MACK MP8 Repair Manual

REPAIR INSTRUCTIONS,

PART 1

1.

Assémb e lhe slii'ener

wilh ñN lasl6n€c. Do NOT

plale

NO'E

fh6 6ngin6 siilf€ning fame

f4tene6 are ONE TIME USE

lasleóers musl be installed.

The aváilable lool, 9994649, cañ ba usd io

hold slifening lEme iñ

lnsrallthe oil

cfo$o@r

Using a lorque w rench, lighle¡ lhe alaching

fasl€néB in s€quénc6 amording lo

pfé$uB pipé

p¡pe

bet)€ tofqu+l¡ghtenlng the

Oil Pump Pipes and

lnslallation

aíachlnq

ONLY N&

posillon

wfile

and lh6

Stráiner

2. Asemblelhe

8nd ccsové¡

slide thé oil

punp, posilion

ct4inder block, ¡nslall the lasténéfs

torqué'lighren

Posilion

sklrls óf lhe cyllnder blo¿*,

hsteneE and lorqüetighten to

¡6s¿mblé lhé otl slrainér

pipe-

Slidé the oil

pump, posirion

oil
én9in6 stif€ning fÉmé, insrall rhe

IasteñéE and bJqué'lighlen lo

oi¡ siáher, ;udioni

pipes

inlo lhe

pessure pipe

lhé

to 6pe6ili@tion.

lhe o I ccsder

púñp

pipé

llanqe

p¡pe

and oil

pickup

rhe oil srfa¡ner ro ihe

pip€

pEs6u@

as

inlo lhe oit

lo lhe

and

lo ihe

lnstall the

pickup

inlo lh€

[219

MU,219

NT]

1, Bepacelheo t¡ngsonlheol

oi! suclion

Lubricate the O-dngswith 6ngine

sépaÉte th¿ oil suclion

as needed lo Éplace the o,finq.

iñspect

prpe

lhe oil stEi¡er, suclion

pr6ssuré

and

pipe

and oil dosever

NOTE

pipé

pipá

ror c€cks.

l¡om

p¡pe,

pressúfe pipé,

plpe.

oilbetoe

!hé oil stEiner

cléan and

cos$@r

Feplace il

o

o

o

o

FEPAIR INSTBUCTIONS, PART

1

Front Eng¡ne

1299

Gvl

Support lnsta¡lation

1- ¡l €m@d, dsenbte the loni enqiñé

suppo mounring bfaokel ro rhe

block and lishleñ hsleneB lo specili€llo¡.

qlindef

NOTE

Tho bdckél also setu4 as lhe ¡/C @ñpre$or

2. Assemble lhe lon¡ engine suppo.! onlo lhe

moudád bBckéts a¡d iñslaLlthé sit

bl@k

3. Using a lolque wénch, tghle¡ all lasteneA

iñ sequen@ ro sp6ilicarion.

Pr6r.

l2

2. Apply á 2 mm

lvAcK approred sal¡cone seálañl to thé r6ar

lácé

lhé der

ol

(5/g

lnch) bead

ac@ding to the

sp*ar stes 170

ot

patern

Crankshatt Front Cover and Seal

lnstallatlon

[211

JBl

1. Pla@ lhe cánkshaft lronl cowr wftn

9998170, in lhe cenler oñ a llal sufface.

lnstal

¡n lhe cánkshalt lrcnt mr The

prryenls
carelully lap the crankshatt seát intó lhe

lronr co€r with

9992000, unlii lhe

a

ns

cErkshaft seal wllh

plás1ic

the

fing lrcm

d tl, 68400021

cEnkshaft *d ls le@l

plasl¡c

spacer ¡ng

sljding olf'

and handte,

,

6pacer.

rlng

NOTE

Make sure lhai the cÉnksháft lonl

block tlanges are cleaned thoroughly b6lor6

a 2 mm

(re

inch) bead o' MAcK¡ppr@3

@ver and

siticone

REPAIR

INSTBUCTIONS, PART

1

3. Within 20 minulés

inslall lhe font wer to the éngine bl@k.

Cenle.lhe cEnkshaf lóñl 6v€r againsl rhe

c.anksháf

lnrall lhe

4.

usinq lhe

font @wr Note that the6 a¡€

For éarliéf typé

lnstallal¡on ¡ñstructioñs ápply:

lnsla

ll Ih e bo¡is wiihoui 1¡ghGñh g lh em

Using a stEighrédgé

the cder is flush wilh the leer édaé

ol sealanl appl¡calion,

pl4lic

fiñg.

(a),

rhe

tol¡Nirg

ru e, make sure

ol

F.uE245-FE6vdrÓiquós¿qenc8

5. RemoE the

hub. Dn@ in lh6 cÉnkshaft

48400021

d ft bónoms

plaslic

ring fom the crankshan

sea wilh dr¡ll,

and handle, 9992000, unlil lhe

,

against the c€nkshatt.

For lárér

rype

(B),

the iolrowlng

irsl¿llát¡on inslructoN

lnslallthe bolls in bolh boh ho es lhal

gn

al

Tiohtén by hand so lhállhe

lúed,

cove¡

lhé

lo lhe @@t

lnsiallihe remaininq bo[s.

NOTE

For lho laler

smallerand lhe righr-hánd hole

change

5. Us¡ng a torque wén.h

capscrews iñ sequonc6á@dinq

lvpé @ver, the tef hand hol€ is

lows

a

the laler mrer io bé coreclly

lighlen the

apply:

posltun.

cder is

is ovat. Thts

lo

BEPAIB INSTRUCTIONS,

PART 1

Tim¡ñg

1211

AAI

Gear

Plate lnstallation

NOfE

Roiale the engine b ock so the rear sur'a@ is al

NOTE

fthe cyr¡nder head is lnsralled atrer lhe riminq

geaf plale

cylinder

h€ad ár€a uniil Éády lo as*mble lhe

1. Clean lhe limino

Clean lhé @ñlacl

blockánd cylinde¡heád. Bém@ealing

compolnd fom rhe

Apply

3.

MACK appr@d sili@ne sealanl

lronl laÉ of lhé

i6 in

2 mm

a

pla@,

6/e

do nol apply séáhfn in lhe

qear plale

sulácés on lh€ €nqine

grcoE

inch) bead ol 342SX33

plal€

on bolh sidés.

on rhe englne

(A)

adording lo lhé

lo lhe

4. with¡¡ 20 ñinutes ol ihe appli€iion ot lhe

sealanl¡ assemblelhel¡ming
¿lianm€nl

lnsialied lnlo lhe bloók at disassembly.

quides,

9998267,

gear p¡aie

lhal wee

orer

NOTE

Sealióg @mpound musl be applied ours¡de the

aoM

excess @npound lo be iofced down lffo the

sb@,

in lhe limino

whicn

a[@5 b¡ betersalinq.

oáá¡

plalé.

This causés lhé

Wilhliming

5.

pins.

gear p

inslall n4

ate iñ

liminq

posilion

qea.

@rguide

mounl¡no

REPAIR INSTRUCTIONS,

PART

1

6. Uslng a iorque wénch, tighián

lasléneF in sequen@ ace¡di¡g lo

lhé afia.hing

NOfE

Cl@n away excessive sealing compóund betoré

Cyl¡nder Head lnslallation

[213

The cylind€r h€ad

¡mtatt lñe cyt¡ndér héád wiihout

áasisiánt

dd¡@. FsiluEto h*d

r6ult ln sevée

EVI

b heavy. Do NOT alléñpl to

and lhe us ol a suit¿blé ¡ifi¡nq

thls warnlng may

personal

¡ñjury ánd

the hetp ot ar

NOTE

all lr¡acK héad

g*k¿ts

equire añy lypé ot áddnional s6¿ling

1. lrnéc¿ssary

sle6v€s wilh brush

J 42445 1 w¡th J 42445-2 5 :nslalled lo

pfolécr

aúilábl€ in kil J 4245.

clean lhe unit injetorcopper

lhe fue

paseges.

pÉ@ated

arc

J 428a5-9 and extens¡on

fhess bols á16

and do not

compound,

7. lnslall the compressr slud wnh

sealing ring and n4lasle¡el

a. Rémore alignment

guides,

9994267, Ióm

a

new

Fieure 2sr hj*br

c¡pFr srp{e cr¿án¡nq

NOTE

Wilh any

c¡tcuñsláncea may

wife brushés orsimilarl@s
inieclor
thal the inj¿clor holes

b ocked, eusinq

lnslead, use a Éq soak€d ¡n

cleaninc ol lhé unit iniéctoB,

@lary wúe brushes¡

nozle. Usé ol such rools

@uld be &maged

p@er

delivery

u¡der no

hand

be used óñ th€

poses

probrems.

páEf

a ns k

and

n

or

REPAIR INSTRUCTIONS, PABT 1

2. lnsiall fuél lnlector boé

Ensuro thal ths €ngin€ block ánd dtrk
clean and iree lom any dirt,

Caelú¡ly ¿léáñ rhe cylindd head and indall

the head lifting tool a3a001aa. ched< that

guide

ihe

cyli.de.

washeF on lhe e¡qine bl@k and

head

aE clean and

plúqs,

lree

9994251 .

qfeae

or rusi.

ffi

*fl3fi

ar€

or ol.

6,

App y a

silimn6 s6álánl 10

thé 1ácr ón thé liminq

sh@n in lhe illuslalioñ).

2

mm

(164

üe sudace at tho s¡de ol

NOTE

Tlre cylinder nead musl be

ioq ue-liq hrened

sealanl hs be6n app i€d.

wilhin

20

¡nch) lh¡ck bead cil

géar plate

{as

5. ll in

Place,

clañping lools, 9s96966, Iom

éñde thé cy ind€r

9996966

FlquE253_cy[ddln¿rcl,mplnqTml3

FiguB254_€e¡l¿nlApplldl.nh¡MH¿adb

a ns head

gaskel

on lhe enq¡ne

NOIE

Check that lh€

wilh lheir ho¡es all €ñt¿Bd.

There

lhal will lempoErfy
thé h€ad. Th66e wi I
the head bolls a.€ lighlened.

The héád

head is Emoved. A nN

u6ed whén rhé héád is lñ$ánéd

are

seals are coreotly

pohls

gásk€l

embo$ed

polect

be @mpÉss€d wheñ

should

be dlscaded ilthe

sasker

pos¡l¡oned

qasket

in lhe

th6 s€als ióm

should be

REPAIB INSTRUCTIONS,

PABT 1

a. Caelllly lowerñ€ cylndér hsd

mm (3ts

I

mou¡ling

the cylind€r h€ad

head againl lhe liniñg

guide

guide

lwo
on6 on lhé cylinder head.)

inch) lotuad ol thé

plale

unlilil makes co¡lácl wilh

gaskel.

washeB ar rhe efi side.

Pfe$ lhe cyllnder

g6ar

corer and

w$he6 or lhe ctlinder block and

ÑOTE

A th@-slep

prcce$

ll is li6l l@e@d onro lhe bl@k dek

qásket,

and

bNad oi rhe

Iowered,lhe

pópd

wirh rhe bn slde ol the cyl¡ndef block.

O¡ce lweed, screG i¡serled lhouqh

thé adiustáblé idlér

is used tor inslallalion ol lhe

about I ñm

geaf plare.

quide

washeB

alignñé¡l ol lhe cyliñdér héad

qéar

a€ used io draw lhe cyliñder Éafrard

ln lh6lnalsláp,lhe head

inserted and tighlgn€d lo sp€cllicalion,

securinq lhe cy ¡rdef head io ihe block.

aboul

qéár

(Ih€f€

(3/3

hch)

A5 ¡r is

ensu¡e

hub ánd

bot6 are

lhe

a€

plalé

L TeñpoÉrry rnsrall

hub a¡d lnsért bolr€
plare

and rhe adjlstábra idre.

Tighléñ lhé

(63

i11 lb-ñ) lo dÉw

bolts b a5 +15 N.m

rhe adjosrablo idr€r

lhrough the lim¡ng

gear

the 6ytlnder head

q€ar

hub.

NOTE

h@d botts aÉ tightened.

10. Check the úndilion of lhé cfinder head

anachi¡g €pscf4s and lub¡l€te the heads

(undé6idé)

añd rh€áds with

crean engine

NOTE

Dó NoT o r rhé rhreáds in thé hr6rr<

11,

The cylinder head cap*rews ñust ñot bé

used ñ016 lhan fi@

head @pscBm by

12. lnsert lour cy indér h€ad capsc€ws

l@alions
mpsc@ws

24, 26, 2a a¡d 30. Tighlen

to specil¡cation.

times. Mark the cylinder

punchi¡g

lhem,

lnto

lhe

qear

ffi

13. Remo€ lhé cylinde r

14. Torque-lighlen

head cap*rews ñ s¿quén.e

lnslal

15.

p

lhe lasle¡e 6 secur ñg lhé liminq

á16 to thá rear

¡ghleñ lhs lásle¡eF

Ensure that lhé c€nkshalt

cenre¡

camshalli

(Toc) posilion

ác6rdi¡q ro ihé inslrucl

a nd angtet¡ghten att cyt ñdé I

oi lhe cyl nder h€ad.

camshail

head llfr ing b racksl.

io

to specifcal¡on.

is át th6 lop d€ad

and 4sembe the

géar

ánd dámper

ons und€r Itnt4g

gear

REPAIR INSTRUCTIONS, PABT 1

Camshatt lnstallation

1213

Thé cáñ3hált ¡s h4vy. Do NoT álléñpl to

CHI

¡nsláll lhé cañsh¿ll wilhórd thé hélp ol ar

ássistant or thé use ol a sulable flting

de!¡ce. Falture to heed thls

resut ¡n severe

peBon.l

war¡¡ng máy

injury ánd

ll rcmov6d, iñslaLlthe canshati bear¡ng

saddlesiolhe odginal

lap lhe bea ng saddles onlo

using a soit-la.€d haññé¡ until lully sealed.

lnsenlh6 €mshafi low6r bearings and

2,

appry aceñefous c@1n9 ol clean engine oil

lo lhe camshaí

3,

Make suré
lowér beárlng saddle. The beaf¡ng insefls ai

béarlngs.

lhe¡€ b a b¿áing insrt on each

lhe No. 7 camshat

posilions.

jouhal

Ca€lully

guide pins

th e

haw lnlégEl

6,

lnslalllhe camshai uppe¡ b€aring

iñto lhé.ánshafr bea ñg caps, ¡úbricále thé

inseds

beannls añd l¡siall lhe beariñg caps lo lhe

respeclive bea¡ing saddles. Use a soflaced

mallet tó séal thó b6áriñg €ps d$ th6

lnsen and hand i¡gh1en lhe dhaust slde
beari¡g cap

bolts

and lighien lo

spd¡licalion. Fjnal liohl€nina lo lh€
speil¡ed lofque %lue wlll be done laler

when rhe rccker arm shafi is insralled.

3,

¡¡stallrhe bearing ep

r€qukád) al lh¿ numbér7ánd lhe number

p¡ess

i@r

(1wo

bea ñq €ps ás sh@n in lh8 illuslÉlion.

1

4. C ean and inspect the canshalt usinq

solwnl and comp@sed a¡r

Lower

5

lhe

lifiing lool, 45109034. Folalé lhe

bY hand io énsure tho emshaft is nol

b¡¡ding on the l@er beár¡no saddlés.

ihe camshafl caretully into

lower

bearlnq edd es and €move lhe

place

camshaft

on

NOTE

fhe lootis used when adlústing thétimtng

backlash when

lhe ocker shafi assembly is ¡ot

g€ar

REPAIR INSTRUCTIONS,

PART 1

Timinq Gear Train lnstallatlon

NOfE

Apply á liQhr coal

DO NOI ovdlightú thé Mlkg awé

lastenets when instalkg añy ol the

t¡n¡ng

qeat

ol clean engine oil lo all

^caurroN

géaÉ

tak. oveñjgl,ten¡ng the hstaets

an @M sriwad fh@ds i¡ lhé ct4indd blúk.

1. As*ñbl6 á r4 o dnq on lhe chnkshafr

2. Apply a l¡lm ol ol io lhe O ring and ssemble

lhé chnksháí

Leaw two fáléneÉ lo6e

luming lhe cEnkshatl wilh

gáar

on lh€ c€nkshal hub.

NOTE

pa¡ts

ln the

3. Assembb rhé adiusrábré i¿b;

Figurc

and laslereG

3.adjGbbre dsGs

260), hub, bushins, lhrusl washer

plate.

Hand llohi€n lhé

adlus* rd!¿r &ár

ráñden Puñr

t6

FisuE e

o¡ the

-

I Gd,

7.Af

|

hec<f D,ñe

b@loem

Df 6

3 in

FiguÉ259_cEnk3hliGsrlaHubtrséñbly

4,

Chéck l¡al lhe @mshatl is

posilioned

at

REPAIB INSTRUCTIONS, PART

1

Align lh€
leeth 10 sláddle the al¡gnmenl hole in lhe
riming

gear

Figur€ 262- lnslall

J 4451,1-1?\, using f¡ositior B of th6

p

ate 1oo lo scufe the camshait

punch

geaf plare

wirhoú lhe

márks on lhá camshaft

and inrallrhe camshan

peras

d

1ie

clamp

shan n

plate

geá¡

géa¡

lool,

gaugé

to the

úmshalr and loosely inrall the rwo

7

Femove

lool from

v bdl¡on dampgrand clamp

lasleners- T¡ghlén thé lastenec io

lhe aliqnmenl

camshatr

rhé

pln

¿nd cl¿mpplare

gear

and lnsrall rhe
plale

using n4

NOfE

Mafk the bolrs ro aid ln righrening rhe borts 10 thé

degr¿e rclalion

a. hselta0.1 mm

gauqe.
slighr
Tiqhten ihe bolts bV hand onht

sp&ilicalion.

(0.004iñch)thickhess

Adjur rhe idler

pr€ssu€

onlhé lhickn6ss

geaf

so thar thele is

gaugé.

6. lnsed the alignmenl lool J 47,150.1, iñió lhe

hole in lhe cyl¡nde r hed 10 engaq e lhe

cúshatl

in the slol of the clamp tool- ll may be

necessafy to forare rhe camshafr unul rhis

gear

omuB. Wilh lh6 alignménl

p6ilioned

lhe camshail TDC mark is sl¡ll

¡n theclanp

bo¡reen lh€ lwo limi¡g mafts on lh6

¡eelh

w lh lhe ód

pin prcpé y

plale

sloi, checkihat

po6ilioned

l¡e lool

ol

9. Femde lhelhickness

t'¡oTE

a sllghl resislance on th6

qauqe.

F¡4uÉ263_can.h¡fG.¡l'in¡iqlla*s^liqnmnl

REPAIR INSTRUCTIONS,

PABT

1

10. lnslall the J

thé timang

asainsl ¡¡a

adluslablé idl6r

'V66

,1451,1,5

oear

adjusrab e idler

plate-

q6a¡

clamp

S6re the hotd-down

doés

asémbly tool 10

gear

s the

nol rctaie.

11. lnsrallrhá maqnálic sránd,

dlal i¡dl€tor, 9999643, $ that lhe 1ip ol
dial irdi€lor resls o¡ a 1@th ol thé

Ched< the

@mshati
measuÉ lhé backlash. For

specilicatton, éler to ihe SPEctFtcATtoNS

qear

bacJilash by rotalinq lhe

g€r

back and torrh s iChtly ro

9999696, and

backlash

th¿

12- ll thé backldh

specif@lion, adjust th6

Loós¿n

iool rrom rhé ádjustable

Loossn

lhe J 44514 5 ddp ássémbly

r¡¿ adjustab e ¡d¡er

$r4s slighlly. LoGening

sc@s w¡llalúihé idlérqearlo

mov€d

¡nsert
gauge

adjusrable

cañshafl

gauge

Wh ile holdino th€ adjuslable

in aoa nsl

ۖshaft

lorque lhé adjuslablé idler

slighlly irvoui nom lh€ ám6haÍ

a 0.1 mm

on lhe

hóldér J 44935

measurement is olt ol

llank

sۇr

(0.0er

prássue

qéár

ld er

qear

toolh

loolh by using lۇler

a¡d J

the th¡ckne$

géar,liqhlen,

cleaBnce

gear

ldrer

Oear

the hub

inch) thicknése

side ol the

and

,t4514,6

ld le r

qauoe

but DO NOT

ged

hub.

hub

be

gear

and

hub

Fein6lall and tiqhien th6 J 44514-5

c 5mp a$embly

tool against the

REPAIR INSTRUCTIONS,

PART 1

I Remove thé leeler

adjustabe dler

g.

Fecheck

spécilied b@klashallained¡ repla@

6ach adiuslablé idlér

with ns and lighlen the scrows to

spe¡licarion one ar a rime so rhe

anained backlash is nol d¡slurbed.

lhe backl4h, Wilh lhe

gáuq€

gear

and camshán

aear

13. rnsiarlthe inrermediare idle¡

gearsel

(2)

to lhe timing

gear plare,

from lhé

hub M.ew

(double

idLer)

us

nq

15,

Tiqhten lhe inlemediale

ér)

id

mounl¡ng bo¡ls in seque.ce to

seá6ál

(doutlé

16. lnslalllheauxiliaryidlergearonlothétiñino

17. Bemovelhobea

45109204.

Unit

1221

lnjector lnstallation

GPI

og

cap

pre$

tools,

NOfE

€used, il

1. f not

pr*

sleeve, J 42435-25, a¡d clean the unll

injeclor mppér dé4é

ously

pericrñed,

wilh

musl

be lited

insla I

lhe

app@priale

lo lhe

prol€clive

FisuE 2t rnkrdúr. ¡dr$

|

14. Checklhalnté idlér

the markinqs on the crankshafi

gearmarking

(eude

6 r eñtumpDre

rdre4 G¿'rd

allg¡s with

leelh.

oeár

ir

Frquc te uñn hEdor

Afér cleaning

the inside sulace ollhe

bonom sulace wh6ré lhe injeotor

Any

¡emainir

and musl bé

indicaton ol a discrepancy

aboul súlabilityoflhe sleere lor réuse,

lhe @pper deM, carelully inspe.t

g

contaminalion is u

removed. Also, if lher6 is any

coo@r sreeve creaninq

NOTE

sleeve, espécs ly lhé

seat is ocaled.

na.ce

lhal ra¡ses conceh

olabte

repta@ il

FEPAIR INSTRUCTIONS,

PART 1

Betore
rsquiréd to

Berc're doing ar'y c éaning, rhe injelor

inlel and oullel

connec¡or opening musl be covered lo

prdé¡l

pfo@ss-

¡¡sialled ¡n lhe lnlecior Relérto'uNlT

INJEoToF oLEANING'on

3.

Ren@ lhe boe

9S94251.

FiquÉ 270

1 uni¡ lnlsdo' Prcrdion

Busing añ i.jector, cle inq

€nsure suilability tor éuse.

ports

ánd lh6 el€crical

dnlminarion lrom

Also, lh€ré musl

proieolion

Unft rn¡dor Borc PEr€dion sre#

-

lhe cl4ning

no Lower

be

pag6

deM,

lr.'rnirlnlebeE

js

tuel

o{ing

244 lor

0

FsuE 21

Somé ea
orjginal design copp€r déms with iniegEl

y pbduclion

laised bead ar rhe bonom or rhe copper sr66vé.

rhis désign doés NOT

between lhe ¡njecior tip 5nd the

These oriqinal Eised¡ead d6lon copD6r

sledescan b€ idénrir

gbove

The curent

@pper sle4esi wh¡ch reqúi€ me

sásher) ár lhé

lwo

al all around ih8 upp¿r circumie¡ence,

prod

groov€

áround th¿ uppér circunle¡en@

hFdor Nde G*H

­ÑOTE

MP3

engines ced lhe

gaskel

use a

@pper slewe,

ed by a single

uclion 'flal-botom'

gask€t (llat

iniécrór rip¡ can be identmed by

washeD

llat

groo@,

design

orno

ol

4. lnlallñ6w O{ings on lhe

.

Upper nnS larSé dlamelor, viol¿l

.

Lower ring smalldlañ6i6r, violál

Lubr¡€¡e

5.

inj¿cror boré wilh

hstarr a ñe inieclio¡ noz

washer)

push
seated againsr lhé bofiom

NOT
secure lhe

ñust bé inslalled
pojections

ot lhis

boih Ojlngs and fis cyl nd¿r head

clean eng¡ne o¡1.

on the i¡jéclor, usinq hand

il

@. lhe l¡p and down uñii it is fully

géas6

use

gaskel

or any olher

gaskel

(srippé6)

to lhe ¡¡jetor the

dry Three sñal

on rhe inside dlameler

rctaiñ il to ih€ injéclor during

injecloras

unil

gaskel

e

ot the injecror Do

{ital

lorce to

nale a¡ lo

gskér

F¡sur€2 copF.

srd.

tshwn

¡snmd ror

BEPAIB INSTBUCTIONS,

PABT 1

NOTE

A rwied

rubber maling for impMd séaling was

implemenled ln

2003. Serul.e replacement
rubber coaling, DO NOT remove lhe rubber

The

g4kel

qaskel

7, SLip lhe injécior hold

of cor€ct l6ñoth oñlo lhe lnll ¡nieolol

pbductlon

(llal

washer) is

(llal

washeo havinq a lhln blac(

begln¡lng ñld-auqusl

qaskels

p€assembled

d@n and á n4 srew

n@ have ihe

on new

10. Ensure rhar thé i¡jdtor érécld€r

is @ntEl betreen thé hh€ springd

€qual

@nnector únlll tully enqag¿d. Push in

space on borh sides. ll rhe hañess is

insiállod,

@nnec!o. unlil

pluq

in lhé ¡njecior

you

electrical

hear a diliñct'tlicl\¡.

o

@nllecbr

wilh

the

Fiore2n-Unft ¡nidorRd¡iner

1 nltuf Nod DM %k

Make sue that lhe inletor ts einstatted lo

same cylinderfom

lhé

reñóred

be rep@gEmmed h ihe EEcu).
Cenler lhe un¡l ¡njector ben@en tha Elvé

9.

sp nqs

inj¿clor using

O rings. Hand lighlén lhé nil hold-down

(or

inieclor lrim óds will need

and rhen

hand

2 udrhFdr

I

which il Ms

plsh

down on the lnf

pre$¡re

lo seal lhe

NOTE

lo

Fioue274-Erd c¡rconn*brbrunnh,¿dór

11. Using á lorqué

hold dowñ scéw in daqés to speflicarion.

12_ When Éplacjhg lnil ini€clo6,

unil musl be

injécro/s ldm

lop olthé unit injector élécl

prcgrammi¡O

The

vCADSm

8ñqiné limina

w€nch, l¡ghlen lhe

lhe @nlol

prcqrammed

@des, The code is

silh lh6 .s

plnled

cal.onneotol

péfom€d

ls

and is ne@ssary lo ensub lhál

and emission levels aé

6inq

:3

:E

on

Thé unil ini€clor hold-down

roplac6d when€vér il is rcmMd l.om lhé
hold doM áñd cylinder head

scra

musl

be

Fisure ¿5

rnjedq frm ed6

-

BEPAIR INSTRUCTIONS,

PART 1

NOTE

Due to the Enginé El&lronic
(EECU)

nemssary
PaÉmetórs

enq¡ne ielaled mmponents.

EECU lo leárn the nd @ñpon€nts

behavioi After sedcinq ¡s coñp ete,

pelon

ll rBinstallinq an in¡eclor inlo lhe sané

ocatioñ, rcprooámm nq is not Équned.

sell learn¡ng Épábrity, it is

lo es1 ¡eahed EECU

aftér s¿ruicing

lhé "L¿a¡néd Dala

Cónlol Unit

some

This dlM lhe

Fesef

13. Fepear rhe insrallarion sreps tor the

valve Yoke

t213

NVI

(Br¡dqe)

lnstallalion

NOfE

l6ated

in

yokes

tüáke sufé rhal

Rocker Arm

on

rheir rcspeclive úd€

lhey afe

Shattand Engine Brake

lnstallat¡on

[213

LPI

1. Oillhé vál€

2.

Using lhe lilling toot, a5109250, and an

Gsislanr,
posl¡on

yokés

placé

on ihe inboard sido ol lhe camshaft

and lh¿ camshaÍ

lhe

shall

wilh fockef

NOTE

enq¡ne bÉke, ihe exhaust

an inleg@ ulve

pbpery

lobes

arms in

pisron.

and

yokes

Uséd

Yokes belng returñed 10 seflicé musl bé inslalled

in lhe

same cylinder ¡ocalion lroñ which they

1

, Lubri€le ihe ilp ol a valve stem wilh a small

dop olc éan éngine

2. LubriBr6 lhe

ol clean e.glne oil¡n each o¡e.

have éslablishéd

oil.

yoké

so.*ets with a smatt drop

wear

patterns.

Fsu,€22 Fodersh¿fi

a*ñbthdár'dór

t,

3. Femo@

tlghlen lhe mker

lime, *dy across lhe

lhe

tüake sur€ lhal the rocker
pfoper¡y

béai¡gcaps.

ongin€ bEké, ¡em@
bands oflie slaps) secufi¡g

lhe titling bot. Then,

arm shatt boils á Inb

shail does nol bmme dislórred bént .r

NOTE

arm shan is sealed

guide

ln ihe

On engines equjpped wilh

dowels

lhe fesiáinls

IDB

Fódef

a*mb y

shar

i¡statt and

enti€ shatt so thal

ol the oamsháft

an

(rubbef

lhe exhaust Mker

al a

REPAIR INSTRUCTIONS, PART 1

7. Torqué-lighlgn and

camshaft beadng €p añd óckér

anqle-lighlen all

an

shal

bo[6 in sequence a@rdlno 10 spédfcaton.

NOfE

The bohs have llmired reusabrr¡g and must be

(A)

ma¡kéd

iñslalled i¡ sedice. Bolls wilh lour

when remNd he been lighlened live i¡mes

wilh a

punch

áách limé lhey

punch

ae

márks

Lub.icalé lhé ó.k€r arm bl é8.
lnsen

5,

F¡gúre 279) lhóuqh the shafl, camshan

bearing cap6 and

üe bng

lasleneG

inlo

(Nos.

lhe ctlinder head.

8-20

in

g.

Feplace

6nsine b@ke

eno¡ne báke) oro now adaDier

lhe O{lng al the botlom ot lh€

conrrcl€@

(¡f

equ¡pped w¡rh

NOfE

On eñgines withoul th¿
adapter is used ¡¡

is mounlád in

head ánd is installed
enqine b6ke cofrtrolvdB in sléps S rhrough 13.

fhe

adapler

the eme localioñ on lh€ cytinder

p@¡des

engine bEke, an o¡t ltow

place

ol the oil mnl@l valre. lt

in lhe same mannerasthé

oll to the bckor

shaft-

REPAIR

INSTRUCTIONS, PART 1

9. Clean

aód @p ace lhe O-nngs, Lubn@le lhe
holá i¡ lhe b.*ér am shaii and lhá Oiings

l0- lnsn ñ6 o lpip€ lnlo lhe

engine bÉke cofrtol valre.

ths €nsins brák€ control valÉ oil

holeollhe

oi

NOTE

plpe

pipe

1 1 . Pos¡tion lhe @ntol válvg on lh€ cylind€r

12.

Align lhe englne bÉke oil
wilh lhé holé in rhé ró.i€r sh.fr

pipe

and Or nq

Mak6 suÉ ihár lhe

Ojing is s@ted lully iñ ihe

REPAIR INSTBUCTIONS, PART 1

NOTE

surerhe enqine bake oil

¡¡ak€

13. lnsrállrh6 mnlrolválve bolts añd tighten lo

pipe

ojing is

lully

15. ll

inslalled,

hám€ss ov€r lhé conlrol vdre

qilh

high lehperature tie stráps

eposition rhe

luel

injecior

'

and secure

(943472).

14. rrharnes isinsralledon enqine,

conlbl

EIE harnéss conn€cror

plug

irlhe

Flyürheel Housing lnstallat¡on
f211

lnspecl lhe llyrheel housi¡g

bolt hole! ánd
Feplace the housing il .acks á16 widénl.

HDI

pilot

lo€1ions

1. Thoro!

llywheel

aqáinsl rhe

2. Apply

ol MAcK-app¡owd sealant

gear plaié

ac@rding to the

qhly

clean tho sealing a€a

€sinq and the sealinq suláco

crankshall,

an even 2 mm

side ol the fyrheel

patterñ

ma.hi¡ed suriáces

cEcks

lor

(164

inch) lhick bead

to the liming

or wear,

in lhe

holsing

shówn.

NOTE

The llywheel ho using mu st be inslalled whh in 20

minules

ol

lhe

sealanl

being appl¡ed.

REPAIR

INSTRUCTIONS, PART 1

NOTE

F¡q!rc2s9_Flwt¡élfi.Gi.qs€al,i'Ap.ljolion

NOfE

Be

sure lo apply beads oi salanl around the

holos in the bo$6s ás sh¡M inthé

qEphic,

li ihe enQlne Msorg

gear

idler
bé u

bolts, lhe llyNh€61 housing may need

pdaled

lo block l¡re dler

plugandw6herfrcm pluq

followinq

prccedu

nally buill wllh lhe onger

qear

boll hole w lh

kii21090322. Uselhe

ré lo thr€ad lhé hole

a. Using a 3/4 16 UNF x 11.5 lap, lhroad

lhe hol¿ indicáled in Fig!re290,

b. Apply lh€ad locling .ómpound

(Loclrle@

üreads ol lhe

c. lnÉerr rhe

ro spécilicalion.

2z or €qu €len1l

p

uq,

plug

wirh washef and tiqhren

and

ro

rh€

to

a

nslall

femporari
llyryhee hoLs¡ng

y

irstall

glide pins

in lhe l$o lower

mouding holes i¡lhéliminq

3. Wlhin 20 ñinuiés ol lhe application ol lhe

séalanl,

the

4. lnsrl and hánd-t

Femow the te

a$emble the tlylvheel h ousinq de r

quid8

pins

ín lh€nminq

ghlén

the á¡aching

quide pins

plale.

oéar

áñd inslalt lh€

bolls.

5. Using a lolqu¿

bolls in sequ€nc€ ac@din

Femove any ex€s

6

lnsIalllhe limi¡g

7.

housing bohs

wrench, liqhten thé atla¿hinq

gear plate

(ilem

NOfE

llem

1 s€úés lh6

pump

h6m 3 smures

ilyryheel housing and

i¡slallálion inló thé chassis

mounling

and is not insia

lhe rear engine mounl lo lhé

g

lo specif .a1lon.

sealanl.

to the iywheet

2 in

Figúre 291).

powér

sleering and tuet

led al this

will be instalt upoñ

REPAIR INSTBUCTIONS, PART 1

Lubricaté lhe seallips

2.

wilh clean engiÁe oil.

1 Pore¡ sbs'inq Aturrinq

BsarE¡qhs

13.

Mdún, ro Fr!}hel

I

ándNú

|

lnsenlhe handle,

3.

f emover/inslaller 9994233.

9992000, in lhe

AcaurloN

|repe.x lhe rcnNét/¡rstalü

@elully.

datuae ú lhe loal \|¡I d4ttay lhe ffi|.

4. Posilion lhe n4 seal on lhe dn'f, mak ng

sufé thal thé séaL !s luméd i¡ rhé

dkelióñ. cafelully tap the seal into lhe

llyohe el housing uslng ihe handle and d ritl

unlil lhe dr fi e€nly conlacls th¿ cEnkshalt

NOTE

Position the drift so lhat it does ¡ot iñierleG with

rhe alignmenr dowel durlng insrallarioó. The rear

cEnkshaft seal déplh is sél by lhe

d l loolwhen

y

At

pppér

Crankshatt

[212

JH]

1. li ¡ol

sealinq súlaces ol lhe Íyryheel housing and

lhe cÉnkshaf

Rear

p

€viously done, lho

Seal

qearwheel.

lnstallation

rough

ly clean lhe

5.

lnspecl

t2

lhe seal inO ior

Féáf Mañ s¿ar

proper

sealinq.

mratb.

FEPAIR

INSTBUCTIONS, PART

1

Flywheel and Pilot Bearing

lnstallation

1212VCl

AcaurroN

AtÍerre ¡fackg,

balance hol6 ón tÉ ctutd1 Bida @]JJ¡6

rcbalañ¡ns by a Mch¡he shop.

vehicles

On

üansmiss on, il may bé néc€ssary 10 insláll

dllferenl componenls lo ihe fywheel relalnlng

hsleneB Feter io lhe Automalic Tbnsmi$¡on

D vé Arsngeménl Assémbly lnslruclions¡

1.

Clean lhe sulace in lhe

flywheél li6 llush ágái¡st lhé c€nkshafi

anyíy hel úth dt¡¡led

NOTE

pped

equ

w¡lh an aulomallc

pla.es

5-902,

where lhe

4. Wilh lhé

(rü10x

dowetp¡n and atignment

f'ryheel mountlng surla€ al

aid of lhe 1wo lifiñg bohs'

pcirion

100),

7

rhe iyvhgérowr lhé

studs onlhe

the ear ot the

\+

)

Cl€an rhe tlywheel, Ch4klhal lhe

surfaces lor the llyuh66l sénsor ará cléan

lüake

su€lhallhe fywheelguidá

@fecl¡y inséled in

wheel. Ensure lhalihe@

leakaqe ai thé éa¡ canksháft seal.

3.

lnserihro áliqnmenl

llanqe to a¡d ¡ñ nstattátio¡.

lhe eEnkshafr

is no damaqe of

sluds in lhe oEnkshan

qroded

pin

i6

gۇr

Fqué 2es

lnsla I

dposed mounlinq

liqhlen lhe bolts liñg¿Flighr only,

6.

Femove the two alignmant

lhe re

BémoE the

and inslall cE¡king1ool,

lhe ¡ywheel nounling bo ls in lhe

main ing mou nting bolts.

F¡Éh*r

-

holes, Ai lh¡s t¡me,

plug

lroñ ths llyryhéel housinq

I

ó,--5'

r.d.lldioñ

studs and ¡nsert

3aa00014, ánd a

8, Using a to¡quo w€nch,

in sequence ac@rdino

BEPAIB INSTBUCTIONS, PART 1

,AcauÍtoN

Do tut ¡lghten aqa@nt úM seq@nüatty.

Dokg@@nre

Fa¡luté to h@d th¡s

¡t ¡n meven lwee¡ allgnñút.

@ut¡@ @n @lt ¡n se!ere

@

plug.

n{

cEnking

pllol

lool, lnsérihe

bearing in lh6llywhoel

9.

FemoBlh¿

Using lool asembly, 9991S01 and 9992564,

inslalla

AcauÍtoN

Fot lh¡s eng¡¡e, llo shap ing ¡s Eqúircd on lhe

pilot

b@ n9. Do Nof subs¡¡tute

lhal do nal beat lhe @tred

awliB¡ion. Fzilute tc, h@d ds aú¡¡on ñay

Esu¡t k sete ens¡re danase.

11.

éck

Ch

cleadñcé using the sénsrdelh

delermlne ¡l shims are ¡equ red ior sereor
déplh. Th6 nywhel
cleaÉnce specii€l¡on ls 0.3 1.0 mñ

(0.0118-0,0393

to r

p@pér

llywh€el-lo-positió

pos

n,),

a. Boiare rhe enqine using the lllrvheel

tuñinq lml unlil a lmlh ol ths fwhéél

loolhed wheél is al¡gned with lhe

p¡bt

pan

nunbü bt ¡f'¡s

lion sonsor

b@n@s

ñ senso r

gaooe

lo

@

t@t

FisuF 24

12.

Cárélully

with ihe approp ale shim(s) and new

Or¡nq. S@ure the sensor with a boli

lighléned io spécmcaion

-

jnslalllhe

@'

llywh éél

s€No. Galsa

and

pósilion

plug

sensor

in lhe

b. hs6n ú€ bol inro lhe sener

the ouiér

asainsr the llywheel housinq.

Locen lhelhumbscÉw ol the tool and

pushlhe

conlacls á toolh ol lhe loolh€d wh6¿1.

Tighten the thúmb screw to sécurc

Ca@lully remow ihe lool irom the

llywhoeL sensr bore

ocation ol fte sl6ps béiween rhe inner

and outer

.

.
.

pa¡i

ol the i@l is lully s€ated

inn¿¡pa ót

portlons

Bolh steps bdN lhé suffa@ ol

Ihe l@l
One step bélow th6 surlaÉ ol rhé

Iool = one sh m Équiéd.

Boih slePs abó@ the surfac6 ol

the l@l : iwo shiñs reqúúed.

no shims ¡equned.

=

the lool unli

and observe the

ol the tool:

bo@ until

il

lh¿

Pan lnstallaiion

Oil

BEPAIR INSTRUCTIONS,

PABT 1

I21r

NBI

lhe

(0.079

llyvhee¡

plale,

inch) wide béad oi

houslngand lhel¡htho

Alsq appya 2 mm

1 , Apply a 2 mm

lrAcK-apprcred s€lant ar thé *ams
be¡reen

g6ar

mounling

(0.079
seams belweeh thetmlng

plale

inch) wid€ béad ol sáálánl al rhe

and lhe enqine bock.

Aeár

mounling

3. For

plasl¡c pañ

pan

seal inlolhe

Check thal the séal lo@lnq

prcperlyáliqned

holeson

lie mounÍnqfanqé.

appli.alions, ¡nslá I rhs oil

gb@

and seal€d

ol the ollpañ.

tabs a€

jnrh€

locali¡g

2. Applv a 2 mm

MACK approled sealant lo lh€ seam

belwéén lhé lro¡l seál ¿over ánd the blo.k

(0.079inch)

bead oi

REPAIB INSTBUCTIONS,

PART f

4. For steelpan applicalions, inslalllhe oilpan

qaskel
qaskel

iñsened

and

on lhe oil

lo@1

pán

ilange. check thal tha

ng labs are

.or¿cl

in the

properly

hds on lhe

allgned

6. ¡ghreñ rhe borrs lóm lhé mid;b

dd

l

oul@ds in oder 1 -4 as shówh-

Torqu&lighle¡

Flnish bv ch€ckino the loque

rhe bolrs ro specillcatióñ.

tor bolts A

NOTE

lnsiall lhe tbnsñission oil .oo 6r bEckér studs iñ
l@arions marked

7. lnslalllhe oil dráin

prwlously,

pluq

and lorqué-nghlen lo

LcauÍtoN

Do not u@ a @ppet washet with

ptug.

dta¡n

At$ys

u@ the steel

NOTE

5. Wilh assistance,

engine block and ¡nsrallrhe bolrs ma*ed A

ánd B. Tofquo-r

pGitbn

qhl€n

the of

rh6 bolls lo

pan

NOTE

ca€

Use

The oil
20 minules of lhe sealanl being appled.

Q)(

pr*nl

lo

pan

must bo iñstallod wilhin

damagelolhe oil

to thé

Do nol use alr lools wheñ inslallingihe oild€in

3. Ensurá

popery

aré

rhal ihé 1 2 localinq

seabd inlh6l@alino holes in

pins

on the seal

NOTE

aé suré lhé

oil

pan

seal is

L lf harnBs is inslalled, reconnect

level/leñpe¡alure sensor mnñe.lor

properly pláced

lhe ott

bslirr€

lo lhe

REPAIR

INSTRUCTIONS, PART 1

Oil F¡ller P¡peand D¡pstick Pipe

lnstallation

1 . lnsla I a nw O r ng on lhs oil lill lube ánd

inslalllhe

lneallrhé oilfi

tube to lhe s¡de oftheollpan.

lrube lasrenerc and rlghrenlo

2. lnstall a new O dng on lhe dlpsnck tube,

rhen nsrall rhe iube and secu fe wnh lhe
laslen€r lnsláll rhe dipslick.

Power Take-Off lnstallation

equipped

li

the asámbly

1 . Lubicale

ln the PfO ássémbly housing.

wilh a

2. ¡Gsmb ¿ lhe PTO

ptuer

lsing this

and Nemble a seal iñ lhe

iakg'off

pbcedure.

ssembry o¡ the llywheel

(PTO),

'

inslall

qrcM

3. Fwheer Hds nq

3. Usingalorquewrcnch

ac.ord ¡. o lo specilicalio¡.

lighlen lhe lasteners

REPAIR INSTRUCTIONS, PART 1

Timing Gear Cover lnslallation

1211

AAI

1 . Apply sealanl in the botlom corneÉ wheÉ

the limirg

houing mééI. Als apply s6ala.l lo lh6 lop

of th6 liming

to thé cylinder héad.

gear plale

geár plale (in

and lhe llywheel

t¡_Le corner) next

4. Posftlon ihe liñi¡g

go¿¡

cowr on

fyvheel housi¡g al the rear ól th6

héad. lnsiall rhé f¿sré¡eE márkéd 1 and 2

I

lhe

q/lindér

2, lnsrall rhe riminq

qeaf

@Er sea s and

5. lnstall lh€ nming

451 11422 A and 351 1 1422-8, to lhe

cylinder

illusrral€d. CNér suda.e must

lhe seal sulace of lhe cylinder head.

head

qéar

órer

and liming

qed

NOTE

fhe liming

20 mindes

gear

cover must b6 inslalled wilhin

ol lhe sealant bei¡q ápptied.

ignment

a

cover as

be l¡ush with

toolsj

3. Apply sealáñt to the matlng súóces of the

BEPAIB INSTRUCTIONS,

PART 1

lnslalllhe fema¡nl¡q faslené6,3, 4 áñd 5.

Toque all ol rhe liming

Rémów lhé liming

Posilion

8.

Éár ófth¿ énginé

lhe @r supporl brackel onto the

gear

cMr lasten6rs

@@r .lamp l@ls.

inlalllhe

and

supporl

brrck l l'srsnáB ió s¡.x¡.

lnstallalltiá sl€p3. P-clampl

9.

¡6lain€B Esd lo r6slrain lh€ €ngin6

harnesses, o¡l l¡nes and c@lanl lubes lo lhe

and olher

2.

Check tor

cléa€nce

43400031,ló délBñiñe it

required lor ssn$r déplh.

prcper

using lhe senerdeplh

a. Fotát6 lhe éngine

@mshai i@thed wheél is aliqned uilh

enshai

unlil a loolh of lhe

póaito'n

qáuqé,

shims are

sensor

CAMSHAFT SENSOB DEPTH, CHECK

1. Beñ@ lhs

inslall

and

plug

lom lh6llyuheel holsing

lhe fywheel lur¡¡¡q lool.

b, lnse lhe depih

boé unlil ü6 oulér

lully seated aqahsi the nhhq

c. Looeén lhe

and
until il coólacfs a tooih d ln€ loolhod

Tigr'ién rhe thumb

Ca€lulry réño€ lhé
camshaf señsor bor€ and

localion
outer

.
.
.

thó i¡n€rpa oflhégaugéin

Púsh

ot steps belweén ihe inn6r áñd

pódionsol

Bolh

sleps bel@ lhe sula@ of

gauq6

ihe

Oño slsp b¿low

qauge

Borh steps abM lhe

gauqe

lhe

qauqe

lhumb $r4 ol lhe

inlo lhe sensor

pán

ol tre

$f4 io *curc the

gauge

gauge:

rhe

no shims required.

=

lhe su¡la@ ol lhe

oné shim €qunéd.

=

lwo shims equi6d.

=

gauge

gear

gauge

fom the

obsetue lhe

suúce ot

is

(d,---

-5r

REPAIB INSTRUCTIONS, PART 1

Coolanl Pump lnstallation

@
@

@

3, l.slall

appópnab shrñ(s) and n4 o¡ng. secufe

lhe sersor with a boll and

lhe camshaft

positlon

plug

señsor wlh lhe

in lhé

215 SW

[

remded,

l. lf

plale

block and install the mounling bolts.

the bolls to speoil¡@t¡on.

SG, SBI

posilion

in

placelhe

al rhe font

c@lánt

ot the cytinde¡

púñp

2. Prcss a ns selinq dhQ inlo lhe

repla.emenl

the

@olanl

pump.

b66

Tighleñ

grodé

ol

3. Posilion lh6 €placémérl coolani

hpellerhousing on the base

plalo

NOfE

¡rake sur6lhé

qbde

of the

sealinq ng reñains seaied h ihe

PUnP

imp6llérhous

nq.

4, lJse caE to éhsúre that ihe seal

@mains

mo ant

5. Poslion lh6 l6nsionér

lhe engine and ¡nsialllhe tension$ bolts.
Tlghlen

pbpeny

pump

lhe bolls lo speciñcation.

sealed and inslállrh6

bolts

and lighle¡ lo

pulley

on lhe f.ont of

pump

and a ion

ng r ng

REPAIR

INSTRUCTIONS, PART

1

Thermostat and

[215

NU, NG & LD]

l

Ct,nderH€¿d

Uss cocus cloth 10 r€mow ány su¡lacé

nicks, buft, sharp edges añd lool ñarks

Cover

t

lnstallation

3.Th€,mo,Lar

fom lhe rhermoslal @ver and d/linder head.

Lubn.alé lh€ inner

suda.e ol lhe co@r

Coolant P¡pe lnstallation

[215

UPPEB COOLAI¡II PIPE (BYPASS)

SWI

1 . Lubricato ánd asémble

upper coolanl

p¡pe

housing lláng€.

uppercoolant

a

ñ4

Pipé

HOUSING

seal in the

housing

lnslall lhé néw lhémGral.

3-

NOTE

Make sure lhai the tubber *al remáins

4- Pcilioñ thé lh6moslal cóver lo

head and inslalllhe bolls. Using a lorque

w€nch,liqhien

paliem

acerding lo sp€cilicárión.

lhe lasleneE an a cross

lhe .ylinde¡

proD6

v

FrsuE o1

Using á lo

coolanl

aúoding

Asseñb e lhe lan r¡ng b6ck6l lo the upper

using

ac@rdinq to spéciñcalion

upper cooranr

-

que

wren. h, l¡ghlen thé upper

p¡pe

fa$enere in

lo specinatun.

loque

a

w@nch, liqhten thé lasteneE

p¡pé

hsbÍa

sequence

on

REPAIR INSTRUCTIONS, PART 1

PUMP INLET HOUSING

1 Lubndeand assemble nssealing Íngs

on lhe

pump

inbr

pipe

ar r-he

2. Plae lhá inlel housing in

th6 uppereolantpipo and the

Replacé and lubficale á I sea lno o finos.

joinr

posil¡on

pump

wjlh

belweén

inlei.

rhe

Oil Coolerand Cooling Duct cover

[215

The oll coolor músl be atached
duct cover belo€ aftaohing the Ó@r b lhé

OIL COOLER

Dw' 2r9 EPI

the cooling

1o

INSTALLATION

1

Using a shálp

,

rubber sear

¡n lheoilcooler c@er,

Clean lhe

inspect for danage ló lhe *a inq sulfáce.

Ale, inspecl thecyllnderblocka¡d ensure

lheséaling

2. lnslall a nN lo¡med

pick,

carBlully remde lhe

(norded

cover of ány din, adhesives a¡d

sulae is clean

qasket)

il

notal€ady done.

'fon

and undamagéd.

g*kel

in lhe

the

grcove

g@ove

NOTE

ol

3. lnstall the Ma hsleneG and tiqhlen lo

specilicalión,

3ñd liqhbn to specifiatioñ.

Th€n,

housing trange 10 lhe

inslallrh¿ M10 faslen6r

NOTE

pump

flrsl

Apply a ñ ñimal ámouñt ol slicona saLant in lhs

grcove

sea!

as*nbly.

lo hold rhe seal in

lnslalllhé

mq

3. lnslallnq oil6lers6alng

bé¡reen

sealingojings nto

lhe oi cooler ahd covel lnslallrhe

wilhin

lhe

prace

20

O-nnqs

grooves

durng

minules ot

¡¡ the cover

REPAIR

INSTRUCTIONS,

COOLING DUCT COVER ¡NSTALIAT¡ON

PABT 1

1. Feplace lhe Mler

lormed ¡ubber

Lubricále néw

2. Wilh assislance.

assembly h

gasket

gaslel

pláce.

NOTE

pump

sel the c@ling duct cder

inler

hbuslng

wlih a ñew

upo¡ i¡sta laton.

lnslalllhé uppé¡ éí

gsket,

5,

Using a lorque wrench, t¡qhien the tasteñers
iñ sequgncé amoding ro

lnslallrhe

cooler T¡qtfen tóténaB 1o spécilicalion

oi @derll@

speitiellon.

plate

over the oit

This mouñilng lo@l

3. Using lh€ ass€mb

the cover loeard lo cómp€ss lhé lomed

rubbé¡

the upper ¡iahl corner l4lener

gaskel

on is sloted lor¿dtúsrm€nr.

y

lool,

3a300022,

al lhe waler

pump

NOTE

A small

kéep fóm

lool fool is

p¡e.e

ol ñétál srock

deiormlng thé slamped

pressi¡g

aqainsl.

should be used b

cwer that the

push

inbr. hsla I

frsu6

3¿

coo¡ins oud ca$ adjudm¿ ródl

-

REPAIR INSTRUCTIONS, PART

1

4. Adiusl 6wr as €qui€d

rówéf énrér lasrénéfs ró

NOTE

The uppér cenler mourninq location h6 á liqht€r

ldeÉñe than olher moúñ1iñ0 locaiions.

5. slart a I reñalnlhg m@r lastene6 ahd

lolqle üg}nen bsleners to speciti€lion,

Oil Filter Housing

[21e

EPI

L hsla I the ea¡

wlh a new

clamps in

cde¡, insla I lhe iasleneG and lighlen lo

gaskei.

posilion

lnstallalion

pipe

lo lhe oil @oler

Place lhé rálaining

on lhe oilmolerducl

cow¡

and

gasket

posil

on lhe rear

to the engi.é btock

pipe.

pipe

ear

lnslalllhe

3.

lnsrall rhe oil li[er housing onro rhé énsina

block

lnslall lhé fásl6nérs to rhe

fller hous¡ng. Toque the bolls to

lnstall the lont

lhéoi

fllerhousngandlheóil@o¡ercovei

p¡pe

wilh n4 seals belleeñ

Torqle lhe

n the olt

2. lnsialllwo allgnñenl

gskél

in

place

ard 10 aid in lhe alignmenl oi

pins

-),

to holdlho

pipes

7. hstáll all hárd

(molaff

and oil) lo lhá

ollcooler@rel Beplace and lubricate all

sealinq

O{in$, Alsq Bpla@ sealing

w6he6forlhe banio finino on lhé oil@oler

covei Tiqhlen banjo lili¡nqs to specifications.

REPAIB INSTRUCTIONS,

PART 1

Exhaust

1214

Manifold lnstallat¡on

EGI

NOTE

The éxhaust manilold mounling laslene6

used lire l¡mes u¡less the mánffold ls béino

[e-mail] manitold is being éplaced, use

can be

1, Clean lhe manilold mounling suriace on lhe

2. T¿mpoÉrily insláll án alignm6d slud at each

exhaust manfold fanqe bcal¡on on lhe

NOfE

This is don€ lo hold lhé manifold whil¿

the manifold

gaskels

lof ¡nslallal¡on ol lhe bons

posilioning

o

1. Múibrd s ds

4. Apply ánli-séizá.ompou¡d

and under ths h6áds or contacl

áll lhe mánilold laslé¡e6

(ftbl)

NOTE

2. cv ndsr Hd se

l

(wih

to the threads

sula@s ol

o' o

ae\

(_ll

,o

F'Urc3sAl¡gnm¿dPhh3bll¡lio.

3. lnsrall néw

wilhthe s€a

qaskéts

The

aid i¡ ¡nsla lation. Mak€ su@ lo

gaskel

lhe
gEphil¿

libn side

qakets

side

oñlo lhe

lacing

NOTE

ár€ malkéd "MANIFOLD

lMrd lhe exhaúst ñan told. The

gaskel

ol lhe

ój

l¡re

SIDEI 10

this side ol

da@

laces lhe cyllndar

Anli-s€izé hélps

cofosioñ and ¡€duces ficlion

inlended clamp load oñ the compo¡énl whe¡

qhléning

1

rhé

5. lnsiall lhe dhausl mániióld

alignmenl

in lhé low.

p¡nsen

@placed wnh ñounling lásleneF

p@nt

hsleneF to specifi€lion.

plns.

holes, Now lhe upper alignm¿nr

b6 émowd o¡e

iasiener oxidatioñ

lo help ach¡eve the

oEr lhe

l6tállfast€náE wilh

ala lme and

and the

spacers

NOTE

M¿ké surelhe
in themdilold

Exhaúst man lold laslene6

Tiqhlen

6.

lhe l¿s16n6rs lo

sp¡@É ¿r€ seated

siep bore hole

€n bB uséd

speciti€l¡on.

p@pe¡ y

loc¿xon.

up

REPAIR INSTBUCTIONS, PART 1

Turbocharger lnslallat¡on

[214

SCI

Lcaurror,

Use oity ¡ev md aryove.t

w aB a¡t. oil 4d dhaust Mnectare ¡a

tuftnchatgú. Avaid the @ of *al¡ng d

Le

jakt

úrpoúds ar a|¡ l¡anged @nñec1¡ore.

fhopuoh

pañ¡des

¡nducled dutkg

te to

ha nd I i n

Aftét únpte¿ns úq¡he ea*ñt)ly, l¡¡l the

tutbocharyet ol

o¡l belote sbn¡N

ptace¿úe

ENG¡NE PBEPABA|ION

1.

tnspecl the i¡1ake ánd exhaust systems
leading to and
máke suG there is no foreign ñálelal

incudi¡g búiÍs and ooe lining fagments.

.lea¡tress ¡s rcqu¡ted. Sna

ñ úúse @vee b¡ü danage

h¡gh-speed opetut¡ü. Bé

plug

the inlal and últel

g

th e tu tuocha

undet Tutbocharyet ¡n ¡he

l@n

ry

paege

lha éNke. Befer ló the

lhe

gaskets

q.

wnh dean

AND

lurbochalgér lo

po¡/l'

at the

il

wh¡|e

eryke

z lnsrallrhe rurbochargertlanqe nurs and

spacers ro rh€ Bxhausr mán lold and

to¡qúe t¡ohien to specilletions.

NOTE

Clean the co¡iact suface oñ the *hausl
manifold,

Relaln the

lu¡bochaqe.

oil €lurn/d@ln back

polectl@

po

€ps @f the

s

lo keep deb'is and dúl

oulollho lurbdharger as

apply añi¡ se¡2e ófrpouñd to lhe théads

and under

the fasleneG. Anli-soiz€ h€lps

hstener ox dalio. @clon and redues

l clon ro help

load on the componont when lighlening

'aslene6

5,

lnstaf nee h

betweén

6,

Pósilion lhe lubocharqer and
aqainsl rh€ Bxhausr manilold.

lhe heads

achiwe lhe

to spec¡iielioñ.

gh

the tulbo fange and

or conl,aol sula@s ot

tempé¡á1uÉ

p pé

gngine

pt€wnl

¡ntended

gaskets

qhausl

gaskels

and

clamp

lhé

y

app
undér lhé conlá.i surláés ol lhe laslénérs

a¡i¡-se¡ze compound tó lhe théáds ánd

REPAIR

INSTRUCTIONS, PART 1

a. lnstall the lúrb@hárg¿r oil

9.

(lower)

lnsral

gasket.

with a nN

the oil suppt

Totque-lighlen tho bolts lo

oaskel.

line (uppe4

E¡rrn

pipe

wilh a new

Exhaust Pressure covernortEPG)

lnstallation

gD

234

1. Lower lhe EPG housinq inlo

bétuéen

lhe exhaus!

p¡pe

2. lnsrall a nM hiqhreñpehtué

ho usin

g

and éxhausl

pipe.

posirion

and lurbocharqár

o6két

EPc

/AcauÍtoN

Pra-lill Ihé tutbodÉger w¡lh
S¡añlhg the eñgiñe wiktut oil

Ary" lubaúaget @ dmage lhe luúo.

cl@n úgjre oi¡.

pressure

and

a

3. Tighton lhe clamp

pipe

lo EPG housina.

atiaching lhe dhausi

REPAIR INSTRUCTIONS,

PART

1

4. lnslalllhe dhausl clamp lom

EPGrorubocharger

lhe

Siarter lnslallation

1272

The staner is held ln

Nér sruds ireérléd in the bró.k rr á sr'd ii

DHI

plács

by nuls

1 . Using a loque wrcnch,

siuds a@ordhg lo spéciñcalion.

lighten repla@ñóñt

assembled

2. Asseñble lh€ süner on the sruds

in lhe

5. Con¡eclthea¡r súpoly li¡e to lhé EPG.

F.goÉ343_shghbra¡on

3. Using a torqu€ wEnch,

ac@d¡nq to spejlicarion.

lghten the nLns

REPAIR

Air Compressor lñstallation

1261

CKI

INSTRUCTIONS, PAFT

2,

Asemble lhe alr coñprá;ior

moonring llange

ollhetimi¡q

1

on ine

géar plate.

1- lnsiall a nNseal inlhe

housinq hou¡lihg fl

ange.

alrcompEssor

3.

Using a lorque wrench, iighleh ihe atlaching

¡úls iñ two slages

aeodlnq lo specitlcatlóó.

REPAIR

INSTRUCTIONS, PART

d

1

lnsláll1he cmlanl linás lo lhe

5.

lnslall the lubication tiñes to the an

Tandem Pump

(Fuel

and Power

Steering) lnstallat¡on

[231

AA,262 EBI

1-,nsiall

landeñ

a na OÍng in the

pump

mounlinq llange.

2- Assmble lh€ tándem

pump

ai

qrcove

on

lhe lttaheet

on the

LL)

F¡surc 7-r.nd.ñ

3, Using a b¡que wrcnch,

hsteneB accordinq tosp€cilicalion,

Punp

(Fuer

tighten the attachiñg

'nd

pú.r

srs nq)

REPAIR

lnlet Manifold lnstallation

INSTBUCTIONS,

PAHT 1

[214

HD]

1. Usinq a 6haD

rubb€r sai (nolded

¡n the lntaké nañilóld, il nol alréady done.

Clean lhe úanifold ol arry din, adhésivos
and inspeci lor aw damaqe io the séarñq

su¡lace Also, nspecl lhe cylinder head and

ensu¡e

the

2. lnslall a ns rubbor s6ál

lnto the

gl@e

plck,

carelullv renove ths

qaske0

8€alinq sudace

ol lhe iffake man¡hld.

is

(mold€d

lrom the

clean and

s6k€t)

groove

NOTE

Apply a m i¡ imal amo unr ot sil¡cone seala nt in rhe

growe

s@l

a$eúbly. lnslalllhé ñáñilód wilhln 20 ñl¡utes

lo hold

lhe seal

nplacedu ng

Torqle-righren

s6q u€ nce lo sp ecifi@lio..

the

iniake

manilold bolts in

SeuBlhé 6noiné hamésslolhe inlake

ná¡ihld usi.g

l¡siáll rhé

ai l€mp€Elur6 sn.or localed

the inlake and *curelhe hahé* wlh li6

pdiously

eLeclrical con¡ecto. to the charge

r€mowd

on the lop oi

Posirio¡

3.

pGviou!¡y

molnt¡ng bolis with mounring

hold ihe man lold

alig nm€ rn

ma¡¡hld bolts wilh spáÉB.

the intake nanifotd onlo lhé lwo

imlalled

pins

aligrmenl

placé,

in

and install the ¡ema¡n¡no

NOfE

use f4 scf6m wllh mounling

¡nslall¡rg lhe ¡¡lake mañilold.

piós.

siarl hro

space6lo

ihen r6move lhe

spacefs when

(Bocr)

7

Using á torquo wench,

a€oding

io spec licaton.

sen$'

I

qhlen

the sensor

REPAIR INSTRUCTIONS,

Englne Prehealer/Spacer

lnstallation

PART 1

[214

HL]

1. Cléán

intak€ ñdilold, ai

lhé lomd $aling sudae on

preheargr

or spac€r, and

2. Posilion lh6 inlál adepr€r and inlér áir

p¡ehearer

n4

$an $e bolls lo hold lh€ Gsémbly

using a 1o¡qué wreñch, tighten lhó lástgnéB

ió

a crcss

lnsrall rhe lan ñnq suppon bEcket mounr¡ng

fásl6ñ6r Torqu€-tqhl6n lhé boh ló

(rf

equ¡pped), of spacer brock w¡rh

gaskers

onro rhe inrake ñanilold, Nexl,

Figu65_l¡l3lAd¡pl€l

patlern

a@ordlng lo specitldlion.

rhé

lo lhé

EECU
t230

EKI

añd Cooler

lnstallation

NOfE

The sóquénc6 iñwhich lhá luél iinér

housing, luel lines and EECUar6asmbled

lhe engine depends on the

uséd. For €nginé slánds rhar

atáched lo th€ l€lt sid6 ol lhe

.omponenis cannol be ¡¡sialled unt¡laltd lhé

6ngiñé hás béé. Émw€d lrcm

Fuél lEsh lróm

EECU. Th6 mol6r

the luel lrcm the lank inló lhs lu6lpump.

the tank serves as @otant tor lh€

@nnets into lhe line cary¡nq

Vpe

use an adaplef

engine, lhese

ELve

ol enqhe sland

lhe fepa¡f sláñd.

on

plate

f equapped,

p€hearer

10 ths mounring surla@

man¡bld. conne.t and seué the

ground

and

postt

on añd iñstátt thé intél air

relay

bE ker

cables é marked al

(wlrh

on lhe

élay atrached)

inlake

pMér

NOTE

l¡ake sure the @olinq

1. PGilionlhe

insiall ihe ñóunling la6te¡e6.

plar€

EECU on the engine btok and

and EECU mat¡ng

REPAIR

NOfE

INSTRUCTIONS,

4.

Uslng alorque sr6nch,lighteñ1hé
in séquence

PART 1

hstenere

adordinq to spéciÍcation.

i¡áke suÉ lhal rubber isolatoE

¡nsialled and thal lh€

Usi.q a

adording to specil ca1 on.

Assemblé lhe coo 6ron lh€ EECU. When

loque wrench,

pcilioning

snalgmund sl@p

unil s

properly

grcund

lhe module, ñake sureihallhe

al lhe uppef r¡stf oi ihe

secured ánd

áre corectty

sl@p is

riqhlen rhe fasieners

prcssád

gounded

in

10

Fuel L¡nes añd Filter

Housing

lnstallation

NOTE

Thesequencéinwhichthéluélf ltérhous¡¡q,

lines and EECU
depends on lh€
engine slands that lse án adápler
lo lhe láft side ol
cannol bé inst¿l sd uff I altér lhe
been removed lom lhe ¡epair sland.

areassembled on lhe enqiné

ol

Vpé

lhe engine,lhese componéñ1s

engine siand ced. For

plalé

ana.hed

engine has

tuet

NOfE

FisuEs

1,

Asemble lh€ tuél finer

2,

Using á lorquo w€nch.

Fü.r Firsf ¿nd HoG¡nq asñbt

acmding lo speciliEi on.

3. Allach

al lhe réaf

p¡pe

lhe

bellveen

a¡d the lilte.hous ng.

housing onlh6 btock.

t¡ghten the taslénerc

the s¡de ot the h€ád

REPAIR INSTRUCTIONS, PART

1

Atach the

lnslalllhé iuél rélum liné

cyliñder h*d at lh€ lorn and lh€ lifter válw

lnsrallrhe line ro rhe b¡ock w¡rh P-clamps.

lnsrall lhe lue I relu

line

lo the bl@k with a

line

rn

be¡réen

con¡ect lng the

P-clamp,

rhe

liller Etue housing lo thé EECU ód¿i

lnsrall lh6 lu€l supply and ré1un I nes

belween lhe lue¡

L

U3ing

llttlnqs accordino to specif calio¡.

aloque wE¡6h,lighlen

pump

and thelillér

lhe bahlo

Lop.P,eure Fler

5.

súpp¡y

Pump

Crankcase Ventilation

1.

Clean lhe cankÉse venlilallon sepaáto¡

malinq sulacé o. lhe éngine

n4 rubber

aáskel

iffo {ré s6pa6ror

(Mounr€d

ro Poref

Separator

btock. lnstalt a

2. Assemble the sepaábr on lhe blóck

and

BEPAIB INSTRUCTIONS,

PART

1

3. l.rsing a ioque w€nch, l¡ghlen lhe lasleneB

ac6rdi¡g

4. Assemble

ou el conneclor a¡d instal hose clámps.

lo

specif calion

lhe ouíel hose on lhe separalor

5. ljslng a torque wrench, liqhlBn the hc6

clamp

6. Assmblé 1¡e lnler hce

inlel and

in a iulu@ slep, lnsiattho* ctamps.

7.

Using a lorque wench, tlghlen the h66

clamp tasl€nerc ác@.ding

laslenerc

pr€pa€

ac@rding !o sp4¡l¡*¡on.

on the separator

fo¡ € re cov6r

connslion

lo sp4iti€lion.

1. Assémblé the

ánd I¿¡

.Enkshafl vibration'damper

puloyon

rhe

cÉñlshail hub Ging

NOTE

F¡duress.FanDvePu'le'.ndc

virüaion o¿npér

t2

c,¡nrshaft Hub

t3

Crankshaft Vibration Damper and

Fan

Pulley lnslallatlon

[212

RB,2'16'tA]

AcaurroN

When

to dañage llÉ fo6kg. Denls

hús¡ng

v¡b@üú

h*d ¡h¡s autim nay

lnspecllhe vibElion

llu d leaks in lhe outer housing. ll any

widénr, rhe

clos€ cloaEnce

¡nd lhe rolorinsids, denrs ór nrcks

conlact belween lhe two componenls.

will dele o¡ate lhe dampeñi¡q eftucl oJ rhé

handling a tbnton darpéL bé a6tul

ln the au¡er

s¡l¡ rcndq the danpet

danpe. @nnol be Epated. Failure to

re'u|t in see engine

damper lof dents, n¡cks or

dampermustbe reptac6d. Duelolhe

beñveen lhe damper housing

inefecfive. rhe

oi l¡ese are

nayeuse

Fluid loss

na¡

Using aloquewcnch,tghlenlhe

l6léneF in

a@odhg to sp6cilicalion.

3.

Asseñb e lh€ fonl

(FEPTO)

last6néc in

a@ordina ro

sequence in two stéps

engine

il equ¡pped. Tighrén rhe

sequencé in ldo sleps

spe.ilication.

p@er

ataching

láke of

atachlng

BEPAIR INSTBUCTIONS, PART

A*emble

6.

compGssoron lhei

the allernalor and reriqeÉ;l

1

pads.

F¡qure 3@

-

FDnt

E

Po@ Tar.¡r

qiru

Alternator and Ref r¡gerant

Compressor

1271

C8,264

Assemble lhé allémalo. mouñrinq brackel
onlo lho cylind6r block. Ighlon ih6

Iastere6 a.cordang to spe¡licalion.

2,

ll ¡emoved and nol

á$émbl6lhé lronl énginé supporl mounling

báckel on lhe cy inder block. This brackel

pr@ldes

also

Using á lorque wBnch,lighlén

lor the b€ckei ánd ñou áccording lo

lf €mN¿d,

Using a lorqúe wrench,

ácordino to specf cár on.

lnstallation

DP1

ppiolsly

lhe mounlinq

assemb e the bett tensioñ idter

lighlen lhe lalene6

installed,

poinls

lhé

(FEProl

io¡ lhe

lasleneB

s. m 6mp,ésor

I

6. Mounr¡m Bccb| Fron'

|

Enané súppod

I

usinq alorque wrench, l¡ghlenlhelasleñefs

a€oding lo specmcatun.

ll a hárnBss is installéd. secuely

the eLectlical wi nqáslagg€ddu ng

L

Assemble lhe be I
and

compressor hubs, r reñóved.

pulleys

on lh€ állénaror

connect

REPAIB INSTRUCTIONS,

Wiring Harness lnstallat¡on

wñqHafÉss

l3

PABT 1

1. Roule añd

engine s noled durlng di6a6sembly,

2. lnsén lhé unil injéclor

throqgh the holé l¡ the tlñlnq

pGition

the harnéss on fie

ponion

ol lhe h.me$

gear

housi¡g.

3. Connecl ihe hamess lo each iñiectóf.
4, Conneclthehamessiotheengiñébáké

mnlrcl valve t

Usinq hioh-lémpéÉlue wne
aliach ihe harness lo lhe cyLinder head.

previously

¡t nol

6.

wiring harness

valve. secure the hafn€ss lo lhé cónrfol

Blve as shown iñ Figué 363. i¡ák€ suro

thal lhé ham€s is

the boss al the lóp of the Elw assémbly.

lnslalléd.

Íes. 983472,

done, caelul

@er lhe engine brake control

pGilioned

y

ror,lo lhe

lo the s¡de of

/AcaurroN

Do Nof mute

lop oÍ the engine tuake
enough deatatu belween the valve

wive

@ver far lhe hatñess when rhe

insblled. fhe hatress

s¡de af the b6s ro awid da@ge

the hames o@¡ the bos at rhe

@nlrcl hlve. Therc ¡s nat

añd the
@ver

ñusl be

pós¡ioned

¡o the hahess.

is

¡ó lhe

2. cúLrclva €

|

ahe énernal

encGed in a@fdion lubinq. Th€rá afa séváEl

unils éách of which

permn

thai

allachmerl

CONNECTING THE EECU

L Ch€ck l¡\é lénsio.

p¡ns

podon

.o¡veniont st

lo the block in úrious localions.

úshq ihe tésl

ol lhe w

¡s tilled w¡lh end connecto6

ol lhe lermanal ¿on n6cto I

pins

ng hame6s is

jóininq

ging

n

¡

roól

kit 999000a.

a¡d

NOfE

ll

lerminal

2.

pins

are damaged

or coroded, ¡ep ace

Caelullyengagetheuppera¡dlowerwiring

haiñess connécroF

lhe connecloG are lalched

lo lhe EEcu. v€rify lhai

propedy

and

Ue aE to

aE sla¡qft an.l undanaged,

^caurroN

entute ¡hat the EECU teminat

pks

REPAIR INSTRUCTIONS, PABT 1

3. lnslall lhe bolls

lo

secufe

lh6 wiing hafness

Cylinder Head

(Valve)

Cover

lnslallation

[211

JBI

1.

ean lhé

C

cylhder héad. The su¡la@s shóuld bó cléár

of a¡y di¡l or debrls and l¡ee ol any oil.

2. lnspecl lhe

@pla€mént

ñe

lhat I ¡s

@nrour

g6két

gaskel

is necéssary caEtully

gdk6t

intó the channel, ñákiño sué

propeny

of rhé chanñé|.

sáaling

lof damage. li

sllace ol lhe

*aled and tollds lhe

r

plácá

a

Cónnecl thé vanous le¡mináls as lagged al

di*ssembly lo áll ssnso6, rslays áñd

componenls such as ihe stailef, allernalof

and Élli96€nl cómprcssrámong olhé6.
Anach rh€ clamps lo hold lhe hamess

5.

on lhe

FlguEscyn.&fH*dcov¿lG'3k¿t

3. Appry a 2 mm

i0.079

séalanliolh¿ areawhere lhe liming @ver

ándlhecylinderhoad mééi. This

is on bolh s¡des of the cyli¡der héád.

Ca€lully

cylindsr h6ad and make

rema¡ns

posilion

pope y

¡nch) bead of MAoK

valve

lhe

séátéd.

cover on the

lhal

su€

paning

liné

lhe seal

REPAIR

INSTRUCTIONS,

PART 1

4. lñstálllhé sp ngloaded

covei Tofqúe tlqhloñ lha

sequen@

io speoilication.

bolts ¡n lhe utve

@l€ cover bolts in

NOTE

The cyl¡nder head cdór musl b€

wilhin 20 mi¡utes ol lhe séálánl beinq

inlake

pov¡de

manitold. Torquerlghlen

e@n te¡sion on lhé

The boll springs

lnsla¡llh€ last€néB securino lhe

5.

venl¡bnon tube and bÉcket lo the vd@

cover and
lh€ fásl€néc lo specilicalion.

in$aned

c@nkcse

NOTE

l¡spetthecEnkcase ventllatión lubóOjing and

Fan Hub

[216

and Drive Beli lnstállation

AAI

1. Pla@ lhe iáñ hub bráckét

pos

lion

al lhe f@nl of ihe cylind$ héad

block. lnslalllhé

lighleó 10 sp4jfi calion.

mounting tasleneG and

a$embly ¡n

and

t1&€soryod€Bd

Puñe Bor'

I

Pláce lhe 1áñ

lens¡oneriñ

housing.

ll nor ¿keády

drire bsll i€nsioner

cylindef block. lnsralllhe l4te¡e6

Check lhe @nd¡llóñ of borh of rhé óridi¡sr

A/c/áltemalor

Check tor dry

@Place wilh nd b€lls I ány

P€rlhe

¡Llo/alterñalo¡ and lan/water

d ve and

posirion

lnslatt lh6 tasleners

done,

a¡d waier

cEcks or scuf marks ánd

ac@$ory rouling d8cal, bure

puñp

on lhe coohfn

pt¿c6 rhe

pGrlonon

m

pumpÍan

rssiomf

driw beh

pump

and l¡qhten ló

a@essory

th6

and

belrs.

ol these

lhe

pump

betts.

REPAIR INSTRUCTIONS, PART 1

7. Using lool

/14392,

J

eay fom ihe ran and wátér

and insralllhe belt. Reléass lh€ lénsion

pry

lhe be¡l lens¡oner

pump

dnw beh

Removing Engine ftom Eng¡ne
Sland

and

6. Place a 1/2-¡nch Elchel or speclal lool

J4€92inlhéa@essoryd

nolch. lñs1álllh6 dfive belt by

lenslonef away fom lhe bell lo €li4e lhe
lénsion on lhé adiúste! ánd állow thé bélt lo

srip ó¡io ihe ¡l/c @npfes$r

Feleaé the léñsion and r¿move lhe tod .

vebelllánsionér

pryiñ0lhe

purréy.

t200

fhe

ñwr he exnise.l whíle

the stan !. Faitut¿ to u*

aDd ,allure to keep

in e¡iffi

EBI

qglre

ls very heaw an.¡ at@e úuüú

¡t is belng úfted lrcn

p*@I

pñpü

yoú

bo.,y ct@t ñay re tt

¡n¡ury

éqlipúent

ot.l@th ÍtE

úgíre shoúLt la d s¡r.rdúly ah¡ft

1. Atach

J 47033-6 and

a. S idé lhé

b Placelhe
c. Sl¡de thé réár lifting

d,

engine lifung ioo s J 47033-1,

4703a4

J

centerengine liftiñq barder

thé cylind€r head

cl4is

clévis lo
ey€s ánd s*ure

pin.

Connect thé c€nlé¡ lifiing

lhe chain on lhe hoisl.

l¡fing cha¡n toihe é¡giná tift

lifting bar and iñslalllh6

goll

on lhe floñt sectioñ ol lh€ 6ng ne

lifting bBckel

installth6

lo lhe cyl¡nde¡ héád áñd

pin

in

as lottows:

cwerard instal lhe

lhe chain lo th6

plare

inlo

pin.

lhe bai

out of

bar

the @nter

é. Torqué'lighlen litt ng

bracket hslene6

REPAIB INSTRUCTIONS,

PART 1

U* on¡y the ch¿¡ns, ctév¡B dnd tiking

prov¡ded

úé ¡hé @ret

¿Iów lhé úg¡re to fa,

pet@nal

3.

wilh th* spec¡al tals. Fail* Io

sp@lal too¡ @nponents náy

@u.¡ng 4 @5

ln¡úry ú rlééth.

Supportlheweighl of th6 én9in6 usinq a

mobile ll@rcEnesuch as OfC 16.1313 or

equivalentcrane capable ot lifing lhe

€ngi¡é. Posilion th6 cEné and hook up ló

the bar as d6e as

slighrly ro apply rension rolhe chain.
With

€ngi¡e
fasleneBlrom the enq¡ne stánd.

Using theenlhe hoisl,

suitable supporr Éck or insiall rhe engine i¡

lhe @hicle

REPATR TNSTFUCIIONS,

the

w€ight,

lifting

(sée

pos

ble. Baiso lhe cnno

device now suppo ing rhe

@mov€

F¿o,h€ /rs¿tlrli¿, in lhe

the mou¡ling

pla@

lhe engine in a

PART 1 secrion).

pla¿e

1. r nól ak€ady don

oompo¡enls onlh6 éngine

p

ocedu fes cove red ea i6r in this

.

Enginewkins harné*

I

cfa¡kcase ventilát on lubing

.

EEC|Jandcoolinqplal6

Fuel l¡lter valve hóusing and luéllines

Cra.kcase venlilalion sepa€lor

e, asser; blé thd lottowjns

using lhe

6eclion.

F¡lters and Miscellaneous

Components

[219

This seclion coveG lnslallation ol lill6B ánd olhér
componenls thar might

a$embly opéaiions and to which nólhing is

EV,2t5 LDI

lnstallation

gel

in

lhe way 01 olher

NOfE

Ths sequ6nc¿ in which

housing, tuell¡nesá.d EECU ဠssembled

lh6 ¿nq né dépendsoñ
u@d. Fof engin€ slands thal

attached lo lhe len s¡dé of lh6 ánginé, rhese

cóñpoñ6¡ls cannol

engine h6 b$n fomoved t@m

the luell¡ller hl@

the lype ól6nQiné sland

use an adapler

be ¡nslalled uñti aft€flhe

lhe repa¡¡ siand.

on

p

até

i . Eno n6 w?iñq

Hamess

I
I

I

2. Assem ble thé fu ll-llów

lo

.onlacl

Assemblelhe

3.

contácr

assémble

contáó1Plus 3/4 lo 1

plus

3L/4lo I lurn.

Plus

bypasso nleránd

3/4 lo 1 lurñ.

lhe coolanl flteránd tghren 10

4. EECU

6.Cankasvéñúárón
s+¿mbr

oil tilte 6 and tig ht€n

Ughtenlo

lurn.

REPAIR INSTRUCTIONS, PART 1

ENGINE INSTALLATION

Special Tools

General lnstructions

Détails

lfom one Éhicle to snolier This setioñ

gene@l guidelin6

oi

rhé

enqine

insla

Jor insralling an MPB enqine in

lalion

p.océdue

prdidos

NOTE

Belore insiafing lhe enqin6, mak8 su€

equipme¡t a@ inspecred lor sfety and

1. Positlon the vehiclo 0n a fat, lwel 6u.lace

Apply lhe

wheels.Obse@allsatelypreautións.

parklng

brako añd block ihe

Ery

NOfE

R6rer to th€ SPECIFICATIONS

lnirfrá¡oñ ¿boll lhe laslénéB mé.lioned

Some

sp€cilc sequence,

speciñed i¡ the lorquo sp€cili@tion

groups

ot

Paflens ol sequence are also

'aslene6

lnsrallation

Thé engine ¡3 obv¡ously

handle. Obta¡n a helper

l¡ftlng devlce to support il salély during

iBrállátion-

esú ir séveÉ

FailüE to hedthis r¿rniñg ñáy

p€bonal

and

section lor

musl be tlqhtened in a

seclion,

heavy and difñcult lo

prd¡de

a súitable

¡njury

be ou

REPAIR INSTRUCTIONS,

PART 1

wh¡lé i.sratl¡ng

lhal ñay ktañée. such ae eng¡ne

@rnpúeñl' bhcke.ls, clanps and other

a¡tached to the lqñe and @b. Fá¡lurc to heetl

¡h¡B 6úim n6y

ghe

aúl other

1

Cryérlhé

^caurroN

the engke, wat h lot abstucl¡ús

and chassÉ

pañs

Esult

in

sevee danage to ¡he

@pú4ts.

valvé méchanism and

géarlÉin

wlh a suitable clolh or simlaf covedng 10

p@enl

3,

Aiach the €ngina lifting tool, J 47034, lo ñe

e ñOine. Secure lhe enq lne llftlng tool to lhe

ircnl ol rhe cylinder head and ro lhe rear al

di¡l and debris lom enleing lhe

thelywh6el housinq. Adlusllhá1oo to

hsral lhe

w¡ench, 1
screws ácerding 10

Wlhdaw lh6 lEnsmission

12.

a. lf hañual lE nsm iss

rEnsmr$ron ahd, u]eind a

ghlen

the l€nsmissiú áltaching

specilicalion,

io n. atlach lhe

. uich linkage añd bfacker Gia¡ñing

b, lf aulomatic

tofque conrener accéss

Aflach the h@d esl crossmember ll

Co¡nect slartBr wnes and cables,

15.

Attach thé

AIlach lhe exhausl syslem braókels.

17.

Aliach lhe exhaust syslém lo lhe

peérsiée

fansmission, attach ihe

ng hoses

jack.

pan€l

lorque

and

and

Ensurc aI bofts a'.t

posl

the eng¡ne stú.1, Fallwe to

bóIts ¿nd

rcsult ¡n

one.r

píre

petsorat

priot

to rñoúng thé úg¡re hoñ

ól lhé éng¡n. lifting tool en

ínjury .ltor dédh.

4. Usinq lhé €ngine iiftinglool,

wlih lhe ald of the helper, lifi and lower lhé

Alig n lhé áng i¡e wilh

5.

lnslalland, using a

lhe rear engine suppon aftaching screws

amo dinq

lnslall and,

lhe lóñt enqin6 suppó
a@ofding 10 specllication

Femo@lhe

L App

y

án évén 2

s€lantátlhe

cyli¡der head a¡d tholiming óEr,

pe.ll¡catlo

1o s

u6¡ng a loque we¡ch, lighlen

engine litl¡.o lool lrcm lhé

joinr

arc @récüy

üns

propúly

47034,

J

lhe I ransm¡sslo n.

toque wEnch, tiqhten

n.

aiaching scr4

(t64

mm

lines

inch) bead ot

between the

lnaan an

and

The rád¡álor and CAC ásseFbly

ls hdy and

d¡fi¡culllo handle, Prcvidé á su¡tablé lifiing

dev¡e á¡d á hélpér

lnslallation, Failuré to héed this

Esult

19.

To all@ Jór chssis

appllcatlohs, tho lan

ilush

qap

belween the fonl lacé ot

lhé back lacé óf lhé rán sh.ó'

in

severc

Anach

agai¡st1he shroud on cU modetchass¡s.

of 15-20 mm (0.59

ihe adialor and CAC 6sembly.

lo supporlltsalelydur¡ng

waming may

Dersonal

N OTE

anlculatlon in s6ver6 service

¡n¡ury.

ing rubbefsea doés notlil

4.79 iñch) disls

the aluminuñ tan nng b

'd

A

NOTE

¡stalllhe va@ 6v€r wilhin 20 minules oi

10. lnslá lrhé varvé cóvér

BEPAIB INSTBUCTIONS,

PART 1

21- Co.necl üE

fan

aclualor

22. Connecl lhe engine c@lanl lemp€@luré

23. All5ch the chafge air @oler oullel

24. Atach the charge

air

cmlér

inlél

25. Aia.h thé dolant dpanslon lank.

29. IttheBhicLs is €qu¡pped wlh;ú "

@nd¡lio¡¡.9:

a. Conñ€ct lh€ ¡/C comprGso¡

r

di$harge

h conner rhe ¡Jc ln6 al tho
c.

Connel

d. coñn6ct ih6low

lhe

p@ssu@

présuÉ

s¡l6h on lhe

cutour

e, Recharqe lhe NC syreñ wnh

réfigéErn

usiñg cl

dd recycling equipñenl for R134A.

30. lnstall lhe ¡nlei a¡r system componénls

31. Connecl lhe ¡nlel a.r healer ¡,

32. Atach lhe oil and tuel t¡lle6 and lhe coolanl

Closé all dhins ánd dain Elwa

33.

04. Connect all so¡so6 a¡d acluatoB,

gérant

p€senl.

rccd6ry

26. Anach ihs l@sr Édiálor lube.

27. Conn4l the eb h@ler and luel heáer

c@lanl

€rurn lines ¡o rhá ld6r Ediaror

24. atlach ihé úpper radlalor lubé.

Add oil and molant. lf

36-

qtEclor¡njeclorwhen

aEilable, use @dal

add¡nq óolánt.

37. Atiach the h@d, or Épla@ lhá lih€d

cab.

REPAIR INSTRUCTIONS, PART 2

REPAIR INSTRUCTIONS, PART 2

rN-cHASSTS

PART/COMPONENT

PROCEDURES

This séclion

opeálions wh¡ch €n bé doñé in chasis withóú

a comprere enqlne @fhau¡. The* ope€rions

.

CAMSHAFÍgEAFINGBFACKETS,

BEPLACEMENT

.

OIL fHEBMOSTAT ANO
SAFETY VALVE

.

CFANKSHAFT

!

CRANKSHAFT

.

CBANKCASE VENIIIAfION

SEPAFATOF

.

OIL

.

INJECTORCOPPERSLEEVE

pÉsenls

PUMP REPLACE¡'ENT

slandalone rcplacemenl

PFESSURE

BEPLACE¡¡ENÍ

FBOÑT

BEARSEA!

REPLACEI¡ ENT

SEAL

{CCV)

CAMSHAFT BEARING

BRACKETS, REPLACEMENT

(MACK

[2r3

This inlorñátióñ cdé6

€placing iaclory or aferñárkél camshalr báárino

bEckets

Preliminary Steps

fh. lóllówing eñFótunts m¿d lo b.

retuved ¡ú a@ss to the @ñ.haft bñing

CompEsion BEke Solenoid Valve

'

t

Camshaft Assembly

MP8 ENGINE)

CJ]

(lMr

jourñals)

guidélinés

on ihe MAoK MPB

wheñ

.

UNIfINJECfOFCLEANING

.

VALVÉ STEM HEIGHT MEASUFEMENT

.

VALVE STEM SEAL REPLACEMENT

Du€lólháEngine Eléctronic

sell lear¡iñg capability, il is nsBssary lo €s€l
learned EECU

€nainé{élá16d componénis, This állNslhe

EECU lo leañ lhe new conponsnts béhávior

After sedl.inq is comp ele,

pa€melers

Codról Uni

atlerseruic¡ng some

pefom

(EECo)

lhe 'Leamed

General lntormallon

Cams hatl bearinq

wilh malchina uppér

nole and mark the 6resp¡ndino

numbeF and insralllhem i¡ rhe cofecr *quén6

wirh marchéd uppérand lwer

jou

rnals are nuñbered 1 7,

lower

and

halves. Ae sure 10

iournal

halves,

REPAIB

INSTRUCTIONS, PART 2

Camshaft lnsp€ction

F¡gUl¿3ñfubñB¿'ngBrcchlL¡krHátr

WHEN BEPLACING FACTOBYINSIALLED

JOUFNALS

.

rt a camshaf

túlx á r€plácaménl báaring bEckél wirh rh6

o rig lnal laclory-inslalred bearinO brack€rs.

This is

were alion bored whe¡ lhé 6ñ0iné wás

manutacluEd. A lsden bEckels must be

bsause lhe o¡iqinal bearing b€ckels

jourñar

has se¡zed, Do NoT

To arcid

lhoroogh iñsp€clio¡

feinsralling áner fépracing lhe

u¡neoe$ary derhaúti.o, co¡duct

ol lhe camshait b€for€

beafing báckei

Brackel Replacement Procedure

L Bemow lh€ lower

pry

bar The rearnosl Nó 7 b€ckál €n bé

Bnded

tapping sid€ lo sidé.

should come oll the cyl¡nder héád with lhó

bEc*érs. lr ¡or, remove

by usinq a soft-hced manet and

bea¡inq b€.kets us¡ng a

Crhealignmenl

pins.)

the

pins

a

.

Wheñ réptácing a cylindér héád.

¡4 bearing b6ckelswith original b€ánng

bEckers |lom

onlv new beá n0 bÉckéls on a néw cvlinder

WHEN REPLACING¡NSTALLING

AFTERMARXEfJOURNALS

.

ll the@ are aleady repla@nént b€arlng

bEcksl assmblies

or ñore ass€mblies áre

4senblies nusl be eplaced. Raplac€ménr

backét assmblies
dal-shaped aliqnm6ff

.

For replacement báck6l assmblies

lo€lions 2lhrough

holes ar6 oval-shaped

adjushenl. For bdckéls used in

and 7,

for l@nr-lo{ear

hole is ound wirh an á ignmenl
lüárk thé boaring caps lo lndi€le

allermaiket beáing back6t

ássémblies haE béén in$ánéd

onealiqnméntpin hol6 is

lhe old cytinder head. Use

on the eng¡né, a¡d on€

damaged¡ all s*n

can be ¡defillied by lh6

pin

holes,

6, both alignm6rf

iof sideles¡de

oval-shaped

adjushert ihe se6nd

pln

and cap

nol mix

do

usd ln

pin

lo@lions 1

piñ

lhal

2.

Clean lhe conlact sulacés of rhe

hóád and lhe

3. Usinq

mark thé ñ4 beanng

wilh

a meiatstamp or e édric éiching

lhe nuñb6rs, 1

loclion

Do not e dces¡@

l@e¡ béa ng bráckets.

b€ckeis and caps

th@ugh 7, ¡¡dlcaliñg the

¿r whch eách ¿ssémblywilrbe

^caurtoN

lc@ la

asñü$ whú ñatk¡ng rheit

ctündet had. Dañage

lo úrponenE

pnch

p6il¡an

oylinder

tool,

lhe ba.ker

on the

ca, resu¡¡.

REPAIB INSTBUCTIONS, PART 2

lnslall 12 nM l@liro

ar rhe ctlinder head ocalions illuslhled

(Fisur6

to dahaÍe the lomlina

5,

lnsrallrhe

378).

new

Uێ a

lower bea

lhei €spocliw marked

plns

plasüc

plns.

positions

lóh the

mallel

ng

brackels al

p¿¡ls

so as nol

on ihe

kil

F¡nal Sleps

lnstall ihe followíig cñpóNnta which

rcmoved fot @s to lhe añshak beaúng

bttukets

insbnatun

!

r
r
.

1. lnsiall all

(eé

dppto4iate

cmporent lor

ptuédrcs):

Camshaft Asambly

Compbssion Braké Sol€noid VaN€

Va w and Unn lniéclor Adiushénr

Va vé Cd¿r A$6mbly

prdiously

qbund (negatrve)

rémowd €blés to lh6

báttery temrñars.

2. Stárl lhe énoine, check lo¡ léáks áñd

@re

pópór

6.

Chec* lhal lhe bearing bEckels can m@
s¡iqhly on the

.

B€ckér Nos. 1 and 7 shoub rurn

sllghlly lodard ahd bad< at one side.

.

Braoket N6. 2 fióuSh 6 should ñove

localing

pins.

BEPAIR

INSTRUCTIONS, PABT

OIL THERMOSTAT AND

PRESSURE SAFEW VALVE

REPLACEMENT

2

Pressure Safety Valve

Belo¡e aliehpthg to rehde lh6 oil

salely El@, apply the

parkirg

Removal

pbssuré

báké, shifi ido

¡ellaland ¡horoughly d@n arcund lhe salely

FiguÉ331_oilPresuEs¿le¡ybfudbd

2. Clen ihe cder and cll ndét

block s@ling

3. Fepl&e lhe O-ihq on the 6€L

2'olP'sUes¿felyv¿b

1. Us¡ng tho

lhe salély klve úer and wlv6 as a uni.

Ensuré lhal

cover and É¡w. Dispose

Ivdw sekel

o

lhe seal is de remowd wilh tha

J43051,remde

ol lhe valre.

'iguE3P-nemd¡ngs.l.lyva¡wcdeldn¡ng

4. lnsl¿l a n4 valve

5. lnslal

6. Usiñg

ac@¡dino to sDécilicalion.

the new Elve and tur inlo lhé

a lDrqué w€nch, lighlen lhe valve

¡n lhe cder

BEPAIR INSTRUCTIONS,

PART 2

Thermostat Valve Replaceñent

Oil

Beloé allempling lo rende the theftuslat

valve, apply the
and lhoouqhly

parking

clean

b6ke, shift ¡nlo ne{nÉ¡

aDU¡d rhé válve head.

1. Femow rhe rhem6rá1 Éúe norith.i oir

tille.

housing and diserd,

2,

2.orPrc!&€s¿htv¿E

|

3,

¡¡srall a nM rhé.moslat vdw wnh a ¡éw

Slart the engine ahd check lor loaks.

REPAIR INSTRUCTIONS,

CRANKSHAFT FRONT SEAL REPLACEMENT

Spec¡al Tools

PART

2

Handls D h Erious u*s

(rb

25 mm hob)

Seal

Removal

1 , Femove lhe fan b ade fóñ lh6 lan clulch

2.

Comp@ss rhe berr re ns¡o ne r

io éleáse

pump

pr6ssu€

dd@ belland remow th6 b€lt.

on lhé fáñ

(u

shg J 44392)

and @olanl

Comp¡4s lh6 accessry

(lsing

lrcm rhá vibBlion
compfessof

lf equipp€d, rcmove

Femove ihe mounring lasleneF

lhé drjve

lh€ cr¿ntshafi

J 44392)and rem@ lhé

damper

pulley

bell

ard alternalor

pulley

hub. Sep¡raF rh€

belt lensioner

puttey,

lhe font engina PfO

and übralion

ve

d

beLl

r6f'iqe€rf

pulley.

thal secufs

damper 1o

pulléy

ánd

REPAIR INSTRUCTIONS, PART

Seal lnslallallon

1.

Clean lhe seal sealing surbce ¡ñ the

cáñkshalt lrcnl cowr ánd
suface ol the cfánkshalt hub.

2

lhe sealing

3 cEnk hdfi fub

l

/AcaurroN

When handlkg a v¡bñnú danper be @@tut

ro damgÉ tha housing. Dals k lhe óútd

hoB¡ñg ún rcndet the danpet ireíect¡@.

dafuged, the

repaired and ñBl be rcPlá@d.

6. Fem@ lhe 6rank6haft seal as tollowsl

viúa¡ion danper @nnat be

2. A$emblé thé handl6

mai¡ seal removerlnslálLer

(9992000)

(33300021).

and lbnl

3. Place a ¡ew c€nkshail flonl seal on the

cÉnkshatlfbnl seal rémowr¡nslallé.

NOfE

The cankshaft lront sۇl

4, Posilion lhe cankshatl fronl seal

cEnkshalt húb ánd cEnkshaf font cowr

Careiully dri@ the seal i¡lo lhe @rer unlil

lhé lool bonoms agáinsl thé cankshaft hub

not

t¡

A,

Apply

chips lom

grease

c,

D lrl@

lhe ñetal rim ól thé cr¿nkshalt llo¡t
s@1.0se lhe holes in the im ol lhe
lmnt main

(33300021)ásaaulde.

mm (0.138 inch) holes in

3.5

rémoEr¡nslaller

s€L

NOTE

on lhe end ol the dnl bil ró

geflinq

Using rwo solhappi¡g M5

su¡lable lengt\ anách lhe dánkshan

l@nl

using Nvo M 10 iasleneB ihfeaded lnto

r6mMr¡nsraller, remrye lhe

i¡lo lhe enqi¡e,

6ea¡ removetiñslal er lo lhe seal.

pr*nl

screws ol

Femove the looland nspecl th6 seallo

maké surá lhai i! is

Pl@e lhe vibalion

the crankshái hub and áiiqn

ho es. lnlalland Íghl€n rtu mounüna

lalene6ln

fivo sleps lo specf¡cat¡on.

pfopefly

damper and lan

i.staLled.

lhe tuslener

pulley

on

REPAIR INSTRUCTIONS,

PART

2

l3

7. ll equapped, ¡nstalllhe

fasléne6. Tighlen

lhe

Pulbylñd,úálioñ

c'alshafi Hub

c¡mp@s6

(úsino

lhe cánkshalt

9.

Conpress the lower béll

J 44:192)

cáñkshaft

Fhu6

lile ac@s$ry ¿íü bei

,14392)

J

pulléy

od install the d¡iv6 boft Ner

pulley,

3e0

Dnw Bd rsn6roner ftor

-

rensioner

and insian fié driv6 bé[

pu

lénsioner

pulley

lley and

lusing

áñd

lan

tan d ve

drl@

@r

the

REPAIR INSTRUCTIONS,

CBANKSHAFT NEAR SEAL FEPLACEMENT

Special Tools

PART 2

Handre *irh vai s usas

náopÉno tvpa si

Neoprene Seal Removal

{fib

(Esnrian

25 ññ horo)

2. lnslall

lwo M10 screws to use as handl6s lo

/Acau¡toN

The

wh@l

the twh@l wjthtut

su¡ta é ifl¡ng devi@. Íeitue

ñaY @tt k @vde

1. C¿ Elu ly rem@

É lEaw Do nc,t atén1pt to Enove

¡lE heb of an ass¡staht ú a

P*tut

llywheel

lhe

heed

t

kiuty éñd

senso(

Lk¡s @ut¡ú

uapeñy

3. F€more lhe llyryheel.

4.

U6inglhepuler,9990192, and the st¡dé

hañmér, 9s96400.

caE u0y

rem@

the

REPA]R INSTRUCTIONS,

Neoprene Seal lnstallation

PABT

2

L CIۇn lhe llywheel,

2. Align

prop€rly

on ihe s€l hstál ér, S998238

hous¡ng ánd c€ñkshaf

and 4semble lhe ñew seal

Freun @-

lnsert

5.

lighr. R¿move

remálnlnq ñounting sr4s.

lhe llyoheel mouff ns sc@s

Fwhé.t ttuhnad

lhe M10 scfss ló hsért thé

N}

linger

3. using lhe handle, 9992000, and lhé

inslallgr, ca@tully
tlywheel houshg uñtil th6€ is

Using lhe M10 scrows as ha¡dles,

help

ol an Gsistant o¡ a tnhg ddiE,

asseñble lhé fyryheel
alignnent

sluds on lh6 mount

lap the seat ¡nto the

@n contact.

o@r the d@d a¡d

ng su¡face.

seal

w¡lh the

using a tofqu€ w@¡chi

scEws in sequenc6 acddiñg

Ca€lully inslallthe

connecl n lo thé hañess

i¡ghlen lhe moufthg

llywheet s6nsór ánd

lo

REPAIR INSTRUCTIONS, PART 2

Teflon@ Séal Removal

Ihé

whed

¡s hav/. Do tul atteñpl lo etuve

^caurtoN

tE flywheel wlhaut the help ol añ a*idant ü a

suitane tilt¡ng dqi@, Fa¡|u@ to h@d ¡h¡s autiú

nay rcsult ¡n sevqe

L Remwe

lh6 clulch Gsénbly

2. Ca@fuly

3,

¡¡stall t¡lo

5.

Usingi¡e

pe6úa1

rámoB lhé llywheel señsr

M1O

scr6m

puller,

haññer, 9996400, É€lully

Mak€ su¡é thal the tools are lee ol

seal.

kjLty and

lo úse as handl€ lo

S9S0192, and the s¡ide

rémow lhe

ptapérly

NOfE

Tetlon@ Seal lnstallation

1- lnsialllhé

9990166, ro rhe c6nkshalt. fiohign lh€

4sembry sc@ws *cu€ly,

platé

ánd lhrust sw

pa

oll@1,

NOfE

firake suB lbal lhe

propo y

nát aga¡nsl the c€nkshall belbfe lighiening lhe

in lhé c€nkshal inl6rnalgu dé and is

plale

ol the looL

pGilioned

is

fake cae

llywhéal soáling súrf¿ces. Slant the tools inMrd

gel

lo

not lo

qood grip

a

damagé

on the c€nkshall rear 6eal.

lhé cEnkshan or

lscldA$¿mbly

2. lnslall the spa@r. a8aaofi 3. ot toot.

9S90166, on lhé rhru6t

NOTE

Ths spac€r is imponad
lhe ¡nstallalion deplh ol lhe c€nkshaf

screw.

beause il delerm¡nes

@ar seal.

fap oul lh€ cEnkshalt €ar sal.

6.

Thorcughly cláan lhá séaling sudaes oJ thé

7.

nylvhBel, flwh€al housinq and cÉnkshaft.

REPAIR INSTRUCTIONS, PABT 2

Th8séaling ng is

3.

¡nsla lalion ¡g that shóuld bé eft

supplied wllh a

5. hstall fté cowr

assembly. cénl€r rhá

cBnkshaf feaf seal and thféád lhe

ló kép lhé cover

and ha¡dle o@r úe

c@¡ oEr he

pos¡lion.

in

handle

4. lnsralllhéséalwlhourrcmovingrh€

installato¡ ring o@¡ lhe thrusl sc€w, speór 6, Turn

/

ih¿ handle lo

seal óver lh6 c€nkshal

l¡ruheel hous¡ng, when ihe cdér bonoms

od áqáinsl the .pacer,

7. Bem@ lhe c6ñkshall €ar séal

pre$

lhe crankshail Éar

inlo

úd

the rear s€l ts in

lhe

installation

REPAIB INSTRUCTIONS, PART 2

7N

\+

lnséri rh€ nywh€elmou¡ting

l¡qhl. Rémow ihe Mlo *Éws

emaining mouñllng sctu.

úsing a lorque w¡ench, llqhtén thé

e@E in *quence a@od¡no 10

1

caÉfully in€lall i¡e

1

,

\

^

llywheel sen$r and

rcreB lthqer

lo inse the

nounri.g

F¡Ñf.sss_Fl9$li*l|rel.lljlon

REPAIR INSTRUCTIONS,

PABT 2

CRANKCASE VENTILATION

(ccv)

SEPARATOR

REPLACEMENT

CCV Separalor Removal

1. D¡sennect thé batt€ries, or iurn of lhé main

2- Clean the cyliñder block afound lh€ ccv

sepaÉlo¡ mounli¡g.

3_

Remow the ccv sepaátor foñ the

OIL PUMP REPLACEMENT
t219

MUI

(IN

Special Tools

CCV Separalor lnstallation

1, Clean the mounlingsudaces

block and lhe CCV sápaGloi

2.

Using a re

sepaElor

3. Usinq alorque wrehch, tighten

amording 10

4. Anach r,há

5. Turn on lha

6. Slart the enline and chdk for leaks.

CHASSIS)

on th6 cytinder

gaskél,

on lhe cy inder block.

6peclical¡on.

CCV hoses.

main

assémble the CCV

swit6h,

or r@nnect thé

'

thé screws

FrpheelTunie roor

(Bsén¡aD

REPAIB INSTRUCTIONS, PART 2

'7'\'\''

o

311

O

i#btlionsysl¿m

2PUmpodlelP'pe

Oil Pump Removal

1 . ll nol akeady done, remow tre oil

2. R€mov€ the

3. Bemde lhe

pump

púhp

4. Reñove lhe cbssder

5. Beñow lhe blod( st¡lle¡e¡

iñlet
outlet

p pe.

pipe

and straiñer

plpe.

platé.

AcaurtoN AcauÍtoN

gloves

Weat

platé.

h has .haP edg6. Faitu@ to heed

úu¡¡on @old Esúlt in sMre

whú hand¡ng ¡he úock st¡ienet

pe@ml

pan.

th¡s

¡niurv.

ll

6.

necessary,

wáy usinq llywh€61 turning lool, aBa0O014.

7. Remove lhe oil

rctalé

pump

cBnkshan oul oi

thé

lom lhé béárjna €p.

Oil Pump lnstallation

1. Clean a[

2. Atlach the oil

pans

b be ¡eúsed.

puñp

lo the No. 7 main

3. Usinq a lorque wrenoh, liqhten the scé6

amordino to speciñcalio¡.

Make cenak hat

cohdinú and

@p. Fai¡ue lo h*d ¡h¡s aut¡on nay esul

everc mnp@eit

Using ¡€w scréws
9994649, anach üé block slitlener

lhe block. Oo NOT lorque-1ighlBn the M@ws

lhe b@ing ¡reeú ¡s ¡n

propely

insfaled

dañage.

a¡d asseñbly 1oo¡,

on the búing

g@d

plale

t¡¿

in

lo

Lub

5.

cale and 4semble na O nhgson lhe

i¡lát, crossowr

and

oul

el

pipes.

REPAIB

INSTRUCTIONS,

PART 2

Aseñbl6 lh¿ cro*@er

pump

lhe

scrcws ro

Usiñg a lóqle

plalé

in sequence ác6ding to sp€cifi€tio¡.

a.

Ass€mbl6lhe inlel

Asémblálhe

housi¡g and on lh€ block.

housing ed instal ih¿

secufe rhe

wre¡ch, lighteñ thé slif6nér

*r€ws

(incruding pipe

pipe

and oullei

plpe

lranses lo lhe

p pe

and strainei

and slEiner inlhe

Usi.g á loqu€ wrcnch, liqhlén lhe

á@ordlng to specil et on.

11.

lnspecl thé oll

neéssary Lubricale

pan

séal ánd réplae il

and assemble thé sear

p¡pes

molnt¡ng

llange scr&s)

pump

6c@s

jl

¡n

12. Apply a 2 mm

¡rAcK-appoved

bel@¡

geaf plale

and lhe cyli¡der block.

lhe

¿nd béhreen

inch)

t5/64

seah¡n b lhá

llywheel

bead ol342sx33

wms

housing and timrnq

lhe mouni¡na

p

até

appry

¡,IACK appoved
belw@n lhe lronl s65l 6ver

attách lhé

14.

a

2

nm

o¡l

(164

¡nch) bead or

sealan¡ to thé *áms

ard the cyt¡ndér

pa¡

to the cytindér btock,

Usingáloquewénch,nghlénrhesc@wsln

seqúen¿o ádcódinq

lospecilicalion.

AcaurtoN

Use a s,leel washer

Do

not u@ an ¡npac¡ wrcnch

plúq.

Fa¡luÉ to h@d

16.

Check sysl6m oil

1T_

pressure

Do rct use a úWet

¡h¡s @u¡ion nay

pre$uc

sensor

poa.

in

lo insta rha da¡n

through

lhe oil l¡ller housing.

342sx33

@sher

resu? ¡n

lhe

REPAIR INSTRUCTIONS, PART 2

INJECTOB COPPER
[213

Tools and Equlpment

Ev]

lñledr coF sleN r4

rnjeb copper sre4 EnHior

SLEEVE

itu*dial)

REPLACEMENT

unr hledo' P'ord'on sr*€s

unr ¡n¡dd Bo€ cdb'y *a¡nq Fñqs

unii rnidor BoE seafú Pruo

uñir hje see

f¿p (Esedd)

(&d'áD

(Es^riaD

0

))

REPAIR

INSTRUCTIONS,

PART

2

unr ñ16ftf sre&F¿namf

F *heerluñriE Éd

sre¡q¡nq rm bf hr'a iq

(Esdiat)

(E$ádiar)

uñi!rñjdü

unir

hiftre.rc cre ino K[

(EssrhL)

t__-l I

r

offi

REPAIR INSTRUCTIONS, PART

Preliminary Steps

2

fha lolow¡ng

.@po@ts need to be

ñovérl fú ¿@s to tlÉ ¡njEclot @PFt

sl@@s

.

Copper Sleeve Removal

1.

(@

Et'¡Gr'lE DrsassEMBLv Íor

Cyliñdér Head Cover

lf

inj€clor d6w6 is nót bei¡g reñoved

lhe

lñmedlately, ¡nslalllhe

lhe unll ¡njeclo¡ boe

pDlecl

itl@m d6bris.

pfoleclive plug

or lhé cyrindér head to

inlo

NOfE

Twosealing nqs are required lo coverlhe luel

Esuée

unr

hFcbf

2. lnsialltwoseal¡nqr¡ngs

én16 ng lh€luéigalléry

Eo6 Pd¿di@ Pruq

3. Bemow lhé

lhellywheelhousi¡g and ¡nsrall lhe llyryheel

lurning tool. Turn lhe i

ls át its lów6st

plug

lrcm lh6 lówer i@nl

ywheel

posilion

in lhe

unl¡l lhe

oylinder.

side oj

plston

F¡sur€ 4o5

Fwheer tumrnq roor

-

REPAIR INSTBUCTIONS,

PART 2

NOTE

This is lo

lool does ¡ot damagé

E¡súétheluming lool

afl emPi¡¡o ló lurn th6 nwvhéé|.

ensure lhat the @pper slede iappinq

pislo.

the

is we lqreased beloé

due lo tool

4. Adjusl the I nm ráp s lhal il éré¡ds

mlnimum ol25 mm o¡ t hch

l¡óm

lhe e¡d ol lhe lappiñg lool.

(dimension

NOTE

Applying

prryenl

6- Th€ad lhe

a

A)

gÉas6

lhem l@m lal ing dMn inlo

the lap and w

sleevé shaüñgs. Apply fésh

reinslall

the copp6r sleéve.
thread lhe tap a I lhe w5y lhrcuqh lhé copper

slerye

túr.sf¡eelrTáppino in small

rem@ing lhe shaviñgs ñinimzeslh6
chance ol

and the sledo lurn ng in

Ensure lhal thé 1ap is coñplBl€ly through rhe

willcaplure

lap in small lhdemenls. Bemo@

pe

olf

copper cuttlngs and

the oytinder

grease

the

añd óopper

greas,

l¡e lapp¡ng looland th6ad mo€ ol

C.ñiinue this

unlil no res¡slance is iélt ánd the rap

shavings talling into the cttinder

lhe

process

inc@menIs and

cylinder

head.

to

NOTE

This é¡slres
lapped ál the way throuqh,

thatihe tip ot the copper stérye is

AcauÍtoN

tt

the @pper sleere is not @nptete¡y

thtoúü to

the t¡p nn brcak

5. Llbrl€lo the iip oi lhe

lhe apen¡hA of the liD. an end

off and fall kto tÉ cylkdet

I mm

tapped

p¡@

ol

FlguEoT_f¿pP¡ngTodhddl'oi

Í

tueads are no¡ cú conplelely

¡he cappet

¡nlolhe cyl¡nd¿

.ylindet

^caurtoN

sleeve, lhe t¡p @n béak

fh¡tdñ rcsu ndan¿qetothe

p'ston.

vatves ar turbochatueL

thtough the t¡p ot

7. Femove the tap and lappinq

L Us¡ng the chipÉcuum, remove

remaininq

shavinqs lóm lhé coppér sleeve.

oll an t la

t@ .

any

REPAIB INSTRUCTIONS, PAFT 2

L lñsiall lhe énddor boli in10 the ehd of the

qrfacror

approximalely
end or the lool

rool. Adjust rhe bolr unrl ir exrends

22 mm

(dimension

(0.9

inch)

A).

beyond ihe

AcaurtoN

Make

cñplelely into the 6ppet

atle¡npl¡hg lo rúove ¡l ar the np af the elee@

nay úeak oft as ¡t ¡s ewed. Th¡s btatén

steM tip en súiusty

thé extÉ.ror

e

bo¡¡ ¡s ¡tneaded

ele* belae

danage the

p¡ston,

Fsur€ .oa

ghlen

T

10.

secure the bolt- Makesuéü1atlhe set sc@

is seated against

ad¡usrino copper sl*rc Enccbr Eoh

-

lhé sél scréw of lhe exlEclor lml lo

rhe llat

pan

ol lhe

qt€.tor

11. Plac6lh€ 6n.aclor lool w lh lhé boll inro th6

¡njeclor bore, Make sure lhe nut oñ lhe
sp¡ndlé is backed ofi so that
end can be coúplelely installed lhrouqhlhe
copper sle4e 1

bonons oul in lhé déM.

p,

Hand lighlen unlll the boli

lhé lhréadéd

NOTE

When lhe coppei deM is rémov€d, maké

lhal lne exlEclor
th¡ead beyond lhe coppér slede.
sufe thal no

of ánd lallén i¡lo

Do not ue .n

danaae to lhe ¡n¡ectot bore

bolt is extended at teast one

It not, make

paft

oilhe copper déM has

lhe ctlinder

^cauÍtoN

bds la Eño@ úwet d@ws, ot

@ñ t*ult_

sure

broken

REPAIR IÑSTRUCTIONS,

13. Fem@e lhe leo @aliñO rings ffom rh¿ luel

p6sage.

any remáining débis

using rhe chip Éeuum, rem@

fom lhe injector bore.

PART

2

\r

lnslall lhé ¡nletor bore ealino lool

(J 42885-25)

área and

lhe unh ¡njeclor hold ddn boll io seu6 lh€

15.

Usins

lhe @pper sle* seal of thó ¿-ylinder héád.

prd€nl

lh€ inislor

prc1e6r

ro

rhe tuel

déb sfom

bo@ clea¡ing kil clean

pássge

enle ng, Use

NOTE

Thé i¡j€c¡or

pBsnl

bo€ seali¡g tool ñust b6 us6d lo

did lrcm

€nlenna fte tuelpasege.

16. Using lhe bfush, clean the cyllnder héád

iñiécld boÉ wáll6 lor

lhe @pper deM.

NOTE

The inje.lor bore seallng toor musr b¿ used

prwenl

d€bris from

e¡leÍnq lhe iuel

passáoe.

to

REPAIR INSTRUCTIONS, PART 2

17. Using lhe brush, 6lean

opening ¡n lhe cylindé.

Frqurc 4r4

crdn¡nq hl*r fp BoE

-

:tr>.-

fr

\/

Copper Sleeve lnstallation

place

pisron

l¡e

is at the lMst

piston

al its l@ost

1 . Ensuó lhé

the cyllnder ll not, us6 lh€ ryryheel
lool lo

r

.

positlon

luming

oGilion.

iñ

NOfE

Thé injéclor boré saling lml musl bá uséd lo

prdent

when replac¡ng lhe copper sleeves, ¡l ¡s

impódanl lo check lhal

cylind€r hsad is lrs€ from any carbon d€posils or

olher Esidue

nstalling a ¡éwcoppér dé*. Réclean ii

10

debfis lfom enrering the luel

lhá .lewe bo€

pie@s

0.e,,

U6ing lhe chipEcuuñ, remove álldebris

from lhs @pp€r sle@

ol O ¡ing, eic,) beloe

bore.

p6sge.

in

ihe

SEFVICE HINI

so can resuli in eyé i¡iúrv.

19

Bemow ¡he inleelor bore searins lool rom

the cylinder head, Using lhe chip vacuum,

róñow árry rémáiniñg deb

s.

Flsuɿ15_Fly}hsdruninlftol

NOfE

This is 1o sNuB lhál lh€

installation t@t does ¡ot damaqe the

@pper slese

piston

dué

REPAIR

INSTRUCTIONS,

PART 2

2. BéfoB inslalling

fo ensure th6t It is th€ 6r@l

3. Lub cale a néw @pper sleqe Ojinq wilh

c@lanl. lnslall lhe O ngóñth6mpp€r

dee and

Always use a nN

Place the n* @pper s e€v6 on lhé

the copper steeve, ¡nspect tt

pa¡t.

lub

cale again w¡lh coolanl.

Oii¡g.

AcauÍroN.

Failute

btffik¡ng of klo

lo u@ lhe

proper

the cyt¡nc!ü head.

bi¡

can result ¡n the b¡l

AcauÍtoN

qelorc

t@¡, ¡nsp@¡ lhe taol lo ensurc lhat n

l@1. The úrdt taol ¡s ¡dentil¡ed

su¡la@ lhal has a nachked

of a ¡@l wnh a

dafuqé to the úpper

insta ing ¡he slee@

penedu

on the ¡ñs¡a at¡ón

flal bonon ñay

s¡eqe.

5. Us¡ng .alip66, measu@

make suré lhal lhe

u*d, Measuremenl shou d €ad

appmximarely 7

ength of lh6 Medgi¡g

pDper

I mm. Also, vefily lhal the

by a bonM

c¡rculat rcces. Use

ihe $edoing bil lo

swedqing lool ¡s

bil is 10a mm.

js

he carect

esult ¡n

Filure413-sred!¡n!B¡rv¿rl||¿afon

REPAIR INSTRUCTIONS,

PART 2

6. Thread th€ sw€dging bll complelely inlo

llaringiool undl lt siops

(linaertiqht).

NOTE

Swédqinq bil cañ bo ord€réd s á sparé

pad

i¡e

if

s. cafelurry

(w¡lh
unil injeclor

Carelully

irno lhe njector bor€ so lhar lhe

guided

is

cyli¡der

iñslallalion lool using hand
coppei sledé downwad until it bonoms óL¡

on

lhe injeclor sle* seal ¡n the bottom ol

lhs ini€clor bor6.
dow¡ and bolt to hold ihe lool in

énsuré

lh€ cy ind6r h€ád,lighlén lhá unil inietor

hold down bolt io speilication.

pra€

the slé4

new copper deM anachéd) inio

bo¡e ol the eylrnder háad.

lhe

moE

.opper deae dMwárd

insialláion l@l

$edging bn

inlo ihe injector tip boB in

h@d. Push downwárd on lhe

torce io move lhe

lhé

Usé

thal lhe @ppef sleere ¡s bollomed iñ

unil

rhé

ini4lor

pc

hold

lion. To

the

NOTE

ñemo@ any oll lom lhe iñiector hold down bo l

holes

1o a@id

whon tho inieclof is lnsla led.

trydraulic

l@k lor lhis slep and

7. Loosenlhe s€dq ng b 1a0deqrcésbéiórc

installing the tool n lhe cytinder héád.

Failure to l@en
lhe bit bekg twE¡ed ot bfaken.

^caurroN

the s@dg¡ng bit ún re ¡¡ in

a. Lublcale the swedginq

REPAIR

INSTHUCTIONS, PART

2

10. Fla€ lhé coppe¡slede

(1)

clockwlsewhrle holdlng lhe spindlé unlil

lhe swedqinq bil has been

lhrcugh

the copper sleere,

^caurtoNFa¡lute ta hold ¡he spkdie an esuh in a twisléd

by turning the nui

pul

ód complétélv

Flnal Steps

1 1 . Remove the s ewe inslallárion rml from lhe

NOTE

Itlhe inleclor is ¡or being

¡nstal lhe folowlng

rcñove.r fot

sl*v6

.

Cy inder Head Corer

@s Io the inlector coppü

(@

ENGt|r'E EEASSEMBLV

coñpo@ts wh¡ch were

lot

REPAIR INSTRUCTIONS,

PART 2

UNIT INJECTOR

CLEANING

Prel¡minary Sleps

Rem@

ángine (s€é ENGINE DISASSE¡¡BLY

.
.

lnslalllhé s¿áling

iñiector bore ol the cyl ndér héád io

and debris foñ entering lhe bo€,

lhe ioll@ing .omponents rom thé

inder

Cy
Rocker Arn ShanA$embly

l¡@d Cove¡

plug,9998251,

inlo th¿ u¡it

ior

pfaént

dirt

Cleaning and Inspect¡on

NOTE

Since the lnil iñjectors opeEle

injeclion

añd lhe inmédiale

rehain cl6an and l¡é6

leaves the cap nut seai suffacB as lhé ónly

sudas which requires

cleán rhe injeclor cáp nut

1. Fen@

2. Cov€r lh€

pEsures,lhé

lhe two Ojiñgs foñ the ¡njector

ánd d¡scard th€ O{ings.

O{

arca between the

equi€lenl lo

q6lling

inlo lhé iniecloi

no2zlolip spEy

a¡ea around the spEy holás

ol @|bon depG¡ls. This

a thorouqh cleañinq.

g@@es

ns

qroóvés

prdent

3. Cdérlhé opéning lorll)e

4- Sr¡de a shoii séctióñ of 6 mm

hose

over lie injeclor nozzle lip untl il

cov€B apprcÍmalely

length. Thls is ñécassary ro

no¿le

cl€aning lhe

sp€y hobs nom dámaséwhen

cap ñul sal suface.

at very h¡gh tue

holes

surface 6lotl@s:

and the conplete

with lapá o¡

conlaminanls lrom

elect.i€l

inch)

{0.25

halt lhe nozzle 1¡p

prcrecl

lhe

lD

FisúÉ

¡r23

rn:brrins ¡n¡sdo' BoE s¿ar.E Pruq,

-

r.rnjeddc6eNds¿¡r

H@lrurn4

2

rip)

Nd¿6

REPAIR INSTRUCTIONS, PART

2

5. with th€

prolected,

sulace of hard caóon deposits úsing

unil iñjéclor nozzle lip sp6y holes

Éretullv d€ú lh¿ €p nln

seal

wlb

a

whsl. Apply o¡ly ligh¡ nominalprasué ló

hold lh€ wiré whéél

suÉáce tor short

425

Frsu6

Cr..n¡nq

-

agaiEt lhe injector

périods

rñl.0ror

ót llmé.

Nor

c,p

s6r srÍac.

AcaurroN

rhe@úonwi

mow. Aw¡d the I dercy to

p@e

ínjé.tü úp nut Eurta@. E@4¡@

danúge ¡ha cap nú tucé, naking ¡lB kjectü

¡n hald¡ng ¡lÉ wlre wh@l aga¡nst lhe

be

very

had añ d¡fi¡@ü ¡o

@

qc*g¡ve

lot@ @n

cl6aD any

lools slch a

Ailer clean¡nq, iñspecl th€ iniácto.

cap

nul seal6ufla@ bf

dáñage. lf lhée i!

@maining @rb;n tjs¡nd hañd

hand MEper

a

or medium

nozle

pttiñq

piting

or €laléd

or olher danage,

NOTE

Piting on sufaces olher lhan thó €p nd s6ar

does ñol

3, lnsrall new o rings ¡¡ rhe

9.

F¡ñal

lnslallthé ñ.llowhq 6ñpoñéñts on lhá é¡gine

{s@

.
.

atfecr rhe tuncüon ol rhe unir i¡jeciof and

gfooves

Lubncale

rhe

injslor

Ojings wilh clean

Steps

ENGINE

Rocker Arm Shaft Assoñbly

FEASSEMBLY lor

CllinderÉ4d C¡rer

pócedur6s):

o¡ me

git

REPAIB INSTRUCTIONS,

VALVE STEM HEIGHT

MEASUREMENT PROCEDURE

PART 2

I213

On enginés exhlbllng

(ar

symproms

honet, may be an indicalion ot

€cássion. A d€.É6é in ¿r¿ádñcó

b6iw6en the valÉ rocke¡ and válve
can be measured al lhe valves 10 delermine ii
seal e@ssioñ

fece$ion

cañ be úsed 10 ñeasue valve slem heighl, fo

peíorm
measu€me¡l

depth ñicómeler are requúed.

FBI

poor péforman€,

i¡mes) and a noriceabre enq¡¡e m¡ss

gefling

is suspscr6d, lh6 following

lhis

worce as rhe engine

valve

is occufinq. ll vdre sáal

measuremenl.

sauss

(lool

val€ slém hélghl

a

No. 35112461) ánd a

seal

(Élv6

yoke

p@edúfe

smok€

(wirh

gers

lásh)

(bridge)

rhe

NOTE

For deta¡led

r€movál and installalion
appl¡cable sclion ot lhis service mañual.

I . Femo@

inlorñation

conporénls

on rccker am

procodures,

as necessary 10

á@es to lhe cy inder héad

reler to lhe

(€lw)

sh¡ft

gain

creL

2. Remove the cylinder head cover and r@ker

On énak6 équipped wjk an
su¡¡able ¡ie s¡Eps ü ñehaniB w¡e lo eták Lhe

pi.tús

tke

Fe¡lure L. s@ute the úgine bñke

in

p¡store

rcmv¡ng thé teker

pist@s

lf a

to drcp fton Ihe búe of the

p¡stan

nay be dit'ficulf ta

the borc al ¡he rcclér am. Also,

nalú-l¡¡ lo lhe bciet am, and só ¡nadve ent

nk-Lp of úatpúúts

A*end¡¡ig tha

apeat¡hg an úq¡he w¡th tÉ Bng¡ne Úaké

ñot fully

btakage al
siq"iliBnt engine danage.

^caurtoN

t@ket

the

and rccket

añ' fhe ñatch betweeñ

ams

6halt as@nbly, allows the

enq¡ne bek, use

nust

be nakta¡ned,

p¡stús

befo6

ocket atns,

drcps au¡, ¡¡ ñigt¡t not be tut¡@d. at n

p6h

¡he

pjston

fu¡|y back ¡nto

pislons

are a

nust be avoided.

@cket an shalt to lhe eng¡ne, or

pjs¡ús

et@¡ed

(ot

ñ¡ss¡ns), rcsLlE ¡n

vahe

tñ¡n @nponents and

3. Femore lheulre

yokes

{bridses).

NOfE

The valve
sel of válws thal lh€y wa€ removed lrcm.

femoving lhe valve

lhek l@alion

hstalled válve

damaqe due lo a dropped valve. For
yok€

appbpriaie *ctioñs in lhs séruic¿

yokes

removál

musi be installed on the same

yokes,

and or¡enlaüon, A¡ in@fecily

yok€

caus¿s sdéc e¡glne

inslalLalion,

and

mafk lhem lo id€nlify

propér

fetef lo lhe

ma¡ual.

Beio@

valvé

2. hbr brF b'c

I

REPAIR INSTBUCTIONS,

PART 2

4. Fém@lhescrews

¡hjecior ha.nss
Slide lhe lié bar outward to

deaEn@ lor lhe lalve steh height

m@surcmenr

Él@ springs. Do nol d sconnecl

harness únnecio6 lrom ttu un¡t iniéclors

cul the lie st€ps lhat secu€ the hanó$ b

secur¡ng lhe unit

bar

lié

qauge

lo the cylinder head.

ro be insialled orer rhe

prwldé

lhe

suficient

o¡

6.

Plae lhe valve slem helqk rigadlrcmáff

(loor

No.

oause

spring ol the vatué

85112461) der the vatue

bé

lo

measu@d_ Make

sue lhe lool is lully seabd on a clean

NOfE

Mak€ sur6

bébveen the bottom of lhé valvé slem height

measuremenl

lhéE aB no

gauge

sul@8. Parlicl$ belween

cylinder hed súlacé r$olls in an i¡mnlé

parlicles

and the eyllndei head

lhe

ol a¡y k¡nd

qauge

and lhe

|1wnryH

res

5. Set lhe doplh m cromálér b A.l0 mm

(0,319

lnch) ro meas!rc slem

pfot¡usron-

il

FiqJE4_seD4üjMi@mder

REPAIR

INSTRUCTIONS, PART 2

Plácá lh€ déplh micromeler

€lve siem helghl ñeásuréñént

nole i, Ihere is cleá€nce bétueeñ lhé end ol

on lop ot lhe

gaugé

and

fre micomeler spindle and lhe lip ol lhe

.

ll lhere is cl€aEncé b€rweenlhe

lhe va¡w slem and thé lip

micromeref spindre, €rve hólghl is

wilhin spécilicat¡o..

€lve sl6ñ héighl Ginq

.

li El@ stem height is l€s lhán

8.10 mm

thé lip ot thé déprh

(0.319

Measure lh€ n€xl

lhe same

i¡ch), as ¡ndrÉted by

mi.rcmete¡ spindle

corfacli.g lhé lip ól th€ válve srém, lhé

valve

seal is rece$ed, Fepla@me¡l ol

thé ¿rliñdér héad is n#$áry

Posnion lhs unil inj€cIor haméss lie

ihe cylindef head,lnslalllhe sc@s and

righleñ adording lo speciicalior.

¡nsrall rhe vdre

9,

lnsla I lhé rock€r am

¡emove the élalneÉ sécuñnq thé éñ9in6

bEke

1l_

pislons.

lñslalllhé cyl¡nder háad

yokes

to rheir o

shaft ssembly and

Adjur vdE lash as

@Ei

tD ol

of lhe depth

lo

bar

ginar

lnslall lh€

qah

components lhat were removed to

access 10 the cvliñdé¡ héad cov€r

REPAIB INSTRUCTIONS,

PART 2

VALVE STEM

[2r3

Special Tools

MVI

vár€ sFne compresor

SEAL REPLACEMENT

{EssiiáD

ñ

Fwhed fúninq

Toor

(E€snriar)

REPAIR INSTBUCTIONS, PART 2

Prelim¡nary Steps

fhé fo ow¡ng @po¡ent nee.r b be

túóvéd fú ae*s to thé váIvé sléñ $áIs

(*

EN6lt'lE D¡SASSEúBLV lú

.

cyliñdérHéadc@r

.

Focke. Am Shaft Assembly

Seal Removal

NOTE

pro@.¡urcs):

When eplaciñq

musl

thal the ulves do nol dop inlo lhe cvlind€r.

al fDc when the vd6 are fele4ed so

bé

lhé vd€ sléñ sals, lhe

p¡slons

1, Usinglhelywh€ellurninglool,43400014,

pan

ol cylind6B

p¡slons

rclale the cÉ.kshafl so lhal the

al TDC ior lhe app¡opr

álé

wh6€ stom *ds are belno épla@d.

are

3. Beóore and dl*ad lhe valve steñ seals.

4. Uslng a dean clo1h, thoouqhly clea¡ all

lolhe

guid€

it

as

qulde.

lool

is

eñgine oi¡ of lhe €lve slem and valve

Seal lnstallation

L Applyálhinllmolcleanéngi¡eoi

outsidé d¡aneter ol thé Él@ seal

and ro the sealing ¡ips oa rhe n4 var@ stem

soal lo ávoid damaqe lo lhe séal

NOTE

Do NoT apply o¡t 10 the ¡ñner suda@s ot thó s6a

thal conlacl rhe valve

2. Place th6 s€a!

posilion

onlhe valve stém.

guide.

qDidé

These suriaces ñust

lml¡

8890001 1 , in

2, Usinq lhe valve spr¡¡g @mpressor l@1,

9090210,

a liúe) and .emove rhe valw r€rainérs

spfinqs fo f lhe cylinder

prored¡ve gogglés

Use

prcss

down on l,te springs (one

or éye in¡ury could

and

al

3. Place a n* útue sr€m s6al in

guide

lhe

Using

inslsllalion lool,

slem seal o. lho vd€

lapping lhe ¡nstallation lml wirh a ljghl

plaslicor

tullyseat6d, a nomd"sp ng-bacL

sealwlll occur, le inq a mdmun

apprcximately 0.5 mm

ih6 boltom of lhé séal

sula@ on theElw

lool a¡d onlo ihe válve st6m.

lhe

appoprialé eñd ol lh€ seal

851 12460i seal the vatve

guide

rubber mallel. when ihe séális

(0.02

and lhe shoulder

9ud€.

by

¡nch) betrveeñ

posilion

genlly

otlhe

gap

over

of

REPAIR

LcaurroN

Usé óhty

salkg ¡he séal ¡o awid danage

6kg as wdl as tlé lop t¡hbet

g4

é taps wik

the haññet when

INSTBUCTIONS,

5. Usins lhe Élw spriño comp¡d6sdr,

9990210,

relain€B. CaBtully

to the sea¡

potliú

at ¡,re

wilh a

i¡at lhé

PART 2

installthe valve spring ánd val@

lap on the €tve st6m

pl4l¡c

or rubb€¡ hammer

€lve leepeE aB

1o ensu@

pG¡lioned

NOTE

seal inrallarion r@1, 851 12460, is deslgned ior

use or MP7, MPO and MP10 enqines, U* lhe

apptopriat6 énd of ihe toól lór lhé éngine b6ing

preiéct¡É goggl€s

use

6. Mo€ lh6 wtué spring

ndl cylinder ol th€ cylinder

prc@do¡e.

lhe

piíons

thé
palr

and repeal lhe

Final

Steps

and €péat lh6

á16 ar TDc fór rhe nen

or eyé lnlury

comp@$r to the

pai

Foiate ihe cEnkshaf so lhat

prcc€dure-

pl@duelorlhenñal

IñhI tlÉ lóllowing coñponents

rffiove.! ¡ot @ss to llB valve

(ee

ENGNE

.

Bocker Arm Shatt Assembly

.

c\,tinder Head cover

REASSEMBLY tot

@úld

and epeal

cylinder

Conlinue on

vh¡.h werc

slen seals

ptuce.ruñs):

REPAIR INSTRUCTIONS, PABT 3

MP8 EURO 3

ENGINE

SETUP

AND ADJUSTMENT

[200

EA]

NOfE

Due lo lhe Eng¡¡e Eleclbnic Conlrol Unil

sell-le n¡nq capabilily, il is n€.6áry

learned EECU

enginé{élaléd

EECU lo l€arn the ñew componenl s behávior

Alld seMcang is @mpLele,

Dará R6él" ocáréd in vcaDs.

paEmelers

cómpónents. Th¡s allM lhe

ár€r sgflicinq soñe

pelfom

Special Tools

(EECU)

lo ési

lhá "L€afned

@

REPAIR

rnrno

Gd cM Aiqnmd tul

INSTRUCTIONS,

PABT

3

REPAIR INSTBUCTIONS, PART

3

Valve and Un¡t lnjector Adjustmenl

[213

GENERAL INFORMAT¡ON

NB,222 KGI

(4

c.p

Rúr¿r

sh.wn)

NOTE

4 Focker Markedas E1 E6.
3 Fockér Márkéd ás v1-v6

apply thá

eng¡ne ovei Remove rhe EMS

luse lo avo¡d

unidédioñally- M¿kó su6 lhal lrré

rrársmission ls not ¡n

Wilh lhe e¡qlnecold,60'C
and adjusr the Elves and ¡njecrof as req!úed lor
each cylinder belo¡e

üris soqu e¡ce ol cylindeG wh6n ád

cleaEnces: 5, 3, 6, 2, 4 and 1.

párk¡nq

b¡áké bélofé bá¡iinq thé

stá¡ting rhé éng¡né

gear

moving

p

er suppry

(1,10'D

to lhe nd], Foll@

or l6ss, ch{k

na

iusi

1. Usingthellylvheeliuñingiool,3a300o14,

bar lhe enqiné

apprcpriál€ camsháñ ma*ing fór

adJusimeni ot the ¡nlet valres and iniéclor for

over

manuallylolhe

fimi¡g ma*s tor basic camshalt liminq and

adjusrménl of lhá valves úd u.ir injécroG a€
located at ihe lont of the @mshaft

lhé No 1 fonl bearinq
lop ollhe lrod benng cap má¡k lhé alignménl

poinl

The top dead cenler

camshan
lhe 1wo ljnes oñ the lonr camsháll béa nq

whenlhefly{heel

The

b6lorá

cámshalt

.

pG¡l¡onlng

lor

tm ng. The TDC ñalk musl be beleeen

engine musl be cod,60.C

making rhese adjushe¡rs.

na¡kings lor settlng ot valles á.d

w¡rhout

apply ro adiuslmenl
valves and injecloG.

W¡ih PowerLéashr": Marki¡Ss 1-6 apply lo

ádjuslneni ol inLel valres and injoclors.

MarkinosEl E6/V1 V6 apply lo adjuslñeñt

Powerlashr rMarkinSs 1 6

journal.

ol the @mshan and ñakihg

(Toc)

¡sal0'

Two llnes al lhe

márk is used for basic

(opdead

(140.F)

nlél

of

EN€s, exhausl

lotuard of

lust

centerror

or r6ss,

cap

2.

Using a Geler

b€ñeén lhe rocker arm

the valve

Beter

lo

gauge,

yoke (bndse)

Figure

I

chec* the e eaÉn@

adjusling sdew and

ol lh6 inl€l valvés.

436,

+

@-

REPAIR INSTRUCTIONS,

PART

3

3- lf lhá d@6nce

looseñ llló locknul and adiusl

4. Hold rhe adjusliñq s. lo

luhing and l¡ghlen the lockñúl to

is nol wilhin specllcalion,

the 6leaance

p¡weni

n

r@m

5. Recheck lhe clearance aller tlqhtenlng th6
6, Mark lhe @ker arm when adjusiñe¡n ls

UNfT INJECTOF ATUUSTMENT

Th€ unil i.iéclor adiushénl is doná wilh lhé
enqine a¡d cahshaf ¡n the sañe

lhe inlel valve adjshenl on each 6ylinder

Lo6en lhe lnjeclor rccker arm adlusl¡ng

1,

scréw

(couniercrockwi@)

out

Turn the adjusr¡ng sc€w h

I I mly coniacls

iam

nú and

lurn

lhé injécloi Do lol

lo felieve tbe

poshon

lhe

adiusli¡g scr¿w

(crockwrse)

6 for

péroad.

uniir

EXHAT

POWERLEASHT¡)

1. Al lhe

ST VALVE ATUUSTMÉNi (Wlnlouf

curenl camshalt soiing

¡nlet válws,

tolld¡nq thé sam€

adjusrmed ol me irrér varEs,

valv€ cl€aBnce

adjut the exhalsl wñEs

specilicaion is difisrénr.

pr@edu@

u6ed lor the

descrbed ror

H{)wef, rhe

Túrn lhe adjust¡nq scew ln a lúrther 240'

(tour

llals

on lhe hq head).

0-

@

Fiqufs 437

adjudhq únh ¡ntedor

-

creÉnce

Malk üe

t slngüo llywhéeliuming

engineoverñánuallylo

maÁing

%lBq un¡l inieclor

rccker arm whén adjushenl

tof $e nexl cvljndeL adiusl lhe

and

qháusi

iool, bar the

lhéappopr¡ale

valv6

is

i¡let

al

Hold

lhe adjusllng scre to

iurning

nqhbñ rh6

t'rark the

luarher and, using a torque wre¡ch,

jam

r@ker arm when adjushenl is

prmnt

nll ro spsmcaio¡.

il lrom

REPAIR INSTRUCTIONS, PART

3

EXHAUST VALVE AOJUSÍMENT

+BOCKER POWEFLEASHTT)

(WITH

NOTE

The ¡umbe6 o¡ the camshalt

ae used lo adjust lhe exhausl valves when lhe

e¡gine is equipped wlh Pore

I.

Using lhe

bar

lhe

numb3r mafkinq lor the respeclive exhausl

valve is be1{een lhe lines on lhe cañshal

Press down on lhe
Figuré

bÉké

al ihe same lime 4 lhe

p€sséd

wilh the valve slem. Use a sl@ng wie wilh a

hooked end lo @lch and
spring. When the

lwhed

engine over so thal the appropriate V

439. ll the rocker arm spnngsi the

p

sron spring should be

d@n lo make ánd ensúre @ntact

lurning lool,98800014,

rockér arm ás shown in

pislon

tom its sear, rhe residual oil iilm €raininq

lhá 6pr ng is

adJuslment sel¡nq to be moE accufale.

punclur€d,

preceded

-eashrM,

pul

r@ker

compráss lh6

spring is looséned

allowing lh€

by a v

ed ourwad

is

arm

4. lf clea.ance is nor withiñ specii cation, adjusr

cléaEncé as rcquned, lsing shims

üe

(Fiqure

441)

pláced

óñ top ol lhé válv€

yók6

a. Femove rhe shim fetain¡ng screw and

Emove lhé shim(s).

b, Delérminé

équifed to malch lhé measuréd

lhe rhicknessotlhe shim(s)

3. Measurá üe cleaEnce belwee¡

pislon

ah

lbridoe)

and the shim on lop ol thé

as sh(M in Fioure440.

the @cke¡

yoke

6. Make sure lhai lhe vd@

shim(s) are 6lean. Place rhe shim(s) in
position

on lhé valve

yoke

voke.

NOTE

DO NOT use ñoé lhan tuo shims.

aEilable in 0,05 mm

lhé lhickness
are requir€d io lák6 up lhé cleaance,
should be ol neadv equal thicknéss.

ma*ed on lhe su¡t¿ce. lt Nlo shims

(0.002

inch) increnerns with

Shims are

S-

and

the shims

F¡quE er Enqrn¿ conpEs¡on BFh.

adiu.rú6¡

REPAIB INSTRUCTIONS, PART

3

wirh

rhe requifed sh¡ñ(s) in

rétain¿r *wseunng

yokó

valve

lhe

toke

6.

Fecheok lhe clearance behreen thé dhausl

w vá r@ker

d liahlén lo .pecilical

securely while llohtenina the

arm and lhe valve

pra@,

lhe shim(s)lolhe

yoke.

SEFVICE HINT

Mark lh€

adiuslm€nl is 6mpléled.

EXHAUSf VALVE

4-FOCKEB POWERLEASHT¡)

The nlmbe6 oñ ü€ cmshafi

Éspel

ae used ro adjusl rhe

enoi.é is équipDed wilh Püvé[eash¡M.

ve

rccker arm as each va w

ADJUSTMENT

(WIH

NOTE

pr€€ded

qhausr

varves when the

hsian the

on. Hold

by an E

Loose¡

l.

lo € éae lhe

énginé bbk6 ¡ocké.

lhe sces holdinq thé

spri¡gs

spring lens¡on agdlñst th€

a.ms,

d¡le

Enginos €quipped

bEke have iwo rmkér

@mbinalion 1o mnlm¡1he

aE lhe exhaust rockef afñ and rhá
reck6r árn which

dekibed in lhe lollowing

w¡th the Powe 6sh

ans workiñg in

qhaust

are adllsted sepa@lely

p@edu€.

vatres. They

brake

e¡gine

as

Using lhe iLywheel lurn ns roor,

ba¡ lhé éngine

over e that lhe appóprial6 E

¡umbermarkinq ! bénreen rhe

Íionl

@mshaí beárins ep.

i¡easu@

3.

@ker am

valve

lhe clearance bétw€én rhe

yoke

pislon

(bndse)

and the shim on lop ol

6 shown n F¡gurc 444.

80800014,

llnes oñ thé

qhaust

the

REPAIR INSTBUCTIONS,

PART

3

4. ll cleaÉnce is nol wlhin spéciñcalion, adiusr

lhe cleaEn@ as lollows, using shims
lFigu@

Adjusl

441)

ng Exhaust

pla@d

Focké. Arm CleaEnce

oñ Iop ol lhe Élve

yoké

a. Flemove lhe shim relaining screw a¡d

@mow l¡e 6him(s).

b, oerermine rhe Ihickness ol the shh(s)

requircd ro

c,

¡¡aké

shiñ(s) áfe creañ. Pracé thé shim(s) in

posn¡on
rhe eiaining

lo spdilicalion.

DO NOT úse mofe than hdo shlñs. shlms aé

a€ilable in 0,05 ñm

lh6 lhicknss már*6d on th€ sulác6. lf lwo shims

ae requircd lo iake up the cleaÉ.@, the shlms

should bé ol nea

p@ide

su@

on the va !e

thal

lhe valw

sre.

NOTE

(0.002

y

équallhic¡<nes.

lhe specitied

yoke

and

yoke

and inslall

Tiqhrén

inch) inc@menls wllh

lhe scre

Usins th6 dial

ere¡s¡on and b6é

851 I 1493 and 999s6s6),

ollhe dia

possibls

as

indicator wilh ángÉl

(9989876,.

gauge

on the

io lhé ro.ker

p¡acé

yókó

afm

the iip

6 closé

yoke

pad.

5. Leave ihé lééler

exhaust rockor am
yoke

shim and adjusl the b¡ake rccker

Adjusling

B€ke Bocker Ah clearánce

gauge

pislon

a. Loosen lhe iocknLn A on the

fooker arm adiusiihq srew

S-

pla@

i¡

belrveen the

and lhe Elre

bBke

arm

Fisure 446

Bhke R.cbr h adtBrñod

-

lBAdusrinqscrew

c. fghlen lhe tuckér am adjusiinq

B

unlil lhe dial shows that the

pushed

beon

d, Loosen lhe rockér

accord¡nq to sp6cilicalion.

d@nward

arm adjusling sre

e Hold ihe adjusting scrs

rrom

lurn¡n! lurherand, using

wrench, 1¡ghlen

Femove thé dial indicator

6.

Usinq a leeler

belwéen
cam lobe. ¡llhe cléafance

repeal the bako rockér arm

Oaugé,

lhe brake rocker árm rcller

the locknul to

and the teeter

checklhe

¡s ¡ncórect,

clearancé

lo

prevent

lo

clearance

Inh Diar

scr4

yoke

has

aloque

and the

il

REPAIB INSTRUCTIONS,

PART

3

a. Mark rh€ resp€clivo .ocker

am as each

El@ adjuslmenl ¡s compléled.

CONTINUAT'ON OF ADJUSIMENTS

Conli¡ue lh€

lhe apprcplale liñiñq marks and adiust na

válves
cylandes. Fo lów th€ sl6ps désc¡ibed
ádjusl lhe inlel

For €nginás

añd unit injeclors al each or lhe ¡emáiñiñg

Po@fl€ash¡N e¡gine

sp ng afiach¡nq screws b speciñ.arion

válv¿ ánd unil injeclo¡

prccéduré

and exhausl valves, and unil

equipped wllh lhe 4,rock€r

by bari¡g

brake, lighten the

adjustmenls hav€ been

the englne to

ábove to

ptate

after lhe

the

OPEBATIONAL

Ane¡ lh€ vaLve

been compleled, .heck énglné

1.

Usinq I he llywheel turñiño ioo, barrhe

eñ9iñ6 owr ñanualLy

rerclulions to 6nsu¡e

contacl o€urs. lf contáct doós mcur,

readjusi rhé Élves

2, Slaftlhe engi¡e ánd

opeÉling

CHEC(

and unil injeclor adjushenis have

opeEtion as

nro @ñpl€16

lhal no

as needed BEFoRE

bring

p¡slonlo

it

utj to ñofña

lempeatuf€.

3. Or@ normal opé¡á1ing rámpeEtuÉ

álráinéd, ler

tlve minules. Du
engiñe manaoem6nr sysrem (EMS)

p¿dorm

in smooth éngine

oO NOT u$ ¿ny r.o

equipñenl,

whon cyl

nde r balancino isbeina cadedout

lhe engihe idt6 tor

nq thist¡me, the ét€ctronic

irs

own eylindof bálanclno

idling-

NOTE

p@er

ol

such as PTo

or air cond oninq,

añ additionat

onsum nq

valw

is

wjtt

j resulinq

BEPAIB INSTRUCTIONS,

Checking and Adjusl¡ng Tim¡ng

Gear

Backlash

PABT 3

(Camshaft

Apply the

eng¡ne ovér Réno@ lhé EMS

Gear to ldler Gear)

park¡ng

b¡aké beloE

bar¡ng

pó@r

lú$ to 4oid slarling lhe engine

únlntentlonally, lrrake sure lhat the

lransmiss¡o¡

RemoElh€16r€rainingsc@sandsp nqs

añd émove the varve @ef lom rhe cylinder

D¡sconn4l lhe wiring harness

unil inielors and camshalt sensor

coñneclor Plllthe hame$ outlhfouqh lhe

3, FemoE lhe

Loosén and rémow lhé capsréws s€cu ng

theiimhg

Renow lhe liminq

e¡gine. lJse care w¡ren remding the cder

lo

abid

llywhee I housinq. Beúde the ¡ubber seals

lbm rhe cover and dls.ard.

¡5 nol ¡n

.omp¡e6sor @olanl lines.

qear

lhé rubber seals

geár

leads

úer lo the cyl¡nder héád.

qearc@rlrcm

falling inlo lhe

thé

supPly

lhe

al

lhé

i@,-

(

_/_-'_=\

7. Loosen añd feñore r¡6 six scr€ws sécu ng

lhe vibralion damperand

€mhan.

Bemove lhe damper fon the

€ñshait, but DO NOT rémw6 ñé €mshall

3. lnstalllhe

gauqe plalet@1,

qeariome

J 4451{-lA.

6. Usingrhé llywheelturning

enqlne orer manually s lhal lhe camshail

posirioned
aligning lhe TDc márkon the eñshaft with

thé liming marks on lhe No. 1 oamshatl

ar top déád @nref

tool, barlhe

(TDc)

by

lnsen$e

is

9.

liminq
géa¡

of lhe 6lanp tool. Rolale lh€ camshati

a iqnmentbolin lhe hole in

gear plale

teeth wlh the rcd

lo engaqe ihe camsháf

ol the toot in the stot

the

until

REPAIR

INSTRUCTIONS, PART

3

Tighlén

10,

camshafi s€l al fDc, lhá doublá

malks on lhe

lhe malking hole i¡ the

¡nstallthe ctamp aseñbty toot, J 44514 5.

11.

¡nstall a diar

€mshafi

gear

qear

The backlash read¡nq should be wllhin

lhe bolt6lo specijicalion. W¡lh lhe

qear

should be allgned sith

qearplale.

gauge

qear

locked in

back and

against a toolh on lhe

(Figufe

posilio¡,

lorlh

452), W¡ih the idref

@lale lhe camshan

measuré

lo

liming

bacidash.

Whil€ holdins thé idler

lhe lh¡ckn6s

qear,

lighlen, bul DO NOf torqu6, rhe

Tjghl¿n r¡á clamp

Reheck lhe

f.

gauqe

backlash, Wlh lhe

gear

ánd emshaft

$semb¡y tool.

spelffed ba.klash atainsd, réplacá

each adJusrable ldler
w¡lh ñew

and liqhten lhe sorss lo

geár

/n aqainst

hub scf4

13, ¡i lhe backlash measuéñef$ is óut of

spécifiÉron,adjusrrhe

geartlankcleaance

a. Looson lhé clamp assembly looL.

Loosen

b.

rhe @mshaft idler

scrss. Looseninglh¿ hub scBs will

all@ lhe idlergearlo be mowd siigtfly

in/oull@m lhe €mshaft

qear

qear

hub

F¡qu6 453

14,

Fémow rhe

camshalt
gear

15.

Fei¡stalllhe

ánd cahshafi] lnsralli¡e
screws añd tighlen lo sp€cilicalion,

APPIY a 2 mñ

MAo(-approved

@¿r mounli¡g

rubber seals

rdl.. Gsa. Frank crüEnF Adiudns

-

gauge plale

g€ar

rema¡¡s ¡n

v b€tion damper on the

(Figuré

ca@ lo

Use

p

ácé dd

(5/54

inch) béád ól

sealañt on lh€ limina

surf¿ce and ¡nsiall new

454).

loolss! nqlhe

ensurc lhal lhe

p¡opé

six new mounling

yalign¿d

géar

qear

c. lnsela0.l mñ

galqe

and camshaft

on rhe

p€ssufe

séar

(0.004

léélh

inc h) lhickn ess

s¡de ot rhe idrer

(Fiquré

453).

BEPAIR INSTRUCTIONS,

Using alignmenttoots, s5111422Aán;
051114228, ensurclhallheuppe¡á¡dlower

seals are

suíace ol the cóv6r sflushwilhlhelopoi

lhe cylinder head

PART 3

prcpedy

sealed

(poi¡ts

and lhal lhe upper

A in Fisuro 4s5).

17. Pla@ lheliming

lhé ángi.¿.lnslállrwo

Fiqúfe 455) áñd hañd

gear

lnslall lhe ihree remaininq cápscr€ws

in Fiqure 455)

Fe@n¡ecr rhe wúing harne$ leads ai thé

jniéclo.s

unil

appry añ e@n 2 mñ

sealarr ar rhe
lhé cy ind6r háad and the liming covel

lnstall lhe válvé covér and r¡é 16 rélain ng
screws and splnos. Tighten lhe scéús io

and lighlen lo specil¡€tlon.

and camsháll sénsor

(5/64

iñch) béád or

joint

lines

(polnrA)

(ir€m

berween

2

REPAIR INSTRUCTIONS,

PABT 3

ENGINE FINAL PREPARATION

AND

Afler Engine

OPERATIONAL CHECK

Overhaul

Procedures

Filter Element lnstallation

Al

ille6 and @olanl condilioneE mus!mee!

1. lnslallá nd airlihérin lh6 airfih$ housi¡g.

2. Usiño á tórqué wréñch,lighlén lhé átláchi¡g

Using a tltér wrerch, tighten

Aliach lhe nte6

5,

Using a

6.

íllerwrench. lighten

lhe valw

lo

PRIMING

1. Filllhe ensine cránkc66with

2. Usinq

THE !I.tBBICATION sÍSTÉM

quanli¡/

specilied oil,
syslem lbf a mln mum ol liw

of lhe specilied éñqin¿ o

pressu¡e prelubri€ror

a

p

me

the engtne tubrication

lhespecilied

L

lilléd wiln

minutes.

3. Cheklhe cnnk€se oill4l,
4, li ne@ssary, ádd oil to 6ach lhe FUL!

NOTE

the

mafk

Engine Lubdcation

An of lilm c@ls rclal¡nq
ov6rhauléd 6nginé, bur rhis may nol
sufñclenl lubricatio. whsn lh€ €nginé is daned
ior

the liFt lime, Followi¡q is the rMmmended

pro@duié

for

oovidinq

System

pads

and beaflngs ol án

p@ide

ad€quáré lubd@lion

/Ac^urroN

Do rc¡ n¡x bñnds or typés ol htbdcar¡s.

Chúi@l add¡l¡v$ nay be ¡Mr@at¡t e and ñav

cútlbute lo lhe t ¡mtm ol 61udge,

Fa¡lute

lo heed lhis aúú ñay rcsuft k severe

SERVICE HINT

vánous

lih6 may be opened,

use lhe o¡lpéssurá sénsor

points

a.jd and

on lhe engiñé

bul ii no

REPAIR

INSTRUCTIONS,

PART

3

Turbocharger

LcaurtoN

ll is

n*essary to

p@.l|bt¡ñlDn

rct

been apeñtéd lot

lo évaid

en ded

l@

dañage to rhe

pe¡¡od

¡he bahg

1. R€move

supply ljñ6wirh

no¡ilaññabl€

allowellenllo

debris lh€n blów lhé I'ne dtu wirh .léáñ

comp@ssed

perfotm

pa@du@

¡he

anylme the

pet¡ad

a

sysbnl

dceed¡ñg

twbochaqs¡ Durkg

alt a¡l w¡tl

and shah sudaces

and iush th€ luóocharge¡

a suilabte, ctean,

solrenr.

have dñtned aw¿v

SERVICE HINT

run r¡roughrhehne

alr

/AcaurroN

b lurhany

rehicte has

30 davs

th¡s

oit

Fuel

Beforc

l¡É

neutal .nd

th¡s wahihg

no@ení

lo

a¡ry

tt lh¿

sudaces, ot wheo

úg¡re.

resull in lhe

P*ñl

System

wrkíng

pa*|ng

and

avoi.!

potentiat

part

ol thé Í!él sys.b'm

préerc

Fallurc to hed

in¡ury

oo ot ¡nspect¡ng

bhke,

btock the whÉts.

@n resuk ¡n

@4 séé

ol llams,

which can

q

p¡a@

t¡re haá¡d, do

thé tánsmi*¡a

Fa¡|ure

unexpéctéd vdrtdé

peEonat

white snoklng

spa*s ot hot

woúinq on

this wam¡ng

prcduce

dealh.

an ooentinq

a vehicte,

to h@d

jniuty

not seru¡ce

.an

*verc

set

io

ot

A ¡utbo.haryet lailure

cútan¡@hng

is

EATBEMELV

and thaoughly

enqne Faitue

seveE Mparen¡

2.

Feinratt rhe

the t|rbochane¡

tMpoRtANf to ffi.vp trt<h

.iea.

¡a haed th6

and

oit suppty tine.

3. Pr¡ñe lhé lubr¡cation

prccedufe

4. Foil@¡ng

diáqnosticcómpule¡to

gemdrylurbochaqér

Cooling

1.

Chéck
piugs

a€ ¡nslalled

2.

Mak6 sure

3.

lnslallanqcoota

Fill the system

tüake su€

d6sc

¿ngine

System

ihe @oli¡g

a¡d coolánl dEin

and a€ light.

lhe lhermctat

w¡th lhe ¡ecoñnended

NOTE

lhal all air is

can rcsuÍ ¡n

oil supDty

the hne

pdot

au an my

g¡ne

damge.

syslem

bed eafte. in

owrhaut,

syslem. ¡rake

nfter

puEed

uselhé

catibEtélhe

quick

is insla ted.

fmm lhe

debns

hne.

b sta¡1na Lhe

tst

tolowino lhe

lhs section.

váriabte

su€ á I

dis@¡neds

cootinq

n

W4t adequaté ptutectl@

sh¡é14 h*w

Mútng

bum lrú

Fail@ lo heed

.ew

Do ñot work

pe@nat

ror¡ng.

gloves,

on d hot

ensi;e to

.!íect contact

Ih¡s wn¡ng

¡nluty ot .reath.

nésrrhetun

The

engiñ. tá¡

aÍtrcn,

.nyl¡mee¡thoutsañi.g.

w¿rning

Beloré turninqlh€

one ls

warni¡q

1.

2. Slat

ca¡ résu[

nerrhei¿n.

ca¡ fesun

Check thé luélsyslem

ennections

the eñginé and

approximalely

fapped in

¡n sewré

iqnitlon

Fá¡tufe

¡n séve¡e

áre

light.

5 minuleslo

the tuelsyslem

ctothins

etc.) when

eu

viÍh hot

cú But

w¡th rhe

car bécome

(tacé

d a@intt

fGL

iñ

enqine

active

Fa[úróto hee.Ilh¡s

peFonat

on. make

lo h€ed

peBonát

lo

make suré1hal

tun il al idte

remwe

i¡iury,

suré no

tñ¡s

tniury.

irr

a f

at

au