Komatsu M11 User Manual

Foreword

This manual contains complete rebuild specifications and information for the M11 model engines, and all asso­ciated components manufactured by Cummins Engine Company, Inc. A listing of accessory and component
suppliers’ addresses and telephone numbers is located in Section C. Suppliers can be contacted directly for any
information not covered in this manual.

Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in this
section.

The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some
rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in
the procedures.

When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be
used in place of the recommended item.

A series of specific service manuals (Troubleshooting and Repair, Specifications, Alternative Repair, and so on.)
are available and can be ordered by filling outand mailing the LiteratureOrder Formlocated in the Service Literature
Section L.

Reporting of errors, omissions, and recommendations for improving this publication by the user is encouraged.
Please use the postage paid, self-addressed Literature Survey Form in the back of this manual for communicating
your comments.

The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Cummins Engine Company, Inc. reserves the right to make any changes at any time without obligation. If
differences are found between your engine and the information in this manual, contact a Cummins Authorized
Repair Location, a Cummins Division Office, or the factory.

The latest technology and the highest quality components are used to manufacture Cummins engines. When
replacement parts are needed, we recommend using only genuine Cummins or ReConT exchange parts. These
parts can be identified by the following trademarks:

Table of Contents

Section

Introduction ................................................................................................................................... i

Engine Identification...................................................................................................................... E

Engine Disassembly and Assembly – Group 00 ........................................................................... 0

Cylinder Block – Group 01 ............................................................................................................ 1

Cylinder Head – Group 02 ............................................................................................................. 2

Rocker Levers – Group 03............................................................................................................. 3

Cam Followers – Group 04 ............................................................................................................ 4

Fuel System – Group 05 ................................................................................................................ 5

Injectors and Fuel Lines – Group 06............................................................................................. 6

Lubricating Oil System – Group 07............................................................................................... 7

Cooling System – Group 08 .......................................................................................................... 8

Drive Units – Group 09 .................................................................................................................. 9

Air Intake System – Group 10 ....................................................................................................... 10

Exhaust System – Group 11.......................................................................................................... 11

Air Equipment – Group 12............................................................................................................. 12

Electrical Equipment – Group 13 .................................................................................................. 13

Engine Testing – Group 14............................................................................................................ 14

Instruments and Controls – Group 15........................................................................................... 15

Mounting Adaptations – Group 16 ................................................................................................ 16

Specifications – Group 18 ............................................................................................................. V

Vehicle Braking – Group 20........................................................................................................... 20

Service Literature .......................................................................................................................... L

Component Manufacturers: Names and Addresses ..................................................................... C

Index ............................................................................................................................................. X

Cummins’ 22-Group System Exploded Diagram

Section i - Introduction
M11 Page i-1

Section i - Introduction

Section Contents

Page

About the Manual................................................................................................................................................ i-2

Definition Of Terms ........................................................................................................................................... i-11

General Cleaning Instructions .......................................................................................................................... i-10

Glass or Plastic Bead Cleaning ...................................................................................................................... i-10

Solvent and Acid Cleaning.............................................................................................................................. i-10

Steam Cleaning .............................................................................................................................................. i-10

General Repair Instructions................................................................................................................................ i-9

Welding on a CELECT™ Controlled Vehicle....................................................................................................... i-9

General Safety Instructions................................................................................................................................ i-8

Important Safety Notice .................................................................................................................................... i-8

How to Use the Manual....................................................................................................................................... i-2

Illustrations ......................................................................................................................................................... i-7

Simbolos ............................................................................................................................................................ i-4

Symbole .............................................................................................................................................................. i-5

Symboles ........................................................................................................................................................... i-6

Symbols ............................................................................................................................................................. i-3

About the Manual Section i - Introduction

M11Page i-2

About the Manual

This M11 Shop Manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding and
assembly of components on M11 engines. The manual is divided into sections. Section 0 outlines the disassembly
and assembly of the engine while the other sections detail specific components.

How to Use the Manual

This manual is divided in the same group system used for Cummins’ filmcard system. Each group is organized
in a way that all mechanics, both those who are and are not familiar with the M11 engine models, can reference
the manual. Refer to the Table of Contents at the front of the manual to determine the group that details the desired
information.

Each group contains the following in sequence:

• Section contents at the beginning of each group to quickly aid in locating the information desired.

• Service tools list with recommended tools needed to rebuild the components.

• General information to aid in rebuilding the component, and an explanation of design change differences.

• Step-by-step rebuild instructions for disassemby, cleaning, inspection and assembly of the component.

• Symbols which represent the action outlined in the instructions. The definitions of the symbols, listed in four
languages (English, Spanish, French and German), appear on pages i-3 through i-6.

Topics will be listed alphabetically on the ‘‘Section Contents’’ page. All procedures are described using the ‘‘text
symbol picture’’ (TSP) format. In general, each component rebuild will be described through a 3-step sequence
of: (1) cleaning and inspection for reuse; (2) rebuild; and (3) replacement. Reference numbers (procedurenumbers)
are assigned to each process. Reference numbers are constructed with a section number and a two-digit
sequenced number.

Both metric and U.S. customary values are used in this manual. The metric value is listed first, followed by the
U.S. customary in brackets. An example is 60°C [140°].

Section i - Introduction Symbols
M11 Page i-3

Symbols

The following symbols have been used in this manual to help communicate the intent of the instructions. When
one of the symbols appears, it conveys the meaning defined below:

WARNING - Serious personal injury or extensive property damage can result if the warning
instructions are not followed.

CAUTION - Minorpersonal injury can result, or a part,an assembly,or the enginecan be damaged
if the caution instructions are not followed.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

PERFORM an electrical MEASUREMENT.

Refer to another location in this manual or another publication for additional information.

The component weighs 23 kg [50 lb] ormore. To avoid personal injury,use a hoistor get assistance
to lift the component.

Simbolos Section i - Introduction

M11Page i-4

Simbolos

Los sı´mbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuando
aparece uno de estos sı´mbolos, su significado se especifica en la parte inferior.

ADVERTENCIA - Serios dan˜os personales o dan˜o a la propiedad puede resultar si las instruc­ciones de Advertencia no se consideran.

PRECAUCION - Dan˜os menores pueden resultar, o de piezas del conjunto o el motor puede
averiarse si las instrucciones de Precaucio´n no se siguen.

Indica un paso de REMOCION o DESMONTAJE.

Indica un paso de INSTALACION o MONTAJE.

Se requiere INSPECCION.

LIMPIESE la pieza o el montaje.

EJECUTESE una MEDICION meca´nica o del tiempo.

LUBRIQUESE la pieza o el montaje.

Indica que se dara´ una LLAVE DE TUERCAS oelTAMAN˜O DE HERRAMIENTA.

APRIETESE hasta un par torsor especı´fico.

EJECUTESE una MEDICION ele´ctrica.

Para informacio´n adicional refie´rase a otro emplazamiento de este manualoaotrapublicacio´n
anterior.

El componente pesa 23 kg [50 lb] o mas. Paraevitardano corporal empleen una cabriau obtengan
ayuda para elevar el componente.

Section i - Introduction Symbole
M11 Page i-5

Symbole

In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die
Symbole haben folgende Bedeutung:

WARNUNG - Wird die Warnung nicht beachtet, dann besteht erho¨hte Unfall- und
Bescha¨digungsgefahr.

VORSICHT - Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- und
Bescha¨digungsgefahr.

AUSBAU bzw. ZERLEGEN.

EINBAU bzw. ZUSAMMENBAU.

INSPEKTION erforderlich.

Teil oder Baugruppe REINIGEN.

DIMENSION - oder ZEITMESSUNG.

Teil oder Baugruppe O¨LEN.

WERKZEUGGRO¨SSE wird angegeben.

ANZUG auf vorgeschriebenes Drehmoment erforderlich.

Elektrische MESSUNG DURCHFU¨HREN.

Weitere Informationen an anderer Stelle bzw. in anderen Handbu¨chern.

Das teil weigt 23 kg [50 lb] oder mehr. Zur vermeidungvon koerperverletzungwinde benutzenoder
hilfe beim heben des teils in anspruch nehmen.

Symboles Section i - Introduction

M11Page i-6

Symboles

Les symboles suivants sont utilise´s dans ce manuel pour aider a` communiquer le but des instructions. Quand l’un
de ces symboles apparaıˆt,ile´voque le sens de´fini ci-dessous:

AVERTISSEMENT - De graves le´sions corporelles ou des dommages mate´riels conside´rables
peuvent survenir si les instructions donne´ es sous les rubriques ″Avertissement″ ne sont pas
suivies.

ATTENTION - De petites le´sions corporelles peuvent survenir, ou bien une pie` ce, un ensemble
ou le moteur peuvent eˆtre endommage´s si lesinstructions donne´es sous les rubriques ″Attention″
ne sont pas suivies.

Indique une ope´ration de DEPOSE.

Indique une ope´ration de MONTAGE.

L’INSPECTION est ne´ cessaire.

NETTOYER la pie`ce ou l’ensemble.

EFFECTUER une MESURE me´canique ou de temps.

GRAISSER la pie`ce ou l’ensemble.

Indique qu’une DIMENSION DE CLE ou D’OUTIL sera donne´e.

SERRER a` un couple spe´ cifique.

EFFECTUER une MESURE e´lectrique.

Se reporter a` un autre endroit dans ce manuel ou a` une autre publication pour obtenir des
informations plus comple`tes.

Le composant pese 23 kg [50 lb] ou davantage. Pour eviter toute blessure, employer un appariel
de levage ou demander de l’aide pour le soulever.

Section i - Introduction Illustrations
M11 Page i-7

Illustrations

The illustrations used in the ″Repair Sections″ of this
manual are intended to give an example of a problem,
and to show what to look for and where the problem can
be found. Some of the illustrations are ‘‘generic’’ and
might not look exactly like the engine or parts used in
your application. The illustrations can contain symbols
to indicate an action required, and an acceptable or not
acceptable condition.

The illustrations are intended to show repair or replace­ment procedures. The illustration can differ from your
application, but the procedure given will be the same.

General Safety Instructions Section i - Introduction

M11Page i-8

General Safety Instructions

Important Safety Notice

WARNING

Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily injury
or death.

Read and understand all of the safety precautions and warnings before performing any repair. This list contains
the general safety precautions that must be followed to provide personal safety. Special safety precautions are
included in the procedures when they apply.

• Make sure the work area surrounding the product is dry, well lit, ventilated; free from clutter, loose tools, parts,
ignition sources and hazardous substances. Be aware of hazardous conditions that can exist.

• Always wear protective glasses and protective shoes when working.

• Rotating parts can cause cuts, mutilation or strangulation.

•Donot wear loose-fitting or torn clothing. Remove all jewelry when working.

• Disconnect the battery (negative [-] cable first) anddischarge any capacitors before beginning any repair work.
Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a ‘‘Do Not Operate’’
tag in the operator’s compartment or on the controls.

• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage,
or damage to the fan blade(s) causing premature fan failure.

• If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.

•Donot work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.

• Relieve all pressurein the air, oil, andthe cooling systemsbeforeany lines, fittings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes
pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.

• To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon)
lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied
and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere.
Federal law requires capture and recycling refrigerant.

• To avoid personal injury, use a hoist or getassistance when lifting components that weigh 23kg [50 lb] or more.
Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct
capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting
hooks must not be side-loaded.

• Corrosion inhibitor contains alkali. Donot get the substance inyour eyes. Avoid prolonged or repeated contact
with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case
of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY
CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.

• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH
OF CHILDREN.

• To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes,
and compartments.

• Always use tools that are in good condition. Make sure you understand how to use them before performing
any service work. Use ONLY genuine Cummins or Cummins ReconW replacement parts.

• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener
of lessor quality if replacements are necessary.

•Donot perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.

• Some state and federal agencies in the United States of America have determined that used engine oil can
be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged
contact with used engine oil.

Section i - Introduction General Repair Instructions
M11 Page i-9

General Repair Instructions

This engine incorporates the latest diesel technology at the time it was manufactured; yet, it is designed to be
repaired using normal repair practices performed to quality standards.

• Cummins Engine Company, Inc. does not recommend or authorize any modifications or repairs to

engines or components except for those detailed in Cummins Service Information. In particular, un­authorized repair to safety-related components can cause personal injury or death. Below is a partial
listing of components classified as safety-related:

Air Compressor
Air Controls
Air Shutoff Assemblies
Balance Weights
Cooling Fan
Fan Hub Assembly
Fan Mounting Bracket(s)
Fan Mounting Capscrews
Fan Hub Spindle
Flywheel
Flywheel Crankshaft Adapter
Flywheel Mounting Capscrews
Fuel Shutoff Assemblies
Fuel Supply Tubes
Lifting Brackets
Throttle Controls
Turbocharger Compressor Casing
Turbocharger Oil Drain Line(s)
Turbocharger Oil Supply Line(s)
Turbocharger Turbine Casing
Vibration Damper Mounting Capscrews

• Follow All Safety Instructions Noted in the Procedures.

- Follow the manufacturer’s recommendations for cleaning solvents and other substances used during the
repair of the engine. Some solvents and used engine oil have been identified by government agencies as
toxic or carcinogenic. Avoid excessive breathing, injestion and contact with such substances. Always use
good safety practices with tools and equipment.

• Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures

- The engine and its components must be kept clean during any repair. Contamination of the engine or
components will cause premature wear.

• Perform the Inspections Specified in the Procedures.

• Replace all Components or Assemblies Which are Damaged or Worn Beyond the Specifications

• Use Genuine Cummins New or ReConW Service Parts and Assemblies

- The assembly instructions have been written to use again as many components and assemblies as
possible. When it is necessary to replace a component or assembly, the procedure is based on the use
of new Cummins or Cummins ReConW components. All of the repair services described in this manual
are available from all Cummins Distributors and most Dealer locations.

• Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components.
Completerebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins

Authorized Repair Location. Refer to Section L, Literature, for ordering instructions.

Welding on a CELECT™ Controlled Vehicle

Caution: When welding on a CELECT™ controlled vehicle, to protect the ECM computer circuits, the
procedure below MUST be followed:

1. Remove all three connectors going to the ECM.

2. Disconnect the negative (-) and positive (+) battery cables from the battery.

3. Do NOT connect the welder ground cable to any part of the CELECT™ control system.

General Cleaning Instructions Section i - Introduction

M11Page i-10

General Cleaning Instructions

Solvent and Acid Cleaning

Severalsolvent and acid-type cleaners can be used to clean the engine parts. Cummins Engine Company,
Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer’s instructions.

Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to
95 degrees Celsius [180 to 200 degrees Fahrenheit]. A cleaning tank that provides a constant mixing and
filtering of the cleaning solution will give the best results.

Removeall the gasket material, o-rings, and thedeposits of sludge,carbon, etc., with a wirebrush or scraper
before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible,
steam clean the parts before putting them in the cleaning tank.

Warning: Acid is extremely dangerous, and can damage the machinery. Always provide a tank of strong
soda water as a neutralizing agent.

Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from
all of the capscrew holes and the oil drillings.

If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The
rustproofing compound must be removed from the parts before installation on the engine.

Steam Cleaning

Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good
way to clean the oil drillings.

Warning: Wear protective clothing to prevent personal injury from the high pressure and extreme heat.

Do not steam clean the following parts:

1. Electrical Components

2. Wiring

3. Injectors

4. Fuel Pump

5. Belts and Hoses

6. Bearings

Glass or Plastic Bead Cleaning

Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The
cleaning process is controlled by the size of the glass or plastic beads, the operating pressure, and the
cleaning time.

Caution: Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead
cleaning on aluminum ring grooves. Small particles of glass or plastic will embed in the aluminum and
result in premature wear. Valves, turbocharger shafts, etc., can also be damaged. Follow the cleaning
directions listed in the procedures.

NOTE: Plastic bead blasting media, Part No. 3822735, can be used to clean aluminum ring grooves. Do not use

any bead blasting media on pin bores or aluminum skirts.

Follow the equipment manufacturer’s cleaning instructions. The following guidelines can be used to adapt to
manufacturer’s instructions:

1. Bead size: - Use U.S. size No. 16-20 for piston cleaning with plastic bead media, Part No. 3822735.

- Use U.S. size No. 70 for piston domes with glass media.

- Use U.S. size No. 60 for general purpose cleaning with glass media.

2. Operating Pressure: - Glass: Use 620 kPa [90 psi] for general purpose cleaning.

- Plastic: Use 270 kPa [40 psi] for piston cleaning.

3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic
beads after cleaning. Rinse with hot water. Dry with compressed air.

4. Do not contaminate the wash tanks with glass or plastic beads.

Section i - Introduction Definition Of Terms
M11 Page i-11

Definition Of Terms

A.C.: Alternating Current
ACT

Harness:
AFC: Air Fuel Control; a device in the fuel pump that limits the fuel delivery until

Alligator Clip: An electrical test clip attached to the end of a wire
API: American Petroleum Institute
ASA: Air Signal Attenuator
ASTM: American Society of Testing and Materials
ATDC: After Top Dead Center; refers to the position of the piston or the crankshaft

BDC: Bottom Dead Center; refers to the position of the piston or the crankshaft rod

BTDC: Before Top Dead Center; refers to the position of the piston or the crankshaft

C: Celsius
CAC: Charge Air Cooler
CARB: California Air Resources Board
CELECT™: A fuel control system that electronically controls the fuel injection to improve

The wiring harness used to connect the actuators to the ECM

there is sufficient intake manifold pressure to allow for complete combustion.

rod journal. The piston is moving downward on the power stroke or intake
stroke.

journal. The piston is at its lowest position in the cylinder.

rod journal. The piston is moving upward on the power stroke or exhaust
stroke.

fuel economy and to reduce the exhaust emissions. The system does this by
controlling the torque and horsepower curve, AFC (smoke) function, engine
high speed, engine low idle speed and the road speed.

The CELECT™ system also can control fan clutch operation, engine brake
enabling and turbocharger wastegating.

Additional electronic features include cruise control, PTO, gear down protec-

tion, progressive shifting, automotive or VS governor and idle shutoff.
C.I.D.: Cubic Inch Displacement
Circumferential Direction: In the direction of a circle in respect to the centerline of a round part or a

Cm: Centimeter
Compulink™: A Cummins service tool used for electronic system analysis and to reprogram

Concentricity: A measurement of the difference between the centers of either two or more

CPL: Control Parts List; this listing identifies the specific parts that must be in-

cSt: Centistokes
Cummins Sealant: This is a one part Room Temperature Vulcanizing (RTV) silicone rubber, ad-

D.C.: Direct Current

bore.

the system

parts, or the bores in one part.

stalled on the engine to meet agency certification.

hesive and sealant material having high heat and oil resistance, and low

compression set.

Some of the equivalent products are Marston Lubricants, Hylosil, Dow Corn-

ing, Silastic 732, Loctite Superflex, General Electric 1473, and General Elec-

tric 1470.

Definition Of Terms Section i - Introduction

M11Page i-12

Deutsch Connector: An electrical connector
Dye Penetrant Method: A method used to check for cracks in a part by using a dye penetrant and a

developer. Use Part No. 3375432 Crack Detection Kit, or equivalent.
End Clearance: The clearance in an assembly determined by pushing the shaft in an axial

direction one way, and then pushing the shaft the other way.
ECM: Electronic Control Module.
E.C.S.: Emission Control System
EFC: Electric Fuel Control
EPA: Environmental Protection Agency
EPS: Engine Position Sensor
E.S.N.: Engine Serial Number
ESS: Engine Speed Sensor
F: Fahrenheit
ft-lb: Foot Pound
GPM: Gallons Per Minute
GVW: Gross Vehicle Weight
Hammer: A hand tool consisting of a hard steel head on a handle.
Hg: Mercury
HP: Horsepower

0: Water

H

2

ID: Inside Diameter
in-lb: Inch Pound
kg: Kilograms
km: Kilometers
km/l: Kilometers per Liter
kPa: Kilopascal
l: Liter
Loctite 290: A single component, anaerobic, polyester resin, liquid sealant compound that

hardens between closely fitted metal surfaces producing a tough, hard bond

with good characteristics. An equivalent product is Perma-Lok HL 126.
Loctite 609: A single component anaerobic, liquid adhesive that meets or exceeds the re-

quirements of MIL-R-46082A (MR) TYPE 1.

Some of the equivalent products are Loctite 601 and Permabond HL 138.
Lubriplate 105: A mineral oil base grease with calcium soap (2 percent to 6 percent), and

zinc oxide (2 percent to 4 percent) additives.

m: Meter
Magnetic Particle Inspection: A method of checking for cracks in either steel or iron parts. This method

requires a Magnaflux machine, or an equivalent machine that imparts a mag-

netic field on the part being checked.
Mallet: A hand tool consisting of a soft head; either wood, plastic, lead, brass, or

rawhide on a handle.
MAX: Maximum allowed
MIN: Minimum allowed
Mini-Gen: Speed Sensor

Section i - Introduction Definition Of Terms
M11 Page i-13

mm: Millimeter
MPa: Megapascal
MPH: Miles Per Hour
MPQ: Miles Per Quart
N•m: Newton-meter
No.: Number
OD: Outside Diameter
OEM: Original Equipment Manufacturer
OEM

The wiring harness used to connect the ECM to the vehicle
Harness:

OS: Oversize
PCU: PACER Control Unit
ppm: Parts Per Million
Protrusion: The difference in the height between two parts in the assembled state.
psi: Pounds Per Square Inch
PTO: Power Takeoff
REPTO: Rear Engine Power Takeoff
RPM: Revolutions Per Minute
S.A.E:. Society of Automotive Engineers
SCA: Supplemental Coolant Additive
SEN

The wiring harness used to connect the engine system sensors to the ECM
Harness:

STD: Standard
TC: Torque Converter; used when referring to the torque converter cooler.
TDC: Top Dead Center; refers to the position of the piston or the crankshaft rod

journal. The piston is at its highest position in the cylinder. The rod journal is

pointing straight up toward the piston.
TIR: Total Indicator Reading; used when measuring the concentricity or the run

out. The TIR refers to the total movement of the needle on a dial indicator,

from the most negative reading to the most positive reading.
VOM: Volt Ohm Meter
VS: Variable Speed
VSS: Vehicle Speed Sensor
Water Pump Grease: A premium high temperature grease that will lubricate antifriction bearings

continually from minus 40C[minus 40 F] to plus 150C[plus 350 F].

Some of the greases meeting this requirement are Aeroshell No. 5, Chevron

SRI, Amoco Rykon Premium No. 2, Texaco Premium RB, and Shell Dolium

R.

Caution: Aeroshell No. 5 is not compatible with the other greases and

must not be mixed. Cummins Engine Co., Inc., uses Aeroshell No. 5 on

new engines and components.

Definition Of Terms Section i - Introduction

M11Page i-14

NOTES

Section E - Engine Identification
M11 Page E-1

Section E - Engine Identification

Section Contents

Page

Engine Diagrams ............................................................................................................................................... E-6

Engine Identification ......................................................................................................................................... E-2

Electronic Control Module (ECM) Dataplate .................................................................................................... E-2

Engine Dataplate ........................................................................................................................................... E-2

Engine Specifications ....................................................................................................................................... E-3

Air Intake System ........................................................................................................................................... E-4

Batteries (Specific Gravity) .............................................................................................................................. E-5

Cooling System .............................................................................................................................................. E-4

Electrical System ........................................................................................................................................... E-5

Exhaust System ............................................................................................................................................. E-4

Fuel System ................................................................................................................................................... E-5

General Engine Data ..................................................................................................................................... E-3

Lubricating Oil System ................................................................................................................................... E-4

Engine Identification Section E - Engine Identification

M11Page E-2

Engine Identification

The model name provides the following data:

M

11 - 330 E

= Electronic Fuel System

= Brake Horsepower

= Displacement (Liters)

= Engine Model Designation

Engine Dataplate

The engine dataplate is located on the fuel pump side of
the rocker housing.

The engine dataplate provides model identification as
well as other important information about the engine.

Have the following engine data available when commu­nicating with a Cummins Authorized Repair Location. The
information on the dataplate is mandatory when sourcing
service parts.

1. Engine Serial Number (E.S.N.)

2. Control Parts List (CPL)

3. Model

4. Horsepower and RPM Rating

Electronic Control Module (ECM) Dataplate

On CELECT™ engines, there are two dataplateson the top
of the electronic control module (ECM).

The dataplate on the left contains the part number (P/N),
serial number (S/N) and the date code (D/C) of the ECM.

The dataplate on the right contains the engine serial
number, fuel code and engine calibration information.

Section E - Engine Identification Engine Specifications
M11 Page E-3

Engine Specifications

Metric [U.S. Customary]

General Engine Data

Horsepower (Refer to the engine dataplate)

Engine speed @ Maximum Output:

• Governed Speed (RPM) - Automotive ................................................................................................ 1800

• Governed Speed (RPM) - Vocational ................................................................................................. 2000

• Advertised HP (RPM) ........................................................................................................................ 1600

Bore and Stroke ............................................................................. 125 mm [4.921 in] X 147 mm [5.787 in]

Displacement ............................................................................................................ 10.8 liters [661 C.I.D.]

Firing Order ............................................................................................................................... 1-5-3-6-2-4

Engine Weight (with Standard Accessories):

• Dry Weight ............................................................................................................... 940 Kg [2070 lb]

• Wet Weight .............................................................................................................. 996 Kg [2193 lb]

Crankshaft Rotation - (viewed from the front of the engine) ............................................................. Clockwise

Cylinder Location and Firing Order

Intake and Exhaust Valve Locations

Engine Specifications Section E - Engine Identification

M11Page E-4

Engine Specifications (Continued)

Metric [U.S. Customary]

Air Intake System

Maximum Allowable Intake Restriction with Clean Air Filter Element:

• Heavy Duty Dry Type Cleaner ....................................................................... 254 mm H

Maximum Allowable Intake Restriction with Dirty Air Filter Element ...................... 635 mm H

Maximum Temperature Rise Between Ambient Air and Engine Air Inlet:

(Ambient Above 0°C [32°F]) ................................................................................................ 17°C [30°F]

Maximum Allowable Pressure Drop From Turbocharger to Intake Manifold: ................ 152 mm Hg [6 in Hg]

Maximum Allowable Pressure Drop Across Charge Air Cooler: .................................. 152 mm Hg [6 in Hg]

Lubricating Oil System

Oil Pressure:

• Low Idle (Minimum Allowable) ...................................................................................... 70 kPa [10 psi]

• At 1200 RPM or Torque Peak (Minumum Allowable) .................................................. 207 kPa [30 psi]

Oil Capacity of Standard Engine:

• Combination Filter ....................................................................................... 2.6 liters [0.7 U.S. gallon]

• Oil Pan (High-Low) ....................................................................... 34 to 26.5 liters [9 to 7 U.S. gallon]

Total System Capacity (Including Filter) .................................................................. 39 liters [10.3 U.S. gallon]

0 [10 in. H20]

2

0 [25 in. H20]

2

Cooling System

Coolant Capacity (Engine Only) ........................................................................... 9.5 liters [10 U.S. quarts]

Standard Modulating Thermostat Range: ......................................................... 82° to 93°C [180° to 200°F]

Minimum Coolant Cylinder Block Pressure (Pressure Cap Removed):

Closed Thermostat - 1800 RPM - No Load .................................................................... 138 kPa [20 psi]

Maximum Cylinder Block Coolant Pressure (Pressure Cap Removed):

Closed Thermostat ........................................................................................................ 275 kPa [40 psi]

Maximum Allowable Operating Temperature ......................................................................... 100°C [212°F]

Minimum Recommended Operating Temperature .................................................................. 70°C [158°F]

Minimum Recommended Pressure Cap ................................................................................ 50 kPa [7 psi]

Exhaust System

Maximum Allowable Back Pressure Created by Piping and Silencer:

• Hg ................................................................................................................................. 76 mm [3 inch]

0 .......................................................................................................................... 1016 mm [40 inch]

•H

2

Exhaust Pipe Size (Normally Acceptable Inside Diameter) ................................................. 127 mm [5 inch]

Section E - Engine Identification Engine Specifications
M11 Page E-5

Metric [U.S. Customary]

Fuel System

For performance and fuel rate values, refer to the engine data sheet, or the fuel pump code for the particular model
involved.

Engine Idle Speed: ........................................................................................................... 650 to 800 RPM

Maximum Allowable Fuel Inlet Restriction:

• With Clean Filter .................................................................................................. 152 mm Hg [6 in Hg]

• With Dirty Filter .................................................................................................. 254 mm Hg [10 in Hg]

Maximum Allowable Drain Line Restriction: .............................................................. 89 mm Hg [3.5 in Hg]

Minimum Fuel Pressure:

• During Cranking ....................................................................................................... 172 kPa [25 psi]

• 1200 RPM .............................................................................................................. 827 kPa [120 psi]

• Governed RPM .............................................................................. 1034 to 1241 kPa [150 to 180 psi]

Minimum Cranking Speed: ........................................................................................................... 150 RPM

Maximum Allowable Fuel Inlet Temperature ............................................................................... 71°C [160°F]

Electrical System

Minimum Recommended Battery Capacity

System Voltage Ambient Temperatures

-18°C (0°F) 0°C (32°F)

Cold
Cranking
Amperes

12 Volt 1800 640 1280 480
24 Volt ** 900 320 640 240

* The number of plates within a given battery size determines reserve capacity. Reserve capacity determines

the length of time which sustained cranking can occur.

** CCA ratings are based on two, 12 volt batteries in series.

A minimum of 6.5 volts at the three pin connector is required to power up the ECM on CELECT™ engines.

Reserve
Capacity *
Amperes

Cold
Cranking
Amperes

Reserve
Capacity
Amperes

Batteries (Specific Gravity)

Specific Gravity
at 27°C [80°F] State of Charge

1.260 to 1.280 100%

1.230 to 1.250 75%

1.200 to 1.220 50%

1.170 to 1.190 25%

1.110 to 1.130 Discharged

Engine Diagrams Section E - Engine Identification

M11Page E-6

Engine Diagrams

The following illustrations contain information about engine components, filter locations, drain points and provisions
for instrumentation and engine controls. The information and configuration of components shown in these drawings
are of a general nature. Some component locations will vary depending on applications and installations.

Section 0 - Engine Disassembly and Assembly - Group 00
M11 Page 0-1

Section 0 - Engine Disassembly and Assembly - Group 00

Section Contents

Page

Engine Assembly ............................................................................................................................................. 0-50

Accessory Drive Assembly - Installation ......................................................................................................... 0-86

Accessory Drive Oil Seal - Installation .......................................................................................................... 0-110

Accessory Drive Pulley - Installation ............................................................................................................. 0-111

Actuator Harness - Installation ..................................................................................................................... 0-121

Air Compressor - Installation........................................................................................................................ 0-126

Air Compressor Air Supply Tube - Installation .............................................................................................. 0-127

Air Compressor Coolant Inlet Tube Fitting - Installation ................................................................................ 0-125

Air Compressor Coolant Outlet Tube - Installation ........................................................................................ 0-131

Air Intake Manifold - Installation ................................................................................................................... 0-139

Alternator - Installation................................................................................................................................. 0-142

Alternator and Bracket (Bus Applications) - Installation ................................................................................ 0-143

Alternator Belt (Non Bus Applications) - Installation ..................................................................................... 0-143

Alternator Drive Belt (Bus Applications) - Installation.................................................................................... 0-145

Alternator Drive Pulley - Installation ............................................................................................................. 0-136

Alternator Drive Seal - Installation................................................................................................................ 0-136

Automatic Belt Tensioner - Installation.......................................................................................................... 0-108

Cam Follower Assemblies - Installation .......................................................................................................... 0-90

Camshaft and Gear Assembly - Installation ................................................................................................... 0-82

Connecting Rod Side Clearance Measurement.............................................................................................. 0-79

Coolant Filter - Installation ........................................................................................................................... 0-147

Crankshaft - Installation ................................................................................................................................. 0-57

Crossheads - Installation .............................................................................................................................. 0-113

Cylinder Block - Installation On Rebuild Stand............................................................................................... 0-50

Cylinder Head - Installation............................................................................................................................ 0-92

Cylinder Liners - Installation .......................................................................................................................... 0-50

Dipstick Tube Bracket - Installation .............................................................................................................. 0-138

Drain Plugs - Inspection .............................................................................................................................. 0-147

Electric Fan Clutch (Cummins) - Installation................................................................................................. 0-132

Electronic Control Cooling Plate - Installation............................................................................................... 0-129

Electronic Control Module - Installation........................................................................................................ 0-129

Engine - Removal From The Rebuild Stand ................................................................................................. 0-133

Exhaust Manifold - Installation ..................................................................................................................... 0-138

Fan Belt - Installation ................................................................................................................................... 0-145

Fan Hub (Belt Driven) - Installation .............................................................................................................. 0-132

Fan Hub Support - Installation ..................................................................................................................... 0-131

Fan Idler Pulley - Installation........................................................................................................................ 0-132

Fan Pulley and Fan - Installation .................................................................................................................. 0-145

Flywheel - Installation .................................................................................................................................... 0-72

Flywheel Bore Runout - Measurement ........................................................................................................... 0-72

Flywheel Face Runout - Measurement........................................................................................................... 0-74

Flywheel Housing - Installation ...................................................................................................................... 0-63

Flywheel Housing Bore Alignment - Measurement......................................................................................... 0-66

Flywheel Housing Face Alignment - Measurement......................................................................................... 0-67

Flywheel Housing, REPTO - Installation......................................................................................................... 0-64

Front Crankshaft Oil Seal - Installation ......................................................................................................... 0-108

Fuel Filter - Installation ................................................................................................................................ 0-146

Fuel Filter Head and Bracket - Installation ................................................................................................... 0-130

Fuel Pump Plumbing - Installation ............................................................................................................... 0-130

Fuel Pump Support Bracket - Installation ..................................................................................................... 0-126

Fuel Pump (With Air Compressor) - Installation............................................................................................ 0-128

Fuel Pump (Without Air Compressor) - Installation ....................................................................................... 0-128

Gear Cover - Installation .............................................................................................................................. 0-106

Gear Housing - Installation ............................................................................................................................ 0-80

Hand Hole Cover (Exhaust Side of Engine) - Installation.............................................................................. 0-138

Hand Hole Cover (Fuel Pump Side of Engine) - Installation ......................................................................... 0-125

High Oil Pressure Regulator - Installation....................................................................................................... 0-61

Hydraulic Pump Drive - Installation ................................................................................................................ 0-85

Idler Gear Assemblies - Installation................................................................................................................ 0-87

Idler Gear (REPTO) - Installation.................................................................................................................... 0-68

Injectors - Installation ................................................................................................................................... 0-112

JacobsW Brake Housing Spacer - Installation .............................................................................................. 0-124

JacobsW Brake Oil Supply Hose - Installation .............................................................................................. 0-138

Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-2

Page

JacobsW Engine Brake - Installation............................................................................................................. 0-116

Lubricating Oil Cooler - Installation .............................................................................................................. 0-137

Lubricating Oil Filter - Installation ................................................................................................................ 0-146

Lubricating Oil Filter Head - Installation ....................................................................................................... 0-136

Lubricating Oil Pan - Installation .................................................................................................................... 0-81

Lubricating Oil Pump - Installation ................................................................................................................. 0-84

Main Oil Pressure Regulator - Installation ...................................................................................................... 0-62

Overhead - Adjustment................................................................................................................................. 0-117

Piston and Connecting Rod - Assembly......................................................................................................... 0-75

Piston and Connecting Rod - Installation ....................................................................................................... 0-76

Piston Cooling Nozzle - Installation................................................................................................................ 0-79

Push Rods and Tubes - Installation .............................................................................................................. 0-116

Rear Crankshaft Oil Seal - Installation ........................................................................................................... 0-71

Rocker Lever Assemblies - Installation ......................................................................................................... 0-113

Rocker Lever Cover - Installation ................................................................................................................. 0-125

Rocker Lever Housing - Installation .............................................................................................................. 0-111

Rocker Lever Side Clearance - Adjustment .................................................................................................. 0-114

Sensor Harness - Installation ....................................................................................................................... 0-123

Starting Motor - Installation .......................................................................................................................... 0-131

Static Injection Timing - Checking ................................................................................................................. 0-97

Static Injection Timing - General Information ................................................................................................. 0-96

Thermostat Housing - Installation................................................................................................................. 0-142

Thermostat Housing Support - Installation ................................................................................................... 0-135

Thrust Bearings, Lower Bearing Shells and Main Bearing Caps - Installation................................................. 0-57

Torque Convertor Cooler Disc - Installation................................................................................................... 0-141

Turbocharger - Installation............................................................................................................................ 0-140

Turbocharger Drain Fitting - Installation........................................................................................................ 0-140

Upper Main Bearing Shells - Installation ........................................................................................................ 0-56

Vibration Damper and Crankshaft Pulley - Installation .................................................................................. 0-109

Vibration Damper Eccentricity - Measurement .............................................................................................. 0-110

Vibration Damper Face - Runout Measurement ............................................................................................ 0-110

Viscosity Sensor - Installation ........................................................................................................................ 0-62

Water Filter Head - Installation..................................................................................................................... 0-134

Water Header Plate - Installation.................................................................................................................. 0-134

Water Heater Housing - Installation.............................................................................................................. 0-134

Water Pump - Installation............................................................................................................................. 0-135

Engine Disassembly ........................................................................................................................................ 0-12

Accessory Drive Assembly - Removal ............................................................................................................ 0-38

Accessory Drive Oil Seal - Removal............................................................................................................... 0-38

Accessory Drive Pulley - Removal.................................................................................................................. 0-37

Air Compressor - Removal............................................................................................................................. 0-25

Air Compressor Air Supply Tube - Removal ................................................................................................... 0-24

Air Compressor Coolant Tubes - Removal...................................................................................................... 0-26

Air Intake Manifold - Removal ........................................................................................................................ 0-17

Alternator Adjusting Link (Non Bus Applications) - Removal........................................................................... 0-15

Alternator and Bracket (Non Bus Applications) - Removal .............................................................................. 0-15

Alternator and Brackets (Bus Applications) .................................................................................................... 0-16

Alternator Belt (Bus Applications) - Removal .................................................................................................. 0-15

Alternator Belt (Non Bus Applications) - Removal .......................................................................................... 0-14

Alternator Drive Oil Seal - Removal ............................................................................................................... 0-19

Alternator Drive Pulley - Removal .................................................................................................................. 0-19

Block Mounted Front Sump Suction Tube - Removal ..................................................................................... 0-33

Cam Follower Assemblies - Removal ............................................................................................................. 0-32

Camshaft - Removal ...................................................................................................................................... 0-40

Coolant - Draining ......................................................................................................................................... 0-12

Coolant Filter - Removal ................................................................................................................................ 0-13

Crankshaft and Upper Main Bearing Shells - Removal .................................................................................. 0-46

Crankshaft Front Oil Seal - Removal.............................................................................................................. 0-39

Crankshaft Pulley and Vibration Damper - Removal....................................................................................... 0-38

Crankshaft Rear Oil Seal - Removal .............................................................................................................. 0-35

Crossheads - Removal................................................................................................................................... 0-31

Cylinder Head - Removal............................................................................................................................... 0-31

Cylinder Liners - Removal ............................................................................................................................. 0-47

Electronic Control Cooling Plate - Removal.................................................................................................... 0-24

Electronic Control Module - Removal............................................................................................................. 0-23

Engine - Cleaning.......................................................................................................................................... 0-12

Engine - Installation On Rebuild Stand .......................................................................................................... 0-22

Section 0 - Engine Disassembly and Assembly - Group 00
M11 Page 0-3

Page

Engine - Preparation for Cleaning.................................................................................................................. 0-12

Engine Barring Tool - Installation ................................................................................................................... 0-42

Exhaust Manifold - Removal .......................................................................................................................... 0-17

Fan and Fan Hub - Removal.......................................................................................................................... 0-14

Fan Drive Belt - Removal............................................................................................................................... 0-13

Fan Hub Support - Removal .......................................................................................................................... 0-23

Flywheel - Removal ....................................................................................................................................... 0-34

Flywheel Housing - Removal ......................................................................................................................... 0-35

Flywheel Housing, REPTO - Removal............................................................................................................ 0-35

Front Engine Support Bracket - Removal ....................................................................................................... 0-39

Fuel Filter - Removal ..................................................................................................................................... 0-13

Fuel Lines - Removal..................................................................................................................................... 0-25

Fuel Pump - Removal .................................................................................................................................... 0-25

Fuel Supply Hose and Filter Head - Removal ................................................................................................ 0-23

Gear Cover - Removal ................................................................................................................................... 0-39

Gear Housing - Removal................................................................................................................................ 0-41

Hand Hole Cover and Dipstick Tube Bracket - Removal ................................................................................. 0-21

Hand Hole Cover (Fuel Pump Side) - Removal .............................................................................................. 0-26

High Oil Pressure Regulator - Removal ......................................................................................................... 0-47

Hydraulic Pump Drive - Removal ................................................................................................................... 0-26

Hydraulic Pump or Cover - Removal .............................................................................................................. 0-26

Idler Gear Assemblies - Removal................................................................................................................... 0-39

Injectors - Removal ........................................................................................................................................ 0-31

Internal Actuator Harness - Removal.............................................................................................................. 0-29

JacobsW Engine Brake - Removal ................................................................................................................. 0-28

Lifting Brackets - Removal ............................................................................................................................. 0-22

Lubricating Oil - Draining............................................................................................................................... 0-12

Lubricating Oil Cooler - Removal ................................................................................................................... 0-18

Lubricating Oil Filter Head - Removal ............................................................................................................ 0-18

Lubricating Oil Filters - Removal.................................................................................................................... 0-13

Lubricating Oil Pan - Removal ....................................................................................................................... 0-33

Lubricating Oil Pump - Removal .................................................................................................................... 0-40

Lubricating Oil Transfer Tube - Removal......................................................................................................... 0-33

Main Bearing Caps, Lower Bearing Shells and Thrust Bearings - Removal.................................................... 0-44

Main Oil Pressure Regulator - Removal ......................................................................................................... 0-46

Piston Cooling Nozzles - Removal ................................................................................................................. 0-42

Pistons and Connecting Rods - Disassembly ................................................................................................. 0-48

Pistons and Connecting Rods - Removal....................................................................................................... 0-42

Push Rods - Removal.................................................................................................................................... 0-30

Rocker Lever Assemblies - Removal .............................................................................................................. 0-30

Rocker Lever Cover - Removal ...................................................................................................................... 0-27

Rocker Lever Housing - Removal................................................................................................................... 0-31

Rocker Lever Housing Spacer - Removal....................................................................................................... 0-28

Sensor Harness and Sensors - Removal........................................................................................................ 0-27

Starting Motor - Removal ............................................................................................................................... 0-24

Thermostat Housing - Removal...................................................................................................................... 0-18

Thermostat Housing Support - Removal ........................................................................................................ 0-20

Torque Converter Cooler Disc - Removal ....................................................................................................... 0-18

Turbocharger - Removal................................................................................................................................. 0-16

Turbocharger Oil Drain Connection - Removal ............................................................................................... 0-21

Viscosity Sensor - Removal ........................................................................................................................... 0-46

Water Filter Head - Removal.......................................................................................................................... 0-21

Water Header Plate - Removal....................................................................................................................... 0-21

Water Heater Housing - Removal................................................................................................................... 0-20

Water Pump - Removal.................................................................................................................................. 0-20

Engine Disassembly and Assembly - General Information ............................................................................. 0-10

Assembly....................................................................................................................................................... 0-10

Disassembly .................................................................................................................................................. 0-10

Engine Lifting Brackets .................................................................................................................................. 0-11

Service Tools - Disassembly and Assembly...................................................................................................... 0-4

Service Tools - Disassembly and Assembly Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-4

Service Tools - Disassembly and Assembly

The following special tools are recommended to perform procedures in Group 00. The use of these
tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins
Authorized Repair Location.

Tool No. Tool Description Tool Illustration

Standard Puller

Remove alternator drive pulley. Use with two (5/16 x 18 x 2 1/2)

ST-647

capscrews.

ST-669

ST-821

ST-1178

ST-1293

Torque Wrench Adapter

Tighten rocker lever adjusting screws.

Piston Ring Expander

Remove and install piston rings on pistons.

Main Bearing Cap Puller

Remove main bearing caps.

Belt Tension Gauge

Measure drive belt tension.

ST-1325

Dial Gauge Attachment

Attaches to crankshaft flange to provide measuring of flywheel
and flywheel housing runout with dial indicator gauge, Part No.

3376050.

Section 0 - Engine Disassembly and Assembly - Group 00 Service Tools - Disassembly and Assembly
M11 Page 0-5

Tool No. Tool Description Tool Illustration

Oil Filter Wrench

Used to remove and install lubricating oil filter.

3375049

Pipe Sealant

Used to prevent leaks when installing pipe plugs or fittings.

3375066

Dial Bore Gauge Kit

Used to measure inside diameters.

3375072

3375194

3375629

3375784

3375957

Engine Rebuild Stand

Support cylinder block during engine rebuild.
Used with adapter plate, Part No. 3376432.

Universal Cylinder Liner Puller

Remove cylinder liners from cylinder block. Requires cylinder
liner puller plate, Part No. 3376049.

Light Duty Puller Kit

Remove high oil pressure regulator retainer plug.

Nylon Lifting Sling

Aid in removal and installation of crankshaft, flywheel and other
components which weigh more than 23 kg [50 lb].

3376015

Universal Cylinder Liner Puller

Remove cylinder liners from the cylinder block. Requires two
puller arm extension feet, Part No. 3376649.

Service Tools - Disassembly and Assembly Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-6

Tool No. Tool Description Tool Illustration

Connecting Rod Guide Pins

Guide connecting rods over crankshaft during removal or in-

3376038

stallation of connecting rods.

Dial Indicator and Sleeve Assembly

Use with dial gauge attachment, Part No. ST-1325 to measure

3376050

flywheel and flywheel housing runout. Use with magnetic base,
Part No. 3377399, and extension, Part No. ST-537-4, to measure
gear end clearance and backlash.

Cylinder Liner Driver

Install cylinder liner in cylinder block.

3376056

3376057

3376326

3376388

3376432

Engine Support Stand

Support engine when not in-chassis or on the engine rebuild
stand.

Pulley Installation Tool

Install drive pulleys.Use pulley pusher adapter, Part No. 3377401,
to install the alternator drive pulley.

Camshaft Guide Pilot

Aid in removal and installation of the camshaft in cylinder block.

Engine Stand Adapter Plate

Adapt M11 cylinder block to the engine rebuild stand, Part No.

3375194. Requires 12 (M10-1.5 X 80) hex head capscrews, Part
No. 3376434, and lockwashers.

3376489

Regulator Retainer Plug Driver

Install the high oil pressure regulator retainer plug in the cylinder
block to a specified depth.

Section 0 - Engine Disassembly and Assembly - Group 00 Service Tools - Disassembly and Assembly
M11 Page 0-7

Tool No. Tool Description Tool Illustration

Inch Pound Torque Wrench

Required to make consistent settings of the injector. Screwdriver

3376592

socket, Part No. ST-669-13, must be used with this tool.

Flywheel Housing Alignment Plate

Align flywheel housing with cylinder block.

3376606

Guide Pin Kit

Aid during installation of flywheel, flywheel housing, vibration

3376695

damper, and air manifold. The kit contains two each of guide
pins, Part Nos. 3376488, 3376638, 3376696, 3376697, and

3376698.

3376807

3822372

3822479

3822512

Filter Wrench

Used to remove or tighten spin on fuel filter(s) and coolant filter.

Expansion Plug Driver

Install expansion plug to specified depth. Use with expansion
plug driver handle, Part No. 3376795.

Cylinder Head Lifting Bracket

Remove and install cylinder head to the cylinder block.

Engine Lifting Fixture

Used for lifting the engine.

3823309

Piston Ring Compressor

Compress piston rings on pistons during installation of pistons
in the cylinder block.

Section 0 - Engine Disassembly and Assembly - Group 00 Service Tools - Disassembly and Assembly
M11 Page 0-9

Tool No. Tool Description Tool Illustration

Engine Barring Tool

Used to bar the engine by hand. Also used with a slide hammer

3824270

3824272

3824519

to remove the hydraulic drive adapter.

Cylinder Liner Clamping Tool

Used to seat the liner in the cylinder block while measuring
cylinder liner protrusion.

Cam Follower Assembly Removal and Installation Tool

Used to remove and install the cam follower assemblies.

3824652

Slip Fit Camshaft Gear

Used for checking static injection timing during engine assem­bly.

General Information Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-10

Engine Disassembly and Assembly - General Information

These procedures apply to M11 engines. The differences between engine models, due to the application and
optional equipment on an engine, is included in the instructions. Omit the steps that do not apply to the engine
being rebuilt.

1. A Warning statement is included for any component or assembly that weighs more than 23 Kg [50 lb]. To avoid
personal injury, use a hoist or get assistance from more than one person when removing or installing these parts.

2. Most of the capscrews used on the M11 engine are metric. Some components, such as the air compressor and
fuel pump, are installed using U.S. Customary capscrews. All fasteners have right-hand threads unless a Caution
states that a fastener has left-hand threads.

Disassembly

Warning: Some state and federal agencies in the United States of America have determined that used engine
oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged
contact with used engine oil.

The instructions in this procedure are organized in a logical sequence to disassemble the M11 engine. This is not
the only sequence to disassemble a M11 engine. Certain parts must be removed in the sequence indicated. Use
this sequence until you become familiar with the engine.

Discard all gaskets, seals, hoses, filters, and o-rings unless these parts are needed for a failure analysis.

Label, tag, or mark the parts for location as they are removed. This will help find all of the parts that can be involved
in a failure, and simplify the assembly procedure.

Label, tag, mark, or photograph all special equipment prior to the removal from an engine. This engine assembly
procedure does not include the installation of special optional equipment.

Force must be used to remove certain parts. A mallet can be used when force is required. All of the fasteners must
be removed before using force.

Avoid as much dirt as possible during disassembly. The accumulation of additional dirt will make it more difficult
to clean the components.

Assembly

This procedure assumes that all of the components and assemblies have been cleaned, replaced, or rebuilt and
are ready to be installed on the engine.

Torque values are listed in each step. If a torque value is not specified, use the chart listed in the specifications
section, Group 18, to determine the correct torque value.

Many of the gaskets and o-rings are manufactured from a material designed to absorb oil. These gaskets will
enlarge and provide a tight seal after coming in contact with oil. Use ONLY a recommended contact adhesive or
a vegetable based oil to install these parts.

Always use a capscrew of the same system, metric or U.S. Customary, the same dimension and the same grade
as the capscrew removed. The use of a longer capscrew than the capscrew that is listed can result in damage to
the engine.

Section 0 - Engine Disassembly and Assembly - Group 00 General Information
M11 Page 0-11

Engine Lifting Brackets

Warning: Theengine lifting equipment must be designed
to safely lift the engine as an assembly.

Use a properly rated hoist and engine lifting fixture, Part
No. 3822512, attached to the engine mounted lifting brack­ets to lift the engine.

Refer to Section E for the weight of the engine you are
working on.

Install the engine on two engine support stands, Part No.

3376057.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-12

Engine Disassembly (0-01)

Engine - Preparation for Cleaning

Install caps or tape on all engine openings to prevent
moisture and dirt from entering the engine:

Protect all electrical components and wiring from the full
force of the cleaner spray nozzle.

Engine - Cleaning

Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.

Steam clean and dry with compressed air.

Lubricating Oil - Draining

Warning: Some state and federal agencies in the United
States of America have determined that used engine oil
can be carcinogenic and can cause reproductivetoxicity.
Avoid inhalation of vapors, ingestion, and prolonged con­tact with used engine oil.

The oil pan capacity is 34 Liters [9.0 U.S. gallons].

Remove the oil drain plug from the bottom of the oil pan.

Drain the oil into a suitable container.

Coolant - Draining

Remove the plugs from the following points:

• Lubricating oil cooler (1)

• Water pump (2)

Drain the coolant into a suitable container.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-13

Coolant Filter - Removal

Turn the coolant valve to the ‘‘OFF’’ position before the
filter is removed.

Use fuel and water filter wrench, Part No. 3376807, to
remove the coolant filter.

Lubricating Oil Filters - Removal

Use oil filter wrench, Part No. 3375049, to remove the oil
filter.

Fuel Filter - Removal

Use fuel and water filter wrench, Part No. 3376807, to
remove the fuel filter.

Fan Drive Belt - Removal

Loosen the idler pulley shaft locknut.

Turn the adjusting screw counterclockwise to release
tension, and remove the belt.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-14

Fan and Fan Hub - Removal

If an electric fan clutch is used, disconnect the fan clutch
connector from the base wiring harness.

Remove the six capscrews and the fan.

NOTE: The six capscrews also hold the fan drive pulley in
position. Do not allow the pulley to fall.

Remove the fan drive pulley.

Remove the four capscrews and the fan hub.

Alternator Belt (Non Bus Applications) ­Removal

Loosen the adjusting screw locknut (1).

Loosen the adjusting link capscrew (2).

Loosen the pivot capscrew and nut (3).

Turn the adjusting screw (4) to release tension, and re­move the belt.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-15

Alternator Belt (Bus Applications) - Removal

Insert a 3/8 inch breaker bar into the space provided on
the tensioner.

Rotate the tensioner away from the belt until it stops.

Remove the alternator belt while holding the tensioner
back.

Alternator Adjusting Link (Non Bus Applica­tions) - Removal

Remove the capscrew (1) from the alternator.

Remove the capscrew (2) from the thermostat housing
and the adjusting link.

Alternator and Bracket (Non Bus Applica­tions) - Removal

Remove the nut from the alternator mounting pivot bolt.

Remove the pivot bolt and alternator.

Remove the mounting capscrews, the bracket, and the
spacers.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-16

Alternator and Brackets (Bus Applications)

Loosen the alternator pivot mounting capscrew.

Remove the alternator brace link.

Remove the alternator pivot capscrew and the alternator.

Remove the mounting nut from the rear of the gear hous­ing and the four cylinder block mounting capscrews from
the lower alternator mounting bracket.

Remove the lower alternator mounting bracket.

Remove the belt tensioner from the front of the engine.

Remove the three mounting capscrews and the tensioner
bracket from the gear cover.

Turbocharger - Removal

Remove the oil supply line and gasket from the top of the
turbocharger.

Remove the other end of the supply line from the lubri­cating oil filter head.

Remove the oil drain line and gasket from the bottom of
the turbocharger.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-17

Remove the v-band clamp, discharge elbow and o-ring
from the turbocharger compressor discharge outlet.

Remove the four turbocharger mounting nuts.

Remove the turbocharger and gasket.

Plug the supply and drain holes in the turbocharger.

Exhaust Manifold - Removal

Caution: The exhaust manifold assembly has three sec­tions which can separate and fall causing personal injury
during removal. Hold the assembly on each end to re­move it.

Remove one capscrew from each end section of the ex­haust manifold and install two guide pins, Part No.

3376488.

Remove the remaining capscrews.

Remove the exhaust manifold, gaskets and the two guide
pins.

Air Intake Manifold - Removal

Remove the intake manifold pressure sensor and the
intake manifold temperature sensor wire connectors from
the top rear end of the intake manifold.

Tag the wires as they are removed for future identification.

Remove the boost pressure sensor (1) and the intake
manifold temperature sensor (2) from the manifold.

Remove the wire clamps holding the harness to the
manifold.

Remove the air intake connection and gasket from the top
of the manifold.

Remove two of the mounting capscrews and install two
guide pins, Part No. 3376488.

Remove the remaining capscrews, beginning at the ends
and moving toward the center, intake manifold and gas­ket. Remove the guide pins.

Use four (M10 x 25) capscrews and install the front lifting
bracket on the rocker lever housing.

Torque Value: 47 N•m [35 ft-lb]

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-18

Thermostat Housing - Removal

Loosen the bottom coolant bypass hose clamp.

NOTE: If the housing is stuck, hit the housing with a mallet
to loosen it.

Remove the four capscrews, the housing, and the ther­mostat.

Torque Converter Cooler Disc - Removal

The torque converter cooler disc (2) restricts the water
flow through the thermostat housing (1) to water pump
bypass hose (2). This allows coolant to be circulated
through a remote mounted torque converter oil cooler.

Remove the disc (2) from the thermostat housing to water
pump bypass hose connection.

Lubricating Oil Cooler - Removal

Remove the four oil cooler to thermostat housing support
flange mounting capscrews.

Remove the four oil cooler to lubricating oil filter head
mounting capscrews, oil cooler and gaskets.

Remove the oil cooler water inlet and outlet tubes and the
mounting flange.

Lubricating Oil Filter Head - Removal

Remove the JacobsW engine brake oil supply line, if
equipped.

Remove the capscrew from the turbocharger drain line
bracket.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-19

Remove the nine capscrews, oil filter head and gasket.

Remove the turbocharger oil drain line from the cylinder
block drain connection.

Alternator Drive Pulley - Removal

Remove the pulley retainer capscrew.

Use standard puller, Part No. ST-647, and two capscrews,
(5/16-18 x 2 1/2), to remove the pulley.

Alternator Drive Oil Seal - Removal

Remove the five capscrews, clamping ring, oil seal and
gasket.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-20

Water Pump - Removal

Remove the two water transfer connection capscrews.

Remove the three water pump mounting capscrews.

Rotate the water pump outward so the water transfer
connection can be removed from the water pump.

Remove the water transfer connection from the water
pump.

Twist the water pump outward from the top and angle the
rear of the pump downward as it is being removed to allow
the pump to pass the thermostat housing support while
being removed.

Thermostat Housing Support - Removal

Remove the wiring harness from the coolant temperature
sensor. Tag the harness connection for future identifica­tion.

Loosen the air compressor water return tube
connection (1).

NOTE: If the support is stuck, hit the support with a mallet
to loosen it.

Remove the four capscrews (2) and the support.

Water Heater Housing - Removal

Remove the four mounting capscrews, the housing and
gasket.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-21

Water Filter Head - Removal

Remove the three capscrews, filter head and the two
o-rings.

Water Header Plate - Removal

Remove capscrews (1) and (2), and install two guide pins,
Part No. 3376488.

Remove the remaining capscrews beginning at the ends
and moving toward the center of the plate.

Caution: Care must be taken to ensure no surface
scratches occur on the water header plate or cylinder
block mounting surfaces. Scratches on these surfaces
will cause future leak paths.

Remove the water header plate, gasket and guide pins.

Hand Hole Cover and Dipstick Tube Bracket ­Removal

Remove the four capscrews (1), the dipstick tube bracket
and gasket.

Remove the four capscrews (2), the hand hole cover and
gasket.

Turbocharger Oil Drain Connection - Removal

Remove the turbocharger oil drain tube connection fitting
from the side of the cylinder block.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-22

Engine - Installation On Rebuild Stand

Use the engine rebuild stand, Part No. 3375194, and
adapter plate, Part No. 3376432.

Use five capscrews (5/8—11 X 2 inch) grade 5 capscrews
to install the adapter plate to the rebuild stand.

Torque Value: 180 N•m [135 ft-lb]

Install two guide pins, Part No. 3376488, in the water
header plate mounting capscrew holes at points (1) and
(2) (No. 3 capscrew hole from each end).

Warning: To avoid personal injury, use a properly rated
hoist to lift the engine. The engine weighs approximately
940 kg [2070 lb].

Use the engine lifting fixture, Part No. 3822512, to lift the
engine.

Install the exhaust side of the engine to the adapter plate
of the rebuild stand.

Align the top of the adapter plate (3) to the top row of the
water header plate mounting capscrews holes (4).

The cylinder block must be positioned so two capscrew
holes (5) and (6) in the bottom row will show on each side
of the adapter plate.

Align the guide pins with the bottom row of holes in the
adapter plate at points (7) and (8).

Use eight capscrews, Part No. 3376434, to install the
adapter plate to the engine block.

Torque Value: 47 N•m [35 ft-lb]

Remove the guide pins and install two capscrews, Part
No. 3376434.

Torque Value: 47 N•m [35 ft-lb]

Lifting Brackets - Removal

Remove the front lifting bracket.

Remove the rear lifting bracket.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-23

Fan Hub Support - Removal

Remove the three mounting capscrews and the support.

Fuel Supply Hose and Filter Head - Removal

Remove the fuel supply hoses at points (1) and (2).

Remove the fuel filter head.

Electronic Control Module - Removal

Remove the ambient air pressure sensor wire connector
and the ambient air pressure sensor (1), if equipped, from
the front electronic control module (ECM) mounting
bracket.

Remove the harness wire clamps from the support bracket
at points (1) and (2).

Loosen the AMP connector mounting capscrews from the
actuator harness and the sensor harness. Remove the
actuator and sensor harness connectors from the ECM.

NOTE: The actuator harness is the top connector nearest
the engine, and the sensor harness is the bottom connector.

Tag the connectors as they are removed for future iden­tification.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

Remove the six ECM mounting capscrews, star washers
and the ECM.

M11Page 0-24

Electronic Control Cooling Plate - Removal

Remove the four mounting capscrews, the electronic con­trol cooling plate and the mounting brackets.

Starting Motor - Removal

The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

The starter mounting capscrews can be one of several
different sizes. These sizes could be in metric or U.S.
Customary. Use the correct wrench size to avoid damage
to the capscrews.

Remove the three capscrews and the starting motor.

Air Compressor Air Supply Tube - Removal

Remove the capscrew (1), loosen the two hose clamps (2)
and remove the tube.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-25

Fuel Lines - Removal

Remove the fuel supply tube (1) and the fuel drain tube
(2) from the cylinder head.

Remove the fuel pump gear pump cooling tube (3).

Fuel Pump - Removal

Remove the actuator harness wire from the fuel shutoff
valve.

Tag the wire for future identification.

Remove the two support bracket capscrews.

Remove the four fuel pump mounting capscrews, fuel
pump and gasket.

Remove the coupling spider.

Air Compressor - Removal

Remove the coolant inlet tube (1) and coolant outlet tube
(2) from the air compressor.

Remove the nuts (3) from the two top mounting capscrews.

Remove the four air compressor mounting capscrews (4),
air compressor and splined coupling.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-26

Air Compressor Coolant Tubes - Removal

Remove the inlet tube (1) and fitting (2).

Remove the outlet tube clamp capscrew (3) and the tube.

Hand Hole Cover (Fuel Pump Side) - Removal

Remove the four capscrews, the cover and gasket.

Hydraulic Pump or Cover - Removal

Remove the two capscrews, the pump and gasket.

Hydraulic Pump Drive - Removal

Remove the three pump drive adapter mounting
capscrews.

Install a slide hammer and the engine barring tool, Part
No. 3824270, to the hydraulic drive adapter. Use two
(M10-1.50 x 30) capscrews, Part No. 3335003, for SAE "A"
drives. Use two (M12-1.75 x 40) capscrews, Part No.
3018671, for SAE "B" drives.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-27

Caution: Do not allow the hydraulic drive gear to slide
out of the adapter or the gear housing during removal.
Damage to the gear will result.

Remove the hydraulic drive adapter, o-ring, and hydraulic
drive gear.

Sensor Harness and Sensors - Removal

Tag all connections as they are removed for future iden­tification.

Disconnect the connector (1) that connects the sensor
and actuator harnesses.

Remove the sensor harness connectors from the follow­ing sensors:

• engine position sensor (2) (back of gear housing),

• oil temperature sensor (3) (fuel pump side of block),

• oil pressure sensor (4) (fuel pump side of block).

Remove all the sensor wiring harness clamps from the
engine and the sensor wiring harness.

Remove the harness bracket from the cylinder block.

Remove the oil temperature sensor (1) and oil pressure
sensor (2) from the cylinder block.

Remove the engine position sensor (3) from the rear of the
gear housing.

Rocker Lever Cover - Removal

Remove the breather tube and the tube retaining clip (1)
from the side of the cylinder block.

Remove the 16 capscrews, isolators and spacers from the
cover.

Remove the cover and gasket.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-28

Rocker Lever Housing Spacer - Removal

If the engine is equipped with a JacobsW Engine Brake,
disconnect the two electrical connections from the ter­minals on the inside and outside of the spacer.

Disconnect the oil supply hose connection.

Remove the oil supply hose.

Remove the 16 capscrews and spacer.

JacobsW Engine Brake - Removal

If the engine is equipped with a JacobsW Engine Brake,
press the connector into the front housing to allow clear­ance for housing removal.

Remove the mounting capscrews and remove the
JacobsW engine brake, if equipped, from the engine.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-29

Internal Actuator Harness - Removal

Use a Torx screwdriver (T25) to loosen the screw which
secures the two sections of the actuator harness together
at the rear of the rocker lever housing.

The screw head is accessible from inside the rocker lever
housing.

Disconnect the two sections of the actuator harness.

Disconnect the ground wire connection of the actuator
harness (1) from the engine.

Tag the end for future identification.

Remove the external section of the actuator harness.

Use care not to damage the plug as it is being removed
from the rocker housing.

Disconnect the wire connectors from the injectors.

Tag the connectors for future identification. The connec­tors must be connected to the same injector as they were
removed from when the engine is reassembled.

Remove the five capscrews and wire clamps which hold
the harness section to the rocker housing.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

Remove the internal section of the actuator wiring harness.

M11Page 0-30

Push Rods - Removal

Mark the location of the valve push tubes and injector
push rods as they are removed. The push tubes and push
rods must be installed in the same location when the
engine is assembled.

Loosen the adjusting screws and remove the valve push
tubes and injector push rods.

Hold the push tubes and push rods while loosening the
adjusting screws. Do not let them fall into the engine while
rotating the accessory drive pulley.

NOTE: Some push tubes and rods are under compression
due to the valves being open. Rotate the crankshaft clock-
wise with the accessory drive pulley to relieve the spring
tension.

Rocker Lever Assemblies - Removal

Install a piece of one-quarter inch key stock 18 inches
long on top of the four front rocker lever assembly sup­ports. Use four (M10-1.5 x 25) flange head capscrews to
secure the bar stock to the supports.

The two capscrews on the end supports will fasten on one
side of the bar stock to the engine brake mounting holes.
The two capscrews on the center supports will fasten on
the opposite side of the bar stock to the engine brake
mounting holes.

Loosen, but do not remove, the eight rocker shaft
capscrews. The capscrews hold the rocker lever assem­blies together.

Grasp hold of the bar stock and lift the front rocker lever
assembly from the engine.

Repeat the process to remove the rear rocker lever
assembly.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-31

Crossheads - Removal

Remove the crossheads.

Number each crosshead with the cylinder number and
position as it is removed.

NOTE: Each crosshead must be installed in the same po­sition as it was removed from when the engine is assembled.

Injectors - Removal

Remove the injector hold down capscrews and hold down
clamps.

Use injector puller, Part No. 3823579, to remove the in­jectors from the engine. Insert the pin of the tool into the
hole provided in the body of the injector.

Number each injector with the cylinder number as it is
removed.

Rocker Lever Housing - Removal

NOTE: Do not drop the capscrew washers into the engine.

Remove the capscrews, washers, rocker lever housing,
and gasket.

Cylinder Head - Removal

Remove the seven 12 point capscrews from the camshaft
side of the cylinder head.

Remove the three capscrews inside the intake ports.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

Remove the remaining 32 capscrews starting from the
ends and moving toward the center.

NOTE: The illustration shown is for torquing the cylinder
head during installation. Reverse the order for removal.

Install cylinder head lifting bracket, Part No. 3822479, on
the center of the cylinder head.

NOTE: If the capscrews are not available from the kit, install
two rocker lever support capscrews (M14—2.00 x 135) (1)
and two rocker lever housing capscrews (M10—1.50 x 115)
(2).

Torque Value: 47 N•m [35 ft-lb]

M11Page 0-32

The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

To prevent damage to the cylinder head, lift it straight up.
The cylinder head is doweled to the cylinder block. To
prevent damage to the combustion face of the cylinder
head, place it on wooden blocks after removal.

Use a hoist or hydraulic arm to remove the cylinder head.

Remove the gasket.

Cam Follower Assemblies - Removal

Remove the nuts and washers from the seven supports.

Do not allow the nuts or washers to fall into the engine.

NOTE: The cam follower assembly consists of two shaft

assemblies with a common center support.

Slide the cam follower removal and installation tool, Part
No. 3824519 under the cam follower and around the
supports.If necessary, bump the dowel supports to loosen.

Slide the tool forward until the adjusting screws on the top
of the tool can be finger tightened in to the socket of the
injector cam followers.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-33

Lift the cam follower assemblies to remove them from the
engine.

Remove the tool from the cam follower assemblies.

Lubricating Oil Pan - Removal

Rotate the engine on the rebuild stand to position the
engine on its side.

Remove two capscrews at points (1) and (2) and install two
guide pins, Part No. 3376488.

Remove the remaining 32 capscrews and oil pan.

Use a mallet to loosen the oil pan if it is stuck.

Remove the guide pins.

Lubricating Oil Transfer Tube - Removal

Remove the oil transfer tube from the oil pan on rear sump
lubricating oil pans.

NOTE: The straight transfer tube is used on some aluminum
front sump oil pan applications.

Remove and discard the two o-rings from the transfer
tube.

Block Mounted Front Sump Suction Tube ­Removal

If the engineis equipped with a block mounted front sump
suction tube, remove the suction tube retaining capscrew
from the cylinder block.

Remove the suction tube from the cylinder block.

Remove and discard the o-ring from the suction tube.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-34

Flywheel - Removal

Install two capscrews (M10-1.50 x 40) at points (1) and (2).

Remove two mounting capscrews (3) and install two guide
pins, Part No. 3376696.

NOTE: On engines equipped with a rear engine power take­off (REPTO), two guide pins, Part No. 3376696, are required
to support the crankshaft gear until the rear crankshaft oil
seal is removed.

The clutch pressure plate capscrew holes are U.S. Cus­tomary threads. They can be (3/8-16), (7/16-14), or (1/2-

13). Make sure to measure a pressure plate mounting
capscrew before installing the "T-handles" for lifting to
prevent damage to the flywheel.

Install two ‘‘T-handles’’ (4) and (5) into the flywheel.

Remove the remaining seven mounting capscrews from
the flywheel.

The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

Install the nylon lifting sling, Part No. 3375957, on the two
‘‘T-handles’’ and attach a hoist to the lifting sling.

Tighten capscrews (1) and (2) in alternating sequence to
loosen the flywheel.

Use a hoist to remove the flywheel.

Remove the capscrews (1) and (2) and the guide pin.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-35

Crankshaft Rear Oil Seal - Removal

Remove the 12 capscrews and clamping ring (1),

Use a heal bar to remove the oil seal (3) and dust seal (2)
together.

Remove the gasket (4).

Flywheel Housing - Removal

Remove the capscrews and both rear engine mounts.

Remove capscrews (1) and (2) and install two flywheel
housing guide pins, Part No. 3376697.

The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

Remove the remaining 12 capscrews and the flywheel
housing.

Use a mallet to loosen the housing if it is stuck.

Remove the guide pins.

Flywheel Housing, REPTO - Removal

Remove the REPTO oil supply line from the flywheel
housing and the oil galley connection.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

Remove the crankshaft drive gear.

Remove the two guide pins from the crankshaft.

Remove the idler shaft retaining capscrew.

Use idler shaft puller, Part No. 3823709, to remove the
idler shaft.

M11Page 0-36

Manufacture a sleeve from 38.1 mm O.D. [1.50 inch O.D.]
(D) PVC, aluminum, or equivalent, to the following di­mensions:

Length (L): 25.4 mm [1.00 in]

Slot (W): 6.3 mm [0.25 in]

Caution: Do not drop the idler gear bearings as the idler
gear is removed. Damage to the bearings can result.

Install the tool into the idler gear bore through the idler
shaft bore to hold the idler gear and bearings together
while they are removed.

Remove the idler gear to gain access to the rest of the
housing capscrews.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-37

Caution: Do not attempt to back out or rotate the plugs
out of the housing. The cup plug bore will be damaged
and oil leakage will occur.

To gain access to the housing capscrews, use a drift to
drive the cup plugs straight through into the housing.

Retrieve the plugs from inside of the housing.

NOTE: Do not reuse the cup plugs that are removed. The
cup plugs must be replaced with new ones.

Remove two of the mounting capscrews and install two
guide pins, Part No. 3376697, to support the housing
during removal.

Use offset wrench, Part No. 3823711, to remove the
capscrews which are not in view.

The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

Remove the remaining capscrews. Use a rubber hammer
to loosen the housing.

Remove the housing and the guide pins.

Accessory Drive Pulley - Removal

Remove the pulley retaining capscrew.

The crankshaft must be held in position to allow the
capscrew to be removed.

NOTE: This is a slip fit pulley and does not require the use
of a puller.

Remove the pulley.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

NOTE: Some pulleys have an oil seal dust seal installed on

the pulley hub. If a dust sealis installed, remove the dust seal
from the pulley. The dust seal can be slipped off the hub by
hand.

M11Page 0-38

Accessory Drive Oil Seal - Removal

Remove the five capscrews, clamping ring (1), seal (2),
and gasket (3).

Accessory Drive Assembly - Removal

Remove the six mounting capscrews, accessory drive
assembly, and gasket.

Crankshaft Pulley and Vibration Damper ­Removal

Remove one of the damper mounting capscrews and
install guide stud, Part No. 3376696 in the hole.

Remove the remaining capscrews, pulley, and damper.

Do not use a hammer or a screwdriver to remove the
viscous damper. These tools can damage the damper.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-39

Crankshaft Front Oil Seal - Removal

Remove the six capscrews, the clamping ring (1), the oil
seal (3) and dust seal (2) together, and the gasket (4).

Front Engine Support Bracket - Removal

Remove the six capscrews and bracket.

Gear Cover - Removal

Six of the gear cover capscrews were removed with the
front support bracket.

Remove the remaining 14 capscrews and the gear cover.

Remove the rectangular seals from the grooves around
the mounting surfaces of the gear housing.

Idler Gear Assemblies - Removal

Three idler gear assemblies are used:

• water and lube pump idler gear (1),

• camshaft idler gear (2),

• hydraulic pump idler gear (3).

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

To remove the camshaft and water pump idler gear as­semblies, remove:

• the three retaining capscrews,

• the gear retainer (4),

• the front thrust bearing (5),

• the idler gears (6),

• the rear thrust bearing (7),

• the idler gear shafts (8),

• the camshaft idler gear assembly includes a wear
plate (9).

NOTE: If SAE ‘‘B’’ hydraulic drive is used, mark the idler
gear shafts for position as they are removed. Each shaft
must be installed in the same position it was removed from.

To remove the hydraulic drive idler gear assembly, re­move:

• mounting spacer (1),

• rectangular seal (2),

• three retaining capscrews,

• gear retainer (3),

• rectangular seal (4),

• front thrust bearing (5),

• idler gear (6),

• rear thrust bearing (7),

• idler gear shaft (8).

NOTE: SAE ‘‘A’’ drives do not use a rectangular seal (4) on
the rear surface of the gear retainer.

M11Page 0-40

Lubricating Oil Pump - Removal

Caution: Do not pry on the gear pump flange when re­moving the oil pump. This can result in damage to the
pump.

Remove the three mounting capscrews, and two spacers
if applicable.

Use both hands to pull, or insert two capscrews (M8-1.25)
into the puller holes to push the pump from the engine.

Camshaft - Removal

Rotate the camshaft to align the holes in the camshaft
gear with the thrust support capscrews.

Remove the two capscrews.

Remove the three capscrews, the rear cover plate and
gasket.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-41

Install camshaft installation pilot, Part No. 3376388.

1. Install the expander (1), Part No. 3376923, in the cam­shaft through the rear cover plate opening.

2. Turn the screw inside the expander clockwise to ex­pand the swell plug.

3. Install the arbor sleeve (2) over the expander.

4. Install the locating pilot extensions (3) to the expander.

Use one hand to slowly rotate and pull the camshaft from
the cylinder block and the other hand to balance the
camshaft as it is removed.

Remove the camshaft pilot tool.

Gear Housing - Removal

Remove the gear housing mounting capscrews and the
housing.

Remove the rectangular seal from the back side of the
housing.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-42

Engine Barring Tool - Installation

Use two flywheel mounting capscrews (M14—1.50 x 40)
to install the engine barring tool, Part No. 3824270, to the
flywheel end of the crankshaft.

Piston Cooling Nozzles - Removal

Caution: The nozzles must be removed before the pis­ton and rod assemblies to avoid damage to the nozzles.

The crankshaft must be rotated to allow access to remove
all the nozzles.

Remove each retaining capscrew and nozzle.

Pistons and Connecting Rods - Removal

Caution: Do not use emery cloth or sandpaper to re­move carbon from the cylinder liners and cylinder block
top deck surface. Aluminum oxide or silicon particles
from emery cloth or sandpaper can cause serious engine
damage.

Rotate the crankshaft to expose the carbon ridge above
the ring travel area in the cylinder liner.

Use a fine fibrous abrasive pad such as Scotch-BriteW
7448, Part No. 3823258 or equivalent, and solvent to
remove the carbon.

Use the barring tool to rotate the crankshaft to position the
rod caps at ‘‘bottom dead center’’ (BDC) for removal.

Loosen the connecting rod capscrews.

Do not remove the capscrews from the rods until the caps
have been loosened.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-43

Hit the heads of connecting rod capscrews with a mallet
to loosen the caps from the dowel rings.

Do not drop the bottom bearing shell when the cap is
removed.

Remove the connecting rod capscrews and caps.

Caution: Do not mark on the bearing to crankshaft mat­ing surface. Damage to the engine can occur if bearings
are used again.

Mark the cylinder number and the letter ‘‘L’’ in the flat
surface of the bearing tangs.

Install two connecting rod guide pins, Part No. 3376038,
in the rod capscrews holes.

Use a wooden dowel, hammer handle or equivalent to
push the rod away from the crankshaft.

Push the rod until the piston rings are outside of the block.

Use both hands to remove the piston and rod assembly.

The piston and connecting rod assemblies must be in­stalled in the same cylinder number they were removed
from to insure proper fit of worn mating surfaces if parts
are used again.

Use a tag to mark the cylinder number each piston and
rod assembly was removed from.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

Place the rod and piston assemblies into a container to
protect them from damage.

A unique number, not cylinder number, is stamped on the
connecting rod and matching cap. When the rods and
caps are installed in the engine, the numbers on the rods
and caps must match and be installed on the same side
of the engine.

M11Page 0-44

Remove the upper rod bearing.

Caution: Do not mark on the bearing to crankshaft mat­ing surface. Damage to the engine can occur if the bear­ings are used again.

Mark the cylinder number and the letter ‘‘U’’ in the flat
surface of the bearing tangs.

Main Bearing Caps, Lower Bearing Shells and Thrust Bearings - Removal

Rotate the engine on the rebuild stand to position the oil
pan mounting flange facing up.

The main bearing caps are marked for position as shown.
The caps must be installed with the number on the cap
matching the number on the oil pan flange of the cylinder
block. The caps must be oriented so they are lock tang
to lock tang.

Use a steel stamp to mark any caps without a number
before the cap is removed.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-45

Caution: The number ‘‘4’’ main bearing cap is doweled
to the block. To avoid damage to the cylinder block, do
not rock the cap to remove, pull straight up.

Remove the main bearing cap capscrews.

Use main bearing cap puller, Part No. ST-1178, to remove
the main bearing caps.

The tool must be centered on the cap. Pull straight up to
remove the cap.

NOTE: The No. 4 main bearing cap has thrust bearings.

Remove the lower main bearing shells from the caps.

Caution: Do not mark on the bearing to crankshaft mat­ing surface. Damage to the engine can result if the bear­ings are used again.

Mark the bearing shells with the journal numberthey were
removed from in the flat surface of the bearing tang.

Remove the thrust bearings from the number ‘‘4’’ cap.

Mark the thrust bearings with the letter ‘‘L’’ and front or
rear.

Caution: Do not damage the crankshaft when removing
the thrust bearings.

Use a blunt tool to remove the upper thrust bearings from
the number ‘‘4’’ main bearing journal.

Mark these bearings with the letter ‘‘U’’ and front or rear.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-46

Crankshaft and Upper Main Bearing Shells ­Removal

The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

Lift the crankshaft straight up to avoid damage to the
crankshaft or cylinder block.

Install nylon lifting sling, Part No. 3375957, around the
number ‘‘3’’ and ‘‘4’’ rod bearing journals.

Attach the sling to a hoist and remove the crankshaft.

Use both thumbs to remove the upper bearing shells.

Mark these bearing shells with the journal number they
were removed from in the flat surface of the bearing tang.

Do not mark on the bearing to crankshaft mating surface.
Damage to the engine can result if the bearings are used
again.

Main Oil Pressure Regulator - Removal

Warning: Use caution while removing the retainer plug
(1). The pressure regulator spring (2) is under compres­sion. Wear face and eye protection.

Remove the retainer plug (1), the pressure regulatorspring
(2) and plunger (3).

Viscosity Sensor - Removal

Remove the viscosity sensor with a 7/16 inch socket, an
extension and ratchet.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-47

High Oil Pressure Regulator - Removal

Warning: Use caution while removing the retainer plug
(1). The pressure regulator spring (2) is under compres­sion. Wear face and eye protection.

Use light duty puller kit, Part No. 3375784, to remove the
retainer plug (1).

Remove the pressure regulatorspring (2), washer (3), and
valve disc (4).

NOTE: The high oil pressure regulator seat will remain in the
cylinder block.

Cylinder Liners - Removal

Rotate the engine on the rebuild stand so the head deck
is facing up.

Use universal liner puller, Part No. 3375629, with plate,
Part No. 3376049, to remove the cylinder liners.

Caution: The liner puller must be installed and used as
described to avoid damage to the cylinder block. The
puller plate must be parallel to the main bearing saddles
and must not overlap the liner outside diameter.

Remove the liners with universal liner puller, Part No.

3375629.

The liner puller must be centered on the top of the cyl­inder block to prevent damage to the cylinder block.

Turn the puller jackscrew clockwise to loosen the liner
from the cylinder block.

Use both hands to remove the liners.

Engine Disassembly (0-01) Section 0 - Engine Disassembly and Assembly - Group 00

When the liner is removed from the cylinder block, use
DykemW or equivalent, to place a mark on the camshaft
side of the liner to show liner orientation.

Use DykemW or equivalent to mark the cylinder number
of each liner.

M11Page 0-48

Pistons and Connecting Rods - Disassembly

Caution: The piston pin can fall from the piston assem­bly when the retainer snap rings are removed. The piston
and pin can be damaged.

Use internal snap ring pliers to remove the retainer snap
rings from both sides of the piston.

Caution: Do not use a hammer to remove the piston
pins. The piston can be distorted and damaged.

If the pin cannot be removed by hand:

• install the piston and rod assembly in a container of
water,

• heat the piston in boiling water for 15 minutes,

• use a blunt tool to push the piston pin from the piston
and rod assembly.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
M11 Page 0-49

NOTE: When the piston pin is removed from an articulated

piston, the skirt will separate from the crown. Use care to
prevent damage to the piston.

Mark the cylinder number the piston, crown, skirt, and pin
was removed from on the parts to make sure they are
installed in the correct cylinder if they are used again.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-50

Engine Assembly (0-02)

Cylinder Block - Installation On Rebuild Stand

Use adapter plate, Part No. 3376432, with the engine
rebuild stand, Part No. 3375194, to assemble the engine.

Use ten (5/8 - 11 x 1 3/4) grade 5 capscrews to install the
adapter plate to the rebuild stand.

Torque Value: 180 N•m [135 ft-lb]

Install two guide pins, Part No. 3376488, into the water
header plate mounting capscrew holes (1) and (2).

The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

Use a hoist and engine lifting sling, Part No. 3375957, to
lift the cylinder block.

Install the exhaust side of the cylinder block to the adapter
plate of the rebuild stand.

Align the top of the adapter plate (3) with the top row of
water header plate mounting capscrew holes (4).

The cylinder block must be positioned so two capscrew
holes (5) and (6) in the bottom row will show on each side
of the adapter plate.

Align the guide pins with the bottom row of holes in the
adapter plate at points (7) and (8).

Use eight capscrews, Part No. 3376434, to install the
adapter plate to the cylinder block.

Remove the guide pins and install two capscrews, Part
No. 3376434.

Torque Value: 47 N•m [35 ft-lb]

Cylinder Liners - Installation

The current o-ring has been produced by two distinctly
different manufacturing processes. Following are those
two methods and the installation procedures.

• The molded o-ring has a symmetric cross section.
The edges are rounded. It does not require specific
care in orientation of the o-ring other than normal
prevention of rolling the o-ring.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-51

• A lathe cut o-ring which has a straight outside with
sharp corners and the inside which has two 45 de­gree chamfers, so there are no sharp corners next
to the liner. This o-ring must be installed with the
straight side facing the block, and the chamfered
side next to the liner. If the o-ring is not installed this
way, liner bore distortion can occur.

Make sure the cylinder block and all parts are clean
before assembly.

Caution: The liners must be installed within 30 seconds
after being lubricated with oil. If the liners are not in­stalled within this time limit, the o-rings will swell and be
damaged when the liner is installed.

Use clean 15W-40 oil to coat the liner o-ring seals.

Install the o-ring seal on the liner.

Install the liner into the cylinder block.

When acceptable reused liners are installed, rotate the
liner 90 degrees from their original position in the engine.
The thrust and anti-thrust surfaces must face the front
and back of the cylinder block.

Use the cylinder liner driver, Part No. 3376056, and a
leather mallet to drive the liner into the cylinder block
bore.

If the liner does not seat properly, remove the liner. In­spect the counterbore seat and liner for nicks, burrs, or
dirt. Install the liner again.

Use cylinder liner clamping tool, Part No. 3824272, to
seat the liner into the cylinder block.

Place the force plate (3) across the top of the liner with the
step inside the liner bore.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

Put the installation tool bridge (1) across the liner and
install the two cylinder head capscrews finger tight to hold
the bridge down. Rotate the force plate until the areas
where the protrusion measurements will be taken are
exposed.

Caution: Do not use an impact wrench to tighten the
liner force plate screw. Excessive torque will cause dam­age to the liner installation tool.

Tighten the forcing screw (2).

Torque Value: 136 N•m [100 ft-lb]

Check for correct protrusion.

M11Page 0-52

Use a depth gauge, Part No. 3823495, to measure the
liner protrusion at four points 90 degrees apart.

Cylinder Liner Protrusion

mm in

0.00 MIN 0.000

0.13 MAX 0.005

If the protrusion varies more than 0.025 mm [0.0010 inch]:

• Remove the liner.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-53

• Inspect the liner seating edge for burrs, dirt or dam­age.

• Replace the liner if it is damaged.

• Install the liner again.

• Measure the liner protrusion.

If the liner protrusion still does not meet the specifica­tions, use counterbore ledge tool, Part No. 3823558, to
cut the cylinder block liner bore for shims. Refer to the
Alternative Repair Manual, Bulletin No. 3810310, for the
correct procedure.

Use a feeler gauge to measure the liner to block clear­ance at the four block casting points.

Cylinder Liner to Block Clearance

mm in

0.25 MIN 0.010

If the clearance is less than 0.25 mm [0.010 inch]:

• Remove the liner.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

• Inspect the liner and cylinder block for dirt or
damage.

• Replace the liner if it is damaged.

• Install the liner again.

M11Page 0-54

Measure the liner bore for out-of-roundness at points ‘‘C’’,
‘‘D’’, ‘‘E’’, ‘‘F’’ and ‘‘G’’. Measure each point in the di­rection ‘‘AA’’ and ‘‘BB’’. The bore must not be more than

0.10 mm [0.004 inch] out-of-round.

NOTE: The cylinder block can be distorted when mounted
on the engine rebuild stand. If the liner bore does not meet
the specifications, remove the engine from the engine re­build stand and set it on a clean flat surface. Measure the
liner bore out-of-roundness again.

If the liner bore is more than 0.10 mm [0.004 inch] out­of-round with the engine on a flat surface:

• Remove the liner so the cylinder block liner bore can
be measured.

NOTE: The block counterbore diameters above and below
the cylinder block counterbore area are not critical dimen­sions and do not need to be measured.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-55

• Measure the cylinder block upper liner bore (A).

Cylinder Block Upper Liner Bore I.D. (A)

mm in.

145.900 MIN 5.7441

146.027 MAX 5.7491

• Measure the cylinder block liner seal seat bore (B)

8.0 to 13.5 mm [0.32 to 0.53 inch] below the count­erbore.

Cylinder Block Liner Seal Seat Bore I.D. (B)

mm in.

138.063 MIN 5.4355

138.113 MAX 5.4375

• Measure the liner outside diameter (A).

Cylinder Liner Top Press Fit O.D. (A)

mm in.

145.938 MIN 5.7456

145.976 MAX 5.7471

NOTE: The cylinder block liner counterbore flange diameter
is not a critical dimension and doesnot need to be measured.

Measure the liner outside diameter (C).

Cylinder Liner Seal Seat Bore Fit O.D. (C)

mm in.

137.937 MIN 5.4306

138.013 MAX 5.4336

• Inspect the cylinder block liner bore and liner for
burrs, dirt or damage.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

Replace the liner if it is damaged.

Inspect the liner bore (A) and measure the protrusion (B)
again.

Replace the liner if it does not meet the specifications.

M11Page 0-56

Upper Main Bearing Shells - Installation

Caution: The bearing shells are marked with the words
‘‘upper’’ and ‘‘lower’’. Each must be installed in the
correct location to prevent engine damage.

If used bearing shells are to be installed, each must be
installed in its original location in the engine. The bearing
journal numbers should have been marked in the bearing
tangs during disassembly.

Caution: The tang (1) on the bearing shell must be in the
slot (2) of the bearing saddle to correctly position the
bearing and prevent engine damage.

Install the upper main bearing shells.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-57

Use LubriplateW 105, or equivalent, to coat the bearings.

Crankshaft - Installation

The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

Use a hoist and nylon lifting sling, Part No. 3375957.

Install the sling around the numbers ‘‘3’’ and ‘‘4’’ rod
bearing journals.

Do not damage or move the bearing shells when the
crankshaft is installed.

Install the crankshaft.

Thrust Bearings, Lower Bearing Shells and
Main Bearing Caps - Installation

Production thrust bearings, Part No. 3822062, include an
interlocking design to make sure the bearings are in­stalled correctly.

NOTE: 0.25 mm [0.010 inch] oversize thrust bearings, Part
No. 3050589, are available if required.

Use LubriplateW 105, or equivalent, to coat the upper
thrust bearings.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-58

Push the crankshaft toward the rear of the engine to install
the rear thrust bearing, and to the front to install the front
thrust bearing.

The grooves in the thrust bearings must be installed
toward the crankshaft to prevent damage to the crank­shaft and cylinder block during engine operation.

Install the upper thrust bearings into the number ‘‘4’’
main bearing saddle.

Install the lower main bearing shells with the tang (1) in
the slot (2) of the main bearing cap.

Use LubriplateW 105, or equivalent, to coat the inside
diameter of the bearing shells.

Use LubriplateW 105, or equivalent, to coat the lower
thrust bearings.

Caution: The grooves of the thrust bearing must be fac­ing out from the bearing cap to prevent damage to the
crankshaft and cylinder block during engine operation.
The locating dowels must not protrude above the thrust
bearing surface.

Install the thrust bearings to the number ‘‘4’’ main bear­ing cap.

Use clean 15W-40 oil to coat the main bearing capscrew
threads and on both sides of the washers.

Drain the excess oil from the capscrews before installing
them in the cylinder block to prevent hydraulic lock and
possible engine damage during engine operation.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-59

The main bearing caps are numbered. The caps must be
installed with the number on the cap matching the num­ber on the oil pan flange of the cylinder block. The caps
must be oriented so they are lock tang to lock tang.

Install the main bearing caps, capscrews and washers.

Caution: Do not hit the main bearing caps with a ham­mer. The main bearing cap and bearings can be damaged.

Caution: The number ‘‘4’’ main bearing cap must be
aligned with the dowel pins in the bearing saddle. If the
dowel pins and main bearing cap are not in alignment,
the cylinder block and main bearing cap will be damaged
when the capscrews are tightened.

Caution: Do not use an impact wrench to tighten the
capscrews; the capscrews must be tightened alternately
and evenly in specific steps to the correct torque values
to prevent damage to the cylinder block, main bearing
caps and crankshaft.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-60

Complete the following steps to tighten the capscrews in
the sequence shown:

Torque Value: Step 1 - 68 N•m [ 50 ft-lb]

2 - 142 N•m [105 ft-lb]
3 - 210 N•m [155 ft-lb]
4 - Loosen completely
5 - 68 N•m [ 50 ft-lb]
6 - 142 N•m [105 ft-lb]
7 - 210 N•m [155 ft-lb]

Use your hands to turn the crankshaft. If it does not turn
freely, loosen the main bearing capscrews one at a time
to locate the bearing that is too tight.

If a tight bearing is found, remove the cap and bearing.

Check for dirt, dings and proper fit.

Replace the bearing if necessary.

Use dial indicator, Part No. 3376050, and base, Part No.
3377399, to measure the crankshaft end clearance.

Crankshaft End Clearance

mm in

0.10 MIN 0.004

0.56 MAX 0.022

If the end clearance is not within specifications, complete
the following steps:

• Remove the number ‘‘4’’ main bearing cap and
thrust bearings.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-61

• Inspect for burrs, dirt or damage.

If nicks or burrs cannot be removed with fine crocus cloth,
the cap and bearings must be replaced.

Measure the thrust bearing thickness and replace the
bearings if they are not within specifications.

Crankshaft Thrust Bearing Thickness

mm in

4.83 MIN 0.1902

4.89 MAX 0.1925

High Oil Pressure Regulator - Installation

Use a spring compression tester, Part No. 3375182, to
measure the relief valve spring tension.

Compress the spring to 29.1 mm [1.15 in] height.

Force Required to Compress Regulator Spring

Newton lbf

263 MIN 59
322 MAX 72

If the spring does not meet the above specifications, it
must be replaced.

Install the valve disc (4), washer (3) and regulator spring
(2).

Use plug driver, Part No. 3376489, to install the new
retainer cup plug (1).

Measure the retainer plug depth in the cylinder block.

Relief Valve Retainer Installed Depth

mm in

8.03 MIN 0.316

8.53 MAX 0.336

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-62

Viscosity Sensor - Installation

Install the viscosity sensor in the cylinder block.

Torque Value: 24 N•m [18 ft-lb]

Main Oil Pressure Regulator - Installation

Measure the free length of the regulator spring.

Regulator Spring Free Length

mm in

84.1 3.31

Use a spring compression tester to determine if the spring
is defective.

Replace the spring with a new spring if it is defective.

Main Oil Pressure Regulator Spring Load at 48.3 mm

mm in

91.1 MIN 20.50

94.7 MAX 21.30

[1.90 in]

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-63

Measure the retainer plug to determine if it is defective.

Main Oil Pressure Regulator Retainer Plug

mm in

11.1 MIN 0.44

13.4 MAX 0.53

Warning: The regulator spring must be compressed to
install the retainer plug (1). Wear face and eye protection.

NOTE: A counterbore plunger and orifice is unique to en-

gines with a viscosity sensor. Low oil pressure will result if
a solid plunger is used with a viscosity sensor.

Install the plunger (3) and spring (2). Install and tighten
the retainer plug (1).

Rear Sump Oil Pan Retainer

Torque Value: 75 N•m [55 ft-lb]

Block Mounted Front Sump Suction Tube (BMFSST)

Torque Value: 122 N•m [90 ft-lb]

Flywheel Housing - Installation

Measure the inside diameter of the housing bore to de­termine the SAE number and size of the housing being
used.

Flywheel Housing Maximum Bore I.D.

mm SAE No. in

787.7 00 31.01

648.0 0 25.51

584.4 1/2 23.01

511.3 1 20.13

447.8 2 17.63

409.7 3 16.13

Use four oil pan capscrews (M10-1.50 x 25) to install the
flywheel housing alignment plate, Part No. 3376606, to
the oil pan flange at the rear of the cylinder block.

Torque Value: 47 N•m [35 ft-lb]

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

Rotate the engine on the rebuild stand to position the
cylinder head mounting surface facing up.

Install two guide pins, Part No. 3376697, into the flywheel
housing mounting holes of the cylinder block.

Applya2mm[1/16 inch] bead of silicone sealant, Part No.
3823494, on the mounting surface of the housing and
around each of the mounting capscrew holes.

Install the flywheel housing over the guide pins.

Install the ten capscrews (M16-2.00 x 55).

Remove the guide pins and install the remaining two
capscrews (M16-2.00 x 55).

Tighten the capscrews to the following value:

Torque Value: 7 N•m [60 in-lb]

NOTE: This is not the final torque value. The flywheel hous-

ing bore must be aligned with the crankshaft. The capscrews
will be tightened to the final torque value after the flywheel
housing is aligned.

M11Page 0-64

Remove the four alignment plate capscrews and the align­ment plate.

Flywheel Housing, REPTO - Installation

Use four oil pan capscrews (M10-1.50 x 25) and install the
flywheel housing alignment plate, Part No. 3376606, to
the oil pan flange at the rear of the cylinder block.

Torque Value: 47 N•m [35 ft-lb]

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-65

Rotate the engine on the rebuild stand to position the
cylinder head mounting surface facing up.

Install two guide pins, Part No. 3376697, into the flywheel
housing mounting holes of the cylinder block.

Applya2mm[1/16 inch] bead of sealant, Part No.
3823494, on the mounting surface of the housing and
around each of the mounting capscrew holes.

This component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

Install the REPTO flywheel housing over the guide pins.

Install the five of the seven long capscrews (M16-2.00 x

130) and the five short capscrews (M16-2.00 x 60).

Remove the two guide pins and install the two remaining
(M16-2.00 x 130) capscrews.

Tighten the capscrews to the following value:

Torque Value: 7 N•m [60 in-lb]

NOTE: This is not the final torque value. The flywheel hous-

ing bore must be aligned with the crankshaft. The capscrews
will be tightened to the final torque value after the flywheel
housing is aligned.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

Remove the four alignment plate capscrews and the align­ment plate.

M11Page 0-66

Flywheel Housing Bore Alignment - Measure­ment

NOTE: On REPTO flywheel housings, dial gauge attach-

ment, Part No. ST-1325, must be spaced out from the fly­wheel and longer mounting capscrews used. An alternative
method is to use a magnetic base with the dial indicator
gauge.

Use dial indicator gauge, Part No. 3376050, (1) and dial
gauge attachment, Part No. ST-1325, (2) to measure the
bore alignment.

Install the attachment and gauge as shown.

Install the engine barring tool, Part No. 3824270, to rotate
the crankshaft.

Position the indicator at the 12 o’clock position. Adjust the
gauge dial to ‘‘0’’ (zero).

Rotate the crankshaft one complete revolution (360 de­grees) and record the TIR.

Flywheel Housing Bore Alignment Maximum TIR

mm SAE No. in

0.31 00 0.012

0.25 0 0.010

0.25 1/2 0.010

0.20 1 0.008

0.20 2 0.008

0.20 3 0.008

If the maximum bore alignment does not meet the speci­fications, use a mallet to move the housing in the nec­essary direction.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-67

Repeat the above steps until the maximum bore TIR is
within specifications for the determined housing size.

NOTE: If the bore alignment is not within specifications and
the bore is not round, the housing must be replaced.

Flywheel Housing Face Alignment - Measure­ment

Caution: If the tip of the gauge enters the capscrew
holes, the gauge will be damaged.

Position the contact tip of the gauge against the flywheel
housing face.

Push the crankshaft toward the front of the engine.

Adjust the gauge dial to "0" (zero).

Rotate the crankshaft one complete revolution (360 de­grees) while keeping the crankshaft end thrust pushed
forward, and record the TIR.

Flywheel Housing Face Alignment Maximum TIR

mm SAE No. in

0.31 00 0.012

0.25 0 0.010

0.25 1/2 0.010

0.20 1 0.008

0.20 2 0.008

0.20 3 0.008

If the maximum face alignment does not meet the speci­fications, check for nicks, burrs and foreign material be­tween the cylinder block mounting face and the flywheel
housing mounting surface. If none is found, the housing

must be replaced.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

Use the gauge block, Part No. 3823495, to measure the
alignment of the oil pan mounting flange of the housing
with the oil pan mounting flange of the cylinder block.

The housing flange must be even with the cylinder block

flange within ±0.15 mm [0.006 inch]. If it does not meet

these specifications, the bore and face must be realigned.

Complete the following steps to tighten the capscrews in
the sequence shown:

Torque Value: Step 1 - 68 N•m [ 50 ft-lb]

2 - 129 N•m [ 95 ft-lb]
3 - 197 N•m [145 ft-lb]

M11Page 0-68

Measure the bore and face alignment again.

NOTE: If the bore and face alignment does not meet the
specification, loosen the housing capscrews, tighten the
capscrews again, and measure the bore and face alignment
again.

Remove the barring tool and flywheel housing alignment
measuring tool from the crankshaft.

Idler Gear (REPTO) - Installation

Use LubriplateW 105, or equivalent, to lubricate the idler
shaft o-ring and install the o-ring onto the shaft.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-69

Manufacture a sleeve from 38.1 mm O.D. [1.50 in O.D.]
(D) PVC, aluminum, or equivalent, to the following di­mensions:

Length (L): 25.4 mm [1.00 in]

Slot (W): 6.3 mm [0.25 in]

Apply LubriplateW 105, or equivalent, on the outer races
and the bearings.

NOTE: The outer bearing races of new replacement gears
are already pressed into the gear.

Install the bearing and spacer into the idler gear. Use the
manufactured sleeve to hold the bearing assembly to­gether when installing the idler gear assembly.

Apply a thin film of LubriplateW 105, or equivalent, into the
idler shaft bore of the housing and on the idler shaft.

Install the idler gear assembly into the flywheel housing.

Hold the idler gear and bearings in place and remove the
plastic sleeve.

Caution: Do not use a hammer when installing the idler
shaft and capscrew, or the part can be damaged.

Hold the gear assembly in place and insert the idler shaft
through the housing and idler gear bearings.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-70

NOTE: Check the gear for freedom of rotation while using the

capscrew to install the shaft. If the gear does not turn freely,
it can indicate misalignment between the bore and the shaft.
Remove the idler shaft and install it again.

Apply LubriplateW 105 under the head of the idler shaft
capscrew. Insert the capscrew through the idler shaft.
Tighten the installation capscrew to draw the shaft into the
bore.

After the idler shaft has been seated, remove the
capscrew.

Apply pipe sealant, Part No. 3375066, to the threads of
the idler shaft capscrew. Apply LubriplateW 105 under the
head of the capscrew. Install the capscrew and tighten to
its final torque value.

Torque Value: 102 N•m [75 ft-lb]

NOTE: New cup plugs must be used. Do not use the cup

plugs that were removed from the housing.

Apply a film of cup plug sealant, Part No. 3375068, to the
outside diameter of the cup plug.

Use driver, Part No. 3823710, to install the cup plug into
the housing as shown.

Install two guide pins, Part No. 3822784, into the crank­shaft flywheel mounting flange 180 degrees apart.

Make sure the crankshaft and crankshaft gear are clean.

Install the crankshaft gear on the guide pins. Use flat
washers as a spacer and install the gear with two
capscrews (M14-1.50 x 110).

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-71

Use a magnetic base and dial indicator gauge, Part No.
3376050, to measure the idler gear backlash from the
output shaft. Mount the gauge so the tip of the gauge is
reading at the outmost edge of the output shaft.

REPTO Idler Gear Backlash

mm in

0.15 MIN 0.006

0.38 MAX 0.015

Rear Crankshaft Oil Seal - Installation

NOTE: On REPTO units, it is necessary to remove the crank-

shaft gear mounting capscrews before installing the oil seal.

The oil seal must be installed with the lip of the seal and
the crankshaft clean and dry to provide a proper oil seal­ing surface.

Use the installation sleeve provided with the seal to install
the seal and gasket on the crankshaft.

Install clamping ring using the 12 capscrews (M8-1.25 x

20). Tighten in a star pattern.

Torque Value: Step 1 - 7 N•m [ 60 in-lb]

2 - 20 N•m [180 in-lb]

Place a light film of oil or anti-freeze on the inside diam­eter of the dust seal.

Install the dust seal on the crankshaft with the larger
outside diameter facing toward the engine. Push the dust
seal back by hand on the crankshaft until the entire dust
seal contacts the oil seal case.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

M11Page 0-72

Flywheel - Installation

Install one guide pin, Part No. 3376696, into the crank­shaft flange.

NOTE: On REPTO units, install the crankshaft gear on the
guide pin before installing the flywheel.

This component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.

The crankshaft flange must be clean and free of damage.

Install the flywheel on the guide pin.

Install the engine barring tool, Part No. 3824270, to the
flywheel.

Caution: Capscrew length is critical. Capscrews of dif­ferent length can result in loss of flywheel integrity that
can cause engine damager and personal injury.

Install seven capscrews:

• Standard Flywheel Housing (M14-1.50 x 35)

• REPTO Flywheel Housing (M14-1.50 x 110)

Remove the guide pin and install the one remaining
capscrew. Tighten the capscrews in a star pattern.

Torque Value: 183 N•m [135 ft-lb]

Flywheel Bore Runout - Measurement

Use the dial indicator gauge (1), Part No. 3376050, and
the dial gauge attachment (2), Part No. ST-1325, to check
the flywheel bore (3) and face (4) runout.

Install the attachment to the flywheel housing. Install the
gauge on the attachment. Install the contact tip of the
indicator against the inside diameter of the flywheel bore.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-73

Rotate the crankshaft one complete revolution (360 de­grees).

The maximum TIR must not exceed 0.127 mm [0.0050
inch].

If the TIR exceeds the specifications:

• Remove the flywheel.

• Inspect the flywheel mounting surface for burrs, dirt
or damage.

• If burrs cannot be removed with crocus cloth, or the
flywheel is damaged, it must be replaced.

• Inspect the crankshaft flange for burrs, dirt or dam­age.

• If burrs cannot be removed with crocus cloth, or the
crankshaft is damaged, refer to the Alternative Re­pair Manual, Bulletin No. 3810310.

Install the flywheel and tighten the capscrews to the cor­rect torque value.

Measure the bore runout again.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

If the TIR still exceeds the specification, the flywheel

must be replaced.

M11Page 0-74

Flywheel Face Runout - Measurement

Install the contact tip of the indicator against the flywheel
face as close as possible to the outside diameter to mea­sure the face (4) runout.

Push the flywheel forward to remove the crankshaft end
thrust.

Rotate the crankshaft one complete revolution (360 de­grees) while keeping the crankshaft end thrust pushed
forward.

The maximum TIR must not exceed the following speci­fications.

Flywheel Face Runout

Radius (A) Maximum TIR

mm in mm in

203 8 0.203 0.008
254 10 0.254 0.010
305 12 0.305 0.012
356 14 0.356 0.014
406 16 0.406 0.016

If the face runout does not meet these specifications, the
flywheel must be replaced.

Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
M11 Page 0-75

Piston and Connecting Rod - Assembly

Articulated Piston

The retainer snap ring must be seated completely in the
piston pin groove to prevent engine damage during en­gine operation.

Install a new snap ring in one piston pin bore of each
piston skirt.

Position the skirt over the piston crown.

NOTE: It is not necessary to heat the articulated pistons
before assembly. The piston pin is slip fit.

Caution: Do not use a hammer to install the piston pin.
The piston can be distorted and damaged.

Align the pin bore of the rod with the pin bore of the piston
skirt and crown, and install the piston pin.

The snap ring must be seated completely in the piston
groove to prevent engine damage during engine opera­tion.

Install a new snap ring in the piston pin bore.

A cross sectional view of an oil control ring is shown.

The two-piece oil control ring must be installed with the
expander ring gap 180 degrees from the gap of the oil
ring. Do not overlap the ends of the expander ring.

Engine Assembly (0-02) Section 0 - Engine Disassembly and Assembly - Group 00

Use piston ring expander, Part No. ST-821, to install the
rings on the piston.

The top piston ring is a positive twist design that has a
cutback notch on the top side of the ring.

The intermediate ring is a negative twist design with a
cutback notch on the bottom side and a two degree taper
face. It also has a black phosphate coating which helps
to readily distinguish it from the top ring.

M11Page 0-76

Piston and Connecting Rod - Installation

Use a clean ‘‘lint free’’ cloth to clean the connecting rods
and bearing shells.

Do not lubricate the back of the bearing shells. The
operating clearance of the bearing will be reduced and
the bearing can be damaged during engine operation.

If new bearings are not used, the used bearings must be
installed on the same connecting rod from which they
were removed.

Install the upper bearing shell into the connecting rod.

The tang of the bearing shell (1) must be in the slot of the
rod (2). The end of the bearing shell must be even with
the cap mounting surface.

Use LubriplateW 105, or equivalent, to coat the bearing
shell.

Apply a heavy film of 15W-40 oil to the cylinder liner bore.