Service manual
ENGINE
DISASSEMBLY
DISASSEMBLING
THE
MAIN
ENGINE
With the transmission/or generator separated from the
engine, begin the following step by step procedure to
disassemble the engine.
NOTE:
Mount
the
engine
on
a suitable stand or work
bench.
1.
Remove the transmission
damper
plate from the
engine flywheel.
C
O~~
~
i~O~
~t~
o 0
DAMPER
PLATE
BOLTS
2.
Remove the engine oil cooler
and
oil hoses. Note oil
hose connections from the oil cooler to the engine.
3. Remove
the
engine
heat
exchanger.
If
possible, leave
one end
of
each hose connected to the part being
removed.
4. Remove the bell housing (propulsion engine) and the
circuit breaker/preheat solenoid mounting bracket.
5. Loosen the front crankshaft pulley bolt and remove
the
flywheel.
WHEN
REMOVING
THE
MOUNTING
BOLTS
LOCK
THE
FLYWHEEL
WITH
A
RING
GEAR
BREAK
TOOL
6.
Remove
the
engine
back
plate.
ONE
BOLT
DEVIATES
!J'
FROM
THE
6(J'
SET
UP
7.
Remove
the
start
motor, drive belt
and
the alternator.
Label the wires and cables.
8. Remove the engine mounted
raw
water
pump,
adap-
tor
mounting plate,
and
drive from the front cover.
The drive is removed by turning in a counter clockwise
direction.
See RAW
WATER
PUMP for parts breakdown.
9.
With the hoses disconnected, remove the thermostat
housing
and
housing gasket, leaving the temperature
sender in place.
10. Remove the coolant recirculating
pump.
See
COOLANT RECIRCULATING PUMP for parts break-
down.
11.
Remove the
air
intake silencer
and
the intake manifold.
12. Remove the oil filter
and the oil cooler mounting bracket
from the engine block.
PLUNGER
3
SPRING
__
O-RING
__
PLUG_
13. Unbolt the elbows and remove the exhaust
manifold
in its entirety.
Injection
Pumpnnjectors
Disassembly
OIL
FILTER
14. Detach
aU
the high pressure injection lines from the
injection pump to the injectors. Leave the two upper line
clamps in place.
NOTE:
Cap
the
ends
of
the
lines
and
the
connections at
the
injection pump and at the injectors
to
prevent entry
of
foreign material.
15.
Remove the fuel
return
line from the top
of
the injec-
tors
and
from the fuel injection
pump
by removing the
four 12
mm
attaching bolts. (Note the washer arrange-
ment on fuel return line banjo bolts. Cap all the openings
on the fuel return line, injectors and injection pump.)
Engines & Generators
9