Groater than Stes then or equate. >. Groctorthan or equal to ‘pair cimaneion (.., oversize! lncersize part avai) AP Pane torepice @ Mose tins GD Check condition of parts Danger fos persone, vaicle or equipment porte Figure 1 — Symbol Use Chart Pages«e VISUAL IDENTIFICATION VISUAL IDENTIFICATION Page ®a VISUAL IDENTIFICATION ENGINE IDENTIFICATION Identification Plate Sega ne non Saten ek Dea Ie SREY Se Sa Ae nae [RENAULT Wi PORTANT ENGINE NFORMATION - RENAULT Vi, RENBE\ 2002 | sesamiae poner. a cm 378.073 ote a | J FOE 3m0492743 DSU A UE ANG SRST SASmCE MER AT] Bi veore Sebi ae eASabRSien ca RauNee ce prend Stour Derea Lan ‘TEiCAC EGR ECM; ane Se AFG 990 Page 10 Figure 2— Engine Identification Plate& REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS Page 11ENGINE REMOVAL AND INSTALLATION PROCEDURES Engine Removal 2 3. 8. 10. 1. 12. 13, Tilt the cab to gain access to the engine and ‘components. Disconnect the vehicle's batteries. Remove the negative cable first. Clean all extemal engine surfaces as necessaty, Make sure to cover or protect any openings. Drain the engine olf and coolant. if necessary, remove the front bumper to gain access to front components. Rofer to service manual MV17-101. Release fuel system low circuit pressure. Refer to table on page 92. Release chassis air supply system pressure at the rear brake air tank pressure test port. Remove the transmission and all associated components ftom the vehicle. Refar to the ‘Transmission Removal and installation Service Manual, MV10-101, for procedures. Disconnect all transmission-associated wiring hamesses from the transmission. Remove all wiring hamess clamp bolts and clamps and any tie-straps securing the harnesses. if equipped, disengage the engine block heater hamess connector. Loosen and remove the turbocharger ‘exhaust outlet-o-exhaust pipe bolts, nut, ‘springs and exhaust flange. Remove the muffler-to-frame fasteners. Remove the exhaust system from the Vehicle, Set aside for later installation. Disconnect the battery positive cable from the starter motor and main wiring hamess. Isolate the cabie from the frame. Remove the nuts securing the hamess terminals to the starter motor and statter relay and Femove the harness. Remove the fasteners securing the starter motor to the fiywheel housing, and then remove the starter motor, Page 12 REPAIR INSTRUCTIONS oetran Figure 3 — Starter Motor and Relay 7 Harness Terminals 2. Starter Motor Assembly & Startor Motor Fasteners 14, 15. 16. 17. Disconnect the engine wiring harness connectors at the Engine Electronic Control Unit (EECU). Pulll the harness and connectors through the frame rail. Remove any hamess clamp bolts and clamps and any tie-straps securing the hamess. Loosen and remove the botts securing the power steering pump te the alr compressor. Leave the high-pressure and low-pressure lings attached to the pump. Cap any ‘openings to prevent contamination, sonnet the air supply line at the frame flex union coupling, Plug and cap all ‘openings to prevent contamination. Remove the Inlet hose from the air ‘compressor. Cap to prevent contamination.se REPAIR INSTRUCTIONS 18. Disconnect ail fuel lines (at the engine) Jeading to the various fuel supply system ‘components. Plug and cap all openings to prevent contamination. Tag and label the fuel lines for ease of reinstallation. 49. I AIC equipped, evacuate the alr conditioning system using an approved R134a recyoling and recovery unit. NOTE ‘When necessary to evacuate the air conditioning system, use approved R134a refrigerant recovery and recycling equipment to prevent leakage into the atmosphere. Cap any exposed air conditioning lines or components as necessary to prevent system contamination. 20. Disengage the AIC pressure switch connectors. Disconnect A/C pressure and suction lines from: * AIC condenser * AIC expansion valve 21. Remove the upper and lower radiator hose clamps and hoses. 22, Remove the air inlet system hose clamps and hoses at the charge air cooler. 28, Remove the radiator, AIC condenser (if equipped) and charge air cooler from the chassis. 24, Loosen and reposition the clamp securing the engine oil fill tube to the timing cover. Position the fill tube out of the way. 25. Loosen the clamps, and then remove the alr Inlet hose (elbow) from the turbocharger and air filter assembly, 26. Connect a hoist and lifting hardware to the ‘engine lifting brackets at the front and rear of the cylinder hoad. The liting equipment must have a minimum capacity of rating of 2,500 lbs. Flemove the engine mounting bolts and lift the engine from the chassis, ‘The threaded hole in the tiywheel housing {if present) must not be used as a lifting point, Sudden release of the lifting equipment if used at this point can cause engine damage or severe personal Injury. Figure 4— Fiywheal Housing Hole (if Present) 7. Flywheet Housing Hole (Do Not Use as Litt Point) Figure 5 — Engine Removed from Chassis Page 13ip REPAIR INSTRUCTIONS Placing Engine on Stand Out-of-chassis engine overhaul is best achieved by first installing the engine on a suitable rotating engine stand. The following instructions are based on the use of a typical engine stand. Procedures and adapters vary depending on the actual engine stand used. 1, Hnot already done, remove the air outlet tube bolt and outlet tube from the turbocharger. 2. Remove the two exhaust manitold-to-engine brake housing bracket bolts at the exhaust manitoid, 3. Loosen and remove the air line fitting at the ‘engine brake actuator, 4, Remove the turbocharger oil return tube bolts ftom the turbocharger and the engine block. Remove the oll return tube and discard the gaskets. 5. Remove the two bolts securing the oil pressure feed tube to the turbocharger. Remove the gasket and discard, 6, Remove the banjo bolt securing the turbocharger oil pressure fead tube to the engine biock. Discard the copper sealing ‘washers. 7. Remove the four nuts retaining the turbocharger to the exhaust manifold and remove the turbocharger and ste! gasket, 8. Remove the oll level dipstick tube from the engine block. Remove the bolt securing the bracket and one clamp at the base of the tube. teva Figure 6 — Right Sido of Engine 1. Braokot Boks 2, Turbocharger Air Outlst Tube 8, Oil Lovel Dipstick Tube “& Turbocharger OF Ratuen Tube 5. Al Ling Fitting 6, Turbocharger Retaining Nuts Page 14> REPAIR INSTRUCTIONS 9. Loosen the air compressor outlet tube fitting and remove the tube, 10. Remove the four bolts securing the air ‘compressor to the front timing cover and remove the air compressor. 11. Hequipped, remove the A/C tubes and A/C ‘compressor from the engine. Remove the bolts as necessary from the brackets: Remove any tle-straps and clamps as necessary, Figure? — Ai Compressor and A/C Compressor 1 A Compressor “NG Compressor 2, Air Compressor Outlot | 5. Tubes Attached to AC “Tube Fiting| Compressor 8. Drive Belt 12, Install the engine mounting plate (bracket), Kent-Moore part No, J 36475, as shown, Page 15Prise REPAIR INSTRUCTIONS 30475, Figure 6 — Attach Engine Support Mounting Bracket fo Engine 18, Mount the engine with engine mounting plate and fabricated plate (reler to “DCI 6 ENGINE TOOLS" on page 134) onto the engine support stand. Never position any portion of your body under the suspended engine. Fallure of the lifting equipment could result in severe A CAUTION Use only Grade 8 hardened mounting bolts to secure the engine mounting plates to the engine support stand, Page 16in] REPAIR INSTRUCTIONS Figure @— Engine Mounted in Stand Removing Engine from Stand 1 Connect a hoist and lifting hardware to the engine lilting brackets at the front and rear of the eylinder head. The lifting equipment must have a minimum capacity of rating of 2,500 libs, Using the hoist, remove the ‘engine weight from the support stand and ‘engine mounting plate. Remove the ‘mounting bolts sacuring the engine ‘mounting plate (J 88475 or equivalent) to the ‘engine support stand. Using the holst, lit the engine from the ‘engine stand. Remove the engine mounting plate and bolts from the engine block. 4. Install the oi! level dipstick tube to the engine block. Secure with the bracket bolt and {ighton the clamp at the base of the tube. Position the air compressor to the front timing cover and secure with four bolts. Tighten to 80-46 lb-ft (40+ 8 Nern). Position the A/C compressor to the brackets and install the fasteners. Position the drive beit around the A/C compressor pulley. Tighten the air compressor fasteners. Position and install the A/C compressor tubes to the back of the compressor. Route the tubes as necessary and install new tle~ straps. Install any clamps as needed. Page 17REPAIR INSTRUCTIONS Figure 10 — Air Compressor and A/G Compressor 77 Air Gompresser = ANG Compressor 2. lt Gomprassor Outlet | 5, Tubes Attached to AIC ‘Tube Fiting Compressor 3. Drive Belt 7. Position the turbocharger to the exhaust manifold with a new steel gasket and install the four mounting nuts. Tighten to specification. 8. Install the turbocharger oil pressure feed tube to the block and turbocharger housing with new gasket and sealing washers. Tighten the bolts to specification. 9. Install the turbocharger oil return tube to the blook and turbocharger housing with new gaskets. Tighten the bolts to specitication. 10. Install the exhaust manifold-to-engine brake housing bracket bolts at the exhaust ‘manifold. Tighten the botts to specification. Engine Installation 1 10. 1" 12, 13, 14, 15. Install the fan shroud to the brackets on the timing gear cover. Tighten the fasteners to standard specification. Install the fan assembly onto the engine. Tighten the nuts in a criss-cross pattern to standard specification. Attach the upper and lower radiator hoses. and charge alt cooler hoses to the engine, Position and tighten the clamps to secure the hoses. Using the lifting equipment, carefully position the engine into the chassis. Install the ‘engine mount bolts foosely until all bolts can be installed. Tighten the engine mount bolts to standard specification. After the engine is installed and secured to the chassis, remove the iifting equipment from the engine. Position the oil fill tube to the fiting on the timing cover. Secure with clamp. If ternoved, Install the oil fill tube bracket bolt and tighten. Reconnect the air supply line at the frame flex union coupling. If equipped, reconnect the engine block heater hamess connector. Position the power steering pump to the rear of the air compressor and secure with bolts, Tighten to standard specification. Install the radiator, charge alr cooler and A/C condenser (if removed}. Install all fasteners and tighten to standard specification. Reconnect upper and lower radiator hoses ‘and charge air cooler hoses and secure with clamps. Reconnect and secure any heater hoses that were removed. Reconnect the A/C pressure switch connectors. Reconnect A/C pressure and suction lines to the A/C condenser and A/C expansion valve. Reinstall the receiver/dryer assembly. Realtach the air cleaner elbow to the turbocharger inet and secure with hose clamp. Reconnest the air inlet hose to the air compressor and secure with clamp. ee Page 18> REPAIR INSTRUCTIONS 16, Reroute the hamess and connectors for the Engine Electronic Control Unit (EECU). Push through the frame rail and engage the ‘connectors to the EECU. Install any hamess ‘clamp bolts, clamps and tie-straps te secure the harness. 17. Reinstall the transmission and all assoolated components. Refer to the Transmission Removal and installation Service Manual, MV10-101, for procedures. 48. Reinstall the starter motor and cables. Tighten the bolts and cable fasteners to standard specification. Figure 11 — Starter Motor and Relay 20. Position and route ail transmission- associated wiring hamesses to the transmission, Install all wiring harness clamp bolts and clamps and replace any tie-straps to secure the harnesses. Plug in all associated connectors. 24, Position the muffler and exhaust system to the brackets and isolators on the frame. Install the frame fasteners loosely. NOTE It necessary, loosen the muffler clamp straps to reposition the exhaust system so that the exhaust pipe and flange can be installed to the {urbocharger exhaust outlet. 22. Position the exhaust pipe to the turbocharger exhaust outletengine brake housing, install the boits and one nut, washers, springs and exhaust flange. Tighten the fasteners to standard specification. Tighten the muffler clamp straps and frame fasteners as necessary, NOTE Rreattach and secure any miscellaneous items. ‘Check your work to make sure all items are installed and properly tightened and adjusted. 23, With engine installation complete, lower the cab. 24. Reinstall the front bumper. Refer to service manual MV17-401, 28. Refill the engine with the recommended oll and coolant. Fill to the specified capacity. 26. Start and run the engine at idle while ‘checking for leaks. inspect the engine and chassis for coolant, oil, air and exhaust Jeaks. 3 Starter Motor Fasteners rnoss Terminals ter Motor Assembly 19, Reinstall the ground strap from the chassis {io the engine, Tighten securely, NOTE any leaks are foundl, shut down the engine, inspect the source of the leak and repair as necessary. 27. Check electrical components for proper function, Check the transmission, clutch and linkage for proper function. Page 19es REPAIR INSTRUCTIONS CYLINDER HEAD OVERHAUL Figure 12 — Exploded View of Gylinder Hoad Page 20REPAIR INSTRUCTIONS 7. Gylinder Head Cover 2. Rocker Arm Pedestal Stud and Washer 3. Push Rod 4. Valve Stom Cap 5. Valve Stem Keeper '. Valve Spring Retainer 7. valve Stem Seal 8. Valve Springs 2. Valve Spring Seat 40. Valve Spring Seat Washers 11. Cylinder Head Top Core Plug 12, Cylinder Head Bot 19, End Covering Plate and Gasket 14. Cyiinder Had Side Core Pag 16. Inlet Manifold 16, Iniot Manifold Verturt 17, Cylinder Haad Gaskot 18. Inlet Manifold Gasket 46, inlet and Exhaust Valves 20, Water Pump-to-Thermostat Housing Flange 21. Seal 22 Thermostat Housing 223, Watar Pump-to-Thermostat Housing Flange Bolt 224, Exhaust Manifold Gasket 2. inlat and Exhaust Vaiva Guides 26, Exhaust Manifold ‘The numbers indicated in the text refer to the callout numbers used in Figure 12, unless noted otherwise. (The caltout legend above Is for Figure 12,) Page 21REPAIR INSTRUCTIONS Cylinder Head Removal 1. Remove the following fuel injection system ‘components. To assist in fuel injection system component removal, refer to “FUEL INJECTION SYSTEM SERVICE" on page 78. NOTE AAs fue! injection system components are removed, plug all tubes, lines and component ‘openings to prevent contamination, Remove the fue! tubes from the manual fuel hand priming pump and prefitter assembly. b. Remove the two capscrews securing the manual fuel hand priming pump and profiler assembly, and then remove the assembly. ¢. Remove the fuel tube coupling nuts at the fuel injectors and fuel rail. Remove the fuel Injector tubes. Leave the tube clamps and insulators attached to the tube assemblies. d. Remove the high-pressure pump-to- {uel rail fuel ube bracket capscrew at the cylinder head. Leave the tube clamps and insulators attached to the tue! tubes. ‘8. Remove the two fuel tube coupling nuts at the high-pressure pump and at the fuel rail. Remove the two high-pressure fuel tubes. 4. Disconnect the fuel injector return tubes at the injectors. @, Remove the protective caps, and then disconnect the electrical leads from the fuel injector terminals. h. Remove all wiring harness clamp bolts, and then remove the wiring hamess. 1. Remove the six fuel injector clamp internat hex bolts, injector clamps and fuel injectors. Romove the fuel injector nozzle sealing washers from inside the injector bores of the cylinder head. AcAuTION Do not use the upper part of the fuel injectors to extract them. Damage to the injectors can result. 2. Loosen the clamps, and then disconnect the coolant hose from the Exhaust Gas Recirculation (EGR) cooler and the water pump. 8, Remove the cylinder head cover retaining nuis and sealing gaskets. Remove the oylinder head cover (1). 4, Remove the six rocker arm pedestal studs and washers (2). Remove the rocker arm shaft as an assembly. ACAUTION Gradually loosen the rocker arm shaft assembly studs alternately to pravent damage to the shaft. 5, Remove the caps (4) located on the top of ‘each valve stem. 6, Remove the 12 push rods (8). NOTE Tum the push rods stightly while lifting, to unstiok them from the lifters. 7. Remove the two thermostat housing-to- water pump flange bolts (23) and washers. 8. Remove the 25 cylinder head bolts (12). Loosen the cylinder head bolts in reverse order of tightening (refer to the tightening ‘sequence found in Figure 32). 9. Attach suitable lifting hardware to the lifting brackets at each end of the cylinder head. Using a suitable hoist of sufficient capacity (2,500 ibs.), remove the cylinder head from the cylinder block.REPAIR INSTRUCTIONS 10. Remove the cylinder head gasket (17). NOTE Do not use the EGR tube to handle the cylinder head. 11, Remove the thermostat housing-to-water pump flange (20) and flange O-ring (21). Figure 13 — Liting Cylinder Heed from Engine Block 12, Using tool J 29485-B, temporarily immobilize the cylinder sleeves to prevent them from dislodging Figure 14 — immobilizing Cylinder Sleeves Cylinder Head Disassembly For reference when removing the following ‘components, see Figure 17. 1. Loosen the clamp, and then disconnect the EGR system coolant hose (11) from the thermostat housing. 2. Remove the bolt and clamp (7) securing the EGR crossover tube (6) to the stand-off bracket on the thermostat housing, 3. Remove the EGR crossover tube (6) bolts at the EGR valve (4) and at the inlet manifold, Remove the crossover tube (6) and retain the steel gaskets (5). Disconnect the air fine (3) from the EGR control valve (2) and the EGR valve (4). For reference when removing the folowing ‘components, see Figure 12. 5, Remove the capscrews retaining the inlet manifold (15) to the oylinder head. Remove the inlet manifold (15). Discard the inlet manifold gasket (18). 6, Remove the intemal hex bolts and spacers retaining the exhaust manifold to the cylinder head. Remove the exhaust manifold (26), EGR vaive and EGH cooler as an assembly, Retain the steel exhaust manifold gaskets (24), 7. Remove the capscrews retaining the end coveriifting plate (18) at the rear of the cylinder head. Remove the plate and gasket. Discard the gasket. 8, Remove the capscrews retaining the thermostat housing (22). Remove the thermostat housing and gasket, Discard the ‘gasket. Page 23a» REPAIR INSTRUCTIONS 9. Using a suitable vaive spring compressor (Figure 15), compress the valve springs to Femove the following (refer to Figure 16): * Valve stem keepers (1) * Valve spring retainers (2) * Valve stem seals (3) © Valve springs (4) * Valve spring seats (6) © Valve spring seat washers (6) + inlet valve (8) and exhaust valve (7) Figure 15 — Compressing Valve Springo Page 24 Figure 18 — Valve Components “valve Stem Keeper 2. Valve Spring Retainer 3. Vala Stam Seal 4. Valve Springs (Inner and Outer) 5. Valve Spring Seat 6. Valve Spring Seat Washer 7. Exhaust Valve InlotVaivoREPAIR INSTRUCTIONS EGR System Service 2eriam Figure 17 — EGR System Components REMOVAL Refer to Figure 17. The illustration symbol is explained in Figure 1. 1, Remove the air hose (3} that is located between the EGR control valve (2) and the EGR vaive (4), 2. Remove the bolt and clamp (7) securing the EGR crossover tube (6) to the stand-off bracket on the thermostat housing. 3. Remove the EGR crossover tube bolts at the EGA valve (4) and at the intake manifold. Remove the EGR crossover tube (6) and retain the steel gaskets (5). 4, Loosen the hose clamps, and then remove the coolant hoses (17 and 12) from tho EGR cooler (8). 5. Romove the capsorews and spacers securing the EGR elbow tube (10) to the exhaust manifold and EGR cooler, Remove the elbow tube and gaskets. 6. Loosen the clamps (8) securing the EGR cooler (8) to the exhaust manifold. NOTE Loosen the EGR cooter retaining clamps so that the clamps can clear the exhaust manifold castings that support the cooler. 7. Remove the EGR cooler (9) from the exhaust manifold. 8. Loosen the clamp securing the EGR valve (4) to the EGR cooler (9), and then remove the EGR valve. 9. if necessary, remove the EGR control valve (2) from the inlet manifold. EGR COOLER CHECKS ‘The EGR cooler can be checked for internal (or extetnal) leaks by applying air pressure to the, cooler while the cooler is submersed in water. Air bubbles will appear if any leaks are present. Perform the following test if any coolant or exhaust leaks are suspected, 1. Ifremoved, attach the coolant hoses and hose clamps to the EGR oooler. Tighten the hose clamps. Plug the end of one coolant hose using a bolt. Secure the bolt in place with a clamp. Page 25> REPAIR INSTRUCTIONS 2. Connect too! 2586 to the end of the other coolant hose (see Figure 18). Secure the tool to the hose with a hose clamp, Refer to “ENGINE CHARACTERISTICS AND SPECIFICATIONS’ on page 118 for tool preparation, Gt =e 2586 Figure 18 — Tool and Coolant Hoses Attached to EGR ‘Cooler for Testing 3, Submerse the EGR cooler in a hot water tank with water temperature at approximately 176°F (80°C). 4. Apply alr pressure to the tool {2586). Use alt pressure of no more than 14.5 psi (i bar). 5, Check that there are no air bubbles coming out of either end of the EGR cooler or from the coolant fittings in the side of the EGR cooler, NOTE Verify that any leaks found are not caused by loose hose olamps or leaking coolant hoses. Replace the EGR cooler if any leaks are found. INSTALLATION 1. Reverse the removal procedure. 2, Tighten all bolts, capserews and clamps to specification, Page 26 Cylinder Head Pressure Check To make sure that the cylinder head is not cracked and is satisfactory to overhaul, perform the cylinder head pressure check. 41. Install suitable cover plates with gaskets (see Figure 19), NOTE The bottom cover plate for the face of the oylinder head is secuted by bolts installed from the opposite side of the cylinder head. Figure 19 — Gylindar Hoad and Cover Platos 7. End Cover Plate with Ai | S, Bottom Cover Plate Pressure Fittng 4. Bol 2. End Cover Plate 2. Immerse the cytindar head in a hot water tank at 176°F (80°C). 8, Apply 87 psi (6 bar) air pressure to the fitting in the cover plate. 4, Check that there ate no alr bubbles that could indicate cylinder head leakage. NOTE IW leakage is found, determine the cause and correct if possible. If the cylinder head is cracked or leaking between the coolant passage and ‘combustion chamber, replace the cylinder head.Core Plugs Hf itbecomes necessary to flush the coolant passages In the cylinder head, the core plugs ‘must be removed. Also, core plugs can become corroded, which can cause coolant leaks Replacement is nacessary for corroded or damaged core plugs. 1. Remove the core plugs as necessary. 2, Thoroughly clean the core plug bores in the oylindor head. 3. Apply Loctite 271 sealant, or equivalent, to the edges of each top core plug. 4. Install the top core plugs (11) using toot J29479-A, or equivalent. Drive them in and properly seat them with the tool. REPAIR INSTRUCTIONS areste orto Figure 20 — Top Core Plug and Tool 4 29479-4 5. Apply Loctite 271 sealant, or equivalent, to the edges of each side core plug. Assembie the side core plugs (14) and seat them. 6. Install the side core plugs (14) using too! J 29483-A, ot equivalent. Drive them in and properly seat them with the tool. Figure 21 — Side Core Plug and Too! J 29483-A NOTE Side core plugs should be installed flush to ‘approximately 0.020 Inch (0,508 mm) below the surface of the oylinder head. 7. Cheok for leaks after instaiing the core plugs. Valve Guides INSPECTION 1. Inspect the valve guides for visible wear, damage or looseness, 2. Check the valve stern-to-guide radial clearance as follows: a, Insert a new valve into the valve guide boing checked. b. Install the valve so that the clearance between the head of the valve and the valve seat insert is approximately 0.12 inch (3 mm). Maintain this clearance. 8. Position the tip of a dial indicator on the stem of the valve, as near as possible to the guide. d. Measure the radial play (side clearance) of the vaive stem to the guide (see Figure 22). The specifications for vaive stem-to-guide clearances are as follows: * Exhaust (now) — 0.0031-0.0043 inch (0,08+0.11 mm) Page 27a> REPAIR INSTRUCTIONS © Exhaust (wear limit) — 4, tnsert the valve guide through the vaive seat 0.0079 inch (0.20 mm) side of the cylinder head, chamfered end © Inlet (new) — 0.0020-0.0031 inch ‘toward valve guide bore (0.05-0.08 mm) 5. Press the valve guide into the cylinder head * Inlet (wear limit) — 0.0071 inch using too! J 28482-B. (0.18 mm) 6. The valve guide should be pressed into the cylinder head so that the guide protrudes above the valve spring seat area (see Figure 23), The valve guide protrusion measurement is 0.779 inch (19.8 mm). A CAUTION The valve guide must be installed trom the ditection shown to avold damage to the upper (chamfered) end of the guide. Damage could cause excessive oil passage between the valve guide and vaive stern during engine operation. zoteota Valve Seats Figure 22 — Checking Valve Stomrlo-Gulde Clearance = RESURFACING VALVE SEATS When resurfacing a valve seat, remove only the REMOVAL AND INSTALLATION minimum amount of metal to clean up the seat. 41. tnecessary, remove the valve guides using _Valve recess or setback is affected by seat ‘a press and tool J 294828, resurfacing. 2. Place the cylinder head in the press (valve seats facing up) and press out each guide as required. Use a valve seat resurfacing tool that pilots ‘snugly into the valve guide (see Figure 24). The too! cutter head angle should match the recommended angle of the valve seat being resurfaced. Refer to Figure 168 for vaive seat angles. 329482. Do NOT lap the valves. Figure 23 — Setup for Removingfinstalling Valve Guide 3. When installing the valve guides, apply a vegetable-base lubricant to the outside of the guide. Figure 24— Resurfacing Valve Seatep REPAIR INSTRUCTIONS 1. After resurfacing the valve seats, check the amount of valve recess. 2, Check the valve recess using a dial indicator as shown in Figure 25. Valve recess specifications are as follows: © Exhaust valve — 0.0197-0.0268 inch (0.50-0.68 mm) * Inlet valve — 0.004-0.018 inch (0.10-0.33 mm) Figure 25 — Checking Valve Recess Rocker Arm Assembly 1. Check the outside diameter of the rocker ‘arm shaft in the aroa that the rocker atrns ‘operate, The rocker arm shaft outside diameter for a new shatt is 0.787—0.788 inch (20.0-20.015 mm). 2. Check the inside diameter of each rocker ‘arm bushing using a dial bore gauge. The rocker arm bushing inside diameter for a new rocker arm (with bushing) is 0.789-0.790 inch (20,04-20.085 mm). 3, Check the rocker arm push rod pins for excessive wear, Check the threaded end of the pins and jam nut for damage. NOTE Hf the rooker arm shaft Is excessively worn or damaged, replace the shaft. If the individual rocker afms, rocker arm bushings or other ‘components are damaged or excessively worn replace as necessary. Injector Nozzle Protrusion 1, Place the cylinder head on the bench so that the injector nozzle tips will not become damaged when installed. 2. Install the injector sealing gaskets into tne injector bores of the cylinder head. 3. Install the injectors into the injector bores of the cylinder head. 4, Install and tighten the injector clamp bolts to 81 i 12 Ib-tt (6049 Nem), 5. Position the cylinder head so that injector nozzle protrusion can be checked. 6. Check the injector nozzle protrusion using a dial indicator as shown. The protrusion specification for injector nozzles is 0.10-0.194 inch (2.63-3.39 mm). 7. IFinjector nozzle protrusion is incorrect, replace the sealing gasket and recheck protrusion. Figure 26 — Checking Injector Nozzle Protrusion 8. Remove the injectors. 9, Remove the injector sealing gaskets. 10. Lay the parts out in the order that they were removed trom the engine, Page 29REPAIR INSTRUCTIONS Valve Springs 1 Check that the valve springs (Inner and outer) ate not damagad, broken, wom or out of square. ‘Check the free length of the valve springs and compare to spacitication. Using spring tester J 22738-02'or equivalent, check the spring heights at recommended compression loads and compare to specification. Valve spring specifications for both iniet and exhaust valves are: Valve spring (outer) free length — 2.56 inch (65 mm) + 15% Valve spring (inner) free length — 2.96 inch (60 mm) + 15% Valve spring (outer) compressed length at 421.3 Ibs. (65 kg) — 1.40 inches (85.6 mm) £15% Valve spring (inner) compressed length at 60.6 tbs. (27.5 kg) — 1.24 inches (31.6 mm) ‘+ 15% ‘046108 Figure 27 — Checking Spring with Valve Spring Teater "J 22738-02 Cylinder Head Reassembly For valve and spring reassembly, refer to Figure 28, 1. Lubricate the stem of the valve belng installed. insert the vaive stem into the appropriate valve guide. 2, Lubricate, and then install the valve stem seal (8) over the valve stem, Seat the seal on the vaive guide, 8. Install the vaive spring seat washer (6) into place on the cylinder head. 4, Install the valve spring seat (6) into place ‘over the washer. 5, Install the inner and outer valve springs (4) over the valve stem and into place on the valve spring seat. NOTE ‘The closest spirals of the valve springs {ends that are painted) are mounted toward the valve spring seat on the cylinder head. 6. Place the valve spring retainer (2) over the valve stem and onto the valve springs. Page 30REPAIR INSTRUCTIONS Figure 28 — Valve Components. 7. Using a suitable valve spring compressor, compress the valve spring enough to install the valve stem keepers — Figure 28 — Compressing Valve Springs 8. Instalt two valve stem keepers (1) into the valve spring retainer, Make sure that the keepers are positioned correctly in the grooves of the valve stem, For the foliowing steps, refer to Figure 12. 9. Install the thermostat housing (22) with a new gasket. Apply sealing compound to the gasket. 10. Place the end covering plate (13) in position at the rear of the cylinder hoad with a new gasket, Install and tighten the capscrews to specification. 11, Install the exhaust manifold (26), EGR valve and EGR cooler as an assembly. Position the exhaust manifold on the cylinder head with the oxhaust manifold gaskets (24) and tall and tighten the internal hex bolts and spacers to specification. Apply an anti-seize compound to the threads of the internal hex bolts, 12. Position the inlet manifold (15) on the cylinder head with a new inlet manifold gasket (18). install and tighten the capscrews to specification, For reference when installing the following components, see Figure 17. 13. Connect the EGR system coolant hose (11) onto the fitting of the thermostat housing and seoure with clamp. 14, Install the EGR crossover tube (6) to the EGR valve (4) and at the inlet manifold with steel gaskets (5). Install and tighten the bolts 10 specification. 16, Install and tighten the bolt and clamp (7) to ‘secure the EGR crossover tube (6) fo the stand-off bracket on the thermostat housing 16. Install the air line (3) to the EGR control valve (2) and the EGR vaive (4). Page 31a> REPAIR INSTRUCTIONS Cylinder Head Installation 1 2 Remove the oylinder liner retaining too! J 29485-B from the cylinder head. Make sure the dowel pin (A) is in place on the engine block, -29485-8, Figure 30— Dowel Pin and Too! J 29485-B. ‘Thoroughly clean the deck surface of the cylinder head and cylinder block before assembly, Place a new cylinder head gasket (17) onto ‘the engine block. Align the gasket with the dowel pin. Install the thermostat housing-to-water pump flange (20) and flange O-ring (21) onto the water pump. Attach suitable iting hardware to the lifting brackets at each end of the oylinder head. Using a sultable hoist of sufficient capacity, carefully lower the cylinder head Into piace over the cylinder block. Make sure the cylinder head is aligned with the dowel pin. Page 32 NOTE Do not use the EGR tube to handle the cylinder head. Figure 31 — installing the Cylinder Head onto the Engine Block 7. Lightly tubricate, and then install the 25 cylinder head bolts (12). Tighten the cylinder head bolts in the proper sequence. Refer to the tightening sequence in Figure 32. 8. Tighton the cylinder head bolts to 92 tb-ft (125 Nem) in the sequence indicated. Then, continue tightening the oylinder head bolts to 180 degrees of rotation, Use tool BT-81104 to achieve the 180 degrees (refer to Figure 93). 9. After cylinder head bolt tightening has been achieved, completely loosen the bolts and telighton to 92 Ib-ft (125 Nem) pius the 4180 degrees of rotation, in the specified order.REPAIR INSTRUCTIONS 18. Lubricate the valve stem caps (4), rocker arms and push rod ends. 8 14. Place the rocker arm shaft assembly into position on the cylinder head, Make sure the =e rocker arms are aligned with the push rod us ends and the valve stems. one ose 68) 2S Sa 15, Instalt the six rocker arm pedestal studs and = EOE 56) Lol washers (2). Tighten the studs to 59 + 6 lb-ft 2 Pate # (80 +8 Nem). an i rh A CAUTION series | Gradually tighten the rocker arm pedestal studs alternately to prevent damage to the shaft. Figure 82 — Gylinder Head Bolt Tightening Sequence. || 16. Adjust the rocker arms and valve lash before proceeding with oylinder head reassembly. ROCKER ARM ADJUSTMENT 1, Adjust the rocker arms to achieve the proper valve lash on a cold engine. 2, The cylinder to be adjusted must be at Top Dead Center (TDC) compression stroke. 8. Rotate the crankshatt so that the valves of a cylinder are in a balanced position (end of ihe exhaust stroke, beginning of inlet stroke). Adjust the valve lash of the ‘sortesponding cylinder (refer to the table on page 34). As an example, when the valves of oylinder No. 6 (front of engine) aro in the ‘balanced position, the valve lash for cylinder No. 1 (rear of engine} can be adjusted, 4, Loosen the jam nuts on the adjusting Brati04 2arisia screws. = 5. Loosen of tighten the rocker arm adjusting Figure 08 — Tightening Cylinder Heed Bots with Tool Saree e ocave tee poner Wie ane ‘exhaust valve lash, Tighten the jam nuts to 10. Install the two thermostat housing-to-water ‘specification, and then recheck valve lash, pump flange bolts (23) and washers, Tighten Rocker arm adjustment and valve lash ‘the flange bolts to specification. Make sure settings (cold engine): ‘he flange O-ring is in proper position. © Exhaust valve lash:'0.020 inch 44. Lubricate and install the 12 push rods (3). (0.50 mm) Make sure the push rods are seated in the © Inlet valve lash: 0.010 inch {0.25 mm) 12. Lubricate and install the valve stem caps (4) onto the top of each valve stem. Page 33Pisce REPAIR INSTRUCTIONS CYLINDER BALANCE FOR ADJUSTING VALVE LASH Cylinder in Balanced Position Adjust Thie Cylinder € 7 6. With rocker atm and valve fash adjustment complete, continue with cylinder head installation. 7. Install the oylinder head cover (1). Make sure the cover seal is properly located on the cover. Install and tighten the cytinder head cover retaining nuts and sealing gaskets to 18 4 2 lb-ft (25 + 2.5 Nem). Follow the tightening sequence as shown in Figure 94, Figure 34 — Cylinder Hoad Cover Tightening Sequence 9. Connect the coolant hose from the Exhaust Gas Recirculation (EGR) cooler to the fitting ‘on the water pump. Secure with the clamp. 10. Install the following fual injection system ‘components, To assist In ful injection system component installation, refer to “PUEL INJECTION SYSTEM SERVICE” on page 78. a i Kk {Install the fue! injector nozzle sealing ‘washers into the injector bores of th cylinder head. Install the six fuel injectors, injector ‘clamps and clamp internal hex botts. Orient the tual injactors so that the electrical terminals face the intet manifold. Tighten the injector clamp hex bolts to ‘specification. Connect the fuel injector return tubes to the injectors, Install the wiring hamess. Secure the wiring harness with the clamps and capscrews. Connect the electrical leads to the fuel Injector terminals, Tighten the terminal nuts to specification. Install the protective caps over the fuel injector terminals. Position the two high-pressure fuel tubes to the high-pressure pump ports ‘and the ports on the fue! rail. Tighten the two fuel tube coupling nuts at the high-pressure pump and af the fuel rail to specication, Install the high-pressure purmp-to-fuel rail fuel tube bracket capscrew at the cylinder head and tighten to specttication| Position the fuel injector tubes to the Ports of the fuel injectors and fuel rail. ‘Tighten the fuel tube coupling nuts at the injectors end fuel ral fo specification. Position the manual fuel hand priming pump and prefilter assembly to the inlet manifold and secure with the two. capscrews, ‘Connect the fuel tubes to the manuat fue! hand! priming pump and prefitter assembly and tighten. Page 34& REPAIR INSTRUCTIONS ENGINE TIMING COMPONENT SERVICE Figure 35 — Engine Timing Components Exploded ViewREPAIR INSTRUCTIONS 9. Camshaft End Play Stop Plate 40. Crankshaft 11, Block Stifaner 32. Ol Pan Gasket 13. Oi1Pan 14, Drain Plug Gasket 16, Drain Plug. 16, lor Goar Beating Suppor Shaft Washer 17 Idler Gear Bearing Support Sha 18. High-Pressuro Pump Drive Gear 18. OF Pump Drive Gear 20, O-Ring 21, Ot Seat Bushing/Spacer 22. Idler Gear Beesing Support Shatt Bolt 23, Washer 24, Crankshaft Gear 26, Camshaft Goat 128. Ider Gear 127. Timing Cover Mounting Piste 28, Gasket 29, Breather Hose 80, Spacer 81, Ant-Noiae Plato 32, Broathar Cover £89, Timing Gear Cover 84, Breather impeller 935, Camehatt Thrust Bearing 386, Oll Feed Tube ‘The numbers indicated in the text refer to the callout numbers used in Figure 35, unless noted otherwise. (The callout legend above is for Figure 35.)> REPAIR INSTRUCTIONS Alternator 2, Pivot the alternator inward, toward the engine. Disengage and remove the drive REMOVAL belts. 4. Loosen the afternator mounting (pivot bolt on bracket) and adjusting arm bolts, oor LW Figure 36 — Front View of Allorvalor 7 Alternator Pht Bok ‘3 Aliomator BO 2. Adjusting Arm and Bolt Assembly 4. Drive Boks Page 37ee REPAIR INSTRUCTIONS 3. Remove the hamess terminal cover. Disconnect and remove the wiring hamess terminals and hamess clamp at the rear of the alternator. 4. Remove the bolt securing the alternator to the adjusting arm and bolt assembly. (Figure 96). Remove the alternator pivot bolt from the bracket on the timing cover. 5. Adjust the tension of the belts to 79 Ibs. (G5 da) using a belt tension gauge such as 81-3373-F, or equivalent, Use the adjustment bolt on the mounting and adjusting arm to tension the belts. 6. Tighten all fasteners to specification. Water Pump Assembly REMOVAL 1, Hfnot already done, remove the fan shroud and fan assembly. 2. Loosen the hose clamps securing the coolant hoses to the water pump assembly. 3. Disconnect the cooiant hoses from the water pump assembly. 4, Remove the thermostat housing-to-water pump flange capscrews. Figure 37 — Rear View of Alternator T Alternator Haass Pivot Bole ang Nut lamp 4 Bracket 2. Hamass Terminal Cover and Terminals INSTALLATION 1, Position the alternator to the bracket on the timing cover and install the pivot bolt and flange nut. 2. Reinstall the alternator mounting and adjusting arm and install the bolts. 3. Connect the wiring hamess to the rear of the altemator and tighten securely Install the terminal cover and harness clamp. 4, Pivot the alternator inwatd toward the engine, Instail the drive belts over the grooves of the crankshaft pulley, water pump. pulley and alternator pulley. Figure 38 — Remove Thermostat Housing-to-Water Pump Flange Capscrews 7. Thenmestat 2 Thermostat Housing Water Pump Flange | &. Water Pump Assembly Capscrews 5. Remove the upper four boltsiwashers and ‘one nutivasher securing the water pump assembiy to the engine block. Retrieve the fan shroud stand-off bracket. Page 38REPAIR INSTRUCTIONS NOTE It is not necessary to remove the two lower bolts securing the water pump body to the water pump. housing unless overhauling or repiacing. Figuro 39 — Remove Upper Water Pump Assembly Fastoners 7 Upper Water Pump 3, Nuland Washer Ascombly Bolte/Washors | 4, Lower Water Pump 2..Water Pump Assembly | Body-to-Housing Bolts 6. Remove the water pump assembly and gasket. Discard the gasket. INSTALLATION 1. Place the thermostat housing-to-water pump flange with O-ring, onto the flange of the water pump. 2. Place the water pump assembly with new gasket over the guide stud and into position on the engine block. Install the four bolts/ ‘washers and one nutiwasher. Tighten the fasteners to the standard bolt torque chart specitication, Refer to Figure 39. 3. Install the two thermostat housing-to-water pump flange bolts and tighten to the standard! bolt torque chart specification. Refer to Figure 38. 4, Reconnect the coolant hoses to the water pump assembly and secure with hose clamps. Vibration Damper and Pulley Assembly REMOVAL 4. If not alréady done, remove the fan shroud and fan assembly. 2. Remove the four bolts (1) securing the vibyation damper and pulley assembly to the crankshatt. 3. Remove the damper (3) and pulley (2) assembly. 4, With three-groove damper and pulley assemblies, remove the spacer (21), Refer to Figure 35. 5. Remove the O-ring (22). Refer to Figure 36. aartisa Figure 40— Vibration Damper and Pulley Assembly Page 38REPAIR INSTRUCTIONS VIBRATION DAMPER DISASSEMBLY 1. Remove the six bolts (4) securing the vibration damper (3) to the pulley (2), 2. Separate the pulley from the vibration damper. Figure 41 — Vibration Damper and Pulloy Assembly VIBRATION DAMPER CHECKS Check the vibration damper for the following typos of damage: © Flutter and ovalization of fastening holes © Cracks * Shock points (dents) © Improper seating © Deformation © Convexity (bulging) ‘* Noise when the damper is shaken Remove the paint on both sides at four points and measure the thiokness of the damper (Figure 42). The difference among the check points must be ess than 0.010 inh (0.25 mm). If any of the above problems ate found, replace the damper, Figure 42 — Measuring Vibration Damper INSTALLATION 1. Position the O-ting (22) in place over the nose of the crankshaft (10) 2. For three-groove pulley type, install the spacer (21) over the nose of the crankshatt. Make sure direction is correct. 3. Assemble the pulley (2) to the vibration damper (3). Refer to Figure 41 4. Insta and tighten the six damper-to-pulley bolts. Tighten to 37 + 4 Ibeft (50 45 Nem) in ‘the sequence shown in Figure 43, Figure 43 — Vibration Damper-to-Pulley Bolt Tightening Sequence Page 40ei» REPAIR INSTRUCTIONS 5. Install the vibration damper (3) and pulley as an assembly onto the crankshaft, 6. Install and tighten the four bolts (1) as. follows: ® — 1st phase — Tighten the bolts in three progressive increments to 74 lb-ft (160 Nem), ita criss-cross pattern. © 2nd phase — Tighten the belts an additional amount of 60 + 5 degrees, in a criss-cross pattem to complate the tightening. Timing Components and Camshaft The numbers indicated in the text refer to Figure 35. DISASSEMBLY 4, Remove the altemator. Refer to “Alternator* on page 37. 2. Remove the water pump. Refer to ‘Water Pump Assembly” on page 38. 3. Loosen the breather hose clamp, and then remove the breather hose (29) from the iting on the crankcase breather cover (32). 4. Remove the eight capscrews securing the crankcase breather cover, and then remove the cover. 5, Remove the crankcase breather Impeller (34). Three 5 mm intemal hex screws (can also be Torx® head sorews) retain the impeller. ACAUTION Before removing the crankcase breather impelier and impeller screws, check the impeller for fooseness. if any looseness is noted, carefully inspect the impelier for oblong holes and inspect tho threads of the screws for damage. If damage is found, replace the impeller, screws or both as necessary. Also, use hardened flal washers (part No. 271AM1) or wave washer depending on production date, with the screws. Do not use any other washers besides those with the part No. listed. NOTE Ifo washers aro present with the original crankcase breather impeller screws and the sctews and impeller have no damage or wear and are satisfactory to reuse, it is necessary to obtain hardened washers (part No, 271AM1) from: the MACK Parts System. tis important to use the ew washers with the screws during impeller installation. 6. Remove the cylinder head cover. Refor to “CYLINDER HEAD OVERHAUL" on page 20. 7. Loosen the studs (A} seouring the rocker ‘arm shaft assembly to the cylinder head. Refer to Figure 44 and to"CYLINDER HEAD OVERHAUL’ on page 20. 8. Remove the rocker arm shaft assembly, It is not necessary to remove the studs (A) from the rocker arm pedestals unless disassembly is necessary. 9. Pull out the push rods. Keep the push rods in the same order as positioned in the engine. NOTE ‘Tum the push rods slightly whe lifting, to unstiok them from the lifters. Figure 44 — Loosening Rocker Arm Shaft Assembly Page 41a> 10. Immobilize the crankshaft using tool J 38047 to prevent the timing and drive gears from rotating. Figure 48 — immoblizing the Crankshaft 11, Remove the high-pressure pump drive gear retaining nut, high-pressure pump drive gear (18} and high-pressure pump assembly. Refer to “FUEL INJECTION SYSTEM SERVICE” on page 78 for procedures. 12. Remove the bolts securing the vibration damper and pulley assembly to the crankshaft. Remove the vibration damper and pulley assembly. Refer to “Vibration Damper and Pulley Assembly" on page 39 for procedures. 13. Position the engine so that thé oil pan is facing up. Remove the olf pan bolts, oil pan (13) and gasket (12), oil strainer, block stiffener fasteners and block stiffener (11). Refer to Figure 35. 14. Loosen and remove the screws securing the ~anti-noise plate to the timing gear cover (33). Remove the anti-noise plate (31). 15. Loosen and remove all bolts from the timing gear cover. Remove the timing gear cover (83). REPAIR INSTRUCTIONS ¥6. Loosen and remove the bolts securing the camshatt thrust beating. Remove the ‘camshaft thrust bearing (85) from the inside face of the timing gear cover (33). 17, Remove the bolts retaining the two engine side covers (6). Remove the engine side covers. 18. Remove the valve lifters (7) from the litter bores in the engine block, Keep the valve lifters in the same order as positioned in the engine, 19. Loogen and remove the nut retaining the of pump drive gear (19). 20, Using a suitable gear puller (Figure 46), Femove the oll pump drive gear (19). serve Figure 48 — Removing Olt Pump Drive Gear 21. Remove the bolts retaining the oll pump. Remove the oil pump. A CAUTION Note the position of the olf purnp housing during removat. Ifthe oil pump Is reinstalled incorrectly, severe engine damage could result. The oll prossure feed and off suction ports of the oil pump should match the oll pressure feed and oif suation ports of the engine block. 22, Remove the bolt (22) and washer (23) retaining the idler gear bearing support shaft. 23. Remove the idler gear (26). 24, Remove the idler gear beating support shaft (17) and washer (18).> REPAIR INSTRUCTIONS 25, Remove the camshaft (8) with drive gear (25) as an assembly. 26. Remove the camshatt end play stop plate {Q) from the retaining dowels protruding from the mounting plate (27). Refer to Figure 170 for a detailed view. NOTE ‘Make sure to provide adequate support at the rear of the camshaft during removal. The lobes and bearing journals of the camshaft can catoh ‘and hang up on the camshaft bore of the engine block. 27. Using a sultable gear puller, remove the crankshaft gear (24), While applying pressure, heat the gear evenly around the gear circumference using a torch (refer to Figure 47.) NOTE Unless the crankshaft gear is damaged or worn and replacement is required, itis not necessary to temove the gear. perso Figure 47 — Removing Crankshaft Gear 28. Loosen and remove the boits securing the timing cover mounting plate (27). Remove the mounting plate and gasket (28). Discard the gasket. 29. excessively wom or damaged, remove the camshaft drive gear (26), using a sultable press setup (see Figure 48). The driver must be no larger than 1.18 inches (30 mm). A CAUTION Catch ihe camshaft as itis pressed out of the drive gear to prevent damage. Ci . Ase? SZ arate Figure 40 — Removing Camshaft Drive Gear 30. Loosen and remove the nut (1) securing the drive gear to the air compressor. 31. Using a suitable gear puller, remove the alr compressor drive gear (2). Figure 49 — Removing Air Comprossor Drive Gear Page 43REPAIR INSTRUCTIONS CHECKS Check the camshaft for the following (refer to Figure 170): © Place the camshaft in V-blocks to check coaxial runout of the shaft. * Measure the inlet and exhaust cam lobe lift ‘and compare to specification. * Measure the diameter of camshatt bearing journais and compare to specification. ® Measure camshatt bearing inside diameter and compare to specification. ‘Check the idler gear for the following (refer to Figure 171): ‘* Check the inside diameter of the idler gear and compare to specification. © Check the idler gear bearing support shaft diameter and compare to specification. ‘Check the push rods and lifters for the following: '® Check the push rad for coaxial runout (bent). © Check the push rod ends for excessive wear. * Check the vaive liter diameter and push rod ‘seat area for wear and compare to specification. Refer to Figure 170. * Check the diameter of the ifter bores of the engine block using a dial bore gauge and compare to specification, * Check oil feed tube (96) for damage and securlty. if loose, swage connector with appropriate tool. if damaged, replace. ASSEMBLY 1. Assemble the timing gear cover mounting plate (27) with a new gasket 28) in place, 2. Install the timing cover mounting plate bolts (A) to the locations shown in Figure 50. ‘Tighten the bolts to standard specification, 8. install the camshaft end play stop plate (9) into place on the pins of the mounting plate (7), 4, If removed, install the timing cover stud (B) as shown in Figure 50. Apply Loctite 542, or equivalent, to the threads, sorts Figure 50 — Mounting Plato Bolt Locations: 5. if the crankshaft gear (24) has been removed, perform the following: @. Check the gear locating pin protruding from the crankshatt for wear or damage and replace as necessary. b. Heat the crankshaft gear to a maximum of 382°F (200°C) using an electric oven, ©. Quickly slide the heated gear onto the Nose of the crankshaft until fully seated. Mak sure to line up the locating pin and the notch in the gear (see Figure 51), Figure 51 — installing Crankshaft GoarREPAIR INSTRUCTIONS 6. Lubricate and install new O-rings onto the oil pump. 7. Lubricate and install the oil pump into the oi! pump bore of the engine block. Make sure to align the oll pressure feed and suction ports Cf the pump with the block (refer to Figure 52). 8. Apply Loctite 642 to threads and install and ‘tighten the oil pump bolts to standard specification. 850 Figure $2 — Installing OW Pump 7 idler Gear and Shatt Location '2. Ol Pump Orientation 8. Grankshaft Gear 9. Ifthe camshaft drive gear has been removed, perform the following: a. Insert the woodruff key into position on ‘the nose of the camshaft. b. Heat the camshaft gear (25) to a maximum of 382°F (200°C) using an electric oven. ©. Place the camshaft in a suitable press set up. d, Place the camshaft drive gear into position over the nose of the camshaft and press into placa (refer to Figure 63). NOTE Make sure the keyway in the camshaft drive gear is aligned with the key on the camshaft. Make sure the camshaft drive gear timing mark is facing ‘outward so that the camshatt can be timed correctly with the crankshaf erie Figure 59 — Installing Camshaft Drive GearCi] REPAIR INSTRUCTIONS 10. Lubricate and install the camshaft assembly (8) into the camshaft bore of the engine block, Adequately support the camshaft to ease installation. Make sure to correctly ime ‘the camshaft gear with the crankshaft gear as the camshaft s installed. Refer to Figure 54 for timing mark locations, 11. Place the idler gear bearing support shaft (17) and washer (16) into position. 12. Lubricate the support shaft and idler gear (26), and then place the idler gear over the shaft NOTE Figure 64 — Timing and Drive Gear Gonfiguration 1. GamshaiCrankshatt ‘Timing Marks 2. Crankshatvidier Gear “Timing Marks 8. Oil Pump Drive Gear 8. Idler Gear/High-Pressura | 7. Crankshaft Gear Pump Drive Gear Timing | 8, Camshatt Dive Gear Marks 8 Ale Compressor Ove ear “4 High Pressure Pump Drive Gear 5. ler Gear Page 46 Notice the timing marks (numbers 2 and 3) on the idler gear. Make sure to align the crankshaft and camshatt timing marks (number 1) and then, align the timing marks of the idler gear to the crankshaft gear (number 2 on gears coincide). ‘The number S on the Idler gear is for timing the high-pressure fuel pump and gear. 19. Install the idler gear support shaft bolt (22) and washer (28) into the idler gear support shaft. 14, Tighten the idler gear support shaft bolt to specification as follows: a. Tighten the bolt to 148 Ib-ft (200 Nem) torque. b. Loosen the bolt and retighten to 55 Ib-ft (75 Nem) plus 70-80 degrees rotation. 15. After installing and tightening the idler gaar and shaft, check the end play of the gear using a dial indicator (see Figure 55). For specifications, refer to Figure 171 2579884 Figure 65 — Checking idler Gear End Play> REPAIR INSTRUCTIONS 16. Using tool J 38047, prevent the crankshaft from rotating, J9g087 S A 0 39 fe Wa erste Figure 56 — Immabllizing Crankshaft at Fiywheet 17. Place the oil pump drive gear onto the shaft of the oll pump. 18. Install the washer and oil pump drive gear retaining nut. Tighten the retaining nut to 80 +9 lb-ft (40.44 Nem), NOTE The oil pump drive gear does net require timing with the Idler gear, 19. Place the camshaft thrust bearing (35) into position on the inside of the timing gear cover (33). Install the bolts and tighten to ‘standard specification. Place a bead of high temperature silicone sealant on the flange of the timing gear over. Place the ting gear cover (99) over the locating dowel pins on the timing gear cover mounting plate. 21. install and tighten the timing gear cover mounting bolts to standard specification. Check the end play of the camshaft as shown in Figure 57. 8 B NOTE Camshatt ond play Is checked at the rear of the timing gear cover mounting plate through the air ‘compressor opening. Figure 67 — Checking Camshaft End Play 23, Lubricate the crankshaft front olf seal (30), and then position the seal over the nose of the crankshaft against the timing cover, Using toot J 38472, press the oll seal into place. A CAUTION To avoid deforming the lp, Keep the oll seal on its protection ring unti tis in place on the tool. NOTE Before installation, lubricate the outside of the oil seal, Do not grease the lip of the seal,REPAIR INSTRUCTIONS 438472 senor Figure 88 ~ Installing Crankshafl Front Of Seal 24, Position the anti-noise plate ($1) onto the timing gear cover, install the serews and tighten to specification. 26. Place a new O-ring (20) over the nose of the ‘rankshatt 26. install the oil seal bushing/spacer (21) into position over the nose of the crankshaft and into the front oll seal. 27. Install the damperipulley assembly onto the crankshaft. Refer to "Vibration Damper and Pulley Assembly’ on page 89 for procedure. 28. Remove tool J 38047. 28, Position the engine so that the bottom faces. up. Use high temperature silicone to seal the block stiffener (11). Then instaii the stiffener ‘onto the engine block. Tighten the blook stiffener bolts in steps as follows: at. a2. a b. ‘Sug the block stiffener bolts by hand. Pre-tighten the block stiffener bolts on the flywheel cover to 4 Ibett (5 Nem). Tighten the block stiffener bolts on the engine block to 18.42 Ibe (25 £2.5 Nem), Tighten the block stiffener bolts on the flywheel cover to 18+ 2 Ib-ft (2542.5 Nem). install the oil strainer and tighten the fasteners to standard specification. Put the oil pan gasicet (12) into place on the oil pan. Place the olf pan (13) to position over the bottom of the engine block. Install he oil pan bolts and lighten to standard specification. Lubricate the lifters (7) and install them into the bores over the camshaft. A CAUTION When reusing the lifters, make sure that the lifters are placed into the same position they were in during disassembly 85, Lubricate and install the push rods through the cylinder heed fo seat them in the lifters. ACAUTION When reusing the push rods, make sure that the push rods are placed into the same position they wore in during disassembly. 96. Install the rocker arm assembly over the oylinder head. Carefully position the rocker aims over the push rods and valve stem caps, Make sute the valve stem caps are in place. Install the six rocker arm pedestal studs and washers (A). Refer to Figure 60. Tighten the Studs to 98 + 6 Ib-ft (60:48 Nem), Page 48ee REPAIR INSTRUCTIONS A CAUTION Gradually tighten the rocker arm pedestal studs altemnately to prevent damage to the shaft. 42. Install the altemator support bracket (A) Figure 62. asrt0%8 Figure 60 — Installing Rocker Arm Assembly 38. Adjust the rocker arms to obtain the correct vaive lash. Refer to "ROCKER ARM ADJUSTMENT" on page 33 for procedures. 89. Position the cylinder head cover over the rocker arm shaft assembly studs, install the ‘cap nuts to secure the cylinder head cover ‘and tighten to specification. 40. Apply a bead of high temperature silicone to the sealing surface of each engine side cover. 41, Install and tighten the engine side cover bolts to standard specification and in the order as shown in Figure 61, Figure 61 — Tightening Sequence for Engine Side Covers Figure 62 —Instatiing Support 43, Install new O-ting seals (3, 4) into the air ‘compressor. 44, Place the alr compressor drive gear (2) onto the shaft of the air compressor. 45, Install the nut (1) and washer onto the shaft * end of the air compressor. Tighton the nut fo (89 £7 Ibett (120 + 10 Nem). ‘The air compressor {along with turbocharger and other components) can be installed when the engine is off the engine support stand, 46. Install the high-pressure pump and pump bolts and tighten to specification, Make sure the high-pressure pump drive gear is properly timed with the idler gear. Refer to "HIGH-PRESSURE PUMP" on page 101 for procedures. 47. Install the crankcase breather impeller (34). A CAUTION Before installing the breather impeller, carefully inspect the impeller for oblong holes and inspect the threads of the screws for damage. If damage is found, replace the impeller, screws or both as necessary. Also, use hardened flat washers (part No, 271AMt) or wave washer depending on production date, with the screws. Do not use any other washers besides those with the part No, listed. Page 49REPAIR INSTRUCTIONS NOTE Ifno washers are present with the original crankcase breather impeller screws and the screws and impeller have no damage or wear and are satistaotory to reuse, itis necessary to ‘obtain hardened washers (part No. 271AM1) from the MACK Parts System. Its important to use the new washers with the screws during impelier installation. if damage is found to the impeller and sorews, replacement is necessary. NOTE Before installing the Impeller, screws and hardened washers, clean the impeller mounting screw threads in the high-pressure pump drive gear. Use Primer T, or suitable solvent, to clean the threads. Also, clean the threads of the impeller mounting screws. Apply a small drop of Lootite 271 thread locking compound to the threads of the impeller mounting screws before installation. Page 60 48. Position the crankcase breather impeller to the high-pressure pump drive gear and install the screws with washers. Tighten the ‘6 mm intemal hex screws to 97 lb-in (11 Nem). NOTE From engine serial No, 83M0516787 and after, oll impelier hex screws are metric grade 10.9. These screws are tightened to 115 th-in (13 Nem) 49, Apply a bead of RTV silicone (MACK part No. 3428X32, or equivalent) to the sealing surface of the cover. Install the crankcase breather cover (32) and retaining screws. Tighten the retaining sorevs to 18 lb-ft (25 Nem). 50. Install the water pump assembly. Refer to "Water Pump Assembly” on page 38 for procedure. 51. install the altemator assembly. Refer to “Alternator’ on page 87 for procedure. 52. Install and tighten the alternator drive belt and AVC drive bett (if equipped). Refer to “Altemator’ on page 87 for procedure.a REPAIR INSTRUCTIONS ENGINE BLOCK AND CRANKSHAFT DRIVE COMPONENT SERVICE The numbers indicated in the text refer to Figure 63, unless indicated otherwise. ‘Figure 69 — Exploded View of Engine Block and Related Components: Page StREPAIR INSTRUCTIONS TA, Cylinder Siosve 1B, Cylinder Sloove O-Rings 2, Engine Block 8. Fiywheo! Housing 4. Flywhoo! Housing Bots 5. Roar Main Ol Seal 5. Oll Pressure Rlgulater Valve 7. Fiywheot Bott 8, Plot Boating (If Equipped) 9, Flywheel 10. Ring Gear 11. Lower Solt Thrust Washers 12, Lower Main Bearing Insert 18, Main Beating Cap 14. Main Bearing Cap Bolt 75. Grankshat 416, Upper Main Bearing inser 17. Upper Spit Thrust Washers 18. Camshaft Bushings 49. Connecting Rod Cap Balt 20. Connecting Flod Gap 21. Gonnecting led Bearing Inserts 22, Connecting Rod 23, Gonnecting Flod Small End Bushing 24. Piston Pin Snap Ring 25, Piston Pin 26, Piston 27, Piston Rings The callout legend above is for Figure 63. Page 52& REPAIR INSTRUCTIONS Disassembly 1. Remove the fuel injection system components {high-pressure pump, fuel tubes, common fuel rail, fuel Injectors, otc.) from the engine, Refer to “FUEL INJECTION ‘SYSTEM SERVICE” on page 76 for procedures. 2. Remove the cylinder head. Refer to "CYLINDER HEAD OVERHAUL" on page 20 for procedures. 3, Remove the timing and auxitary components, camshaft and valvetrain, water pump, alternator, oil pan, block stiffener (Figure 35), oll strainer and timing cover {rom the front of the engine, Refer to “Timing ‘Components and Camshaft on page 41 for removal and installation procedures. 4, Remove the bolts securing the engine oil ‘cooler and filter support to the engine block. Remove the assembly. 5. Remove the bolts and harness connections from the starter motor. Remove the starter motor. 6. If equipped, remove the pilot bearing snap. ring and pilot bearing (8) from the flywheel (@). Use tool J 23907 or suitable puller, to Femove the pilot bearing. 7. Use tool J 38047 to prevent the flywhee! from rotating. aaron Figure 64 — Removing Pilot Bearing trom Flywheel Figure 65 — immobilizing the Flywheel 8 Remove the bolts (8) securing the flywheel tothe crankshaft. Remove tool J 38047. 8, Remove the bolt securing the speed sensor to the flywheel housing, and then remove the sensor. The speed sensor is located on ‘the top of the flywheel housing fo the left. 10. Remove the flywheel (9). Hf necessary, use lifting equipment to lft the flywheel off the crankshaft. 14, When It becomes necessary to remove the ting gear (10) from the flywheel because of wear or damage, heat the ring gear to 392°F (200°C) for a minimum of 30 minutes. Page 53& REPAIR INSTRUCTIONS 12. Remove the ring gear by tapping on it using a brass drift and hammer. Move around the ring gear while tapping to dislodge it from the flywheel Figure 66 — Removing Fiywhest Ring Gear 13, Remove the flywheel housing bolts (4), and then remove the flywheel housing (3). If necessary, use a suitable lit and chain with sufficient capacity (approximately 2,500 ibs.) to lift the fiywhee! housing from the engine block, A CAUTION Do not use the threaded hole in the flywheel housing as a iting point for removing the housing. Refer to Figure 4, Damage to the ‘housing can result. aati Figure 67 — Removing Flywheel! Housing 44, Check that the connecting rods (22) are Clearly marked in numerical order beginning with No. 1 at the flywheel end of the engine. The marks should be on both the connecting rods and rod caps toward the camshaft side of the engine. 15, Rotate the crankshaft as necessary to expose the connecting rod caps (see Figure 68) so that the rod cap bolts and rod ‘caps can be removed. Loosen and remove the connecting rod cap bolts (19). Remove the connecting rod caps (20). partray Figure 68 — Rotating Crankshaft to Exposo Connecting Rod Cape, 18, Remove any carbon buildup from the top of each cylinder sleeve (1A) to prevent damage to the pistons or piston rings during removal.ei» REPAIR INSTRUCTIONS 17. Carefully remove the piston and connecting tod assemblies through the top of the cylinder block. Rotate the crankshaft as necessary to provide clearance for each piston assembly removed. A CAUTION Protect the crankshaft connecting rod journals and cylinder sleeves from becoming damaged ring plston/eonnecting rod removal. Figure 69 — Removing Pistons and Conneoting Rods 18. Retrieve the connecting rod bearing inserts (21) from the connecting rods and rod caps. 19. Lay outthe pistons, connecting rod caps and bearing inserts in the order they were removed from the engine. 20. To service the pistons (26), start by removing the piston rings (27), Use a piston ring expander such as J 28502, or ‘equivalent, to remove the rings. 429502 Figure 70— Removing Piston Rings 21. To separate the connecting rods from the pistons (26), remove the snap rings (24) retaining the piston pins (25). Push the piston pins out of the pistons. Separate the pistons and the connecting ods, NOTE Note the orientation of the connecting rods to the pistons, The valve reliefs in the piston and the numbered side of the connecting rods face the ‘camshaft when installed. Make sure to keep each piston and its components together and in proper order. 22. 23. Page 56ei REPAIR INSTRUCTIONS 24, Cheok the crankshaft main bearing caps (13) for marks indicating position in the engine. If the caps are not marked, clearly mark the caps starting with No. 1 at the rear of the engine. Figure 71 — Location Marks on Main Bearing Caps 25, Remove the main bearing cap bolts (14), 26. Remove the main bearing caps (13), keeping them in the order they are removed. Remove the lower bearing inserts (12) from the caps. 27. Retrieve the lower spilt thrust washers (11) from the sides of the center main bearing ‘cap, Tag the thrust washer halves for proper reassembly. 28. Using a lift and sling of suitable capacity, remove the crankshaft (15) from the oylinder block. porires Figure 72 — Removing Grankshatt 29, Relileve the upper spilt thrust washers (17) from the sides of the engine block center main bearing saddle. Tag the thrust washer halves for proper reassembly, 30, Remove the upper main bearing inserts (16) from the engine block main bearing saddles. 31. Remove the oil pressure relief valve assembly (8) and inspect for damage, wear and contamination. Refer to “Oil Pressure Regulator Valve inspection” on page 70. Inspection and Reassembly CHECK THE CYLINDER SLEEVES 1, Inspect and measure the cylinder sleeves, (1A) for the following (see Figure 73) to determine reuse or replacement: © Using a dial bore gauge such as J 5347-B, or equivalent, check the oylinder sleeves for out-of-round, © Using a dial bore gauge such as 45347-B, of equivalent, check the oylinder sleaves for taper. 0.47 INCH (zuma Figure 79 — Cylinder Stoeve Moasuring Locations: 2. loylinder sieeves require replacement, first, remove the cylinder sleeve retainers J 28485-B as necessary. Page 58.REPAIR INSTRUCTIONS 3. Remove the cylinder sleeves (1A) as CAMSHAFT BUSHING REPLACEMENT necessary, tising tool PT-6435, or equivalent. Removal 1, Drive out the front end and rear end ‘bushings (18) first, Then drive out the remaining bushings using cam bushing remover set J 21428-01 with cam bushing remover and installer J 29484-A, Preass Figure 74 — Cylinder Steave Removal Tool CYLINDER BILOCK 1. Check the cylinder block deck (2) and gasket mating surface for flatness, Use a straightedge and thickness gauge. Measure front-to-back, side-to-side and diagonally across the deck. Refer to Figure 174 for tolerance. 2, Thoroughly inspect ail oil passages, drilings and oil galleries for contamination or plugging. Clean all contaminated openings, ‘especially the oll passages leading to the crankshaft main bearing and camshaft Figure 76— Servicing Camshaft Bushings bearing bores. ‘A. Gam Bushing Remover | B. Cam Bushing Remover and Installer J 20484-A | Set 21428-01 Installation NOTE Apply clean engine cil to the outside diameter of ‘the new camshaft bushings prior to Installation A CAUTION ‘The oil hole in each camshaft bushing must be aligned with the mating ol! supply passage in the eylinder block as shown in Figure 77. Figure 75 ~ Cleaning Oli Passages etoaeoeaaeeee_——« Page 87> REPAIR INSTRUCTIONS NOTE ACAUTION Notice the corract bushing orientation ilustrated by the arrows in Figure 77. Figure 77 — Camshaft Bushing Off Hole Orientation, * Install the center bushings first. Then install, the front end and rear end bushings using cam bushing remover set J 21428-01 with cam bushing remover and installer J29484-A, Use caution when insiaiting the cylinder sleeves. ‘Make sure that the sleeve O-rings do not roll out of place during installation. 4, Restrain the cylinder sleeves using too! J29485-B. Figure 78 — Using Tool J 20488-B to Restrain Cylinder Sleoves 5. With the cylinder sleeves'in place, check the protrusion of the oylinder sieeves above the deok of the cylinder block. Refer to Figure 174 for spocification. A CAUTION The front bushing must be flush with the front of the cylinder block and the rear bushing must be flush with the internal face of the block bor CYLINDER SLEEVES 4. Install new O-rings (18) into the grooves, provided at the bottom outside diameter of the cylinder sleeves. 2. Lubricate the cylinder sieeve O-rings prior to installation into the cylinder block. 3, Install the cylinder sleeves (1A) into the cylinder block bores. Figure 78 — Checking Cylinder Sleeve Protrusion Page 58& REPAIR INSTRUCTIONS CRANKSHAFT INSPECTION AND. INSTALLATION Inspect and measure the crankshaft (15) ‘connecting rod journals and main bearing journals for the following (refer to Figure 172 for ‘spectfications): © Check the crankshaft main bearing and ‘connecting rod joumals for excessive out-of- Found, taper or other abnormal shape. + Measure the connecting rod journal diameter. Compare to specification, * Measure the crankshaft main bearing journal diameter. Compare to specification. © Support the crankshatt in V-blocks and check that the crankshaft is straight and within tolerance using a dial indicator. A CAUTION Do not attempt to straighten tho crankshaft by any means. Doing this can cause crankshaft fatigue. if crankshaft axial runout is excessive, replace the crankshaft and bearing inserts. 1. Thoroughly clean all crankshaft lubrication passages before installation. 2. If the crankshaft main bearings are to be reused, check both upper (16) and lower (12) inserts for wear. 3. Install the upper bearing inserts into the main bearing supports of the engine block. ‘Make sure the surlaces are clean and properly seated. 4, Install the fower bearing inserts into the main bearing caps. Make sure the surfaces are clean and properly seated, 5. Install the upper split thrust washers (17) on either side of the center main bearing support. 6. Using a suitable fit and sling, lower the erankshatt onto the main beating supports of the engine block. Do not iubricate at this time, aersree Figure 80 — Installing the Crankshaft 7. Place a small plece of Plastigage on each ‘main bearing cap to measure the play (clearance) between the journal and bearing 8, Install the crankshaft main bearing caps (13) Into position and the proper order. Do not lubricate at this time. Using the orginal main beating cap bolts, install and tighten to ‘specification. NOTE Do not rotate the crankshaft with Plastigage in place. The Plastigage wil smear and become unmeasureable, 9. Remove the main bearing caps and measure the width of the Plastigage cord {Figure 81). Compare the measurements to specification. Refer to Figure 172 for clearance tolerances. Page 5REPAIR INSTRUCTIONS peritta Figure 81 — Measuring Bearing Clearance 10. Lubricate the crankshaft main bearing joumals and all main bearing inserts. 11. Position the tower split thrust washers (11) in place on either side of the center main bearing cap. 12, Reinstall the crankshaft main beating caps (13) into proper position, A CAUTION Make sure to install new main bearing cap bolts. Also, make sure to install new connecting rod cap batts. 13. initially tighten the main bearing cap bolts (14) t0 74 tb-#t (100 Nem). 14. Finish tightening the main bearing cap bolts an additional 80-90 degrees rotation using tool BT-91104. 18, Check crankshaft end play using a dial indicator such as J 7872, or equivalent, 16. Ifnecessary, correct the crankshaft end play using new split thrust washers (11 and 17). Figure #3 — Checking Crankshaft End Play CONNECTING RODS Check the connecting rods (22) for the following ‘conditions (refer to Figure 173): Check each connecting rod for weight as ‘compared to the other connecting rods. * Check each connecting rod to see if itis bent ‘or twisted (out of square). Check the surface ‘of each connecting rod for damage. © Inspect and measure the connecting rod small end bushing (23) for damage or wea. It necessary, remove the conneating rod bushing. Use J 29467-8 to press the old bushing out and the new bushing in. Figure 82 — Tightening Main Bearing Cap Bolts Figure 84 — Sorvcing Connecting Rod Small End ing Page 60REPAIR INSTRUCTIONS 1. When installing the small end bushing into the connecting rod, apply vegetable-base fubricant to ease installation. 2. Line up the lubrication hole of the bushing with the lubrication hole of the connecting rod. 3, Press the bushing into place. 4, Make sure to ream each newly installed bushing to match the inside diameter specification. Refer to Figure 173. PISTONS Check and measure the pistons (26) for the following (refer to Figure 174): * Check the weight of each piston and compare to the other pistons. * Check the diameter of each piston and compare to specification. * Measure the piston pins (25) for wear and check piston pin tolerances between connecting rod and pin and between piston and pin. * Clean and measure the piston ring grooves and compare to specification, Check and measure the piston rings (27) for the following: . © Measure the thickness of the piston rings and compare to specification, © Check for excessive wear of the piston ring grooves, Measure between installed ring and groove. © Check piston ring end gaps with ring installed in cylinder sleeve. Figure 85 — Measuring Piston Ring End Gap_ 1. Assemble the connecting rods (22) to the pistons. Insert the small enc of the ‘connecting rod into the bottom of the piston and align with piston pin bore. NOTE Note the orientation of the connecting rods to the pistons. The valve reliefs in the piston and the humbered side of the connecting rods face the ‘camshaft when installed. Make sure to keep each piston and its componenis together and in proper order. 2. Insert the piston pin (25) through the piston (28) and connecting rod. install the snap Fings (24) to secure the piston pin. Make ‘sure that the snap rings engage the mating ‘grooves in the piston, 3, Install the piston rings (25) in place into the piston ring grooves using tool J 29502. Refer to Figure 86, 1 e@: Figure 86 — Piston Ring Orientation in Grooves: arson Page 61ep REPAIR INSTRUCTIONS NOTE FRI 8257 Make sure to orient the pistons and rods so that the valve reliefs on the pistons and the numbered. side of the connecting rods face the camshaft side of the block when installed. Figure 87 — Using Tool OEM 6287 to Install Rings 4, install the upper bearing insert (21) into the: connecting rod big end. Install the lower bearing insert (21) into the connecting rod cap (20). 5. Install the connecting rod and piston assembiiss into the cylinder bores using too! 329470. Figure 89 — Platon and Connecting Rod Assembly rientation Figure 88 — Installing Pistons into Cylinder Boras<> REPAIR INSTRUCTIONS CONNECTING ROD ASSEMBLY 1. Rotate the crankshaft as necessary when connecting the rods to the journals of the orankshatt. 2. Connecting rod-to-journal clearance should be checked using Plastigage as done for the crankshaft main beatings (refer to Figure 81). 3. Wipe any cil from the connecting rod bearing and journal, Place a piece of Plastigage on ‘the connecting rod journal of the crankshaft. Assemble the mating connecting rod cap ‘equipped with a bearing insert. Tighten the 10d ¢ap bolts to specification. 2orons NOTE Do not rotate the crankshaft with the Plastigage in place. The Plastigage will smear and become unmeasurable. 8. Figure 90 — Tightening Connecting Rod Cap Bote Check piston protrusion above the deck of the engine biock using a suitable dial indicator setup. Refer to Figure 174 for tolerance, NOTE Before tightening the rod cap to measure play, fully seat the connecting rod onto the crankshaft journal. not fuly seated, the Plastigage will become overly crushed and give a false measurement 4. Remove the connecting rod cap bolts (19) and cap (20). Measure the width of the Plastigage and compare to specification, Refer to Figure 172. 5. Perform connecting rod joumnal clearance on all six cylinders, 6. Lubricate the crankpin journals and connecting rod bearing Inserts. Reinstall all connecting rod caps and belts and tighten to 26 lo-ft (85 Nem) torque. 7. Using tool BT-91104 (see Figure 90), continue tightening the connecting rod cap bolts an additional 140-160 degrees of rotation, Figure 81 — Checking Piston Protrusion| 9. Lubricate and install the oll pressure regulator valve (8). Refer to “Oil Pressure gulator Valve Inspection” on page 70 for information, 10. Locate the flywheel housing (3) and gasket 1. to the engine block. Position over the locating dowel pins on the back of the engine block. Apply Loctite 573 sealant to the flywheel housing bolts, and install and tighten to specification, 12. install the rear main cit seal (5) using tool J 38591-A, . Page 6sREPAIR INSTRUCTIONS A CAUTION To avold bending the tip of the rear main oll seal, keep the seal on its protective ring until it is placed on the tool. Before instalfing the rear main Seal, lubricate the outside diameter of the seal. Do not grease the ip of the oll seal. Figure 92 — Installing Rear Main Ol Seal When installing a new ring gear, the ring gear (10) must be heated to ease inslallation. The preferred method is to heat the ring gear to 392°F (200°C) in an electric oven. The alternate method is to use three thermochrom sticks spaced evenly around the ring gear. if using this method, perform the following: 13. Place the ring gear on a metal plate, and tusing a torch, apply heat to the plate next to the ring gear. Heat transfer from the plate to the ring gear provides even heat distribution. 14. Stop heating when the sticks change color from blue to black. ACAUTION Do not apply any localized heating to the ring gear. Damage to the ring gear can result. Page 64 aera Figure 63 — Alternate Method of Heating Ring Gear 1 Thermachrom Sticks 15, Quickly install the sing gear (11) over the flywheel unti fully seated. NOTE Make sure the ring gear is facing in the correct direction when installed. The chamfered edge of ‘the ring gear teeth face forward, toward the ‘engine (starter motor). Figure 94 — Ring Gear OrientationREPAIR INSTRUCTIONS 16, Install the flywiheel (9) onto the crankshaft. Engage the locating dowel pin. 17. Apply Loctite 542 to the threads of the flywheel bolts (7) and foosely install the bolts at this time. 18. Prevent the orankshatt from rotating by using too! J 38047. Figure 05 — immobilizing the Fiywheet 25. 28. Tighten the engine flywheet bolts in a ctiss- cross pattem to specified torque. Remove tool J 38047. . equipped, install the pilot bearing (8) and secure with snap ring, Position the starter motor to the flywheel housing, install he starter motor bolts and tighten to specification. Reconnect the electrical hamess connections to the starter motor. Install the timing andl auxiliary components, ‘camshaft and valvetrain, water pump, alternator, oll pan, block stiffener, oll strainer and timing cover onto the front of the engine, Refer to "Timing Components and Camshatt” on page 41 for removal and installation procedures, install the cylinder head. Refer to "CYLINDER HEAD OVERHAUL" on page 20 for procedures. Install the fuel injection system components {high-pressure pump, fuel tubes, common fuel rail, fuel injectors etc.) onto the engine, Refer to "FUEL INJECTION SYSTEM SERVICE” on page 78 for procedures. Page 65& REPAIR INSTRUCTIONS LUBRICATION SYSTEM SERVICE Oil Pump Removal 207887 Figure 96 — Timing and rive Gear Configuration and (Gil Pump Location, 1. Gamshaf/Oranishaft | 4 High-Pressure Pump Drive Gear Taming Maks 2.Crankshafvicler Gear | §, Idlor Gear Timing Marks 6. Ot Pump Drive Gear 4. Idler GoartHigh-Prossura | 7. Crankshaft Gear Pump Drive Gear Timing | 8. Camshalt Drive Gear Marks. 8, Air Compressor Drive Gear Refer to “ENGINE TIMING COMPONENT. SERVICE” on page 35 for the following ‘component removal (to gain access to oll pump for removal and installation}: © Alternator and brackets © Water pump assembiy © Vibration damper and pulley assembly © Anthnoise plate * Timing gear cover 4. Loosen and remove the nut retaining the olt pump drive gear. 2. Using a suitable gear puller (Figure 97), remove the oll pump drive gear. srs Figure 87 — Removing Oli Pump Drive Gear 3. Remove the bolts retaining the oil pump. Remove the cil pump. Refer to Figure 98, A CAUTION Note the position of the olf pump housing during removal. Ifthe ail pump is installed incorrectly, severe engine damage could result. The oil pressure feed and oil suction ports of the of! pump should match the oil pressure feed and oil Suction ports of the engine block. 078555 Figure 98 — Off Pump Orientation ‘Tler Gearand Shak | 2. OF Pump Orentation Lovation 8, Crankchatt Gear Page 65> REPAIR INSTRUCTIONS Oil Pump Disassembly 1. Remove the oil pump cover retaining bolts (1) and washers. Figure 99 — Oil Pump Exploded View ON Pump Gover Fstalning Bolt 5 Ot Burp Cover Gude Pin 2. Remove the oil pump cover (2) from the oll pump body (8), baing careful not to bind the cover on the guide pins (5). 3. Remove the inner rotor (3) and the outer rotor (4) from the oll pump body. 4, Remove the O-rings (7, 8) from the oll pump body. Page 87& REPAIR INSTRUCTIONS Inspection of Parts NOTE Clean all parts to be Inspected using fresh safety solvent. 1. Examine the inner and outer rotors and Internal surfaces of the oif pump cover and il pump body, inspect for scoring oF other damage that could reduce oil pressure during off pump operation. Mustration symbol is explained in Figure 1. Figure 100 — Oll Pump Components to Inspect 1. Oi Pump Cover 3 Oulor Rotor 2, Install the inner and outer rotors into the oil pump body. 3. Check inner and outer rotor end play using a thickness gauge and straightedge, Aliowabie inner and outer rotor end play is 0.001-0.004 inch (0.03-0.09 mm). soiree Figure 101 — Checking Oil Pump Rotor End Play 1. Gheck rotor and play here 2. Oil Pump Body 4. Inner Rotor PagoCis REPAIR INSTRUCTIONS Oil Pump Reassembly 1. Apply a thin coat of clean engine oil fo the inner and outer rotors. Install the inner and ‘outer rotors into the oll pump body. 2. install the oll pump cover and secure in position using oil pump cover bolts and ‘washers. Tighten the bolts to standard specification. 3. Install new O-rings at the rear of the pump body. Lubricate before installation. 2onetso Figure 102— Inetall Oil Pump O-Rings Ol Pump O-Rings Oil Pump Installation 1. Lubricate the oil pump O-rings, and then install the olf pump into position in the. engine block. install the oll pump so that the mating oil ports are aligned. ACAUTION Note the position of the oil pump housing during installation. If the oi pump is installed incorrectly, severe engine damage could resuit. The oil pressure feed and oil suction ports of the oil ump should match the oil pressure feed and olf ‘suction ports of the engine block. Figure 103 — Oll Pump Orientation 1 ldler Gear and Shai 72 OF Pump Ovfentation Lonation ‘8. Crankshaft Gear 2. Install the bolts to secure the oll pump and. tighten to standard specification. ‘8. Install the oll pump drive gear onto the shaft ‘of the pump. Install the washer and nut and tighten the nuit to 30-4 3 theft (40 4.4 Nem).& REPAIR INSTRUCTIONS Refer to “ENGINE TIMING COMPONENT Oil Pressure Regulator Valve SERVICE” on page 36 for the following fi tion ‘component installation: Inspect Timing gear cover NOTE 2 Anti-noise plate * Vibration damper and pulley assembly Clean all parts to be inspected using fresh safety * Water pump assembly SR * Alternator and brackets Figure 105 — Oil Pressure Regulator Valve Expioded ViewPian REPAIR INSTRUCTIONS 1, Chock the piston (2) for excessive wear, Checking Oil Pressure scoring or other damage. The oil pressure check is performed with the 2, Clean the calibrated hoe (3) atthe bottom of Snging gompletely assembled and completely the piston (2). installed in the vehicle, Check the olf and coolant 3. Verily that the cit pressure regulator spring _—_‘to make sure they are at the proper levels. has not weakened. Check the spring (1) for 4. Ugin 5 . Using toot J 29925-A olf pressure gauge, compression load using a spring tester such installed as shown (Figure 108), verify that as tool J 2738-8. oil pressure is within specification. Refer to To convert lenath in millimeters and load in “ENGINE CHARACTERISTICS AND kilograms, refer to the “CONVERSION SPECIFICATIONS" on page 118. CHART” on page 5. serine Figure 108 — Compression Load Specification for Oil Pressure Regulator Spring Figure 108 — Cheoking OW Pressure with Gauge ‘etallad Figure 107 — Tool J 22738-B Spring Testeres REPAIR INSTRUCTIONS COOLING SYSTEM SERVICE Figure 109 — Exploded View of Water Pump 1 Pulley 2. Bearing and Shaft Assembly 8. Water Pump Body 4. Cyelam Seal 5. impeller 8, Gasket | 7 Water Pump Housing i Water Pump For water pump removal and installation procedures, refer to “Water Pump Assembiy” on page 38. ‘The numbers indicated in the text refer to Figure 109, unless indicated otherwise. DISASSEMBLY 1. Loosen and remove the bolts securing the water pump body (3) to the water pump ‘nousing (7}. Separate the two components. 2. Remove the gasket (6). Discard and repiace with a new gasket during reassembly, 3. Using a suitable press setup and driver with a maximum diameter of 0.59 inch (15.0 mm), push the shaft and bearing assembly (2} out of the water pump body (3) Page 72 072068 Figure 110 — Pressing Pulley, Shaft and Bearing ‘Assembly Out of Water Pump Body 7. Dlarveter = 0.59 inch (75.0 mem)<> REPAIR INSTRUCTIONS 4, Remove the Cyclam seal (4) and impeller (5) from the water pump. 5, Place the pulley (1) with shaft and bearing assembly {2) ina Suitable press setup. Insert the shaft and beating into a support that allows the shaft and bearing to be pressed ‘out of the pulley, 6. The support should be round and hollow and measure: © Inside diameter = 1.65 inches (42 mr) © Outside diameter = 1.85 inches (47 mm) © Length = 6.1 inches (430 mm) 7. Separate the pulley (1) from the bearing and shaft assembly (2), using a driver with a maximum diameter of 0.59 inch (15.0 mm). Figure 111 — Separating Pulley from Shalt and Bearing ‘Assembly TID = 1.66 Inchos 2, Diameter = 0.58 inch (42 mm), OD = (5 mm) 1.85 Inches (47 mm), Longth = 5.1 Inches. (130 men) ASSEMBLY To reassemble the water pump, perform the following: 1. Heat the water pump body (3) to 248°F (120°C) In a temperature-controlled oven. 2. Using a suitable press setup and driver (hollow with outside diameter of 1.54 inches [39 mm] max.), press the bearing and shaft assembly (2) into the water pump body (3). A CAUTION Never immerse the pump bearings in solvent. 3. Let the assembly cool. ® = Figure 112 — Pressing Shaft and Bearing into Water Pump Body 7 Maximum Diameter = 1.84 Inches (88 man) 4, Using a sultable press setup and hollow driver with inside diameter of 1.40 inches (25.5 mm), press a new Cyclam seal (4) ‘onto the shaft. Lubricate the seal with water and 10% liquid soap solution before installation, = le¢ Sa eran rel Figure 119 — Pressing Oyclam Seal onto Shaft 1 neide Diameter 1.40 Inches {85.5 mn) 2 Oyelam Seal Page 73REPAIR INSTRUCTIONS 5. Heat the pulley (1) to 248°F (120°C) in oven. 8. Using a suitable press setup, press the pulley (1) onto the water pump shaft (2). One ara%ea Thermostat ‘To remove and install the thermostat housing assembly, refer to "Cylinder Head Disassembly” ‘on page 23 for procedures, REMOVAL Refer to Figure 116. 1. Remove the snap ring (3) that retains the thermostat in the housing. 2, Remove the thermostat (4) from the housing. 3, Remove the O-ting (5), washer (2) and ring seal (1) from the thermostat housing. NOTE Figure 114 — Pressing Pulley onto Shatt of Water Pump 7. Heat the water pump impeller (5) to 248°F (120°C) in oven. 8. Using a suitable press setup, press the water pump impeller (5) onto the rear of the shatt 9. Press the impellar on untii the clearance between the impeller (5) and water pump ‘body (8) is 0.028-0.036 inch (0.7-0.9 mm). Figure 115 — Pressing Impelir onto Shaft 10, Assemble the water pump body (3) to the water pump housing (7) using a new gasket ©). 11, Install and tighten the bolts to standard torque specification Page 74 Note the orientation of the seai ring for installation purposes. Figure 116 — Exploded View of Thermostat and Housingae» REPAIR INSTRUCTIONS CHECKS 1. Submerse the thermostat in a tank of water. Heat the water gradually while stirring. 2. Check the temperature at which the thermostat starts to open. Measure the ‘thermostat gap (A) at 205°F (96°C), 3. The thermostat should start to open at 187 £2.5°F (86-4 1.5°C). 4. The gap (A) should be a minimum of 0.31 inch (7.9 mm) at 205°F (96°C). Figure 117 — Checking Thermostat Opening at “Temperature INSTALLATION 1. Install the ring seal (1) into the thermostat ‘housing. 2. Install the washer (2) and O-ring (5) into the thermostat housing. 3. Install the thermostat (4) into the thermostat housing and secure with snap ring (3). Engine Oil Cooler and Filter Support Figure 118 — Exploded View of Engine Olt Cooler and Filter Support Housing ‘The numbers indicated in the text refer to Figure 118, unless indicated otherwise. Page 75REPAIR INSTRUCTIONS REMOVAL 1. Remove the harness connector from the oil pressure sensor. 2. Remove the oli filter from the engine olf ‘cooler and fiter support housing. 3, Loosen and remove the bolts securing the ‘engine oll cooler and filter support housing to the engine block (see Figure 120). 4. Separate the assembly from the engine block, Remove and discard the gasket. DISASSEMBLY 1. Remove the bolts (4) securing the engine oil ‘cooler to the oil fiter support housing. 2, Separate the engine oi cooler (2) from the oll filter support housing (1) and retrieve the gaskets (3). CLEANING 1. To clean the oil flow circuits of the filter support housing and the oll cooler, use ttichtorethylene. 2. To clean the coolant circuit of the support housing, use a solution of water and 5-6% hydrochloric acid, Let soak for approximately 30 minutes white stiring. Rinse parts in a solution of water and 2-8% bicarbonate of soda. Rinse the parts well with clean water and let dry. Page 76 CHECKS: 4. Check the oll cooter for leaks using tool 2584 (refer to Figure 119). Attach too! 2584 and airline to the oll cooler, 2. Place the oil cooler in a tank of hot water with temperature at approximately 176°F (80°C), 3. Apply an air pressure of approximately 87 psi (6 bars) to the olf cooler. 4, Check the oit cooler for leaks (air bubbles). If leaks occur, make sure too! 2584 and air line are tightened property. wor2169 Figure 119 — Use Tool 2584 to Check Engine Oil Cooler tor Leakeee REPAIR INSTRUCTIONS ASSEMBLY 1 Assemble the oil cooler (2) to the oil fter ‘support housing (1). Use new gaskets (3) for sealing between the cooler and support. Install and tighten the bolts (4) to 41 +7 Ib-ft (85 +10 Nem). INSTALLATION 1. Position the engine oll cooler and fitter support housing to the engine block, Use @ new gasket between support housing and. ‘engine block. Install the bolts to secure the housing to the ‘engine block and tighten in the indicated order (see Figure 120). Tighten to 70 + 14 lb-ft (95 + 15 Nem). asratea Figure 120 — Bolt Tightening Sequence for Engine OW Cooler and Filter Support Assembly 3. Install and tighten the ol fier to the filter support, 4. Engage the harness connector to the olf pressure sensor.REPAIR INSTRUCTIONS FUEL INJECTION SYSTEM SERVICE Description and Operation SYSTEM DESCRIPTION The Diesel Common Rail injection (DCI) system is an electronic fuel-injection system that is comprised of the following components: ‘The numbers/letters in parentheses correspond 4o the numbers/letters ih Figure 121. © Engine Electronic Control Unit (ECU) (1) © Fuel tank (2) . Marval uel hand priming pump and prefiiter * Booster pump (4) © Fue’ fiters (6) © Fue! metering housing (6) © Residual pressure valve (7) * Fuel flow regulation solenoid valves (8) ‘+ High-pressure pump (9) © Common fuel rail (10) © Fuel rail pressure limiter (11) © Fuel flow timiters (12) © Fuel injectors (13) © Fuel rail pressure sensor (fuel high-pressure: sensor) (14) '* Engine oll pressure sensor (15) * Engine oll temperature sensor (16) * Engine coolant temperature sensor (17) * Engine oit level sensor (18) * Boost air pressure and temperature sensor (19) * Flywheel speed sensor (20) © High-pressure pump spead sensor (21) ‘* Engine stop control (accessed with cab tited) (22) © Fucl fiter restriction sensor (23) © Accelerator pedal (with accelerator pedal position sensor) (24) Page 78 ‘* Fuel injection system electronic warning lamp (25) * Vehicle Electronic Control Unit (VECU) (26) * — Communication line (CAN bus) between EECU and VECU (27) + Profiter/water separator (28) Various forms of inforination are required by the VECU, EECU and peripheral electronic control units such as the Ant-iock Brake System (ABS) controt unit. This information is provided by the various system sensors and collected by the EECU, which sends the required information to the peripheral electronic contro! units and to the ECU. The sensor information Is in digital form and Is provided over the communication line or “CAN bus.” ‘Some examples of the information communicated over the bus are: © Engine temperature © Engine oi! pressure ‘* Tachograph speed (engine rpm) information * Accelerator pedal position sensor information. © PTO Information ‘© Braking information © Engine immobilizer information Fuei hydraulic circuits are shown in Figure 121 and are defined as follows: Aspiration (A) © Lowpressure fuel (8) © High-pressure fuel (C) © — Fuel rail leak-off fuel return to fuel tank (D)& REPAIR INSTRUCTIONS ‘Figure 121 — Fuot Injection System Components and Fuel Flow Diagrama> REPAIR INSTRUCTIONS SYSTEM OPERATION The current emissions and noise pollution standards and the need to control vehicle ‘operating costs have led to the design and development of more precise and better performing fuel-injection systems, in the matter of environmental protection and specific fuel consumption. To meet poltution standards, the “COMMON RAIL" fuel-injection system operates according to the following principles: * Fuel high-pressure variable according to engine needs, independent of engine load and rotation speed © Timing advance vatlable according to engine needs, independent of engine toad and rotating speed * Pressure/time type fuel metering © Pre-injection if required (to reduce diese! knock) © Allelectronic mutt-point injection. Fuel Metering and Injection ‘The fuel stored in the fuel tank is aspirated (drawn) by the booster pump and delivered at low pressure to the high-pressure pump iniet. The high-pressure veiue 2,901-20,305 ps! (200-1400 bars) Is determined by the amount of fuel taken in by the high-pressure pump. This fuel quantity is piloted by flow regulation solenoid valves located in the fuel metering housing. The {uel is directed to the common rail, and then distributed to the fuel injectors. Fuel injector opening is controlled electrically by the EECU. Fiow limiters on the common rail prevent fuel feaks in the high-pressute circuit, downstream from the common rail, in the event of component failure (cracked fuel tube or line). This is done to protect the engine in the event of injector malfunction. ‘To manage the fuel injection system, the EECU receives Information from the following ‘components: © Vehicle Electronic Contro} Unit (VECU) © Fuet rail pressure sensor © Flywheel speed sensor and high-pressure pump speed sensor * Engine coolant temperature sensor * Engine oil temperature sensor ® Engine oil level sonsor © Accelerator pedal position sensor * Boost air pressure and temperature sensor * Vehicle speed sensor ‘Other controlled or monitored features of the system are: ® Engine cooling management © Cruise contro! © Engine shutdown ‘* Engine protection (overheating, torque linsitation) Exhaust brake management (if equipped) '* Adjustable iting variable according to ‘operating conditions such as A/C compressor load and engine temperature ‘* Fastidling adjustable trom the driving position © Idle adjustment controt Operation in Fall-Back Mode Specific faults detected by the system cause the system to revert to fall-back mode. The effects of {alkback mode can be noticed as reduced engine performance during engine startup or while driving. Some of the symptoms of conditions that ‘can occur during fall-back mode are: * Reduction of maximum common rail pressure (several levels) Longer engine starting time * Shutting off engine brake operation © Limiting or shutting off the operation of one or more injectors: Depending on the severity of the fault (engine speed sensor failure), the symptoms might not be noticeable or could be as serious as the system preventing engine starting. To minimize vehicle oF engine shutdown, in the event of minor faults, the EECU functions by approximate calculations based on sensor values that are stil available or by values contained in EECU mapping. Whatever the fault, it is essential to get the system serviced as soon as possible to avoid ‘major engine failure or poor vehicle operation. Page 80ee REPAIR INSTRUCTIONS Location of Fuel Injection System Components For the locations of the various system ‘components, refer to Figure 122 and Figure 123 for reference. FUEL ASPIRATION CIRCUIT © Fuel injeotor aspiration and fuel leak-ott return pipe (AA) © Manual fuel hand priming pump and prefiter @) * Fuel ral leak-offretum pipe (8B) LOW-PRESSURE (BOOSTING) CIRCUIT *® Booster pump (4) © Lowpressure tubes (GC) * Fue! fitters (not shown) @ Fuel metering housing (6) * Residual pressure valve (7) HIGH-PRESSURE CIRCUIT © High-pressure pump (9) + Fuo! rail delivery tubes (DD) * Common rail (10) * Fue! rall pressure limiter (11) © Fue! fiow limiters (12) ©. Fuel injector tubes (EE) + Fuel injectors (9220/022 1/0222/0228/0224/ 9225) PRIMARY SYSTEM ELECTRICAL, COMPONENTS: © Engine Electronic Gontrol Unit (EECU) (9202) Fuel high-pressure sensor (9208) © Flywheel speed sensor (9228) ‘+ High-pressure pump speed sensor (9262) ‘* Engine cootant temperature sensor (7362) ‘* Boost air pressure and temperature sensor (9200) Engine oil level sensor (8275). See Figure 142. Engine stop controt (access with cab tied) (2268). See Figure 143, Engine oil pressure sensor (7368) Fuel filter restriction sensor (on filter head) (2400). See Figure 145. SECONDARY SYSTEM ELECTRICAL COMPONENTS Exhaust brake solencid valve (8150) Vehicle Etectronic Control Unit (VECU) (9201) Diagnostics socket (7519) (under cover left of driver seat) EGR solenoid valve (9204) DRIVER INTERFACE COMPONENTS Acoslorator pedal position sensor (6266) Steering column controls (cruise control, vehicle/engine information display) (6167) Engine stop warning lamp (7521) Engine service warning lamp (7522) EECU electronic malfunction warning lamp (9267) VECU electronic malfunction warning lamp (9268) Page 81& REPAIR INSTRUCTIONS fam (Am Figure 122 — in-Cab Compenent Identification and Location& REPAIR INSTRUCTIONS 9262 @) 9208 Figure 123 — On-Engine Component identification and Location Page 83de REPAIR INSTRUCTIONS Component Description and Operation ENGINE ELECTRONIC CONTROL UNIT (EECU) ‘The EECU receives information from the sensors, and the Vehicle Electronic Control Unit (VECU). Depending on the input data, it controls fuel injection and additional features such as engine retarder and fast idle. ‘The EECU also provides the driver of system status by means of instrument panel telltale iamps. In the event of a system malfunction, the EECU operates in fall-back mode (emergency mode). The EECU is located in the battery box. MANUAL FUEL HAND PRIMING PUMP AND. PREFILTER The manuat {uel hand priming pump incorporates: ‘a prefilter (mesh screen cartridge) that can be washed using clean diesel fuel. awe (24— Engine Becton Control Un fn Baty Page 24 Figure 125 — Manual Fuel Hand Priming Pump and Prefiter& REPAIR INSTRUCTIONS FUEL FILTERS: ‘The primary fue! fers are cartridge-type spin-on fiers located between the battery box and driver side fender. The fitter head assembly is bolted to the fender bracket. The fiter head Incorporates fuel fiter restriction sensors and a fuel bieed screw, NOTE The fuel fitters, because of specific capacity and filtration level, must be replaced only with filters approved by Mack Trucks, Ino. Figure 126 — Fuel Fite Assembly 7 Fuel Biosd Screw BOOSTER PUMP ‘The booster pump is a gear-type pump driven by the shaft of the high-pressure pump. The booster pump is located behind and fastened to the high- pressure pump casing. If the booster pump Is. determined to be wom or damaged, replace the pump (cannot be repaired) The booster pump has a fiow rate of up to 132 gallons/hour (500 iiters/hour), Figure 127 — Booster Purmp Location RESIDUAL PRESSURE VALVE ‘The residual pressure valve keeps the pressure of the low-pressure circuit to values of 58-73 psi (4-5 bars) at engine idle and values of 87-102 psi (6-7 bats) at an engine speed of 2000 rpm. Figure 128 — Realduat Pressure Valve Location Page 85ei» REPAIR INSTRUCTIONS FUEL METERING HOUSING ‘The fuel metering housing consists of the two fuel flow regulation solenoid valves. The fuel flow regulation solenoids control shut valves that ‘manage the fuel flow rate to the high-pressure pump intet. The fuel metering housing cannot be repaired. Figure 129 — Fuel Metering Housing Location FUEL FLOW REGULATION SOLENOID VALVES The two fuel flow regulation solenoid valves are ‘mounted on the fual metering housing. The purpose of the fuel flow regulation solenoid ‘valves is to adjust fuel flow and maintain fue! pressure in the fuel rai at the required value. ‘When de-energized, the solenoid vaives are in the normally-closed position, which provides ‘maximum fuel rail pressure. When energized, the solenoid valves timit or reduce pressure at the fuel ral. ‘The resistance value when checking the solenoid valves is 15. In the event of solencid vaive ‘ailure, replace the high-pressure pump. Figure 130 — Fuel Flow Regulation Solenoid Valve Location {Solenoid Valve No.t__| 2 Solenoid Valve No, 2 HIGH-PRESSURE PUMP The high-pressure pump consists of two pumping elements. The pistons have three lobes each and are staggered by 60 degrees (one lobe per engine cylinder). The pistons are driven by the ‘camshatt inside the pump. ‘The high-pressure pump is a replace only itern; it ‘cannot be repaired Figure 131 — High-Pressure Pump Page 66REPAIR INSTRUCTIONS FUEL COMMON RAIL The fuel common rail provides the link between the high-pressure pump and the fuel injectors. ‘The fuel common rail is equipped wit ‘* Rall pressure sensor (high-pressure sensor} * Flow limiters (one for each fuel injection tube to the injectors) © Fuel rail pressure limiter ‘The fuel rail pressure fimiter calibration vatue Is 23,931 + 725 psi (1650 + 50 bar). watts Figure 192 — Fuel Common Rail FUEL RAIL PRESSURE LIMITER ‘The fuel rail pressure limiter protects the high- pressure circuit from excessively high fuel pressure. Excessively high pressure can occur it a fuel low regulation solenoid vaive falis and remains closed. If fuel pressure reaches the pressure limiter preset value, the pressure limiter bleeds off pressure into the leak-off return circuit (uel tube to the fuel metering housing). Ifthe fuel rail pressure limiter fails, itis essential to replace it Figure 193 — Fuol Rall Prosaure Limiter Location FUEL RAIL PRESSURE SENSOR (FUEL HIGH-PRESSURE SENSOR) The fuel rail pressure sensor is of the plezo- resistive type. The ECU suppiies the sensor with 5 volts. Depending on fuel pressure in the rail, he sensor resistance value changes. Sensor output (retum) voltage value should be between 0.5-4.5 volts as a function of sensor resistance based on fuel pressure in the rail. The volage value from tho sensor returns to the EECU. The EECU then controis the function of the fuel flow regulation solenoid valves to adjust fuel pressure Inthe rail, The fue! rail pressure sensor can be fully tested using an approved tester. Ft ep perapia Figure 184 — Fucl Rall Pressure Sensor Location Page 87REPAIR INSTRUCTIONS FUEL RAIL FLOW LIMITER ‘The fuel rail flow limiters are located on each rail outlet. The flow limiters isolate the high-pressure Circuit if fuel flow is too great or if there is a continuous leak, such as a break in the injector tubing of an injector maiunction, The maximum flow of the limiters without blockage Is 2.75 cu-in/stroke (450 cu-mmistroke). sree Figure 135 — Fue! Rall Flow Limiter Location FUEL INJECTOR NOZZLE HOLDER Each fuel injector and nozzle holder assembly consists of a solenoid valve that controls injector ‘opening and closing. The fuel injector and nozzle holder assembly is not repairable. The nozzle sealing gaskets in the injactor bores of the cylinder head must be replaced whenever the jjectors are removed. Fuel injector solenoid valve resistance Is 0.33.2 at 68°F (20°C). Page 28 ‘The fuel injector terminals are non-polarized, Figure 135 — Fuel injector Assembly ACCELERATOR PEDAL POSITION SENSOR ‘The accelerator pedal position sensor is made up ‘of a theostatic bridge and a foot lever position contact Accelerator pedal position sensor checks are done using ony approved MACK dlagnostc tools. areata Figure 137 — Acceterator Pedal Assemblyee REPAIR INSTRUCTIONS FLYWHEEL AND HIGH-PRESSURE PUMP SPEED SENSORS ‘The speed sensors are of the inductive pickup type. When excited, they deliver an analog voltage signal, The signal is generated as the flywheel notches oF the toothed wheel in the pump pass the tip of the sensor. The frequency of the generated signal is proportional to the engine rotating speed. ‘The flywheel has 58 notches (60 minus 2). The two missing notches Indicate the top dead center position of No, 1 oylinder. ‘The high-pressure pump toothed wheel has seven teeth, one tooth per top dead center of each oylinder and two side-by-side teeth for the top dead center position of No. 1 cylinder. The flywheel speed sensor and high-pressure pump speed sensor resistance values are the same. Sensor resistanco vaiue is 770-950 £2 at 68°F (20°C). ENGINE COOLANT TEMPERATURE SENSOR AND ENGINE OIL TEMPERATURE SENSOR The engine coolant and engine oll temperature sensors are of the Negative Temperature Coefficient (NTC) thermistance type. As the engine coolant temperature or engine oll temperature increases, the sensor resistance value decreases (refer to the temperature sensor resistance values table). The ECU provides a 5-volt signal to each sensor and based on sensor resistance value, retums something less than 5 volts. The EECU determines fual injection system operating parameters based on the temperature sensor values, areca Figure 198 — Speed Sensor and Connector Cavity Figure 139 — Temperature Sensor and Connector Cavity ‘TEMPERATURE SENSOR RESISTANCE VALUES Temperature °F (°C) Resistance (22) ee) 17,700-19,800 44-10) +10,650-8,250 32(0) '8,650-5,200 68 (20) 2,800-2,200 86 (30) 1,860-1,550 104 (40) 1,900-1,000 149 (60) 640-650 176 (a0) ‘500-200 212 (100) 20-170 Page 89BOOST AIR PRESSURE AND TEMPERATURE SENSOR ‘The boost air pressure and temperature sensor incorporates two measuring elements and is mounted on the intake manifold. The boost pressure element of the sensor is of the piezo- resistive type. The temperature element of the sensor is the Negative Temperature Coefficient (NTC) thermistance type. The EECU supplies the sensor with 5 volts to both elements, Based on clther the pressure or temperature, the sensor elements deliver an output voltage of between 0.5-4.5 volts back to the ECU. REPAIR INSTRUCTIONS svar Figure 140 — Boost Air Pressure and Tomporature Sensor and Connector Cavity, See the following table of resistance values for the temperature element portion of the boost air pressure and temperature sensor (between terminals No. 1 and No. 2). ‘TEMPERATURE ELEMENT RESISTANCE VALUES. Temperature FG) | Aealatance (0) 220) 7 8800-5800 50 (10) 4,200-3,600 68 (20) 2,760-2,600 86 (30) 4,870-1,700 104 (40) 7, 260-4,760 122 (60) 900-830 ENGINE OIL PRESSURE SENSOR ‘The oit pressure sensor is of the plezo-resistive type. The EECU supplies the sensor with 5 volts. ‘Tho sensor deiivers an output of 5 volts as a function of the engine of circuit pressure 0-102 psi (0-7 bars). ‘The sensor can only be fully tested using the approved tester. Figure 141 — Engine OM Prossure Sensor and ‘Connector Cavity ENGINE OIL LEVEL SENSOR ‘The engine oll level sensor is comprised of a thermo-resistive heating wire. The heating wire is supplied current by the EECU. As the heating wire rises in temperatura, the wire resistance changes, The change in resistance allows the EECU to determine the engine oi level, Figure 142 — Engine Oli Level Sensor and Connector Cavity Page 90REPAIR INSTRUCTIONS ENGINE Ol LEVEL SENSOR RESISTANCE VALUES Temparature FCO) Resietance (@) 2230) 23 8 GO} ita 266 (150) 167 ENGINE STOP CONTROL The engine stop control is a switch with normatly closed contacts, Pressing the engine stop control ‘switch causes the engine to shut down (stop running). The engine stop control switch can be accessed when the cab is tited. 20ret0a Figure 143 — Engine Stop Control 1 Engine Stop Control DIAGNOSTICS SOCKET The diagnostios socket is provided so that the DCI system can communicate with the diagnostics too! for the purpose of full diagnostics, and parameter definition, The socket is located ‘on the floor to the left of the driver's seat undemeath a removable trim cover. Figure 144 — Diagnostics Socket FUEL FILTER RESTRICTION SENSORS The fuel filter restriction sensor Is a normally closed switch. The sensor changes state (opens) when the pressure difference between P1 and P2 1s approximately 44 psi (8 bars). The fuel filter restriction information is time- dolayed and sent to the driver display only when the engine is at operating temperature. Delaying the time of the restriction information is done to avold the appearance of faults, due to fuel system pressure peaks or thickened cliesel fuel in cold weather. ; f Pitan Figure 145 — Fuel Fier Restriction Sensor, Connector Cavity and Port Locetions Pr Pe, Page 91REPAIR INSTRUCTIONS Fuel Injection System Repair ‘THE DCI SYSTEM IS A HIGH-PERFORMANCE INJECTION SYSTEM The DCI fuel injection system Is more sensitive to contamination than In-line pump systems. There {sa much greater risk of damage due to dirt or other contamination, For this reason, the original parts guaranteed by the manufacturer must be used and directions on system use, maintenance and repair must be followed. WORKING WITH THE DCI SYSTEM Before disassembling any part of the system, ‘arelully clean the components needing service and the area around the components. Take the necessary precautions to prevent dirt contamination. Use a cleaning solvent to clean the components, and then blow the components off with compressed air. Perform all work on the injection system with the ‘engine stopped and not running. Check system ‘components such as injectors and sensors for voltage and resistance values. Check all components for tightness as necessary. BLEEDING FUEL SYSTEM PRESSURE BEFORE SERVICE The system operates with very high injection pressures (up to 20,306 psi [1,400 bar]) and a ‘medium voltage/current (injector contro! is by condenser discharge). Using an approved fuel pressure gauge (or diagnostic tool), ensure that the pressure in the low pressure side of the system has fallen to zero, During normal operation, the pressure fails rapidly in the high-pressure circuit atter the ‘engine stops running (approximately 1-2 minutes), In extreme cases of malfunction (several or all ow limiters blocked), high pressure can remain longer, or not fall off at all. In this case, create a fuel leak by loosening an injector tube coupling. Protect your hands and ‘eyes and keep as far away as possible from the leak point, Do not allow any fuel to spray you when creating a fuel leak as described. Severe personal Injury can result, WHEN DISASSEMBLING THE SYSTEM * Repairs to the system must be done in a clean dust-tree environment, using the appropriate tools. © Gloves made of fibrous material must not be used. © Clean the parts with a clean solvent and Inspect them carefully, Use high quality cleaning brushes in very good condition, Do not use lint-filled or solled rags. © Seal all opened or exposed orifices or tubing with pigs as soon as removed. ¢ Do not use compressed air to clear out insides of components. * Protect cleaned components to avoid corrosion in the system. ©The injector nozzle holder assembly is not repairable. Always replace the entire assembly whon failure occurs. ‘+ When performing injector spray or high- pressure circuit leak tests, do not lat the fuel- jet spray you. © Disassemble and reassemble in the order indicated in the repair manual. * Reassembiy of components should be done ‘without any modification (welding or bending). Do not constrain or restrict parts when connecting, attaching or tightening, Replace the part if necessary. Tighten parts using the recommended torque specification, Do not bleed the fuel system using the starter motor. ‘The above recommendations are to ensure the quality and reliability of the DCI fuel injection system, Page 92iss] REPAIR INSTRUCTIONS REPLACEMENT FUEL TUBES Replacement fuel tubes are protected inside by an anti-rust product, Fuel tubes should be rinsed with solvent or alcohol and assembled immediately to avoid the risk of rusting. BLEEDING THE FUEL SYSTEM Refer to Figure 146, 1. Open the bleed screw (1) on the fuet filter head 1/4 to 1 turn, and then unscrew the handle (2) of the manuat fuel hand priming pump and prefiiter assembly. Pump the handle until the fuel suns out of the bleed ‘screw without air bubbles. Close the bleed ‘screw and pump the handle until pumping becomes dificult. Screw in the manual fuel hand priming pump handle before starting. 2, Crank the engine using the starter motor until the engine starts, A CAUTION Do not use the starter motor to bleed the system. Damage to the starter motor can result, A CAUTION Ifthe engine does not start immediately, limit cranking periods to 30 seconds to avoid ‘overheating and damaging the starter motor. Figure 146 — Location of Bleed Screw and Manual Fuel Hand Priming Pump 7. Bleed Screw on Fool Filer Hoad 2, Manual Fuel Hand Pring Pump Hangs Page 93ae REPAIR INSTRUCTIONS MANUAL FUEL HAND PRIMING PUMP AND PREFILTER Refer to Figure 147. Removal 1. Unscrew the fuel tube couplings (1) and remove the leak-off fuel retum fine from the No. 1 cylinder fuel injector, 2. Hold the fittings (3) while unscrewing the couplings (1). 3. Remove the bolts (2) securing the manual fuel hand priming pump and prefitter assembly to the inlet manifold. NOTE e careful not to kink or bend the fuel tubes. 4, Remove the manual fuel hand priming pump and prefiter assembly. 5. Unscrew the prefilter fuel bow! (4), remove the mesh screen cartridge and clean the cartridge with fresh diesel fuel. Installation 1. Place the manual fuel hand priming pump and prefiter assembly into position on the inlet manifold. 2, Install and tighten the bolts to standard specification, 3. Sorew on the fuel tube couplings (1) and tighten to 24 + 5 lb-ft (83 +7 Nem), Hold the fittings (2) while screwing on the couplings, 4. Connect the No. 1 cylinder fuel injector teak ff fue! retum line to the fiting on the assembly. LOW-PRESSURE FUEL CIRCUIT PRESSURE Tr 1. Connect a sultable quick disconneot fuet coupling to the fuel bleed screw on the fuel jitter head. Connect a pressure gauge such as J 39278-10, of equivalent, to the coupling on the bleed screw. The fuel pressure gauge minimum capacity should be 180-200 psi (10-14 ber). Figure 148 — Gauge Satup for Checking Fuel Pressure Pago 94in] REPAIR INSTRUCTIONS 2, Loosen the fuel bleed screw (on fuel filter head) slightly between 1/4 to 1 turn. Refer to "BLEEDING THE FUEL SYSTEM’ on page 3. Start and operate the engine and record the pressure values. Refer to “RESIDUAL PRESSURE VALVE" on page 85 for 93 for procedure. pressure values. INJECTOR FUEL TUBES A A A a n 4 2 ‘ ad A FANE. O % at es OVP QD, eS Sa AO aero Figure 149 — injector Fuel Tubes Refer to Figure 149. meron NOTE Removal 1. Unscrew the fuettube couplings (A) from the injectors and from the common ral. 2. When unscrewing the fuel tube couplings, hold the flow limiters (B) and the high- pressure couplings of the injector nozzle holders to prevent them from unscrewing. 3, Remove the fue! injector tubes in the following order: © (5) and (6) © (and @) © (@)and (4) Its not necessary to separate the injector fuel tube pairs from the tube clamps and insulators, unless replacement is needed, 4, Plug all orifices or openings on the common rail, fuel injactors and fuel tubes to prevent contamination. 5. Asnevessary, place each part into a new airtight plastic bag immediately after removal to prevent contamination. Page 95ee» REPAIR INSTRUCTIONS Installation 3. Incase of fuel leakage a any of he 1. Position alt couplings, increase the tightening torque in injectors a cormon ra fo ios. Inererent of 4b (5 Nr) unt fo Serew on all tube couplings. leakage stops. If there is stil teakage when 7 the torque value teaches 97 lb-ft (60 Nem), 2. Tighten the injector fuel tube couplings (A) to replace the defective fue! tubes. 23 Ib-ft (21 Nem) without holding the flow imiters (B). Figure 150 — Tightening Fuel Couplings Page 96ie HIGH-PRESSURE RAIL FEED TUBES REPAIR INSTRUCTIONS Figure 151 — High-Pressure Rall Feed Tubes, Couplings and Supports Refer te Figure 151. Removal 1, Remove the capscrew (2) securing the high- pressure fuel tube bracket to the inlet ‘manifold. 2. Unscrew the high-pressure tube couplings (1) at the common rail and at the high- pressure pump. NOTE {tis not necessary to separate the high-pressure fuel tubes from the tube clamps and insulators, unless replacement is needed. 8, Remove the high-pressure fuel tubes from ‘the common rail and high-pressure pump. 4. Plug ail orifices and openings to prevent contamination. 5. Place each component in a new airtight plastic bag immediately after removing the ‘components. This is done to prevent moisture and other contaminents from entering the components. Installation Strloty follow the high-pressure fuel tube assembly procedure detailed below: 1. Position the high-pressure fuel tubes in place on the common rail and high-pressure pump. 2. Install the high-pressure fuel tube bracket capscraw (2) into the inlet manifold. Do nat tighten at this ime. 3. necessary, apply hand pressure on the {uel tubes to position the tube couplings to the high-pressure pump and to the common rail. The couplings may be moved a maximum of 0.20 inch (5 mm) vertically and horizontally by twisting the tubes. A CAUTION Do not use a pry bar or other levering device to position the tibes. Damage to the tubes can result. 4, Finger tighten the fuel tube couplings (1) on the high-pressure pump and common rail. 5. Tighten the oapscrew (2) securing the fuel tube bracket, 1o standard torque specification. Page 97a> REPAIR INSTRUCTIONS 6. Tighten the fuef tube couplings (1) at the high-pressure pump and common rail to 28 tb-t (31 Nem). Figure 152 —- Tightening Fuel Couplings 7. Incase of fuel leakage at any of the couplings, increase the tightening torque In increments of 4 lb-ft (5 Nem) until the leakage stops, if there is stil leakage when the torque value reaches 37 Ib-ft (50 Nem), replace the defective fuel tubes, RAIL RETURN TUBE ‘The numbers in the text refer to Figure 151. Removal 1, Remove the tube clamp lock nuts (5) securing the rail retusn tube to the common. rail bracket on the engine block. 2. Loosen and remove the rail return tube ‘banjo bolt (3) that secures the return tube to the fuel rail pressure limiter. Hold the end of the return tube (8) with a wrench while loosening the retaining bolt. 8. Loosen and unthread the tube coupling (4) ‘securing the retum tube to the coupling on the fuel metering housing. 4, Remove the rall return tube (6). 5. Plug and cap all orifices and openings to prevent contamination, 6. Retain the rail return tube clamp lock nuts and banjo bolt. NOTE Be careful not to bend the fuel tube. 7. Place each patt in a new airtight plastic bag immediately after removal to prevent contamination. instal 1, Obtain new copper seating washers. 2, Position the rail return tube to the rail pressure limiter and to the coupling on the fuel metering housing. 3. Install the banjo bolt with new copper sealing washors (place one on each side of the return tube). Tighten the bolt (3) white holding the end of the retum tube (6) with a wrench. Tighten to 245 tb-ft {8246.4 Nem), 4. Thread the tube coupling {4) onto the coupling on the fue! metering housing. Tighten to 44 + 7 lb-ft (60 +8 Nem). 5. Bleed the fuel system. Refer fo "BLEEDING THE FUEL SYSTEM" on page 93 for procedure, in RAIL PRESSURE LIMITER The numbers in the text refer to Figure 151. The rail pressure limiter (7) must be replaced it the engine is running at an abnormally high fuel pressure (problems such as flow regulation solenoid valve or injection fuel pressure outside ‘operating limits). Removal 1. Remove the rail return tube (6) as described in RAIL RETURN TUBE” on page 98. 2. Remove the rail pressure limiter (7) by unscrewing from the common rail 3. Plug and cap all orifices and openings to prevent contamination. 4, Place each part in a new airtight plastic bag Immediately after removal to prevent contamination. Page 98& REPAIR INSTRUCTIONS Installation 1, Thread the new rail pressure limiter (7) onto the end of the common rail ACCELERATOR PEDAL 2. Tighten the rail pressure limiter to 33+ 4 lb-ft (45 £5 Nem) 3. Install the rail return tube (6) as described in the "RAIL RETURN TUBE” on page 98. Figure 153 — Accelerator Pedal Assembly Removal 1. Loosen and remove the steering column, cover retaining screws, and then remove the cover. 2, Loosen and temove the screw (1) securing the accelerator pedal assembly, 8, Remove the accelerator pedal by pulling the assembly toward you, disengaging the pedal from slots (3) in the side of the brake and clutch pedal support. 4, Disconnect the accelerator pedal assembly hamess connector (4). Installation 1. Place the accelerator pedal assembly into position on the right side of the brake and clutch pedal support, 2. Slide the accelerator pedal assembly straight into the slots (3) of the pedal support until fully seated, 3. Install and tighten the mounting screw (1) until secure, 4, Reconnect the accelerator pedal assembly hatness connector (4). 5, Place the steering column cover into position, instal the screws and securely tighten.Prise REPAIR INSTRUCTIONS INJECTORS. NOTE To remove and install other components associated with the fuel injactors, such as fuel tubes, refer to the appropriate sections. Never service fuel injectors with the engine running, High voltage (80 volts) and current present at the injector terminals and fuel jection pressures are extremely high. ‘Severe personal injury and vehicle or engine damage can result, perastt Figure 154 — Fuel Injector Assembly The numbers in the text refer to Figure 154, NOTE Removal Do not use any tool that might damage the retu , Je the retum 1. Remove the injector fuel tube clamps and | tube fittings on the injector. If the fittings are tubes. Refer to “INJECTOR FUEL TUBES" damaged they must be replaced, Itnotdone, fuel (on page 85 for procedure. leaks gan result 2. Plug and cap ail orfices or openings to prevent contamination. 8. Loosen and remove the fuel injector clamp 8. Remove the plastic protective cap from each internat hex bolt (4) and washer (5). injector boing serviced. Loosen and remove «6, Remove the tue! injector retaining clamp (6). e Injector electrical terminal retaining nuts 7. Pull the fuel injector (7) out the injector bore . of the cylinder head. 4. Remove the fuel return tubes (8) trom each etyieve the injactor nozzle copper sealing injector being serviced, Inspect the fuel retum tubes and replace as necessary. gasket (6). 9, Place each part in a new airtight plastic bag immediately efter removal to prevent contamination. Page 100ee REPAIR INSTRUCTIONS Installation 3. Install the injector retaining clamp (6). , inj inte When removing o replacing fuel injectors, new # Tatiana weston teh rghten tre clan inlector nozzle copper sealing gaskets (8) must internal hex bolt to 44 +7 lott (6049 Nem), " 5. Position the electrical hamess terminals Replace the fuel return tubes (2) as necessary onto the terminals of the fuel injector. Install with new return tubes during installation. and tighten the retaining nuts to 92 [bin 1, Install a new injector nozzle copper sealing (140.2 Nem). ‘washer into the injector bore of the cylinder head. NOTE 2. Insert the fuel injector (7) into the injector Hold the electrical terminals of the hamess bore of the cylinder head. Push in uni uly securely when lightening the retaining nuts to Seated, prevent terminal damage. HIGH-PRESSURE PUMP Figure 185 — Fuel injection System Components Page 101és REPAIR INSTRUCTIONS Removal 13. Using tool J 38047, turn the engine In the til tr 4. Remove the high-pressure tubes (1) the favhee! appea Fotation until ine target on between the high-pressure pump and through the speed sensor bore on the common tall. Refer to "HIGH-PRESSURE fiywhget hous RAIL FEED TUBES" on page 97 for ‘a procedure. 2, Remove the fuel tubes (2) from the fuel metering housing on the high-pressure pump. 3, Remove the rail return tube (3) from the fiting on the fuel metering housing on the high-pressure pump. Refer to "RAIL RETURN TUBE” on page 98 for procedure, 4. Loosen and unscrew the low-pressure polyamide tube couplings that secure the tube between the manual fuel hand priming pump and prefilter and the booster pump. 5. Plug and cap all orifices and openings to prevent contamination. 6. Disconnect the speed sensor connector and the solenoid valve harness connectors (4) from the high-pressure pump. 7. Remove the solenold valve hamess clamp bolt and clamp (5). Figuro 186 — Target Mark Appears in Speed Sensor 8. Remove the bolt securing the high-pressure Boro of Flywheel Housing pump speed sensor to the pump, and then Temave the speed sensor and shims. LEReSEee [> aston Frees 9. Disconnect the harness connactor from the 2. Fiywheot Housing sing. speed gensor on anes ae ensor 14, Using too! J 38047, tum the engine in the flywheel housing, and the ‘normal direction of rotation and count two the Speed senso holes from the target on the flywheel through the speed sensor bore in the flywheel 10. Place each part in a new airtight plastic bag housing. coreaaton Tomoye 9 Prevent 16. In this position, the woodrulf Key on the pump shaft is facing upwards. This prevents 44, Remove the cylinder head cover retaining the Key from falling Inte the timing gear nuts and sealing gaskets. Remove the housing during drive gear removal, cylinder head cover. 12, Using too! J 38047, turn the engine in the normal direction of rotation until cylinder No. 1 is at TDC of the combustion stroke (balance with cylinder No. 6 at TDG of exhaust stroke). Target on flywheel should appear In speed sensor bore of flywheel housing, Page 102REPAIR INSTRUCTIONS sree Figure 157 — Idler Gear and High-Pressure Pump Drive ‘Gear Timing barks Timing Wats 16. 7. 18. 19. 20, 24. 22, Loosen the breather hose clamp, and then temove the breather hose from the fitting on the crankcase breather cover. Remove the elght capscrews securing the crankcase breather cover, and then remove the cover to gain acoass to the breather impeller and the high-pressure pump drive gear (6). Remove the breather impeller screws and impetier. Refer to "Timing Components and Camshaft” on page 41 for removal procedures, cautions and notes regarding the breather impeller. Hf not already marked or no timing marks exist, mark (1) the idler gear and the high- pressure pump drive gear as Indicated in Figure 157. Loosen, but do not remove, the pump drive gear retaining nut. Place a small 5 mm bolt (cut approximately 5 mm below the head of the bolt) into the ‘end of pump shaft (A). This is done to protect the shaft during gear removal. Remove the gear retaining nut. 23, Using puller tool 1115 (see "ENGINE CHARACTERISTICS AND SPECIFICATIONS’ on page 118 or use puller J 4558-01, or equivalent), remove the high-pressure pump drive gear. NOTE Early engine models may not have the two drive gear pulling holes. In this case, locally Manufacture a puller to remove the gear using the three impetter hoes, NOTE Do not rotate the engine unti the high-pressure pump drive gear Is reinstalied. Figure 168 — Removing High-Proscure Pump Drive Gear 24, Remove the high-pressure pump retaining bolts and nut. The three bols are located inside the timing cover and the nut is focated ‘on the pump side of the timing cover plate. 25, Remove the high-pressure pump. Page 103,REPAIR INSTRUCTIONS installation 10. Replace the oil fill plug sealing gasket and 1. Itany major high-pressure pump tighten to 26 + 4 tb-ft (85 +5 Nem). ‘components are removed, replace all associated O-tings, sealing washers and gaskets with new items. 2. Oil the O-rings before installation. 3. Install the high-pressure pump, locating it ‘over the stud on the timing cover mounting plate, 4, Install the three pump retaining bolts through the timing cover opening and install the nut onto the stud. Tighten the pump bolts and nut to 44 +9 fb-ft (60 + 42 Nem). Tighten in a. criss-cross pattem until torque specification is reached. 5. Install the high-pressure pump drive gear ‘onto the shail of the pump. Make sure to align the key on the shatt with the slot on the gear. 6. Align the timing marks made before sorésea removal. 7 Install and tighten the pump drive gear nut to Figure 159— High-Pressure Purp Oil Fill Location 133-155 Ib-ft (180-210 Nem). Instail and tighten the breather impelier (refer to*Timing 11. Reinstall all high-pressure and low-pressure Components and Camshaft’ on page 41 for {uel lines and tubes. Tighten to specttication. procedure). 12. Reinstail the cylinder cover ang tighten the 8. Apply high temperature silicone sealant to fasteners to specification. the crankcase breather cover. Install the 13. Reinstall the speed sensors and associated cover bolts and tighten to specification. harness connectors. Reinstall solenoid valve Install the breather hose and tighten the hatness connectors. amp to specification. Samp to Specteat 14, Bleed the fuel system. Refer to “BLEEDING 9, Remove the oil fl plig (1) from the pump THE FUEL SYSTEM" on page 93 for (refer to Figure 159). Fill the high-pressure procedure. pump with 0.24 quarts (0.2 fters) of specified engine oll through the fill hole. Page 104a REPAIR INSTRUCTIONS CHECKING HIGH-PRESSURE PUMP SYNCHRONIZATION NOTE The high-pressure pump incorporates two three- lobed triangular-shaped pistons (similar to camshaft iobes) for a total of six lobes. The two three-lobed pistons are driven by the pump shaft and are offset from each other 60 degrees. The six jobes of the two pistons correspond to the six cylinders of the engine. When the engine is running, high-pressure pulses occur in the high- pressure circuit of the fuel system due to these six lobes. In order to make suse that the fuel received by each cylinder from the fuel Injectors is as consistent and equal as possible and that ‘optimum engine performance is achieved, the synchronization of these six lobes at their high point must correspand to the fuel injection cycle ‘of each cylinder. if synchronization of the high- pressure pump and engine is not performed, reduced engine performance and fuei economy ‘can occur. Perform high-pressure pump synchronization as follows (HP pump serial No. less than 182): 1, Disconnect the hamess connectors, and then remove the flywheel speed sensor and the high-pressure pump speed sensor. 2, Remove the cylinder head cover retaining nuts and sealing gaskets. Remove the cylinder head cover. 3. Using too! J 38047, tum the engine in the normal direction of rotation until cylinder No. 1 is at TOG of the combustion stroke (balance with cylinder No. 6 at TDG of ‘oxhaust stroke). Target on flywheel should appear in speed sensor bore of flywheel housing. 4. Using tool J 38047, turn the er normal direction of rotation until the target on the flywheel appears for the second time through the speed sensor bore on the flywheel housing. 059728 Figure 160— Target Mark Appears in Speed Sensor Bore of Flywheel Housing 7, Speed SonsorBore | & Target on Fipwheal 2. Fijheel Housing 5. Using tool J 88047, turn the engine in the normal direction of rotation and count 22 holes from the target on the flywheel. 6. Check that the high-pressure pump target is centered in the speed sensor bors of the pump. NOTE The TDC position of cylinder No. 1 is located at the 36th hole after the target hole, Page 105REPAIR INSTRUCTIONS seantsa Figure 161 — Target Mark Appears in Speed Sensor Bore of High-Pressure Pump 1, Speed Sonsor Bore Pump Target 2. High-Prossure Pump Page 106 Perform high-pressure pump synchronization as follows (HP pump serial No. 182 and higher): 1. Remove the rocker cover. 2. Turn the engine in direction of rotation using engine barring tool J 38047. (No. 1 cylinder Is in compression when there is valve lash ‘on No, 7 and No. 6 rockers when in balance.) 3. Remove the high-pressure pump speed sensor. 4, When the pump is property timed, the pump target (scribe mark} should be in the middle of the opening, NOTE If the mark is not in the speed sensor opening, femove the high-pressure gear and time the pump until the mark is in the middle of the sensor ‘opening.ae REPAIR INSTRUCTIONS COMMON RAIL Figure 162 — Common Rall and Fuel Tubes ‘The numbers in the text refer to Figure 162. Removal 1, Remove the high-pressure tubes (1), between the high-pressure pump and ‘common ral. Refer to "HIGH-PRESSURE RAIL FEED TUBES” on page 97 for procedure. 2. Remove the injector fuel tubes (2, 8, 4) between the common rail and the Injectors. Refer to"INJECTOR FUEL TUBES" on page 95 for procedure. 3, Remove the rail retum tube (6), between the ‘common rail and fuel metering housing fitting. Refer to “RAIL RETURN TUBE” on, page 98 for procedure. ‘4, Plug and cap all orifices and openings to prevent contamination. 5, Disconnect the hamess connector from the {uel ral pressure sensor (6). 6. Remove the nuts (7) securing the common rail (9) and bracket plate (8). Remove the bracket plate and common rall. 7. Place each part in a new airtight plastic bag Immediately after removal to prevent contamination. Installation Posttion the common rail {9) and then the bracket plate (8) onto the locating studs of the engine block. Install the nuts (7) and tighten to standard specification. |. Fleconnect the hamess connector to the fuel rail pressure sensor (6). Install the rail return tube (5), between the common rail and fuel metering housing fitting, Refar to "RAIL RETURN TUBE” on page 98 for procedure. . Install the injector fuel tubes (2, 3, 4) between the common rail and the injectors. Refer to “INJECTOR FUEL TUBES" on page 95 for procedure. Install the high-pressure tubes (1) between the high-pressure pump and common rail. Refer to ‘HIGH-PRESSURE RAIL FEED ‘TUBES’ on page 97 for procedure. . Bleed the fuel system. Refer to “BLEEDING THE FUEL SYSTEM" on page 93 for procedure. eT Page 107REPAIR INSTRUCTIONS FUEL RAIL FLOW LIMITER Figure 163 — Fuel Rail Flow Limiters, Fuel Rall Pressure Sensor and Residual Pressure Valve ‘The numbers in the text refer to Figure 183, Removal 1. Remove the injector fuel tubes as necessary to gain access to the flow limiters being serviced, Refer to "INJECTOR FUEL TUBES" on page 95 for procedure. Remove the necessary flowy limiters (1) from the common rail as needed. Plug and cap all orifices and openings to prevent contamination. Place each part in a new airtight plastic bag immediately after removal to prevent contamination. Instaliation 1. Install the flow limiters (1) by screwing into the common rail. Tighten the flow limiters to 63-4 Ib-ft (855 Nem). {nstalt the injector fuet tubes as necessary. Refer to “INJECTOR FUEL TUBES" on page 95 for procedure. Bleed the fuel system. Rofer to “BLEEDING ‘THE FUEL SYSTEM" on page 9 for procedure. Page 108 FUEL RAIL PRESSURE SENSOR (FUEL HIGH-PRESSURE SENSOR) ‘The numbers in the text refer to Figure 163. Removal 1 2. Disconnect the harness connector from the fuel rail pressure sensor (2). Unscrew the fuel rail pressure sensor (2) while holding the fitting (3) on the common rall Plug and cap ll orifices and openings to prevent contamination, Place each part in a new airtight plastic bag immediately ater removal to prevent contamination. Installation 1. Screw the fuet rail pressure sensor (2} into 2 3. place on the fitting of the common rail Tighten the fuel rail pressure sensor to 334 ib-ft (45:45 Nem). Biced the fuel system. Refer to “BLEEDING ‘THE FUEL SYSTEM” on page 93 for procedure.ae» REPAIR INSTRUCTIONS RESIDUAL PRESSURE VALVE 2. Plug and cap all orifices and openings to ‘The numbers in the text refer to Figure 163. prevent contamination, 3. Place each pat in @ new airtignt plastic bag NOTE immediately after removal to prevent contamination Residual pressure valves are not available separately. Installation a —__ 1, Install the residual pressure valve into the fuel metering housing and tighten to standard specification, 1. Remove the residual pressure valvo (4){rom >. Blogd the fuel system. Refer to "BLEEDING the fuel metering housing on the high- THE FUEL SYSTEM" reasure pump. procedure. on page 93 or Removal SPEED SENSORS, BOOST PRESSURE AND AIR TEMPERATURE SENSOR Figure 164 — Sensor Locations‘The numbers in the text refer to Figure 164. Removal Disconnect the hamess connectors as necessary, fo remove the required sensor. Remove the bolt(s) (1) as necessary, to enable required sensor removal. 3, Remove the required sensor(s) (3). 4, The high-pressure pump speed sensor has a shim(s) (4) between tha sensor and the pump. Retain the shim(s) for reuse. 5. Remove and discard the O-ting (6) as requlred, from each sensor that is removed. Installation 1. Lubricate and install new O-rings (6) as required for each sensor removed. 2. When Installing the high-pressure pump speed sensor, make sure to install the original shim(s) (4) that-came with the sensor. 3. Install each sensor as required, into its proper location. 4, install the bolt(s) (1) as required to secure each sensor removed. Tighten the sensor bolt{s) to the following torque specification: © Speed sensors = 60 + 12 tbsin (541.5 Nem) ‘* Boost pressure and ait temperature sensor = 66: 12 Ib-in (7.5 + 1.5 Nem) NOTE The air gap of the speed sensors is not adjustable, but can be checked for depth. ENGINE ELECTRONIC CONTROL UNIT (EECU) Removal SERVICE HINT This procedure can be made easier by loosening the battery hold down and sliding the batteries back, 4. Loosen and remove the boits (1) securing the EECU to the battery box. There are four bolt iocations, one in each comer of the EECU. REPAIR INSTRUCTIONS 2. Grasp the hamess connector looking atoh and pull to disengage and remove the connector, Perform on bath harness connectors. Figure 168 — Engine Electronic Controf Unit Installation 1. Place the harness connectors into position on the EECU. Grasp the harness connector locking latches and press until each ‘connector and latch are fully locked in place, 2. Place the EECU into position in the battery box. install the four bolts (1) and tighten to standard specification, FUEL FILTER CHANGE PROCEDURE in order to ensure fuel system cleanliness, the following procedure must be used when changing the fue! fitters: 1. Remove the old fuel filters. 2. Use a lint-free cloth or towe! to clean the fuel filter sealing surfaces of the filter head. 3. Lubricate the seals on the new fuet filters with clean engine ail. 4, install the new fuel fitters DRY, Do not pret! the filters with diesel fuel. 5. Bleed the fuel system. Refer to “BLEEDING THE FUEL SYSTEM" on page 93 for procedure. Page 110