Usage:
Disassemble Engine
NOTE: The Engine Overhaul In Chassis was done on a Kenworth Model 900 truck with a Caterpillar 3406 Engine.
NOTE: Put identification on all parts that are removed for correct installation.
| NOTICE |
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Do not let steam get into air inlet, air outlet or alternator. |
1. Steam clean the complete engine.
2. Remove wing nuts (2) and battery cover (1) from the left side of the truck.
 |
Do not smoke when a check is made of electrolyte level. Batteries give off flamable fumes. Do not permit electrolyte solution to make contact with skin or eyes. Electrolyte solution is an acid. Fasten ground cable last, and remove first to prevent sparks near the battery, which can cause battery vapors to burn with much force (explode). |
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3. Disconnect battery cables (3), (4), (5) and (6).
4. Remove plug (7) and drain the coolant from the radiator and cylinder block.
5. Remove two bolts (9) and cover (8) from the left side of the oil pan.
6. Remove drain plug (10) and drain the oil from the oil pan.
7. Use tool (A) and remove oil filter (11).
8. Remove bolts (12) that hold the oil pan in place. Remove oil pan (13) from the cylinder block.
9. Remove suction bell (15) and suction bell tube (14) from the oil pump.
10. Remove oil supply tube (16).
11. Remove the three bolts that hold the oil pump to the cylinder block. Remove oil pump (17).
12. Check the connecting rods and caps for their identification and location.
NOTE: Inspect bearings for damage as the caps are removed. See REUSABILITY GUIDELINES, Form No. SEBF8008, MAIN AND CONNECTING ROD BEARINGS.
13. Turn the crankshaft until two connecting rod caps are at bottom as shown. Remove four nuts (18) and two rod caps (19).
14. Install the rod caps in their original position. Install the nuts but do not tighten.
15. Do Steps 12 through 14 for the remainder of the connecting rods.
16. Remove Nos. 2, 3, 4, 5 and 6 main bearing caps. Inspect the bearings.
17. Install Nos. 2 and 6 main bearing caps and remove Nos. 1 and 7 main bearing caps. Inspect the bearings.
18. Inspect the crankshaft journals for damage and wear.
NOTE: If the crankshaft is not damaged, go to the next step. If the crankshaft is to be ground (a new surface put on) or a replacement is needed, remove the engine from the chassis.
19. Loosen clamp on air inlet piping and remove bolts (20). Remove air cleaner and air inlet piping as a unit.
20. Loosen clamp (22) and remove air inlet piping (21) as a unit.
21. Use tool (A) and remove fuel filter (23) from the fuel filter base.
NOTE: Put plugs or caps on all openings.
22. Disconnect fuel lines (24), (25) and (26) from the fuel block.
23. Remove two bolts (27) and remove fuel priming pump (28) from the fuel filter base.
24. Disconnect fuel line (29) from the fuel filter base.
25. Disconnect line (30) from the inlet manifold.
26. Remove wire and brackets (32) and (34) from inlet manifold. Disconnect brackets (31) and (33) from the inlet manifold.
27. Disconnect line (37) from the starting aid. Remove two nuts (36) and push starting aid (35) clear of the bracket.
28. Disconnect tachometer drive cable (38) from the tachometer drive.
29. Remove twelve bolts (42) that hold inlet manifold (40) to the cylinder head. Remove inlet manifold (40), turbocharger tube (39) and elbow (41) as a unit.
30. Disconnect outer fuel injection lines (43) from the cylinder head. Put plugs in the fuel injection lines to keep dirt out.
31. Disconnect air compressor water line (44) from the air compressor.
32. Remove clamp (45) and disconnect the exhaust piping from the turbocharger.
33. Remove two bolts (46) that hold the oil supply tube to the turbocharger. Disconnect oil supply tube (47) from the oil filter base. Remove the oil supply tube.
NOTE: It is not necessary to remove oil drain tube (48) at this time.
34. Remove two bolts (49) that hold oil drain tube (48) to the turbocharger.
35. Loosen adjusting nut (50) for the alternator. Disconnect wires (51) from the alternator.
36. Remove bolts (52), (54) and (55) that hold alternator (53) in place. Remove alternator (53).
37. Disconnect wires (58).
38. Loosen clamps (56) and (59) for the upper radiator hose. Remove upper radiator hose (57).
39. Disconnect water vent line (62) from the fitting.
| NOTICE |
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Do not disconnect any of the refrigerant lines connected to the air conditioning compressor. |
40. Remove four bolts (61) and (63) and push air conditioning compressor (60) clear of the engine.
41. Remove bolts (64) that hold the elbow to the water temperature regulator housing. Remove elbow (65) from the water pump.
42. Remove three bolts (66), water temperature regulator and water temperature regulator housing (67).
43. Disconnect hoses (68) and (69) from the water pump.
44. Disconnect lower radiator hose (70) from the water pump.
45. Disconnect oil temperature gauge wire (73) from the oil temperature sensing unit. Remove oil temperature sensing unit (74) from the cylinder block.
46. Remove bolts (72) and remove cover (71) from the back of the water pump.
47. Remove two bolts (75) that hold oil cooler bonnet (76) to the water pump.
48. Remove bolts (77) that hold cover (79) and water pump (78) to the timing gear cover. Remove water pump (78) from the timing gear cover.
49. Remove clamp (82). Remove the two clamps that hold tube (81) in place. Remove breather (80) and breather tube (81) as a unit.
50. Remove the bolts that hold the valve covers to the valve cover bases. Remove valve covers (83) and (84).
51. Remove bolts (87) and (88) that hold the valve cover bases to the cylinder head. Remove valve cover bases (85) and (86) from the cylinder head.
52. Remove inner fuel injection lines (89). Install plugs on all injection line openings.
53. Remove six bolts (90) that hold the rocker shafts to the cylinder head.
54. Remove rocker shafts (91) and (92).
55. Remove twelve push rods (93) from the valve lifters.
56. Remove twelve bridges (94) from dowels on the cylinder head.
57. Disconnect wires (95) and (96) from the water temperature sensing unit.
58. Remove bolts (97) that hold the bracket to the timing gear cover.
59. Remove bolt (98) and nut that hold the radiator support in place. Slide radiator support (99) out of the way.
60. Disconnect hose (102) from the cylinder head.
61. Remove bolts (100) and (101) that hold the head to the cylinder block.
62. Remove water temperature sensing units (104) and (105) from the cylinder head.
| NOTICE |
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Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves. |
63. Fasten a hoist and remove cylinder head (103), turbocharger and exhaust manifold as a unit from the cylinder block. The weight is 420 lb. (189 kg).
NOTE: Make a separation of the turbocharger from the manifold and the manifold from the cylinder head to recondition the turbocharger and the cylinder head. For the turbocharger, see GUIDELINES FOR REUSABLE PARTS, Form No. SEBF8018 TURBOCHARGERS AND SEBF8019 TURBOCHARGER SPECIFICATIONS. See DISASSEMBLY AND ASSEMBLY section for the cylinder head.
64. Remove turbocharger oil drain line (106).
65. Remove seals (107) and the head gasket from the spacer plate.
66. Install seven 3/8"-16 NC forcing screws (108) in the spacer plate. Remove spacer plate (109) with the forcing screws.
67. Remove the carbon ridge from the top inside surface of the cylinder liners.
68. Turn the crankshaft until two connecting rod caps are at bottom.
69. Remove the nuts and connecting rod caps from the two connecting rods that are at the bottom. Remove pistons (110) from the cylinder liners.
70. Do Steps 68 and 69 and remove the remainder of the pistons.
71. Remove the cylinder liners from the cylinder block with tool (A) and an air impact tool.
72. Inspect the pistons and cylinder liners. See GUIDELINES FOR REUSABLE PARTS, Form No. SEBF8001 PISTONS AND LINERS.
Component Inspection And Reconditioning
1. Inspect cylinder block walls for pitting and lower liner bore for erosion.
2. Recondition other components such as the air compressor, alternator, fuel pump and starter if inspection or performance gives an indication it is necessary. See DISASSEMBLY AND ASSEMBLY section.
3. Check for minor external engine repairs or replacement such as gaskets, seals, belts, hoses, etc.
4. Clean all gasket and seal areas on the block and removed components.
5. Make a replacement of crankshaft wear sleeves and seals if leaks are present. See DISASSEMBLY AND ASSEMBLY section.
6. Make a replacement of the rear crankshaft wear sleeve and seal if the clutch and transmission are removed for other reasons. See DISASSEMBLY AND ASSEMBLY section.
7. Disassemble pistons from the rods. See DISASSEMBLY AND ASSEMBLY section.
8. Inspect pistons and liners. See GUIDELINES FOR REUSABLE PARTS Form No. SEBF8001, PISTONS AND LINERS.
9. Recondition pistons and install new rings. See DISASSEMBLY AND ASSEMBLY section.
10. Recondition liners, this includes flex honing. See GUIDELINES FOR REUSABLE PARTS, Form No. SEBF8001, PISTONS AND LINERS.
11. Recondition cylinder head. See DISASSEMBLY AND ASSEMBLY section.
12. Test fuel injection nozzles, make replacement, if needed. See TESTING AND ADJUSTING.
13. Recondition turbocharger. See GUIDELINES FOR REUSABLE PARTS, Form No. SEBF8018, TURBOCHARGERS and Form No. SEBF8019, TURBOCHARGER SPECIFICATIONS.
14. Recondition water pump. See DISASSEMBLY AND ASSEMBLY section.
15. Recondition fan drive. See DISASSEMBLY AND ASSEMBLY section.
16. Inspect oil pump. See DISASSEMBLY AND ASSEMBLY section.
Assemble Engine
1. Put tool (A) in oil hole (1) and remove the upper halves of main bearings Nos. 1, 3, 4, 5 and 7. Turn the crankshaft in the direction which will push the end of the bearing with tab out first. Inspect the bearing. See GUIDELINES FOR REUSABLE PARTS, Form No. SEBF8009 MAIN AND CONNECTING ROD BEARINGS.
| NOTICE |
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If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both. |
NOTE: Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.
2. Install main bearings (2) in the main bearing caps.
NOTE: Be sure tabs (3) on the back of the bearings fit in the grooves of the caps and cylinder block.
3. Install the upper halves of the bearings into the cylinder block with tool (A).
NOTE: When the bearing clearance is checked and the engine is in its normal operating position, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication.
4. Check the bearing clearance with Plastigage (B). Put Plastigage (B) on the bearings.
NOTE: Do not turn the crankshaft when Plastigage (B) is in position.
NOTE: Be sure the main bearing caps are installed so the numbers on the side of the cylinder block are the same as the numbers on the bearing caps, and the arrows (4) on the bearing caps are toward the front of the cylinder block.
| NOTICE |
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Do not use an impact wrench to tighten the bolts the additional 120° ± 5°. |
5. Install the bearing caps for Nos. 1, 2, 4, 5 and 7 main bearings. Put clean engine oil on the threads of the bolts. Install the bolts and tighten bolts, at end with tab first, to a torque of 190 ± 10 lb. ft. (260 ± 14 N·m). Turn the bolts an extra 120° ± 5° first at the end opposite of the tab. Remove the bearing caps for No. 2 through No. 6. Remove Plastigage (B) from the caps. Check the thickness of Plastigage (B) to find the bearing clearance. The bearing clearance must be .0036 to .0073 in. (0.091 to 0.186 mm) with new bearings. Maximum clearance with used bearings is .010 in. (0.35 mm).
6. Put clean engine oil on the threads of the bolts. Install the bearing caps for Nos. 1, 3, 4, 5 and 7. Install the bolts and tighten the bolts, at the end with the tab first, to a torque of 190 ± 10 lb.ft. (260 ± 14 N·m). Put a mark on the bolts and caps. Turn the bolts at opposite end of tab first an extra 120° ± 5° from the mark.
7. Remove the No. 1 and No. 6 main bearing caps. Do Steps 1 through 6 for the No. 2 and No. 6 caps.
8. Install the thrust bearings for No. 4 main bearing.
NOTE: Install the thrust bearings with the side that has the identification "BLOCK SIDE" toward the cylinder block.
9. Check the end play of the crankshaft with tool group (C). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings of No. 4 (center) main. The end play with new bearings must be .006 to .020 in. (0.15 to 0.50 mm). The maximum permissible end play with used bearings is .035 in. (0.89 mm).
10. Thoroughly clean the spacer plate and cylinder block surface.
NOTE: Earlier model engines do not have O-ring seals (5) and (7).
11. Install a new gasket (8) between the spacer plate and cylinder block. Put O-ring seals (5) and (7) in position and put spacer plate (6) in position on the cylinder block.
| NOTICE |
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Both surfaces of the spacer plate, top of cylinder block, and both sides of the spacer plate gasket must be clean and dry. Gasket adhesives or other substances must not be used on these surfaces. |
12. Clean the cylinder liners and the liner bores in the cylinder block.
NOTE: If used liners are installed, put the liners in position as shown in GUIDELINES FOR REUSABLE PARTS Form No. SEBF8001 PISTONS AND LINERS.
13. Install cylinder liners (9) in the block without the O-ring seals or filler band.
14. Check the cylinder liner projection as follows:
a) Install the 3/4"-16 NF bolts, 3 in. long and the 2F126 washers of tooling (E) on the cylinder block next to each liner. Tighten the bolts evenly, in four steps: 10 lb.ft. (14 N·m), 25 lb.ft. (35 N·m), 50 lb.ft. (70 N·m) and then to 70 lb.ft. (95 N·m).
b) Put the adapter plate and one plate of tooling (E) on top of the liner and install the remainder of tooling (E). Be sure the bar is in position at the center of the liner. Tighten the bolts evenly, in four steps: 5 lb.ft. (7 N·m), 15 lb.ft. (20 N·m), 25 lb.ft. (35 N·m) then to 50 lb.ft. (70 N·m).
c) Check to be sure the distance from the bottom edge of the bar to the top of the cylinder block is the same on both sides of the liner.
d) Check the cylinder liner projection with tooling (F) at four locations around the liner. SPECIAL INSTRUCTION (GMG00623) is included with the tool.
e) Liner projection must be .005 ± .003 in. (0.13 ± 0.08 mm). Measurements on the same liner must not be different by more than .002 in. (0.05 mm). Average measurements between liners next to each other must not be different by more than .002 in. (0.05 mm).
NOTE: If the liner is turned in the bore it can make a difference in the liner projection.
f) If the liner projection is not .005 ± .003 in. (0.13 ± 0.08 mm), check the thickness of the following parts: spacer plate, spacer plate gasket, and cylinder liner flange (10). The thickness of the spacer plate must be .338 ± .001 in. (8.59 ± 0.03 mm). The thickness of the spacer plate gasket must be .008 ± .001 in. (0.20 ± 0.03 mm). The thickness of the cylinder liner (flange must be .3500 ± .0008 in. (8.890 ± 0.020 mm).
NOTE: The cylinder liner projection can be changed by the correction of the counterbore in the block to a minimum depth of .030 in. (0.76 mm) with a cylinder block counterboring tool. See SPECIAL INSTRUCTION, Form FM055228. Shims are available for the adjustment of the liner projection.
15. Put a mark on the liner and block so the liner can be installed in the same position from which it was removed.
16. Remove (E) and (F). Remove the liner. Install new O-ring seals on the liners.
NOTE: Do not put 7M7260 Liquid Gasket Material on the cylinder block. Put the .030 in. (0.76 mm) shim on top of the shim package if more than one shim is used. Put 7M7260 Liquid Gasket Material on the top and bottom of the shim package.
17. Put liquid soap on the O-ring seals and on the cylinder bores. Put filler band (11) in SAE 30W oil. Then immediately install the filler band on the cylinder liner and immediately install the cylinder liner in the cylinder block with tooling (D) before expansion of the band.
NOTE: Earlier model engines do not have O-ring seals (12).
18. Make sure O-ring seals (12) are in place on the spacer plate.
19. Assemble the connecting rods to the pistons. See DISASSEMBLY AND ASSEMBLY.
NOTE: Make sure the tab in back of the bearing is in the tab groove in the connecting rod.
20. Install upper half of bearing (13) in the connecting rod. Put clean engine oil on the bearing and the crankshaft journal.
NOTE: Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearing for final assembly.
21. Turn the crankshaft until two journals of the crankshaft are at bottom.
22. Put clean engine oil on the piston rings and cylinder liners.
| NOTICE |
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Never install the ring compressor on the piston unless the cylinder liner is used as a guide. Damage to the piston rings can be the result. |
23. Use compressor (G) to install the piston in the cylinder. Use a hammer to push the piston and connecting rod in position. Be sure the number on the tab groove side of the connecting rod is on the opposite side from the camshaft.
24. Install lower half of bearing (14) in the connecting rod cap. Be sure the tab in back of the bearing is in the tab groove of the connecting rod cap.
25. Put Plastigage (B) on the bearing to check the bearing clearance.
NOTE: Do not turn the crankshaft when Plastigage (B) is in position.
26. Put clean engine oil on threads of rod bolts and seat surfaces of nuts.
NOTE: Be sure the cylinder numbers on the rod cap and rod are the same, and are on the same side of the connecting rod. Numbers are on the same side of rod and cap as are the grooves for the bearing tabs. If new rods are installed, put the cylinder number on the rod and cap.
| NOTICE |
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Do not use an impact wrench to tighten the bolts the additional 120° ± 5°. |
27. Install the rod caps. Install the nuts. Tighten each nut to a torque of 60 ± 6 lb. ft. (80 ± 8 N·m). Put a mark on the nuts and cap and tighten nuts an extra 120 ± 5° from the mark. Remove the rod cap. Remove Plastigage (A) and check the bearing clearance. The bearing clearance must be .0028 to .0066 in. (0.071 to 0.168 mm) for new bearings. The maximum clearance with used bearings is .010 in. (0.35 mm).
28. Put clean engine oil on lower half of bearing. Install rod cap again. Tighten each nut to a torque of 60 ± 6 lb.ft. (80 ± 8 N·m). Put a mark on nuts and cap and tighten nuts an extra 120° ± 5° from mark.
29. Do Steps 20 through 28 for remainder of connecting rods, pistons and bearings.
30. Make a rotation of the crankshaft.
31. Put oil pump (15) in position on the cylinder block. Install the three bolts that hold it.
32. Put clean engine oil on the O-ring seals of the tubes.
33. Install oil supply tube (16).
34. Install suction bell tube and suction bell (17).
35. Install new seals (18) and cylinder head gasket (19).
36. Make sure O-ring seal (21) is in position. Put SAE 30W oil on the O-ring seal and install oil drain tube (20).
NOTE: If the exhaust manifold studs were removed, install new studs and tighten the studs to a torque of 20 ± 3 lb.ft. (30 ± 5 N·m).
37. Put 5P3931 Anti-Seize Compound on the exhaust studs.
38. Put the exhaust manifold gaskets in position and install the exhaust manifold on the cylinder head. Tighten the nuts to a torque of 38 ± 5 lb.ft. in the sequence shown in illustration A51108X2.
39. Put the turbocharger gasket in position on the exhaust manifold. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the turbocharger to the exhaust manifold. Put the turbocharger in place and install the bolts and nuts that hold it in place. Tighten the nuts to a torque of 40 ± 4 lb.ft. (55 ± 5 N·m).
| NOTICE |
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Make sure the bolt holes in the cylinder block for the head bolts are clean and free of water, oil and foreign materials. |
40. Fasten a hoist and 8S9906 Ratchet Assembly (22) to the cylinder head. Put cylinder head (23), turbocharger and exhaust manifold as a unit in position on the cylinder block.
41. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in the following sequence:
a) Tighten bolts 1 through 20 in number sequence to 200 ± 20 lb.ft. (270 ± 25 N·m).
b) Tighten bolts 1 through 20 in number sequence to 330 ± 15 lb.ft. (450 ± 20 N·m).
c) Tighten bolts 1 through 20 in number sequence to 330 ± 15 lb.ft. (450 ± 20 N·m) by hand.
d) Put clean engine oil on the bridges and dowels. Install the bridges (24) on the dowels. Keep pressure by hand on the bridges and turn the adjustment screw clockwise until contact is made with the valve stem. Turn the screw an extra 20° to 30°. This will make dowel straight in guide and make compensation for gap (slack) in the threads. Hold adjustment screw in this position and tighten locknut to a torque of 22 ± 3 lb.ft. (28 ± 4 N·m).
e) Install push rods (26).
f) Put rocker shaft assemblies (25) in position on the cylinder head. Put clean engine oil on the bolts and install the bolts in the cylinder head.
g) Tighten bolts 21 through 26 in number sequence to 200 ± 20 lb.ft. (270 ± 25 N·m).
h) Tighten bolts 21 through 26 in number sequence to 330 ± 15 lb.ft. (450 ± 20 N·m).
i) Tighten bolts 21 through 26 in number sequence to 330 ± 15 lb.ft. (450 ± 20 N·m) by hand.
j) Tighten the 3/8" bolts to 32 ± 5 lb. ft. (43 ± 7 N·m).
42. Make an adjustment to the valves to have a clearance of .015 in. (0.38 mm) for intake, and .030 in. (0.76 mm) for exhaust. Tighten the locknuts for the valve adjustment screws to a torque of 22 ± 3 lb.ft. (28 ± 4 N·m) and check the valve clearance again.
| NOTICE |
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Do not cause damage to the O-ring seals on the inner fuel lines. |
43. Install inner fuel injection lines (27). Use tool (H) and (J) and tighten the fuel injection line nuts to a torque of 30 ± 5 lb. ft. (40 ± 7 N·m).
44. Make sure seals (28) are in position on the valve cover bases. Put valve cover bases (29) in position on the cylinder head.
45. Install bolts (32) that hold the valve cover bases in place. Tighten the bolts to a torque of 120 ± 24 lb.in. (13.6 ± 2.8 N·m).
46. Make sure seals (30) are in position on the valve covers. Put valve covers (31) in position on the valve cover bases. Install bolts (33) that hold the valve covers in place. Tighten the bolts to a torque of 120 ± 24 lb.in. (13.6 ± 2.8 N·m).
47. If the fan drive group was not removed, install bolts (34) that hold the bracket on the head to the timing gear cover.
48. Put breather (35) and breather tube (36) in position on the valve cover. Install the three clamps that hold them in place.
49. Connect hose (37) to the cylinder head.
50. Connect air compressor water line (38) to the air compressor.
51. Connect outer fuel injection lines (39). Tighten the nuts to a torque of 30 ± 5 lb.ft. (40 ± 7 N·m).
52. Install water temperature sensing units (42) and (43). Connect wires (40) and (41) to the water temperature sensing units.
NOTE: Install turbocharger tube (47), elbow (45) and inlet manifold (44) as a unit.
53. Put the inlet manifold gaskets in place on the cylinder head. Put SAE 30W oil on O-ring seals (46). Slide turbocharger tube (47) into the turbocharger. Put 9S3263 Thread Lock on the threads of the bolts and install the twelve bolts that hold the inlet manifold to the cylinder head.
54. Connect oil line (48) for the fuel ratio control to the inlet manifold.
55. Connect fuel lines (49), (50) and (51) to the fuel block.
56. Connect fuel line (52) to the fuel filter base.
57. Make sure the gasket is in place and put priming pump (55) in position. Install bolts (54).
58. Install brackets (53) on the inlet manifold.
59. Put the gasket in place and install two bolts (57) that hold the oil drain tube to the turbocharger.
60. Put the gasket in position for the oil supply tube. Install oil supply tube (56).
61. If the fan drive group was removed, install the fan drive. See DISASSEMBLY AND ASSEMBLY section.
62. Put air conditioning compressor (58) in position on bracket (59). Install the four bolts that hold the compressor to the bracket.
63. Put gasket (60) in position. Install water temperature regulator (61) in the water temperature regulator housing. Install the water temperature regulator housing (62) on the cylinder head.
64. Connect the water vent line to the head. Put upper radiator hose (63) in position on the water temperature regulator housing and the radiator. Tighten the clamps that hold the upper radiator hose in place.
65. Make sure O-ring seal (64) is in position. Put water pump (65) in place and install the gasket, front cover and bolts that hold the water pump and front cover in position.
66. Make sure the gasket is in place and install two bolts (66) that hold the oil cooler bonnet to the water pump.
67. Make sure the O-ring seal is in place on the back of the water pump. Install cover (67) on the water pump.
68. Make sure O-ring seal (70) is in place. Install elbow (69) in the cover of the water pump. Install gasket (68) between the elbow and the water temperature regulator housing. Put elbow (69) against the water temperature regulator housing and install the two bolts that hold it in place.
69. Install oil temperature sensing unit (71) and connect wire (72) to the oil temperature sensing unit.
70. Connect lower radiator hose (76) to the water pump.
71. Connect hoses (74), (75) and (73) to the water pump.
72. Connect wires (77).
73. Put exhaust piping (78) in place on the turbocharger and install clamp (79). Tighten the clamp to a torque of 120 ± 24 lb.in. (13.8 ± 2.8 N·m).
74. Put alternator (80) in position on the alternator bracket. Install bolts (84), washers and nuts that hold the alternator to the bracket. Connect wires (83).
75. Put belts (82) in position on the air conditioning compressor and alternator.
76. Put adjusting bolt (81) in place and install the bolt that holds the alternator to it. See SPECIFICATIONS for correct belt tension and tools.
77. Connect tachometer drive cable (85) to the tachometer drive.
78. Put starting aid (86) in place on the bracket and install nuts (87) that hold it in place. Connect line (88) to the starting aid.
79. Install bracket (89). Put bracket (90) and wire (91) in place on the inlet manifold and install the bolt that holds them in place.
80. Install radiator support (92).
81. Install the gasket for the oil pan. Put oil pan (93) in position on the cylinder block and install the bolts that hold the oil pan in place.
82. Install drain plug (94) in the oil pan. Make sure the joint (seam) in the copper gasket material for the plug is against the pan surface.
83. Install cover (95) on the oil pan.
84. Install new oil filter (96).
85. Install new fuel filter (97).
86. Install plug (98) in the elbow from the bottom of the radiator.
87. Fill the engine with oil to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.
88. Fill the cooling system with coolant to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.
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Do not smoke when a check is made of electrolyte level. Batteries give off flammable fumes. Do not permit electrolyte solution to make contact with skin or eyes. Electrolyte solution is an acid. Fasten ground cable last, and remove first to prevent sparks near the battery, which can cause battery vapors to burn with much force (explode). |
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89. Connect battery cables (99), (100), (101) and (102) to the batteries.
90. Install battery cover (103).
91. Prime the fuel system with the priming pump. Loosen the fuel line nuts and remove (bleed) air from the fuel lines.
92. Start the engine. Inspect the engine for any incorrect engine operations. Stop the engine.
93. Put air inlet piping (104) in position on the turbocharger and tighten clamp (105).
94. Put air cleaner (107) and air inlet piping (106) in position on the bracket. Install the bolts that hold the air cleaner to the side of the cab.
95. Slide air inlet piping (106) into air inlet piping (104) and tighten the clamp that holds them together.
96. If a dyno is available, dyno test the engine. If a dyno is not available, road test the engine.