Engine Rebuild Guide/6076 Engine Assembly Sequence 6076 ENGINE ASSEMBLY SEQUENCE The following assembly sequence is suggested when engine has been completely disassembled. Be sure to check run-out specifications, clearance tolerances, torques, etc., as engine is assembled. Refer to the appropriate repair group when assembling engine components. 12. Install flywheels: SAE 1 or SAE 2: Flywheel goes on before housing. SAE 3: Housing goes on before flywheel. 1. Install all plugs in cylinder block that were removed to service block. Install engine serial number plate. 13. Install cylinder head, push rods, and rocker arm assembly. Measure valve lift and adjust valve clearance. 2.
Install clean piston cooling orifices. 14. Install rocker arm cover. Install breather hose. 3. Install cylinder liners without O-rings and measure liner stand-out. Install liner O-rings in block and packings on liners. Install liners. 15. Install exhaust manifold and water manifold. 04 4 NOTE: If new piston and liner kit assemblies are being installed, install the crankshaft first. 16. Install timing gear cover. Install front crankshaft wear sleeve and oil seal. 17. Install air intake manifold. 4. Install main bearings and crankshaft. Rotate crankshaft to assure correct assembly. Check crankshaft end play. 18. Install aftercooler assembly on 6076A Engines. 5.
If installing new piston/liner kits, assemble the respective connecting rods. 19. Install turbocharger with elbow and oil lines. 20. Install water pump. 6. Install engine oil pump assembly. 21. Install injection nozzles and line assembly. 7. Install crankshaft rear oil seal housing, oil seal, and wear sleeve. 22. Install front pulley and damper as an assembly. 8. Install cam followers in hole from which originally removed. 23. Install alternator. Install fan pulley assembly. 24. Install fuel filter base, supply lines, and filter. 9. Install camshaft. Align timing marks (camshaft to crankshaft gears) with No. 1 piston at TDC compression stroke. 25.
Fill engine with clean oil and the proper coolant. Install dipstick. 10. Install fuel injection pump and drive gear. 26. Perform engine break-in and normal standard performance checks. 11. Install engine oil conditioning assembly, if removed. CTM42 (24MAR95) 04-4 6076 Diesel Engines—S.N. (500000— ) RG,CTM42,G4,3 -19-14FEB95 160101 PN=43