Index Page 3 Rocker Lever Housing - Installation ....................................... 0-111 Rocker Lever Side Clearance - Adjustment ........................... 0-114 Sensor Harness - Installation................................................ 0-123 Starting Motor - Installation ................................................... 0-131 Static Injection Timing - Checking .......................................... 0-97 Static Injection Timing - General Information .......................... 0-96 Thermostat Housing - Installation.......................................... 0-142 Thermostat Housing Support - Installation ............................
0-135 Thrust Bearings, Lower Bearing Shells and Main Bearing Caps - Installation................................................................... 0-57 Torque Convertor Cooler Disc - Installation............................ 0-141 Turbocharger - Installation..................................................... 0-140 Turbocharger Drain Fitting - Installation................................. 0-140 Upper Main Bearing Shells - Installation................................. 0-56 Vibration Damper and Crankshaft Pulley - Installation ........... 0-109 Vibration Damper Eccentricity - Measurement ....................... 0-110 Vibration Damper Face - Runout Measurement .....................
0-110 Viscosity Sensor - Installation ................................................. 0-62 Water Filter Head - Installation.............................................. 0-134 Water Header Plate - Installation........................................... 0-134 Water Heater Housing - Installation....................................... 0-134 Water Pump - Installation...................................................... 0-135 Engine Diagrams ....................................................................... E-6 Engine Disassembly ................................................................ 0-12 Accessory Drive Assembly - Removal .....................................
0-38 Accessory Drive Oil Seal - Removal........................................ 0-38 Accessory Drive Pulley - Removal........................................... 0-37 Air Compressor - Removal...................................................... 0-25 Air Compressor Air Supply Tube - Removal ............................ 0-24 Air Compressor Coolant Tubes - Removal............................... 0-26 Air Intake Manifold - Removal................................................. 0-17 Alternator Adjusting Link (Non Bus Applications) - Removal.... 0-15 Alternator and Bracket (Non Bus Applications) - Removal....... 0-15 Alternator and Brackets (Bus Applications) .............................
0-16 Alternator Belt (Bus Applications) - Removal........................... 0-15 Alternator Belt (Non Bus Applications) - Removal ................... 0-14 Alternator Drive Oil Seal - Removal ........................................ 0-19 Alternator Drive Pulley - Removal ........................................... 0-19 Block Mounted Front Sump Suction Tube - Removal .............. 0-33 Cam Follower Assemblies - Removal ...................................... 0-32 Camshaft - Removal............................................................... 0-40 Coolant - Draining ..................................................................
0-12 Coolant Filter - Removal ......................................................... 0-13 Crankshaft and Upper Main Bearing Shells - Removal ........... 0-46 Crankshaft Front Oil Seal - Removal....................................... 0-39 Crankshaft Pulley and Vibration Damper - Removal................ 0-38 Crankshaft Rear Oil Seal - Removal ....................................... 0-35 Crossheads - Removal............................................................ 0-31 Cylinder Head - Removal........................................................ 0-31 Cylinder Liners - Removal ......................................................
0-47 Electronic Control Cooling Plate - Removal............................. 0-24 Electronic Control Module - Removal...................................... 0-23 Engine - Cleaning................................................................... 0-12 Engine - Installation On Rebuild Stand ................................... 0-22 Engine - Preparation for Cleaning........................................... 0-12 Engine Barring Tool - Installation ............................................ 0-42 Exhaust Manifold - Removal ................................................... 0-17 Fan and Fan Hub - Removal...................................................
0-14 Fan Drive Belt - Removal........................................................ 0-13 Fan Hub Support - Removal ................................................... 0-23 Flywheel - Removal ................................................................ 0-34 Flywheel Housing - Removal .................................................. 0-35 Flywheel Housing, REPTO - Removal..................................... 0-35 Front Engine Support Bracket - Removal ................................ 0-39 Fuel Filter - Removal .............................................................. 0-13 Fuel Lines - Removal..............................................................
0-25 Fuel Pump - Removal............................................................. 0-25 Fuel Supply Hose and Filter Head - Removal ......................... 0-23 Gear Cover - Removal ............................................................ 0-39 Gear Housing - Removal......................................................... 0-41 Hand Hole Cover and Dipstick Tube Bracket - Removal .......... 0-21 Hand Hole Cover (Fuel Pump Side) - Removal ....................... 0-26 High Oil Pressure Regulator - Removal .................................. 0-47 Hydraulic Pump Drive - Removal ............................................
0-26 Hydraulic Pump or Cover - Removal....................................... 0-26 Idler Gear Assemblies - Removal............................................ 0-39 Injectors - Removal................................................................. 0-31 Internal Actuator Harness - Removal....................................... 0-29 Jacobs W Engine Brake - Removal .......................................... 0-28 Lifting Brackets - Removal...................................................... 0-22 Lubricating Oil - Draining........................................................ 0-12 Lubricating Oil Cooler - Removal ............................................
0-18 Lubricating Oil Filter Head - Removal ..................................... 0-18 Lubricating Oil Filters - Removal............................................. 0-13 Lubricating Oil Pan - Removal ................................................ 0-33 Lubricating Oil Pump - Removal ............................................. 0-40 Lubricating Oil Transfer Tube - Removal.................................. 0-33 Main Bearing Caps, Lower Bearing Shells and Thrust Bearings - Removal ................................................................ 0-44 Main Oil Pressure Regulator - Removal ..................................
0-46 Piston Cooling Nozzles - Removal .......................................... 0-42 Pistons and Connecting Rods - Disassembly.......................... 0-48 Pistons and Connecting Rods - Removal................................ 0-42 Push Rods - Removal............................................................. 0-30 Rocker Lever Assemblies - Removal....................................... 0-30 Rocker Lever Cover - Removal ............................................... 0-27 Rocker Lever Housing - Removal............................................ 0-31 Rocker Lever Housing Spacer - Removal................................
0-28 Sensor Harness and Sensors - Removal................................. 0-27 Starting Motor - Removal........................................................ 0-24 Thermostat Housing - Removal............................................... 0-18 Thermostat Housing Support - Removal ................................. 0-20 Torque Converter Cooler Disc - Removal ................................ 0-18 Turbocharger - Removal.......................................................... 0-16 Turbocharger Oil Drain Connection - Removal ........................ 0-21 Viscosity Sensor - Removal ....................................................
0-46 Water Filter Head - Removal................................................... 0-21 Water Header Plate - Removal................................................ 0-21 Water Heater Housing - Removal............................................ 0-20 Water Pump - Removal........................................................... 0-20 Engine Disassembly and Assembly - General Information .... 0-10 Assembly................................................................................ 0-10 Disassembly ........................................................................... 0-10 Engine Lifting Brackets ...........................................................
0-11 Engine Dynamometer - Install Engine .................................. 14-22 Air Compressor ................................................................... 14-28 Air Inlet Restriction .............................................................. 14-25 Coolant Plumbing ................................................................ 14-22 Engine Blowby .................................................................... 14-26 Engine Speed (RPM) With a Verified Tachometer ................ 14-27 Engine Throttle Control ........................................................ 14-29 Exhaust Restriction .............................................................
14-25 Fuel Drain Line Restriction .................................................. 14-28 Fuel Inlet Restriction ........................................................... 14-27 Fuel Pressure ...................................................................... 14-27 Fuel Rate ............................................................................ 14-26 Intake Air Temperature Control ............................................. 14-23 Intake Manifold Pressure ..................................................... 14-26 Lubricating Oil Pressure ...................................................... 14-25 Lubricating Oil Temperature..................................................
14-25 Starting Motor ..................................................................... 14-29 Engine Identification ................................................................. E-2 Electronic Control Module (ECM) Dataplate ............................. E-2 Engine Dataplate .................................................................... E-2 Engine Painting ..................................................................... 14-50 Engine Run-In Procedure - Chassis Dynamometer ............. 14-46 Engine Run-In Procedure - Engine Dynamometer .............. 14-33 Engine Run-In Procedure - Without Dynamometer .............
14-49 On-Highway ......................................................................... 14-49 Engine Specifications ............................................................... E-3 Air Intake System .................................................................... E-4 Batteries (Specific Gravity)....................................................... E-5 Cooling System ...................................................................... E-4 Electrical System .................................................................... E-5 Exhaust System ......................................................................
E-4 Fuel System ............................................................................ E-5 General Engine Data .............................................................. E-3 Lubricating Oil System ............................................................ E-4 Engine Storage - Long Term .................................................. 14-53 Remove the Engine From Long Term Storage....................... 14-56 Engine Storage - Short Term ................................................. 14-51 Remove the Engine From Short Term Storage ...................... 14-53