Required Parts

Table 13

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	12	110-6994	Plate-Spacer	Illustration 104 (1), and 105 (1)
2	12	144-5692	Gasket-Plate	Illustration 102 (2), and 103 (2)
3	12	362-8264	Gasket-Cyl Head	Illustration 106 (1), 107 (1)
4	48	420-0652	Seal As-Water	Illustration 104 (2), and 105 (2)
5	48	420-0653	Seal As	Illustration 104 (3), and 105
6	12	495-2063	Head Gp-Cyl Bsc	Illustration 108 (2), and 109 (2)

Installation Procedure

Table 14

Required Tools
Tool	Part Name	Qty
A	Suitable Lifting Device	2
B	Eye Bolt	2

Illustration 102	g06189758

Illustration 103	g06189767

Illustration 104	g06189824

Illustration 105	g06189839

Illustration 106	g06189857

Illustration 107	g06190407

Illustration 108	g06190258

Illustration 109	g06190288

Illustration 110	g06190313

Illustration 111	g06190331

Illustration 112	g06044296

Tighten bolts in the numeral sequence shown in Illustration 112 to a torque of 30 ± 5 N·m (266 ± 44 lb in).

Tighten bolts in the numeral sequence shown in Illustration 112 to a torque of 100 ± 15 N·m (74 ± 11 lb ft).

Tighten bolts in the numeral sequence show in Illustration 112 to a torque of 450 ± 15 N·m (332 ± 11 lb ft).

Loosen bolts in the numeral sequence shown in Illustration 112 to angle of 90°.

Tighten bolts in the numeral sequence shown in Illustration 112 to a final torque of 490 ± 15 N·m (361 ± 11 lb ft).

Tighten bolts on front of head to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Valve Mechanism Cover Base Installation

Parts Required

Table 15

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	12	240-7032	Seal-PIP	Illustration 113 (1)

Installation Procedure

Illustration 113	g06190516

Illustration 114	g06190530

Illustration 115	g06190536

Fuel Injector Installation

Parts Required

Table 16

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	12	361-8207	Seal-Fuel System	Illustration 117 (1)
2	12	361-8206	Seal-Fuel System	Illustration 117 (2)
3	12	361-8205	Seal-Fuel System	Illustration 117 (3)

Installation Procedure

Table 17

Required Tooling
Tool	Part Number	Part Name	Qty
A	5F-4764	Pry Bar	1
B	9U-6862	Tapered Brush	1
C	4C-5027	Tap Wrench	1
D	4C-6774	Vacuum Gun Kit	1
E	1P-0808	Multipurpose Grease	1
F	1U-5512 or 8T-7765	Abrasive Material or Surface Reconditioning Pad	1

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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NOTICE
Remove all carbon deposits from the angled surface at the bottom of the cylinder head bore for the fuel injector. Failure to clean this area may prevent the fuel injector from seating properly. This could result in failure of the fuel injector due to leakage of exhaust gas into the fuel passage.

It is important to clean the cylinder head bore for the fuel injector before you install the fuel injector. Use the following procedure to clean the bore.

Note: A fine grade of Scotch Brite material is recommended for cleaning the cylinder head bore for the fuel injector. The product is available as Tooling (F).

Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (B).

Note: It should not be necessary to use a power tool to clean the cylinder head bore for the fuel injector.

Illustration 116	g06042157

Hold the brush with Tooling (C). Insert the brush into bore (6). Rotate the Scotch Brite material against the lower surface of bore (7). Continue cleaning until the surface is smooth and shiny.

Note: Tooling (D) is recommended for cleaning loose particles from the bore. The vacuum is operated with pressurized air.

Remove all loose particles from the bore.

Remove any fuel / fluid that may have accumulated before installing the fuel injector.

Illustration 117	g06190772

Illustration 118	g06190826

Note: Press the fuel injector into the bore of the cylinder head. Do not strike the fuel injector. Center the solenoid between the valve springs.

Illustration 119	g06190852

Press the fuel injector into the bore of the cylinder head. Do not strike the fuel injector. Center the solenoid between the valve springs.

The fuel injector clamp has orientation pads and alignment tab that fit onto machined injector slots. Fuel injector clamp must be used to draw the fuel injector into the cylinder head bore.

Push Rod Installation

Parts Required

Table 18

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	24	100-3880	Pushrod-Valve	Illustration 123 (1), and 124 (1)

Installation Procedure

Illustration 120	g06190885

Illustration 121	g06190893

Illustration 122	g06190897

Illustration 123	g06190902

Illustration 124	g06190911

Rocker Arm Assembly and Installation

Parts Required

Table 19

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	24	3J-9196	Nut-Jam	Illustration 125 (2)
2	24	9F-7707	Ring-Retainer	Illustration 125 (3)
3	24	154-6389	Button	Illustration 125 (4)
4	24	230-2621	Arm As-Rocker	Illustration 129 (1), and 130 (1)
5	12	230-2633	Shaft As-Arm	Illustration 126 (2)
6	24	265-7538	Bridge-Float (ex)	Illustration 127 (1), and 128 (1)
7	24	358-0768	Screw-Adjusting	Illustration 125 (1)

Installation Procedure

Illustration 125	g06190938

Illustration 126	g06190941

Note: Lubricate rocker shaft before installing into rocker arms assembly.

Illustration 127	g06190948

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NOTICE
Ensure that the slot of the valve bridge goes in-board and the circular pocket goes outboard.

Illustration 128	g06190951

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NOTICE
Ensure that the slot of the valve bridge goes in-board and the circular pocket goes outboard.

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NOTICE
Ensure that the crankshaft and the camshafts are in time with each other. Also ensure that the adjustment screws in the rocker arms are loosened completely before the bolts on the rocker shaft are tightened or damage to the valves and the pistons may occur.

Illustration 129	g06190953

Illustration 130	g06190959

Make sure that the rocker arms and pushrods are aligned. Apply clean unused engine oil to the threads and the shoulder of bolts.

Tighten one bolt to 215 ± 40 N·m (159 ± 30lb ft). Tighten second bolt to 215 ± 40 N·m (159 ± 30lb ft). Retighten first bolt to 215 ± 40 N·m (159 ± 30lb ft). Retighten second bolt to 215 ± 40 N·m (159 ± 30lb ft).

Valve Lash Setting

Table 20

Valve Lash Timing Chart

Consecutive Firing Order

1–2–9–10–5–6–11–12–3–4–7–8

V-12 (CCW) Rotation Engine

A. Set Number 1 Cylinder TDC Compression Stroke

1. Set Number 1, 2, 3, 4, 7, 8 Intake Valves

2. Set Number 1, 2, 5, 8, 9, 10 Exhaust Valves

B. Turn Crankshaft 360° (Number 11 Cylinder TDC Compression Stroke)

1. Set Number 5, 6, 9, 10, 11, 12 Intake Valves

2. Set Number 3, 4, 6, 7, 11, 12 Exhaust Valves

Instructions for valve lash adjustment:

1. Use the two crank position method to set valve lash as shown in timing chart.

2. Tap each rocker arm on adjusting screw to assure roller is seated on camshaft base circle before setting lash.

3. Use a feeler gage or dial indicator to set cold valve lash at 0.50 for inlet valves and 1.00 for exhaust valves.

4. Tighten valve rocker arm adjusting screw locknut to 70 ± 15 N·m (52 ± 11 lb ft) and recheck adjustment.

Accumulator (Fuel Injection) Installation

Required Parts

Table 21

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	24	494-6542	Washer-Spherical	Illustration 134 (2)
2	24	494-7086	Stud	Illustration 131 (1), and 132 (2)
3	24	5P-9186	O-ring Seal	Illustration 134 (1)
4	24	9S-8752	Nut-Full	Illustration 134 (2)

Installation Procedure

Illustration 131	g06190982

Illustration 132	g06190985

Note: An extra 5/8 inch socket will be required. A Snap-on SIM-L200 is recommended.

Illustration 133	g06190990

Illustration 134	g06190996

Note: The spherical end of the washer must seat against accumulator clamp cone.

Note: Do not push the accumulator in by hand. Pushing by hand could lead to damage of the accumulator tip which can result in a fuel leak.

Use one of the nuts to draw the accumulator into the cylinder head until the accumulator bottoms out, contacting the injector. Do not completely tighten the nuts used to draw the accumulator. Loosen the nut used to draw in the accumulator by on full turn.

Illustration 135	g06029402
(8) Sealing band (good condition) - Reusable (9) Scratches that are not on the sealing band - Reusable (10) Scratches that are on the sealing band - Not Reusable

Check the condition of the line end sealing surfaces.

Illustration 136	g06190999

Illustration 137	g06191001

Note: Do not tighten the line nut completely.

Illustration 138	g06191002

Note: Do not tighten the line nut completely.

Illustration 139	g06191005

The line clamp will help align the fuel line during tightening.

Illustration 140	g06191007

Torque fuel line nuts using a 1-1/16 or 27 mm crow foot wrench.

Illustration 141	g06191009

Torque fuel line nuts using a 1-1/16 or 27 mm crow foot wrench.

Illustration 142	g06191011

tighten the accumulator nuts alternately, 90 degrees at a time, to a fin torque of 35 N·m (26 lb ft).

Note: Do not let the stud bolts contact the ID of the bolt holes in the accumulator clamp.

Illustration 143	g06191012

Note: Lubricate the new O-ring on the end plug with clean, unused engine oil.

Torque the existing end plugs of the accumulators at cylinder 11 and 12.

If installing a new accumulator at cylinder 11 or 12, place a new ball and new end plug against the mating cone in the inlet port and hind tighten. Ensure that the ball seats properly on the mating cone.

Intake Manifold Installation

Parts Required

Table 22

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	48	1T-0720	Bolt-12Point HD	Illustration 145 (3), and 146 (3)
2	12	4S-5898	Seal-O-Ring	144 (1)
3	12	7N-5080	Gasket-Maniforld	145 (1), and 146 (1)

Installation Procedure

Illustration 144	g06191247

Illustration 145	g06191220

Illustration 146	g06191263

Exhaust Manifold Installation

Parts Required

Table 23

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	12	320-8974	Gasket As.	147 (1), and 148 (2)
2	48	9L-7373	Bolt-High Temp	147 (2), and 148 (2)
3	96	5M-2894	Washer-Hard	147 (2), and 148 (2)

Installation Procedure

Illustration 147	g06191032

Illustration 148	g06191197

Jacket Water Manifold Installation

Required Parts

Table 24

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	12	127-2176	Seal-Integral	150 (1), and 151 (1)
2	12	241-5928	Gasket As.	149 (1)

Installation Procedure

Table 25

Required Tools
Tool	Part Name	Qty
A	Suitable Lifting Device	2

Illustration 149	g06191300

Illustration 150	g06191376

Illustration 151	g06191382

Fuel Manifold, Fuel Supply and Return Lines Removal

Installation Procedure

Illustration 152	g06191401

Illustration 153	g06191436

Illustration 154	g06191455

Valve Cover Installation

Parts Required

Table 26

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	12	272-0760	Seal	155 (1)

Installation Procedure

Illustration 155	g06191469

Illustration 156	g06191474

Illustration 157	g06191478

Exhaust Cooler (NRS) Installation

Parts Required

Table 27

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	3	399-7288	Gasket-Exhaust	Illustration 158 (1)
2	1	345-0878	Bellow As	Illustration 158 (5)
3	2	302-5889	Clamp-V-Band	Illustration 158 (7)
4	3	440-4377	Bellow As	162 (1)
5	9	378-8994	Clamp-V-Band	162 (3)

Installation Procedure

Illustration 158	g06191511

Illustration 159	g06191515

Illustration 160	g06191517

Illustration 161	g06191518

Illustration 162	g06191522

Illustration 163	g06191524

Oil Filter and Tube Installation

Required Parts

Table 28

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	2	109-2332	Seal-O-Ring	Illustration 164 (1)
2	3	275-2604	Filter As-Lube	Illustration 166 (1)
3	1	3P-0655	Seal-O-Ring	Illustration 164 (2)

Installation Procedure

Illustration 164	g06192069

Illustration 165	g06192074

Illustration 166	g06192077

Air Inlet Tube Assembly Installation

Installation Procedure

Illustration 167	g06191698

Illustration 168	g06191699

Engine Harness Installation

Installation Procedure

Illustration 169	g06191710

Illustration 170	g06191713

Illustration 171	g06191720

Illustration 172	g06191731

Illustration 173	g06191752

Illustration 174	g06191758

Illustration 175	g06191768

Illustration 176	g06191783

Illustration 177	g06191793

Illustration 178	g06191803

Illustration 179	g06191813

Illustration 180	g06191817

Support Assembly Installation

Installation Procedure

Table 29

Required Tools
Tool	Part Name	Qty
A	Suitable Lifting Device	4

Illustration 181	g06191827

Illustration 182	g06191843

Illustration 183	g06191848

Exhaust Installation

Installation Procedure

Table 30

Required Tools
Tool	Part Name	Qty
A	Suitable Lifting Device	2

Illustration 184	g06191892

Illustration 185	g06191898

Illustration 186	g06191907

Illustration 187	g06191912

Illustration 188	g06191915

Discharge Elbow Installation

Required Parts

Table 31

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	1	505-1703	1	Illustration 189 (1)

Installation Procedure

Illustration 189	g06192012

Illustration 190	g06192016

Illustration 191	g06192019