Usage:
preparatory steps:
a) remove front balancer and idler gear
b) remove fuel filter housing
c) remove oil filter housing
1. Remove the fuel line clamp mounting bolts from left aftercooler housing, right aftercooler housing, and rear of engine front lifting bracket.
2. Disconnect wiring from water temperature shutoff sending unit. Disconnect the water temperature gauge sending unit from front of regulator housing.
3. Disconnect turbocharger heat shield water return line from top of regulator housing.
4. Remove the exhaust manifold heat shields front water outlet lines.
5. Remove water bypass line mounting bolts (3).
6. Remove the water temperature regulator housing water inlet line mounting bolts (7) and (8).
7. Remove the aftercooler raw water outlet lines (1) and (2).
8. Remove the six bolts that retain the oil and fuel filter housings support bracket to the engine. Remove the support bracket (6).
9. Attach a hoist to water temperature regulator inlet pipe. Remove the two housing-to-cylinder head retaining bolts (4) and (5). Remove the water temperature regulator housing - weight 200 lbs. (91 kg).
10. Remove the front timing gear plate-to-cylinder block retaining bolts, nuts, and locks. Remove the front timing gear plate - weight 38 lbs. (17 kg).
11. Remove the oil line (9). Remove camshaft idler gear retaining shaft mounting bolts and lock. Remove shaft and camshaft drive idler gear (10). Using tool setup (A), remove bearing from camshaft drive idler gear.
Install Front Timing Gear Plate And Camshaft Drive Idler Gear
1. Using tool setup (A), install bearing in camshaft drive idler gear. Position idler gear and shaft on engine. Install the retaining bolts and lock. Install the oil line.
2. Install a new timing gear plate-to-cylinder block gasket. Trim the gasket flush with pan face of cylinder block. Position the timing gear plate on engine, and install retaining bolts, nuts and locks.
3. Attach a hoist and position the water temperature regulator housing on engine. Install the two housing-to-cylinder head retaining bolts.
4. Position the oil and fuel filter housings support bracket on engine, and install the six retaining bolts.
5. Install the water temperature regulator housing water inlet lines mounting bolts.
6. Install the water bypass line mounting bolts.
7. Install aftercooler raw water outlet lines.
8. Install exhaust manifold heat shields front water outlet lines.
9. Connect turbocharger heat shield water return line to top of regulator housing.
10. Connect the water temperature gauge sending unit to front of regulator housing. Connect wiring to water temperature shutoff sending unit.
11. Install the fuel line clamp mounting bolts in aftercooler housings and lifting bracket.
concluding steps:
a) install oil filter housing
b) install fuel filter housing
c) install front balancer and idler gear