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

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

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

€ñshaft

lorque lhé adjuslablé idler

slighlly irvoui nom lh€ ám6haÍ

a 0.1 mm

on lhe

hóldér J 44935

measurement is olt ol

llank

s€ár

(0.0er

prássue

qéár

ld er

qear

toolh

loolh by using l€áler

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

i6

g€ár

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