Usage:
preparatory steps:
a) remove turbocharger
b) remove camshafts
1. Drain the engine cooling system-capacity 12 U.S. Gal. (45 liters).
2. Disconnect the water temperature sensing unit (4) from cylinder head, and remove instrument panel (3).
3. Disconnect the water bypass line (2) from the regulator housing.
4. Disconnect the outer fuel injection lines (1) from camshaft housing and from fuel injection pump housing. Cap or plug all lines and openings.
5. Disconnect vent line (5) from water pump.
6. Disconnect aftercooler water inlet line (7) from aftercooler.
7. Remove the aftercooler water outlet line (6).
8. Remove the turbocharger mounting bracket (8).
9. Remove the four camshaft housing-to-plate mounting bolts (10).
10. Remove the two camshaft housing mounting bolts.
11. Remove camshaft housing (9).
12. Remove the cylinder head assembly retaining bolts.
13. Install three 3/8"-16NC forged eyebolts in the cylinder head. Attach a hoist and remove the cylinder head assembly-weight 625 lb. (283,5 kg).
NOTE: Always replace the gasket between spacer plate and cylinder block before installing the cylinder head assembly. See REMOVE SPACER PLATE.
Install Industrial Engine Cylinder Head Assembly
NOTE: Be sure gasket between spacer plate and the cylinder block has been replaced before installing cylinder head assembly. Refer to REMOVE & INSTALL SPACER PLATE.
1. Clean the top surface of spacer plate and mating surface of cylinder head. Install the head gasket and water seals.
2. Install three 3/8"-16NC forged eyebolts in the cylinder head. Attach a hoist and position the cylinder head assembly on engine.
3. Lubricate the cylinder head retaining bolts with clean SAE 30 engine oil. Install bolts and tighten in following step sequence:
1 Tighten all bolts in numerical order to 200 lb. ft. (27,6 mkg).
2 Tighten all bolts in numerical order to 330 ± 10 lb. ft. (45,6 ± 1,4 mkg).
3 Hand tighten all bolts in numercal order to 330 ± 10 lb. ft. (45,6 ± 1,4 mkg).
4. Position camshaft housing on cylinder head, and install six mounting bolts. Install the four housing-to-plate mounting bolts.
5. Install the turbocharger mounting bracket.
6. Install the aftercooler water outlet line.
7. Connect water inlet line to the aftercooler.
8. Connect vent line to the water pump.
9. Remove the caps and plugs from fuel injection lines and openings. Connect the outer fuel injection lines to the pump housing and to camshaft housing. Tighten retaining nuts to 30 ± 5 lb. ft. (4,1 ± 0,69 mkg).
10. Connect the water bypass line to the water temperature regulator housing.
11. Connect the water temperature sensing unit to the cylinder head. Fill engine with coolant.
concluding steps:
a) install camshafts
b) install turbocharger
Remove Marine Engine Cylinder Head Assembly
preparatory steps:
a) remove expansion tank
b) remove turbocharger
c) remove camshafts
1. Disconnect the outer fuel injection lines from camshaft housing and from fuel injection pump housing.
2. Disconnect vent line (2) from water pump.
3. Disconnect aftercooler water inlet line (1) from the aftercooler.
4. Disconnect fuel ratio control sensing line (3) from the cylinder head.
5. Disconnect exhaust manifold water inlet line (7).
6. Remove cam followers (4).
7. Remove four camshaft housing-to-plate retaining bolts (5).
8. Remove the two camshaft housing mounting bolts and remove camshaft housing (6).
9. Remove the cylinder head assembly retaining bolts.
10. Install three 3/8"-16NC forged eyebolts in the cylinder head. Attach a hoist and remove the cylinder head assembly-625 lb. (283,5 kg).
NOTE: Always replace the gasket between spacer plate and cylinder block before installing the cylinder head assembly. See REMOVE SPACER PLATE.
Install Marine Engine Cylinder Head Assembly
NOTE: Be sure gasket between spacer plate and the cylinder block has been replaced before installing cylinder head assembly. Refer to REMOVE & INSTALL SPACER PLATE.
1. Clean the top surface of spacer plate and mating surface of cylinder head. Install the head gasket and water seals.
2. Install three 3/8"-16NC forged eyebolts in the cylinder head. Attach a hoist and position the cylinder head assembly on engine.
3. Lubricate the cylinder head retaining bolts with clean SAE 30 engine oil. Install bolts and tighten in following step sequence:
1 Tighten all bolts in numerical order to 200 lb. ft. (27,6 mkg).
2 Tighten all bolts in numerical order to 330 ± 10 lb. ft. (45,6 ± 1,4 mkg).
3 Hand tighten all bolts in numerical order to 330 ± 10 lb. ft. (45,6 ± 1,4 mkg).
4. Position camshaft housing on cylinder head, and install six mounting bolts.
5. Install the four housing-to-plate mounting bolts.
6. Lubricate and install the cam followers. Connect water inlet line to the aftercooler.
7. Connect the water pump vent line.
8. Connect the exhaust manifold water inlet line.
9. Connect the outer fuel injection lines to the pump housing and to camshaft housing. Tighten retaining nuts to 30 ± 5 lb. ft. (4,1 ± 0,69 mkg).
10. Fill engine with coolant.
concluding steps:
a) install camshafts
b) install turbocharger
c) install expansion tank