Disassembly and assembly

Table of Contents
Disassembly and Assembly Section
Inspection of Parts ................................................5
Fuel Priming Pump - Remove and Install ..............10
Flow Control Valve - Remove and Install ..............12
Fuel Filter Base - Remove and Install ...................13
Water Separator and Fuel Filter (Primary) - Remove
and Install .........................................................17
Fuel Manifold (Rail) - Remove and Install ..............20
Fuel Injection Lines - Remove .............................22
Fuel Injection Lines - Install .................................25
Exhaust Cooler (NRS) - Remove and Install ..........28
Throttle Valve (Intake Air) - Remove and Install (Rear
Facing Inlet Elbow) ............................................30
Throttle Valve (Intake Air) - Remove and Install (Side
Facing Inlet Elbow) ............................................32
Fuel Injection Pump - Remove .............................34
Fuel Injection Pump - Install ................................36
Fuel Injection Pump Gear - Remove .....................38
Fuel Injection Pump Gear - Install .........................39
Electronic Unit Injector - Remove..........................40
Electronic Unit Injector - Install .............................42
Turbocharger - Remove (Top Mounted
Turbochargers)..................................................44
Turbocharger - Remove (Side Mounted
Turbochargers)..................................................46
Turbocharger - Install (Top Mounted
Turbochargers)..................................................48
Turbocharger - Install (Side Mounted
Turbochargers)..................................................51
Wastegate Solenoid - Remove and Install .............54
Exhaust Gas Recirculation Valve - Remove and
Install ...............................................................55
Flexible Exhaust Pipe - Remove and Install ...........59
Exhaust Manifold - Remove and Install ................63
Diesel Particulate Filter - Remove (Through Flow
Diesel Particulate Filter) .....................................66
Diesel Particulate Filter - Remove (Wall Flow Diesel
Particulate Filter) ...............................................67
Diesel Particulate Filter - Install (Through Flow Diesel
Particulate Filter) ...............................................69
Diesel Particulate Filter - Install (Wall Flow Diesel
Particulate Filter ) ..............................................71
Support and Mounting (CEM) - Remove and Install
(Option 3) .........................................................73
Support and Mounting (CEM) - Remove and Install
(Option 2) .........................................................75
Support and Mounting (CEM) - Remove and Install
(Option 1) .........................................................76
Inlet Manifold - Remove and Install ......................78
Inlet and Exhaust Valve Springs - Remove and
Install ...............................................................81
Inlet and Exhaust Valves - Remove and Install.......83
Inlet and Exhaust Valve Guides - Remove and
Install ...............................................................86
Engine Oil Filter Base - Remove and Install ..........88
Engine Oil Cooler - Remove.................................89
Engine Oil Cooler - Install ....................................91
Engine Oil Relief Valve - Remove and Install .........92
Engine Oil Pump - Remove..................................93
Engine Oil Pump - Install......................................93
Water Pump - Remove ........................................94
Water Pump - Install ............................................95
Water Temperature Regulator - Remove and
Install ...............................................................96
Engine Lifting Bracket - Remove ..........................98
Engine Lifting Bracket - Install ..............................99
Flywheel - Remove............................................ 101
Flywheel - Install ............................................... 102
Crankshaft Rear Seal - Remove and Install ......... 103
Flywheel Housing - Remove and Install (Stressed
Cylinder Block) ................................................ 105
Flywheel Housing - Remove and Install (Non-
Stressed Cylinder Block) .................................. 107
Power Take-Off Drive - Remove and Install ........ 110
Crankshaft Pulley - Remove and Install .............. 113
Crankshaft Front Seal - Remove and Install......... 114
Front Cover - Remove and Install ....................... 116
Idler Gear - Remove .......................................... 118
Idler Gear - Install.............................................. 120
Housing (Front) - Remove.................................. 121
Housing (Front) - Install ..................................... 123
Accessory Drive - Remove and Install ................ 126
Crankcase Breather - Remove ........................... 128
Crankcase Breather - Install............................... 128
Valve Mechanism Cover - Remove and Install ..... 129
Rocker Shaft and Pushrod - Remove .................. 132
Rocker Shaft - Disassemble .............................. 134
Rocker Shaft - Assemble .................................. 134
Rocker Shaft and Pushrod - Install...................... 135
Cylinder Head - Remove.................................... 137
Cylinder Head - Install ....................................... 139
Lifter Group - Remove and Install ....................... 142
Camshaft - Remove and Install .......................... 143
Camshaft Gear - Remove and Install ................. 145
Camshaft Bearings - Remove and Install ............ 147
Engine Oil Pan - Remove and Install (Pressed Steel
Oil Pan) .......................................................... 148
Engine Oil Pan - Remove and Install (Cast Iron
Engine Oil Pan) ............................................... 150
Balancer - Remove............................................ 154
Balancer - Install ............................................... 155
Piston Cooling Jets - Remove and Install ............ 157
Pistons and Connecting Rods - Remove ............. 158
Pistons and Connecting Rods - Disassemble ...... 160
Pistons and Connecting Rods - Assemble........... 161
Pistons and Connecting Rods - Install................. 162
Connecting Rod Bearings - Remove (Connecting
rods in position)............................................... 164
Connecting Rod Bearings - Install (Connecting rods
in position) ...................................................... 165
Crankshaft Main Bearings - Remove and Install .. 166
Crankshaft - Remove......................................... 169
Crankshaft - Install ............................................ 171
Crankshaft Timing Ring - Remove and Install ...... 172
Bearing Clearance - Check ................................ 173
Camshaft Position Sensor - Remove and Install .. 175
Crankshaft Position Sensor - Remove and Install. 176
Coolant Temperature Sensor - Remove and
Install ............................................................. 177
Engine Oil Pressure Switch - Remove and Install 178
Fuel Temperature Sensor - Remove and Install ... 179
Oxygen Sensor - Remove and Install (Catalytic
Converter) ...................................................... 181
Temperature Sensor (Exhaust) - Remove and
Install ............................................................. 182
UENR0624-03 3
Table of Contents
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