1997 2003 Dt444 Engine Service Manual PDF

SERVICE MANUAL
SERVICE MANUAL
Due to a continuous program of research and development, some procedures, specifications and parts may be altered in
a constant effort to update and improve our products.
Periodic revisions may be made to this publication and mailed automatically to dealers. It is recommended that customers
contact their dealer for information on the latest revision.
INTERNATIONAL T 444E
DIESEL ENGINE
SERVICE MANUAL
MODEL YEARS LATE 1997-2003
SERIAL NUMBER 634234 AND UP
INTERNATIONAL T 444E
FORM EGES-205
DIESEL ENGINE
EGES205, OCTOBER 2003
MODEL YEARS 1997-2003
2003 International Truck and Engine Corporation

Printed in the United States of America
ENGINE SERVICE MANUAL I
Table of Contents
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Mounting Engine On Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Cylinder Head And Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Oil Pan, Vibration Damper, Oil Pump Water Pump, And Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Valve Train: Push Rods, Hydraulic Valve Lifters And Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Crankcase, Crankshaft, Connecting Rods, And Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Thermostat And Coolant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
Oil Cooler And Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
High-pressure Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
Appendix A Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
Appendix B Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Appendix C Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
EGES-205
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
II ENGINE SERVICE MANUAL
EGES-205
ENGINE SERVICE MANUAL 1
Foreword The following literature supporting International

Diesel Engines is available from:
This publication provides general and specific service
procedures and repair methods essential for reliable International Truck and Engine Corporation
engine operation and your safety. Since many Printing & Distribution Center
variations in procedures, tools, and service parts are 61 Clark Road North
involved, advice for all possible safety conditions and Battle Creek, Mich. 49015
hazards cannot be stated. (269) 9684856
Departure from instructions in this publication or 1171737R7 T 444E Diesel Engine Operation and
disregard of warnings and cautions can lead to injury Maintenance Manual
or death, or both and damage to the engine or vehicle. EGES-1201 T 444E Diesel Engine Service Manual
19941997, S/N 634233 And DOWN
Read safety instructions below before doing service
EGES-205 T 444E Diesel Engine Service Manual
or test procedures in this publication for the engine
19972003, S/N 634234 And UP
or vehicle. See related engine manuals for more
EGES-190 T 444E Diesel Engine Diagnostic Manual
information.
EGED-140 Supplemental Coolant Level Ref. Chart
Periodic revisions may be made to publications. (for conventional GREEN coolant)
When ordering publications, the latest revision will be EGED-195 Hard Start / No Start Performance
supplied. Diagnostic Form
EGED-200 Electronic Control System Diagnostic
Form
EGES-205
2 ENGINE SERVICE MANUAL
Service Diagnosis It is also very important that specific diagnostic tests

follow engine assembly before and after the engine is
Service diagnosis is a systematic procedure of
placed back into service.
investigation to be followed in order to locate
and correct an engine problem. The engine is Identification of the symptoms which lead to engine
first considered as a complete unit in its specific failure is the result of proper service diagnosis.
application and then the problem is localized to Effective service diagnosis requires use of the
components or systems; intake, exhaust, cooling, following references:
lubrication or injection. Testing procedures will then
Engine Service Manual
help analyze the source of the problem.
Hard Start and No Start Diagnostics
PREREQUISITES FOR EFFECTIVE DIAGNOSIS:
Performance Diagnostics
Knowledge of the principles of operation for both
the engine and application systems Electronic Control Systems Diagnostics
Knowledge to perform and understand all Service Bulletins
procedures in the diagnostic and service
publications NOTE: Metric values precede English values for test
procedures and reference.
Availability of and the ability to use gauges and
diagnostic test equipment
Examples: 96 kPa (14 psi), 20 C (68 F)
Availability of the most current information for the
This publication is arranged in sections. Any photos
engine application
and artwork are also numbered consecutively from
Although the cause of an engine failure may be the beginning of the publication. An index arranged
apparent, very often the real cause is not found until a according to sections is located at the beginning of
repeat failure occurs. This can be prevented if specific the publication.
diagnostic action is taken before, during and after
engine disassembly and during engine assembly.
EGES-205
ENGINE SERVICE MANUAL 3
Safety Information SAFETY INSTRUCTIONS
This manual provides general and specific service Vehicle

procedures and repair methods essential for reliable Make sure the vehicle is in neutral, the parking
engine operation and your safety. Since many brake is set, and the wheels are blocked before
variations in procedures, tools, and service parts are doing any work or diagnostic procedures on the
involved, advice for all possible safety conditions and engine or vehicle.
hazards can not be stated.
Work area
Departure from instructions in this manual or
disregard of warnings and cautions can lead to Keep work area clean, dry, and organized.
injury or death, or both and damage to the engine or Keep tools and parts off the floor.
vehicle.
Make sure the work area is ventilated and well lit.
Read safety instructions below before doing service
and test procedures in this manual for the engine or Make sure a First Aid Kit is available.
vehicle. See related application manuals for more Safety equipment
information.
Use correct lifting devices.
SAFETY TERMINOLOGY Use safety blocks and stands.
Three terms are used in this manual to stress your Protective measures
safety and safe operation of the engine: Warning,
Caution, and Note. Wear protective glasses and safety shoes (do not
work in bare feet, sandals, or sneakers.)
Warning: Signals conditions, hazards, and unsafe
practices that can cause injury or death. Wear correct work clothing.
Caution: Signals conditions and practices that can Do not wear rings, watches, or other jewelry.
cause damage to the engine or vehicle. Restrain long hair.
Note: Signals a key point or procedure that must be
followed for correct, efficient engine operation.
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4 ENGINE SERVICE MANUAL
Fire prevention Tools

Keep a charged fire extinguisher close by. Make sure all tools are in good condition.
Make sure all standard electrical tools are
NOTE: Three kinds of fire extinguishers are required:
grounded.
1. Type A Wood, paper, Textiles, and rubbish
Check for frayed power cords before using power
2. Type B Flammable liquids tools.
3. Type C Electrical equipment Fluids under pressure
Batteries Use extreme caution when working on systems
under pressure.
Batteries produce highly flammable gas during and
after charging. Follow approved procedures only.
Avoid leaning over batteries. Fuel
Protect your eyes. Do not over fill the fuel tank. Over fill creates a fire
hazard.
Do not expose batteries to open flames or sparks.
Do not smoke in the work area.
Do not smoke.
Keep the funnel or nozzle of the hose in solid
Always disconnect the ground cable before
contact with the metal of the fuel tank inlet. Solid
working on the electrical system.
contact will prevent electrical sparks.
Compressed air
Do not refuel the tank when the engine is running.
Limit shop air pressure for blow gun to 207 kPa
Removal of tools, parts, and equipment
(30 psi).
Reinstall all safety guards, shields, and covers
Use approve equipment.
after servicing the engine.
Do not direct air at body or clothing.
Make sure all tools, parts, and service equipment
Wear safety glasses or goggles. are removed from the engine and vehicle after all
work is done.
Use shielding to protect others in the work area.
EGES-205
INTRODUCTION 5
Table of Contents
Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

General Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Chassis Mounted Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Thermostat Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air Induction and Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Injection Control Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Injection Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
IPR Valve Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Fuel Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Component Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Glow Plug Controller System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
EGES-205
6 INTRODUCTION
EGES-205
INTRODUCTION 7
Engine Identification Emission Label

Serial Number Location
The engine serial number is permanently stamped on
the crankcase pad on the lower rear left side of the
engine.
Figure 2 Emission Label Location
The emission label is located on the left valve cover.

The emission label identifies an engines model code,
the year it was manufactured, the year the engine was
certified to meet government emission standards, and
other relevant information. This label exists in multiple
Figure 1 Engine Serial Number Location languages.
Explanation of the Engine Serial Number

7.4 Engine Identification Code
H Type of Code: H=Diesel, turbocharged, air cooled
and electronically controlled
M2 End Use Code: M2=Truck, A2=Stripped and
service
U Country of Origin: U=U.S.A. or
N Country of Origin: N=Brazil (IESA)
XXXXXX Engine serial number sequence
Other nameplates on the turbocharger and auxiliary
devices like the starter provide manufacturer
specifications and inform the operator or maintenance
personnel of the type of equipment that is on the
engine and its range of operating conditions.
EGES-205
8 INTRODUCTION
Engine Component Location
Figure 3 Component Location, (Front View)

1. Lube Oil Fill Tube 5. Water Pump 11. Coolant Temperature Sensor
2. Turbocharger Air Outlet Tube (to 6. Coolant Filter 12. ECM International Diamond
CAC) 7. Crankshaft Vibration Damper Logic
3. High-pressure Pump Oil Pulley 13. Water Pump Pulley
Reservoir 8. Engine Front Mount Support
4. Water Outlet and Thermostat 9. Camshaft Position Sensor
Housing 10. Water Pump Inlet
EGES-205
INTRODUCTION 9
Figure 4 Component Location, (Left Side View)

1. Fuel Filter 5. Road Draft Tube 10. Oil Pan
2. Turbocharger Air Outlet Tube (to 6. Rear Lifting Eye 11. Oil Cooler
CAC) 7. Exhaust Manifold 12. Coolant Filter
3. Turbocharger 8. Rear Engine Mounting Bracket 13. Valve Cover
4. Crankcase Breather 9. Lube Oil Filter 14. Front Lifting Eye
EGES-205
10 INTRODUCTION
Figure 5 Component Location, (Rear View)

1. Turbocharger 4. Right Side Exhaust Tube With 8. Flywheel Housing
2. Turbocharger Exhaust Outlet Bellows 9. Rear Engine Mounting Bracket,
With Optional Exhaust Back 5. Crankshaft Left Side
Pressure Control Valve 6. Rear Engine Mounting Bracket, 10. Left Side Exhaust Tube With
3. ECM International Diamond Right Side Bellows
Logic 7. Fuel Filter Water Drain Tube 11. Rear Lifting Eye
EGES-205
INTRODUCTION 11
Figure 6 Component Location (Right Side View)

1. Air Outlet 7. Oil Level Gauge
2. Fuel Filter Pre-Strainer 8. Coolant Heater Supply
3. Fuel Filter 9. Coolant Heater Return
4. Fuel Pressure Regulator 10. Oil Pan
5. ECM International Diamond 11. Rear Engine Mounting Bracket
Logic 12. Exhaust Manifold
6. Valve Cover 13. Turbocharger
EGES-205
12 INTRODUCTION
Figure 7 Component Location, (Top View)

1. Turbocharger Air Inlet Elbow 6. ECM International Diamond
2. Crankcase Breather Logic
3. Turbocharger Air Outlet Tubes 7. Glow Plug Controller
(to and from CAC) 8. High-pressure Oil Supply
4. High-pressure Oil Supply Manifold, Right Hand Side
Manifold, Left Hand Side (Integral part of cylinder head)
(Integral part of cylinder head) 9. Manifold Absolute Pressure
5. High-pressure Oil Pump Sensor (MAP)
10. Turbocharger Assembly
EGES-205
INTRODUCTION 13
Engine Description The piston pin is a free floating type. It permits the
pin to move or float freely in the piston and connecting
General Features
rod. The piston pin is held in place with two piston pin
The International T 444E diesel is a four stroke retaining rings.
V8 engine. It features overhead valves and is
The camshaft is supported by five insert-type bearings
water-cooled and turbocharged. The engine is
pressed into the crankcase, and is gear driven from
fueled by a direct injection fuel system with electronic
the crankshaft. The end thrust of the camshaft is
sensors and Hydraulically actuated Electronically
controlled by a thrust flange located between the front
controlled Unit Injectors (HEUI). It has a displacement
camshaft journal and the cam gear.
of 7.3 liters (444 cubic inches).
The aluminum-alloy pistons are fitted with two
When viewing the engine from the rear (flywheel end),
compression rings and one oil ring. The top
the right hand bank of cylinders are numbered 1, 3,
compression is a keystone configuration.
5, and 7. Cylinder number 1 is at the front. The
left bank consists of cylinders 2, 4, 6, and 8. In this The hydraulic valve lifters minimize engine noise and
case, cylinder number 2 is at the front. The engines maintain zero valve lash or tappet clearance. This
numerical firing sequence is 12734568. eliminates the need for periodic adjustment of the
valve lash. The hydraulic valve lifters have roller
The International Diamond Logic Electronic
followers which provide excellent camshaft and lifter
Control Module (ECM) monitors and controls engine
durability.
performance to ensure optimal efficiency, and
adherence to emissions standards. The ECM is also The one piece cylinder heads used on the engine are
able to monitor and control vehicle features. equipped with a positive valve rotating mechanism on
both the intake and exhaust valves. This device is
The crankcase has been especially designed to
called a rotator and it is located at the top of each valve
withstand the loads of diesel operation and utilizes a
spring.
four bolt main bearing cap to assure a rigid support
for the rotating parts. The crankcase also has piston An electrically controlled glow plug system provides
oil cooling jets and their function is to direct oil to the outstanding cold weather starting capability. An
underside of the piston to help dissipate heat to the optional block heater is available to warm coolant at
lube oil. extremely cold ambient temperatures below -29 C
(-20 F).
The crankshaft is a five main bearing unit with fore and
aft thrust controlled at the rear (Number 5) bearing. Some of the features incorporated in this series of
engines include a gerotor lube oil pump (driven directly
Connecting rods are attached to the crankshaft. Two
by the crankshaft at engine speed), cast water and oil
connecting rods share each crankpin journal. There
passages in the crankcase and front cover, spin-on
were two types of connecting rods used on this engine
type lube oil filter, fuel filter/strainer assembly, and
for model years 1997 and above. The connecting rods
spin-on type coolant filter.
are easily identified by the way the connecting rod cap
is secured to the connecting rod.
Forged steel connecting rods were used on Chassis Mounted Charge Air Cooler
engines with serial numbers ranging from 634234
The T 444E diesel engine utilizes a charge air cooling
to 1498318. The connecting rod caps are secured
(CAC) system. The cooler is chassis mounted
to the connecting rod with bolts and nuts.
adjacent to the radiator. Air from the turbocharger
Powered metal forged steel connecting rods were is pushed through a network of heat exchanging
used on engines with serial numbers ranging from tubes before entering the intake manifold. Outside air
1498318 and up. The connecting rod caps for flowing over the fins and tubes serves to cool the air
these later style connecting rods are secured with charge. The resulting cooled intake air is denser than
bolts that thread into the connecting rod (no nuts the compressed (warmed) air, allowing for improved
used). fuel/air ratio in the cylinders during the combustion
process. The results are improved emission control
and increased power output.
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14 INTRODUCTION
Cooling System
Figure 8 Engine Coolant Flow Diagram

1. Water Pump 6. Cylinder Head
2. Thermostat 7. Lubricating Oil Filter
3. Outlet Tube 8. Oil Cooler
4. Front Cover 9. Coolant Filter
5. Crankcase 10. Water Pump Inlet
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INTRODUCTION 15
Description Thermostat Operation

The function of the cooling system is to keep the The thermostat incorporates two outlets that work
engine within a designated temperature range. Major independently to channel coolant to two different
components of most cooling systems include a parts of the engine. One outlet carries coolant to the
radiator and fan combination with a water pump, radiator, the other outlet directs coolant back to the
thermostat, oil cooler, and coolant filter. The water water pump.
pump is a belt-driven centrifugal type, which is set
When the engine coolant temperature is below the
into the front cover.
specified thermostat opening temperature, the outlet
The front cover incorporates two separate passages. to the radiator is thermally blocked. This blockage
One passage channels coolant from the water pump forces coolant to flow through the bypass passage
to the crankcase. The other passage is a bypass back into the water pump. As the engine approaches
that routes coolant back to the water pump when the its normal operating temperature, the thermostat
thermostat is closed. The thermostat starts to open at opens, closing off the bypass passage and allowing
89 C (192 F) and is fully open at 104 C (219 F). coolant to flow towards the radiator.
Coolant flows from the bottom of the radiator into the
inlet tube of the water pump, and into the front cover.
Coolant is pushed by the impeller in the water pump,
through an internal passage in the front cover, and
out into the crankcase. An internal passageway in the
crankcase directs coolant from the front to the rear,
evenly distributing coolant around the cylinders and
into the cylinder heads.
Coolant leaves the cylinder head in the following two
ways:
The coolant is directed, via an internal passage in
the crankcase, to the oil cooler header. Coolant
flows through passages in the oil cooler and exists
at the water pump, to be mixed with incoming
coolant from the radiator.
Coolant exists from the cylinder head, flows
through an internal passage in the crankcase,
and into the front cover. It is then directed to the
water pump passage containing the thermostat.
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16 INTRODUCTION
Lubrication System
Figure 9 Lubrication System Diagram

1. Camshaft Gear 8. Turbocharger Assembly (Typical) 16. Oil Filter
2. Camshaft Thrust Plate 9. Hydraulic Valve Lifter 17. Oil Pressure Regulating Valve
3. Camshaft 10. Push Rod 18. Oil Cooler
4. High-pressure Pump Oil 11. Valve Lever Assembly 19. Oil Cooler Header
Reservoir 12. Intake/Exhaust Valve 20. Oil Pick-Up Tube
5. Piston Cooling Jets (8) 13. Main Oil Gallery 21. Oil Pump
6. Hydraulic Valve Lifter Oil Gallery 14. Main Crankshaft Bearings 22. Connecting Rod Bearings
7. Turbocharger Pedestal 15. Oil Filter Bypass Valve 23. Check Valve
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INTRODUCTION 17
Description drilled passages within the crankshaft. The camshaft

journals receive pressurized oil through passages
The lubrication system is pressure regulated, cooled,
drilled vertically through the main bearing webs.
and full flow filtered. In addition to providing engine
lubrication, pressurized lube oil is used to control fuel Two tappet galleries, which are fed from the main oil
delivery to the HEUI fuel injectors. gallery through the holes of main bearing bolt number
1, intersect each tappet bore to provide pressurized
lube oil to the valve lifters and piston cooling jets. The
Oil Flow valve lever assemblies and push rods are lubricated by
oil passing from the lifter ball socket upward through
Lube oil is drawn from the oil sump, through the pick
the hollow push rods to valve lever arms. Oil drains
up screen and tube, and into the oil pump. The oil
back to the sump through holes located at each end
pump is of the gerotor type with the inner rotor portion
of the cylinder head.
driven directly by the crankshaft. The pump housing,
containing the inner and outer gerotor gears, is The oil reservoir, which is used to maintain a ready
bolted onto the front cover. The pump inlet and outlet supply of oil to the high pressure pump, is filled via
passages are ports in the front cover. Upon leaving two passages. At initial start up, oil is directed from
the oil pump, unfiltered lube oil enters the front oil the oil pump discharge port through a passage in
cooler header through a passage in the front cover. the front cover and crankcase, which also contains a
cold startup bypass check valve. To ensure sufficient
At initial engine start up, a small portion of the oil is
oil pressure to operate the injectors for quick starts,
passed directly from the pump to the high pressure
this reservoir oil supply quickly replenishes oil to
pump oil reservoir on top of the front cover. Oil flows
the high pressure pump during cold cranking. The
from the oil cooler header around the oil cooler tubes
primary reservoir oil supply is continuously fed from
into the oil filter assembly. The oil enters the oil filter
the left bank tappet gallery through the front cover,
through the outside of the filter element and flows
and discharges oil near the top of the reservoir.
through the filtering medium to the center. The filtered
oil now passes through the oil gallery in the crankcase. Pressurized lube oil reaches the turbocharger
The oil pressure regulator controls lube oil pressure bearings from the main oil gallery (left bank) through
via a spring loaded plunger which relays oil back to a passage in the turbocharger pedestal (mounting
the sump once operating pressure is reached. The pad). Oil drains from the turbocharger through
rear oil cooler header supports the oil filter, which also another adjacent passage in the pedestal directly
contains a bypass valve that allows oil to pass directly back to the sump. This oil supply and drain eliminate
to the main oil gallery if the filter becomes excessively the need for external lube lines to the turbocharger.
restricted.
Hydraulic oil pressure that is used to actuate the
The five crankshaft main bearings are oil fed through exhaust back pressure (EBP) warm-up control is
drilled passages in the crankcase directly from the received from the turbocharger lube supply port. This
main oil gallery. Connecting rod bearings receive port is located in the turbocharger support pedestal.
pressurized oil from the main bearings through
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18 INTRODUCTION
Air Induction and Exhaust System
Figure 10 Air Induction/Exhaust System Diagram

1. Charge Air Cooling Tube 5. Turbocharger Turbine Housing
2. Turbocharger Air Inlet Assembly 6. Muffler
3. Turbocharger Compressor 7. Right Hand Exhaust Manifold
Assembly 8. Left Hand Exhaust Manifold
4. Turbocharger Center Housing
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INTRODUCTION 19
Description Some engines are equipped with an optional exhaust

back pressure device to allow for a faster warm-up of
The intake and exhaust systems consist of those
the engine and passenger compartment when heat
components that contain the flow of filtered air
is needed. This device increases heat production.
into the engine cylinders and exhaust gases to the
It uses a butterfly valve located in the exhaust side
atmosphere.
of the turbocharger housing. When the exhaust
The turbocharger is used to increase engine is restricted by the butterfly valve, exhaust back
power output by increasing the air supply to the pressure increases, forcing the engine to work harder
engine, resulting in more uniform performance to expel the exhausted gases. When the valve is
at various operating altitudes. The turbocharger open, exhaust gases flow out freely.
incorporates an exhaust driven air compressor
The hot boost air from the compressor is cooled
that allows filtered air to enter the center of the
by a charge air cooler before entering the intake
air compressor where it undergoes an increase in
manifold. Air then flows into the combustion chamber
pressure from atmospheric to boost as it flows into
where the required quantity of fuel is injected, igniting
the combustion chambers. After combustion, hot and
the combustion phase. Exhaust gases leave the
expanding exhaust gases move out of the cylinders
cylinders through exhaust ports and the exhaust
and into the turbine housing driving the turbine wheel.
manifold. From the exhaust manifold, the expansion
The turbine wheel drives the compressor wheel
of exhaust gases on the exhaust turbine drive the
through a solid common shaft allowing the engine to
turbocharger and are released through an exhaust
respond directly to changing engine loads. During
pipe into the atmosphere.
heavy loads, an increased flow of exhaust gas spins
the turbine wheel faster causing the compressor The exhaust system includes exhaust valves, an
impeller to spin in direct relation, supplying greater exhaust manifold, exhaust piping and a muffler. The
volumes of air (boost) into the intake manifold and turbocharger turbine side is also an integral part
cylinders. Conversely, with lighter engine loads, the of the exhaust system. The compressor side is a
flow of exhaust gas decreases as does the volume component of the induction or intake system.
of air being compressed into the intake manifold and
cylinders.
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20 INTRODUCTION
Fuel System
Figure 11 Major Fuel System Component Locations

1. Fuel Supply (Transfer) Pump 3. Fuel Return Port 5. Fuel Inlet
2. Fuel Pressure Regulating Valve 4. Fuel Filter Canister 6. Fuel Strainer
Description The fuel system consists of the following components:

The function of the fuel system is to deliver fuel from Fuel tank(s)
the fuel tank(s) through a filter to the fuel injectors
Fuel supply lines and return line
at a regulated pressure. The fuel injectors use high
pressure lube oil to pressurize the fuel and inject it into Fuel filter
the combustion chambers.
Fuel passages that feed the fuel injectors
Fuel pressure regulator
Fuel supply (transfer) pump
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INTRODUCTION 21
Operation
The diaphragm stage of the tandem lift pump draws
fuel from the tank through a fuel strainer located on
the fuel filter housing. Fuel is then delivered to the
fuel filter under low pressure of less than 67 kPa (10
psi). Air that is trapped in the filter is vented back to
the tank through an opening (or hole) in the regulator
block mounted on the filter housing. This opening
is protected from plugging by a wire mesh screen
located inside the filter housing.
Fuel in the filter housing passes through the filter
element to a standpipe in the center of the filter
assembly. Clean fuel then passes to the inlet side of
the piston stage located on the tandem pump.
NOTE: The fuel filter element is attached to the

threaded filter cover. When servicing, the element
can be separated from the cover and replaced with
a new element. Fuel flow will be interrupted without
Figure 12 Fuel Supply (Transfer) Pump Diagram the fuel filter element in place. The standpipe in the
1. Low Pressure Fuel Outlet center of the housing contains a shut off valve that is
2. Outlet Check Valve open only when the filter element is in place.
3. Spring The piston stage of the tandem pump raises fuel
4. High-pressure Outlet pressure to ensure proper filling of the fuel injectors.
5. Outlet Check Valve Fuel from this stage is delivered to one end of each
6. Fuel Seal cylinder head. These lines supply fuel to a gallery
7. Oil Seal drilled in each cylinder head. Fuel enters at the rear
8. Camshaft Lobe of the right cylinder head and the front of the left
9. Tappet cylinder head. No fuel returns to the fuel tank from
10. O-ring the cylinder heads.
11. Inlet Check Valve
12. Inlet On some engines, the base of the filter housing
13. Piston contains an electric heating element that is used
14. Spring to warm fuel. Heating helps prevent the fuel from
15. Diaphragm waxing during cold weather. Also located in the base
16. Inlet Check Valve of the housing is a sensor to detect the presence of
17. Fuel Inlet water in the fuel (optional). When sufficient water has
collected in the bottom of the filter, the sensor will
illuminate a water in the fuel lamp located on the
The fuel supply (transfer) pump is a camshaft driven, instrument panel.
two stage diaphragm/piston pump. This pump is
mounted in the engine "V."
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22 INTRODUCTION
Figure 13 Split Shot Injector Fuel System Schematic
These engines are equipped with the split shot fuel The pressure regulator contains a spring loaded valve
injectors. A fuel inlet check valve is used in each to control pressure in the fuel galleries. Return fuel
cylinder head. The inlet check valve dampens the flows through the regulator and is routed back to the
pulses in the fuel rail in the cylinder head. There are fuel tank(s). No fuel is returned to the fuel tank(s) from
no return lines from the galleries on this system. the cylinder heads with split shot fuel system flow.
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INTRODUCTION 23
Injection Control Pressure System
Figure 14 Injector Oil System Diagram (Left Side)

1. Lubricating Oil Pump 5. Injection Control Pressure (ICP) 8. Crankcase Main Oil Gallery
2. Reservoir (Located On Top of Sensor 9. Oil Filter
Front Cover) 6. Cylinder Head High Pressure 10. Oil Cooler
3. High pressure Pump Oil Rail (2) 11. Injection Control Pressure
4. High pressure Lines 7. Fuel Injectors (8) Regulator
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24 INTRODUCTION
Figure 15 ECM And IPR Configuration
Operation The reservoir makes available a constant supply of

oil to a high pressure hydraulic pump mounted in the
The injection control pressure system utilizes a
engine "V." The high-pressure pump is a gear driven
hydraulically actuated injector to pressurize fuel
seven plunger swash plate pump. High pressure oil
inside the injector. The hydraulic fluid used to actuate
is delivered by the high pressure pump, through high
the injector is engine oil.
pressure oil lines, to oil galleries machined into the
Oil is drawn from the oil pan through the pick up cylinder heads. Drilled intersecting passages supply
tube by the engine oil pump. The engine oil pump high-pressure oil to the fuel injectors.
is a gerotor type pump driven by the crankshaft. At
start-up, oil is fed through passages in the front cover
to an oil reservoir mounted on top of the front cover.
Once the engine is running, oil is supplied through
the left lifter oil gallery.
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INTRODUCTION 25
This high-pressure oil is utilized by the Hydraulically module (ECM), injection control pressure (ICP) sensor
actuated Electronically controlled Unit Injectors and injection pressure regulator (IPR) valve.
(HEUI) when the solenoid is energized to pressurize
The ECM is programmed with an injection pressure
and atomize the fuel into the combustion chamber.
control strategy which determines the correct injection
After injection is complete, the solenoid is
control pressure at all engine operating conditions.
de-energized and the oil inside the injector is vented
The ECM receives a 0 5 volt (DC) analog feedback
through the top portion of the injector, splashed on
signal from the ICP sensor located in the high
the valve train and allowed to drain back into the oil
pressure oil supply gallery on the left cylinder head
pan.
that indicates injection control pressure. The ECM
The injection control pressure system is a closed loop processes this signal and controls injection control
operating system that consists of the electronic control pressure by controlling the ground to the IPR valve.
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26 INTRODUCTION
Injection Pressure Control
Figure 16 Closed Loop Operation Diagram
The ECM controls the injection control pressure by pressure pump. The regulator maintains the desired
operating the IPR valve. The result of this control injection control pressure by dumping excess oil
is continuously monitored by the ECM using the ICP through an internal spool valve. The excess oil then
sensor. The pressure signal obtained from the ICP travels, through an internal stand pipe, into the front
allows the ECM to know the actual injection control cover and back to the oil pan.
pressure at all times of engine operation, even during
As the demand for injection control pressure
cranking mode. This operation is known as "Closed
increases, the ECM increases the pulse width
Loop."
(duty cycle %) over the IPR solenoid. This action
Diagnostic codes can be set by the ECM if the ICP forces the poppet against the drain hole, thereby
electrical signal is out of range or if the ICP signal increasing the pressure behind the spool valve.
received corresponds to an out of range value for
As oil pressure increases behind the spool valve, it
the injection control pressure at a given operating
moves forward and blocks the drain ports on the sides
condition.
of the IPR valve.
Should any of these occur, the ECM will ignore the
When the demand for injection control pressure
ICP signal and control the IPR valve operation from
decreases, the ECM decreases the pulse width (duty
previously programmed default values. This condition
cycle %) over the solenoid allowing oil to drain out of
is known as an "Open Loop."
the drain hole. This is accomplished by relieving the
pressure behind the spool valve. This reduction in
IPR Valve Operation pressure allows the spool valve to partially open the
relief port, decreasing the injection control pressure.
The IPR valve is a pulse width (duty cycle %)
modulated valve operating at 400 Hz. The pulse The described operation allows the IPR to
width is modulated between 8 and 60% to control continuously adjust the injection control pressure
ICP pressure. The regulator is mounted in the high commanded by the ECM.
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INTRODUCTION 27
Figure 17 IPR Higher Injection Pressure Diagram
Figure 18 IPR Lower Injection Pressure Diagram
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28 INTRODUCTION
Fuel Injector
Description
The fuel injector is a unitized fuel injector that is
hydraulically actuated and electronically controlled.
Hydraulic actuation is accomplished when the injector
solenoid is energized, opening a poppet valve and
allowing ICP pressure to flow on top of the amplifier
accumulator.
Fuel is supplied to the injector by passages drilled
through the cylinder head that intersect fill ports in the
injector.
The area under the plunger is filled with fuel from
pressure supplied by the transfer pump. As the
plunger moves down, the increase in pressure closes
the fuel inlet check ball. Pressure continues to rise
until the nozzle valve pressure setting is overcome.
Fuel is pressurized through the nozzle orifices and
atomized into the combustion chamber. Injection is
terminated when the solenoid is de-energized and
ICP pressure is released.
Component Description
Solenoid
The solenoid is a very fast acting electromagnet that,
when energized, pulls the poppet valve off its seat.
Poppet Valve
The poppet valve is held on its seat by a spring. In this
closed position, high pressure inlet oil is blocked and
the intensifier cavity is opened to drain.
Figure 19 Fuel Injector Component Location
When the solenoid is energized, the poppet is quickly
lifted off its seat. The passage to the drain is closed 1. Solenoid
and the inlet for high pressure oil is opened. 2. Poppet Valve
3. Intensifier Piston
Intensifier Piston and Plunger
4. Check Ball
When the poppet valve opens the inlet port, high 5. Nozzle Assembly
pressure oil enters the injector and acts on the top 6. Nozzle Valve
of the intensifier piston. Pressure builds on the
intensifier, pushing it and the plunger down. The
intensifier is seven times larger in surface area than Operation
the plunger. This difference allows for an equal
These engines are equipped with split shot fuel
multiplication of force. The downward movement of
injectors. The injection operation is divided into two
the plunger pressurizes the fuel in the plunger cavity,
stages or cycles.
causing the nozzle to open.
1. Pre-injection
2. Primary injection
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INTRODUCTION 29
Figure 20 Stages of Injector Operation
The injection cycle is executed in two stages. Some first shot of fuel is pre-injected into the combustion
fuel is pre-injected into the combustion chamber chamber. Pre-injection is complete when the spill port
to initiate the combustion. Following combustion of the plunger coincides with the slot on the barrel.
initiation, the primary injection takes place. This
At this time, some fuel is allowed to return to the
feature reduces emission levels during light load
fuel supply port until the spill port slot is once again
operations. It also reduces light load engine noise.
blocked by the plunger and the primary injection stroke
The barrel and plunger were redesigned and a spill takes place.
port was incorporated. When injection is initiated, the
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30 INTRODUCTION
Glow Plug Controller System
Figure 21 Glow Plug Controller System Diagram
The purpose of the glow plug system is to warm up light ON time and the activation of the glow plugs
the engine cylinders to improve cold engine starting separately.
and to reduce exhaust emissions during the engine
The glow plugs are activated for a longer period of time
warm-up period.
if the engine is cold or the barometric pressure is low
The ECM is programmed to turn on the "wait to start (high altitude). Battery voltage is monitored to extend
light. The ECM also energizes the glow plugs via the glow plug life. If the battery voltage is high, power to
glow plug relay each time the ignition switch is placed the glow plugs is modulated by turning the glow plug
in the ON position before starting an engine. relay ON or OFF at programmed intervals.
The ECM monitors battery voltage and uses The engine is ready to start when the "wait to start"
information from the Engine Coolant Temperature light is turned off by the ECM. To reduce exhaust
(ECT) and barometric (BARO) sensors to determine emissions during engine warm up, the glow plugs may
the amount of "wait to start light time and glow plug remain ON for up to 120 seconds while the engine is
activation time. The ECM controls the "wait to start running.
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MOUNTING ENGINE ON STAND 31
Table of Contents
Mounting Engine On Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
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32 MOUNTING ENGINE ON STAND
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Mounting Engine On Stand
Figure 23 Location of Oil Drain Plug

1. Oil Pan
2. Oil Drain Plug
4. Remove the oil drain plug. Allow the oil to drain

into a suitable container.
5. After oil has drained, install the oil pan drain plug
and tighten to the special torque value.
6. Dispose of the oil according to local regulations.
Figure 22 Location of Coolant Drain Plugs

1. Right Coolant Drain Plug
2. Oil Level Gauge
3. Left Exhaust Manifold
4. Left Coolant Drain Plug
5. Oil Cooler/Filter Header
1. Drain the coolant from the crankcase by removing

two coolant drain plugs. The drain plugs are
located at the rear of the crankcase, behind the
exhaust manifolds on each side of the engine.
2. After the coolant has drained, install coolant drain Figure 24 Removing Oil Level Gauge
plugs into crankcase and tighten.
1. Oil Level Gauge
3. Dispose of the coolant according to local 2. Stud Nut
regulations. 3. Right Exhaust Manifold
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7. Loosen the stud nut that secures the slotted oil

level gauge mounting bracket to the right exhaust
manifold. Remove the oil level gauge.
WARNING: To avoid personal injury or

possibly death, attach the hoist hook lifting
bracket at the engine lifting eyes before
lifting the engine. Failure to do so can cause
the engine to lift on one end and swing out,
injuring any personnel standing in the area.
8. Attach the hoist hook lifting bracket at the engine

lifting eyes. Use a safety catch on the hoist hook
when lifting the engine.
WARNING: To avoid personal injury

or possibly death, or engine damage, use
only grade 8 or greater metric bolts when
mounting the engine to the stand. Other
bolts may sheer, causing the engine to fall
from the engine stand.
NOTE: For specific directions on the safe use of

engine mounting stands and adapter plates, refer to
the manufacturers instructions included with these
parts.
Figure 25 Installing Engine Stand Adapter Plate
NOTE: Use the correct engine stand adapter plate to Engine
when mounting the engine to the stand.
1. Engine Mounting Adapter Plate
2. Spacer
3. Mounting Bolts (3)
9. Position and secure engine stand mounting

adapter plate to right side of engine. Use three
grade 8 bolts.
10. Mount engine to stand using the specified adapter
plate and grade 8 or greater mounting bolts.
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Special Torque
Table 1 Engine Mounting Special Torques

Oil Level Gauge Tube Adapter Nut 36 Nm (26 lbfft)
Oil Pan Drain Plug 41 Nm (30 lbfft)
SPECIAL SERVICE TOOLS
Table 2 Engine Mounting Special Service Tools

ZTSE4151A Rear Mounted Engine Bracket (Keine Stand) (Not shown)
ZTSE4348 Side Mounted Engine Bracket (OTC Stand)
OEM4137 Engine Turn-Over Stand
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TURBOCHARGER 37
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Bellows Exhaust System Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Standard Torque Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
High Torque Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Disassembly (Standard Torque Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Remove EBP Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Remove Turbocharger Pedestal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Check Exhaust Inlet Adapter/Exhaust Tube Mating Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Compressor Impeller, Turbine Wheel and Turbocharger Pedestal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Check Axial End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Rebuild EBP Piston Rod Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Check Wastegate Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Assembly (Standard Torque Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Install Turbocharger Pedestal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Install EBP Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Standard Torque Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
High Torque Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
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38 TURBOCHARGER
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TURBOCHARGER 39
Description air entering the compressor side of the turbocharger

is compressed and delivered to the engine intake
The turbocharger is an exhaust driven centrifugal air manifold at a pressure greater than atmospheric
compressor. Its purpose is to increase power output pressure. Because more air is delivered to the intake
by supplying compressed air to the engine. The manifold, the net result is more power, improved fuel
internal components are oil and air cooled. Engine efficiency, and the ability to maintain power at higher
oil is circulated through the housing which acts as a altitudes.
heat barrier between the "hot" turbine and the "cold"
compressor. The bearings are sleeve-type and are Some engines are equipped with an optional exhaust
lubricated by engine oil. Oil is pumped directly from back pressure (EBP) device. This control device
the crankcase and circulated in the turbocharger helps bring the engine up to its normal operating
housing. Then the oil is returned to the sump through temperature at an increased rate. The device
an oil drain in the turbocharger mounting pedestal. increases the engines heat production by controlling
a butterfly valve in the exhaust outlet housing. When
NOTE: There are no external oil inlet or drain tubes the exhaust is restricted by the butterfly valve, exhaust
for the turbocharger. Oil is exchanged via machined backpressure increases, causing the engine to work
passages in the crankcase and the turbocharger harder in order to force out exhaust gases. The net
mounting pedestal. result is that the engine warms up at a much faster
rate. When the valve fully opens, the exhaust gas
High velocity engine exhaust gases drive the turbine flows out unrestricted.
shaft assembly at rates up to 130,000 rpm. Filtered
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40 TURBOCHARGER
Figure 26 Standard Torque Non Wastegated Turbocharger, Late 1997 Model Year
1. Identification Tag 6. EBP Device
2. Compressor Air Outlet 7. Turbine Inlet
3. Oil Cooled Center Housing 8. EBP Regulator
4. Turbine Housing 9. Compressor Housing
5. Exhaust Outlet 10. Air Intake
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TURBOCHARGER 41
Figure 27 Standard Torque, Non Wastegated Turbocharger 1998 Through Early 2000 Model Years
(GTP-38 Model Shown)
1. Turbine Housing 7. Exhaust Back Pressure Solenoid
2. Compressed Air Outlet 8. Oil Cooled Center Housing
3. Air Intake 9. Optional Exhaust Back Pressure
4. Identification Tag Valve
5. Compressor Housing 10. Exhaust Outlet
6. Turbocharger Pedestal
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42 TURBOCHARGER
Figure 28 Standard Torque Wastegated Turbocharger Late 2000 Through 2003 Model Years (GTP-38
Model Shown)
1. Oil Cooled Center Housing 5. Identification Tag 9. Exhaust Back Pressure Linkage
2. Wastegate Actuator 6. Compressor Housing 10. Turbine Housing
3. Compressed Air Outlet 7. Pedestal 11. Exhaust Outlet
4. Air Intake 8. Exhaust Back Pressure Solenoid
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TURBOCHARGER 43
Figure 29 High Torque Wastegated Turbocharger, 1997 Through 2003 Model Years (GTP-37 Model
Shown)
1. Identification Tag 6. Pedestal
2. Compressed Air Outlet 7. Wastegate Linkage
3. Air Intake 8. Turbine Housing
4. Compressor Housing 9. Exhaust Outlet
5. Wastegate Actuator
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44 TURBOCHARGER
Figure 30 Standard Torque Turbocharger Piping and Components

1. Turbocharger 8. Exhaust Tube Flange (2) 14. Charge Air Cooling Tube and
2. Exhaust Inlet Adapter Clamp 9. Right Exhaust Tube Crossover Pipe
3. Turbocharger Oil Supply O-ring 10. Turbocharger Oil Drain O-ring 15. Turbocharger Compressor
(2)* (2)* Outlet Seal
4. Turbocharger Exhaust Inlet 11. Turbocharger Pedestal 16. Turbocharger Compressor
Adapter Assembly Outlet Clamp
5. Exhaust Tube Seal (2) 12. Turbocharger Manifold Hose 17. Elbow Clamp
6. Turbocharger Adapter Flange (2) Clamp (4) 18. Turbocharger Air Inlet Elbow
7. Left Exhaust Tube 13. Turbocharger Manifold Hose (2) Assembly
*One O-ring is between the pedestal and turbocharger

mounting pad, one O-ring is between the turbocharger
and pedestal.
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TURBOCHARGER 45
Figure 31 High Torque Turbocharger Piping and Components

1. Turbocharger 9. Exhaust Tube Flange (2) 14. Charge Air Cooling Tube and
2. Exhaust Inlet Seal 10. Turbocharger Oil Drain O-ring Crossover Pipe
3. Exhaust Inlet Clamp (2)* 15. Turbocharger Manifold Hose
4. Turbocharger Exhaust Inlet 11. Turbocharger Oil Supply O-ring Clamp (4)
Adapter (2)* 16. Turbocharger Manifold Hose (2)
5. Exhaust Tube Seal (2) 12. Turbocharger Compressor 17. Elbow Clamp
6. Turbocharger Adapter Flange (2) Outlet Clamp 18. Turbocharger Air Inlet Elbow
7. Left Exhaust Tube 13. Turbocharger Compressor
8. Right Exhaust Tube Outlet Seal
*One O-ring is between the pedestal and turbocharger

mounting pad, one O-ring is between the turbocharger
and pedestal.
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46 TURBOCHARGER
Bellows Exhaust System Feature Service Kits For Standard Torque Engines
Figure 32 Emission Label Location Figure 33 Standard Torque Emission Label
1. Emission Label 1. International T 444E Engine Family Identification

2. Left Side of Engine 2. Horsepower and Torque Ratings
NOTE: The Standard Torque engine is identified Beginning with serial number 1573357 all Standard
as T 444E. The High Torque engine is identified as Torque International T 444E engines are equipped
T 444E HT. with the bellows exhaust system. To add the bellows
exhaust feature to a standard torque engine, match
The bellows exhaust system feature can be used the model year and engine serial number to the
on all International T 444E Standard Torque and corresponding service kit number listed.
High Torque engines. All the information required
for ordering the service kit is found on the exhaust The standard torque engine has the following ratings:
emission label affixed to the left hand side valve 160 HP
cover. The following information is needed prior to
determining which service kit to order: 175 HP
Rating 190 HP
Model year 195 HP
Horsepower rating 210 HP

After the horsepower rating of the standard torque
engine has been identified, compare the standard
torque engine serial number to the table below.
Table 3 Bellows Exhaust Service Kits for

Standard Torque International T 444E Engines
Model Year Serial Number Bellows Service
Range Kit Number
19941998 Prior to 843990 1843486C91
1999 and up 843990 and up 1837872C93
EGES-205
TURBOCHARGER 47
Service Kits for High Torque Engines Removal

Standard Torque Turbocharger
Figure 34 High Torque Emission Label

1. International T 444E HT (High Torque) Engine
Family Identification
2. Horsepower and Torque ratings
The bellows exhaust system feature can be added to

any high torque engine, use service kit 1833800C91.
The high torque engine has the following horsepower
ratings:
Figure 35 Removing Road Draft Tube Mounting
210 HP
Bolts
215 HP
1. Road Draft Tube Mounting Bolts (2)
230 HP 2. Road Draft Tube
250 HP
1. Remove the two bolts securing the road draft tube
to the crankcase. Relocate road draft tube to gain
access to the left side of the engine.
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48 TURBOCHARGER
4. Remove the turbocharger charge air cooling

tube/crossover pipe as follows:
a. Loosen the four hose clamps (two per side)
that secure the hoses to the air intake covers.
The clamps are located on the manifold
hoses.
b. Loosen the turbocharger compressor outlet
clamp that secures the charge air cooling tube
to the turbocharger compressor housing.
c. Remove the charge air cooling tube/crossover
pipe assembly.
d. Remove the turbocharger outlet seal from the
Figure 36 Removing Air Inlet Elbow
compressor housing.
1. Turbocharger
e. Place protective caps onto the air intake
2. Air Inlet Elbow Clamp
manifolds.
3. Air Inlet Elbow
4. Crankcase Breather
5. Road Draft Tube
2. Loosen the air inlet elbow clamp and remove the

air inlet elbow from the turbocharger.
3. Remove exhaust pipe between the turbocharger
and the muffler.
Figure 38 EBP Wiring Harness Connection

1. Wiring Harness Clip
2. EBP Wiring Harness Connector
5. Disconnect the EBP electrical connector from the

wiring harness, if equipped.
Figure 37 Removing Turbocharger Air Charging

Tube/Crossover Pipe Assembly
1. Turbocharger Compressor Outlet Seal
2. Turbocharger Compressor Outlet Clamp
3. Charge Air Cooling Tube / Crossover Pipe Assembly
4. Turbocharger Intake Manifold Hose
5. Hose Clamp(s)
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TURBOCHARGER 49
Figure 40 Removing Exhaust Inlet Adapter from

Turbocharger, Engine With Exhaust Bellows
Figure 39 Removing Turbocharger From Inlet Feature Shown (1998 through 2003 Model Years)
Adapter, Late 1997 Model Year Engine Without
Exhaust Bellows Feature Shown 1. Exhaust Inlet Adapter
2. Clamp
1. Turbocharger Compressor Housing
2. Retaining Bolts (2)
3. Gasket 8. Loosen and save turbocharger V-band clamp.
4. Exhaust Inlet Adapter Remove seal, if equipped.
5. Studs On Inlet Adapter (2)
6. Late 1997 Model Year, Engines Without

Exhaust Bellows Feature: Remove two
retaining bolts and the two retaining nuts at
the exhaust inlet adapter to the turbine housing
flange. Save these two retaining bolts. They will
be reused in the assembly procedure. Discard
the two retaining nuts.
7. Late 1997 Model Year, Engines With Exhaust
Bellows Feature: Remove four retaining bolts at
the exhaust inlet adapter to the turbine housing
flange. Save these four retaining bolts. They will
be reused in the assembly procedure.
Figure 41 Disconnecting EBP Piston Rod (1998
through 2003 Model Years)
1. EBP Piston Rod
2. Control Arm
3. Slide Lock
9. Move the slide lock back and disconnect the EBP

piston rod from the control arm.
10. Late 1997 Model Year Only:Remove the bolts
securing the pedestal to the crankcase. Remove
the turbocharger and pedestal assembly from the
engine.
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50 TURBOCHARGER
Figure 44 Turbocharger Oil Supply and Oil Drain

Ports
1. Oil Supply O-Ring
Figure 42 Removing Turbocharger Mounting 2. Oil Drain O-Ring
Bolts (1998 through 2003 Model Years) 3. Turbocharger Mounting Pad
11. 1998 through 2003 Model Years: Remove 13. Remove and discard the two O-rings located on
and save the two turbocharger mounting bolts. the turbocharger mounting pad. Cover openings
Remove turbocharger from the pedestal by lifting after removal.
the turbocharger up.
Figure 45 Turbocharger Openings to be Capped

Figure 43 Removing Pedestal and O-rings (1998 (Late 1997 Model Year Shown)
through 2003 Model Years)
1. Exhaust Outlet
1. Mounting Bolts 2. Turbocharger Exhaust Inlet
2. Oil Supply and Oil Drain O-rings 3. Turbocharger Oil Inlet and Oil Drain Ports
4. Turbocharger Air Inlet
5. Turbocharger Air Outlet
12. 1998 through 2003 Model Years: Remove the
oil supply and oil drain O-rings from the pedestal.
Remove four mounting bolts securing the pedestal 14. Cap all turbocharger openings to prevent
to the crankcase and remove the pedestal from contamination. If plastic caps are not available,
the engine. use duct tape to cover openings.
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TURBOCHARGER 51
Figure 46 Removing Right Exhaust Tube

Mounting Hardware at Exhaust Manifold
1. Right Exhaust Tube
2. Exhaust Tube Bolt Figure 47 Removing Left Exhaust Tube
3. Nut Mounting Hardware at Exhaust Manifold
4. Right Exhaust Manifold 1. Left Exhaust Tube
2. Exhaust Tube Bolt
15. Remove two nuts and bolts from right exhaust 4. Nut
manifold. These bolts secure the right exhaust
tube to the exhaust manifold.
16. Remove two nuts and bolts from left exhaust
manifold. These bolts secure the left exhaust
tube to the exhaust manifold.
17. Remove the turbocharger exhaust tube assembly
from the engine.
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52 TURBOCHARGER
High Torque Turbocharger

1. Remove air cleaner and pipe to the turbocharger
compressor inlet.
2. Remove exhaust pipe between the turbocharger
and the muffler.
Figure 49 Removing Charge Air Cooling

1. Crossover Pipe
2. Charge Air Cooling Tube
3. Hose Clamps
4. Turbocharger Manifold Hoses
4. Remove turbocharger charge air cooling

tube/crossover pipe assembly as follows:
a. Loosen the four hose clamps (two per side)
that secure the hoses to the air intake covers.
The clamps are located on the manifold
hoses.
b. Loosen the turbocharger compressor outlet
clamp that secures the charge air cooling tube
to the turbocharger compressor housing.
c. Remove the charge air cooling tube/crossover
pipe assembly and the two manifold hoses.
Figure 48 Road Draft Tube Mounting Hardware
d. Remove the turbocharger compressor outlet
1. Mounting Bolts seal from the compressor housing.
e. Place protective caps onto the air intake
3. Loosen and remove the two bolts securing the manifolds.
road draft tube to the back of the crankcase. 5. Remove and save turbocharger V-band clamp
Relocate road draft tube to gain access to the left that secures the turbocharger to the exhaust
side of the engine. outlet adapter. Remove seal.
6. Loosen and remove the two bolts that secure
the turbocharger to the pedestal. Remove the
turbocharger from the pedestal by lifting up.
EGES-205
TURBOCHARGER 53
NOTE: The turbocharger and pedestal must be 10. Cap all openings on the turbocharger assembly.
removed separately from the engine. If plastic caps are not available, use duct tape to
cover openings.
7. Remove and discard the oil supply O-ring and
oil drain O-ring located on the underside of the
turbocharger or on the top of the pedestal.
8. Remove the four flange head mounting bolts that
secure the pedestal to the crankcase. Remove
the pedestal.
Figure 51 Turbocharger Exhaust Tube Mounting

Hardware (Right Side Shown)
2. Exhaust Tube Mounting Bolt
Figure 50 Turbocharger Oil Supply and Oil Drain 3. Exhaust Tube Mounting Nut
Ports 4. Right Exhaust Manifold

2. Oil Drain O-Ring
11. Remove the exhaust tube mounting hardware at
3. Turbocharger Mounting Pad
the left and right exhaust manifolds. Remove the
exhaust inlet adapter and tube assemblies from
the engine.
9. Remove and discard the two O-rings located on
the turbocharger mounting pad.
EGES-205
54 TURBOCHARGER
Cleaning Disassembly (Standard Torque

Only)
NOTE: Do not use a caustic solution on the
turbocharger or its related components. Remove EBP Control Valve
Turbocharger
1. Use a suitable solvent and nylon brush to clean
the turbocharger, pedestal, EBP control valve (if
equipped), charge air cooling tube/crossover pipe
and hoses. Use filtered compressed air to dry the
parts.
2. Inspect the oil inlet and oil drain ports for
restrictions. Clean as required.
Related Components Figure 52 Removing EBP Control Valve (Late

1. Thoroughly clean the piping that connects the air 1997 Model Year Shown)
cleaner to the turbocharger with soap and water. 1. EBP Control Valve Mounting Bolt (3)
Use filtered compressed air to dry the piping. 2. EBP Control Valve Housing
2. Before cleaning the inside of the air cleaner
element housing, remove the vehicle-mounted air
cleaner. Cleaning helps to prevent failure of the Remove the mounting bolts and lift the EBP control
turbocharger or engine. valve housing from the turbocharger.
Remove Turbocharger Pedestal
NOTE: Late 1997 Model Year, the turbocharger and

pedestal are removed from the crankcase as an
assembly. 1998 Model Years and up, the pedestal
and turbocharger are removed separately.
EGES-205
TURBOCHARGER 55
2. Remove and discard the O-rings which seal the

oil passages to the turbocharger.
3. Remove the solenoid valve from the pedestal, if
necessary.
Inspection
Check Exhaust Inlet Adapter/Exhaust Tube
Mating Surface
NOTE: This procedure should only be done if

the standard exhaust tubes are being changed to
exhaust tubes with bellows. If you are not changing
Figure 53 Removing Pedestal Mounting Bolts the exhaust tubes or already have exhaust tubes
(Late 1997 Model Year Only) with bellows on the engine, DO NOT perform this
1. Pedestal inspection.
2. Mounting Bolts
3. Turbocharger
1. Once the turbocharger and pedestal assembly

have been removed from the crankcase, remove
four turbocharger pedestal mounting bolts from
the bottom of the pedestal.
Figure 55 Exhaust Inlet Adapter/Exhaust Tube

Gasket Mating Surface Dimension, Late 1997
Model Year and Up
Figure 54 Turbocharger Pedestal

1. Solenoid Valve
2. O-Ring Locations (2)
3. Pedestal
EGES-205
56 TURBOCHARGER
WARNING: To avoid serious personal

injury, possible death, or damage to the
engine or vehicle, measure and inspect
the exhaust tube mating surface of the
exhaust inlet adapter. The adapter must
have sufficient gasket support surface. If
the width of the gasket surface (X width
dimension of the figure above) on the inlet
adapter measures less than 5 mm (0.19 inch)
a tight seal will not be formed between the
inlet adapter and the exhaust tube, causing
Figure 56 Checking for Turbine/Compressor
an exhaust leak. If the gasket mating surface
Housing Wheel Rubbing
does not meet the minimum width, a new
adapter must be ordered.
2. Set the turbocharger on a work bench with the
Late 1997 Model Year Only: Order exhaust
shaft in a horizontal position. Rotate the shaft and
turbo inlet adapter 1818163C1.
check for any wheel rubbing within the housings.
The wheels must spin freely when turned by hand.
1998 Model Year Only: Order exhaust turbo
inlet adapter 1826618C91. 3. Inspect the turbocharger pedestal for cracks, worn
spots and other damage.
1999 and UP Model Years: Order exhaust
turbo inlet adapter 1828540C91.
Check Axial End Play
Compressor Impeller, Turbine Wheel and

Turbocharger Pedestal
1. Inspect the compressor impeller and turbine
wheel for blade erosion, bending, breakage
or deposits. Replace the entire turbocharger
assembly if any blades are damaged.
Deposits on the compressor impeller, and turbine
wheel can be caused by the following conditions:
High air inlet restriction allows oil to be
transferred from the turbocharger center
housing, resulting in oil deposits.
Excessive oil consumption can result in
turbine wheel carbon deposits. Figure 57 Checking Axial End Play
Engine overfueling can result in excessive 1. Dial Indicator
operating temperatures, which can cause 2. Turbine Housing
aluminum components to melt. Such deposits
may be found on the turbine wheel if such a
failure occurs. 1. With the turbocharger in a stable position, place
the tip of a dial indicator inline with the end of the
turbine shaft. Reset the dial indicator to zero.
EGES-205
TURBOCHARGER 57
2. Move the shaft back and forth by hand and NOTE: Different shapes of pedestals are used on the
record the readings. If the readings exceed T 444E engines. The service kit CAN NOT be used
specifications, the turbocharger must be replaced. on engines having S/N 843990 1825359 and using
hourglass-shaped pedestals. If oil is leaking from
the EBP piston rod housing on these pedestals, the
Rebuild EBP Piston Rod Assembly entire pedestal assembly must be replaced with P/N
1831455C92.
Hourglass pedestals are still being used on some

engines built after S/N 1825359. The service kit can
be used on those later engines.
Turbocharger assembly P/N 1831774C93 already

uses the new EBP piston rod assembly and can be
serviced with this kit. The turbocharger part number
is located on the identification tag attached to the
turbocharger compressor housing.
The different pedestals can be identified by the
Figure 58 EBP piston rod kit contents following characteristics while installed on the engine:
1. Oil supply O-ring (2)
2. Oil drain O-ring (2)
3. Retaining ring
4. End cover with O-ring
5. Piston rod assembly
6. Jam nut
7. Latch end with slide lock
If oil is leaking from the EBP piston rod housing,

installing the service kit may eliminate the need to
replace the entire turbocharger pedestal.
Figure 60 Block-shaped Pedestal Installed

1. Turbocharger part number (location)
2. Visible ledge
3. Solenoid valve deeper
The block-shaped pedestal has a visible ledge where

Figure 59 Different Turbocharger Pedestals
the turbocharger mounts to the pedestal. Also, the
1. Hourglass-shaped pedestal solenoid valve installed in the pedestal, is set deeper
2. Blocked-shaped pedestal into the pedestal than in the hourglass shaped one.
EGES-205
58 TURBOCHARGER
Figure 62 EBP Piston Rod Housing

1. Latch End with Slide Lock
2. Jam Nut (not included on production units)
3. Piston Rod
4. Pedestal
5. End Cover
6. Retaining Ring
Figure 61 Hourglass-shaped Pedestal Installed
1. Turbocharger part number (location)
2. No visible ledge 1. Unscrew the latch (and jam nut, if equipped) from
3. Solenoid valve protrudes the end of the piston rod. Hold the piston rod
securely while unscrewing the latch because it is
crimped to the piston rod.
The hourglass-shaped pedestal does not have a
2. Remove the retaining ring from the housing.
visible ledge where the turbocharger mounts to the
pedestal. The solenoid valve installed in the pedestal 3. Remove the end cover from the housing by gently
protrudes out farther than in the hourglass shape tapping on the threaded end of the piston rod.
valve.
4. Remove the piston rod, spring, spring seat
If leakage is visible from the EBP piston rod housing, and two wiper seals (one black, one white) as
install a new EBP piston rod assembly as follows: an assembly from the housing. Discard the
assembly.
5. Thoroughly clean and inspect the pedestal and
the inside of the housing.
6. Lubricate the inside of the housing and the outside
of the new EBP piston rod assembly with clean oil.
7. Install the new EBP piston rod assembly (without
the jam nut and latch) into the housing far enough
to install the cover and retaining ring.
8. Lubricate the O-ring on the new end cover with
clean oil. Install the end cover and retaining ring
in the housing.
9. Install a new jam nut, slide lock and latch on the
threaded end of the piston rod.
EGES-205
TURBOCHARGER 59
Check Wastegate Actuator Assembly (Standard Torque Only)

Install Turbocharger Pedestal
NOTE: Late 1997 Model Year, the turbocharger and

pedestal are removed from the crankcase as an
assembly. 1998 Model Years and up, the pedestal
and turbocharger are removed separately.
Figure 63 Checking Wastegate Actuator (high

torque model shown)
1. Magnetic Base
2. Dial Indicator
Figure 64 Attaching the Turbocharger to the
3. Wastegate Actuator
Pedestal (Late 1997 Model Year Shown)
4. Air Pressure Regulator 1. Turbocharger Pedestal
5. Wastegate Actuator Shaft 2. Pedestal Mounting Bolts
3. Turbocharger
1. Place the turbocharger on a flat surface. Position

a dial indicator with a magnetic base next to the 1. If removed, install the solenoid valve and tighten
turbocharger. Place the tip of the dial indicator the mounting bolt.
inline and at the end of the wastegate actuator
shaft. Reset the indicator needle to zero. 2. Lubricate and install new oil supply and oil drain
O-rings onto the pedestal.
2. Use a hose and appropriate fittings to connect the
regulated shop air hose to the wastegate actuator. 3. Apply Never-Seez to the threads of the four
mounting bolts. Install and tighten the mounting
3. Connect an air hose to a shop air pressure bolts to the special torque value.
regulator. Adjust the air pressure as specified in
Table 4. Temporarily close off the air supply to let
the air pressure gauge return to zero.
4. Gradually apply shop air pressure to achieve the
air pressure indicated in Table 4. Record the
reading on the dial indicator.
5. If the reading does not meet specifications, the
wastegate actuator must be replaced.
EGES-205
60 TURBOCHARGER
Install EBP Control Valve
Figure 66 Testing Control Rod Preload (Late

Figure 65 Installing EBP Control Valve (Late 1997 Model Year Shown)
1997 Model Year Shown)
1. Turbocharger
1. EBP Control Valve Housing Bolts 2. EBP Control Valve
2. EBP Control Valve Housing 3. Turbocharger Pedestal
4. Jam Nut
5. Spring Scale Tester
1. Align the bolt holes of the EBP control valve
housing and turbine housing.
2. Apply Never-Seez to the threads of the EBP 4. Check the EBP piston rod preload on a workbench
control valve mounting bolts. Install and tighten as follows:
the mounting bolts to the special torque value. a. Temporarily install the turbocharger onto the
3. Connect the EBP piston rod to the control arm. pedestal. Install the turbocharger mounting
bolts finger tight.
b. Connect the EBP piston rod to the control
arm.
c. To determine when the EBP control valve
moves, insert a 0.01 in feeler gauge between
the control valve stop and the stop on the
turbocharger housing.
d. Attach a spring scale tester to the control arm
and pull on the tester. When the feeler gauge
falls out, take the reading on the spring scale
tester.
The reading on the spring scale tester should
be 13 N (10 lbf) when the feeler gauge falls
out.
e. If the preload of the EBP piston rod does not
meet this specification, shorten or lengthen
the piston rod by screwing the latch end in or
out. Repeat the test procedure.
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TURBOCHARGER 61
f. Lock the jam nut against the latch end when

the proper preload is achieved.
g. Disconnect the EBP piston rod from the
control arm. Be careful not to turn the latch
end of the piston rod.
h. Continue on as follows:
Late 1997 Model Year Only: The
turbocharger and pedestal assemby can
remain assembled. Proceed on to the
Installation procedure.
1998 Model Years and Up: Remove the
turbocharger from the pedestal.
Figure 67 Installing Right Exhaust Tube
Mounting Hardware at Exhaust Manifolds
Installation 2. Exhaust Tube Bolt
Standard Torque Turbocharger 3. Nut
4. Right Exhaust Manifold
NOTE:
A. Use anti-seize compound on the mounting
bolts and all other bolt threads used on the
exhaust system to prevent high temperature
corrosion.
B. The same installation procedure is used
for either engines equipped with or without
the exhaust bellows feature, except where
indicated.
1. Pre-assemble the right and left side tube
assemblies to the exhaust inlet adapter with the
exhaust flange gasket (either side up) mounted
between the exhaust tube flange and the exhaust
inlet adapter. Torque the exhaust inlet adapter
flange bolts that secure the exhaust tubes to the
exhaust inlet adapter to the special torque value.
Figure 68 Installing Left Exhaust Tube Mounting

Hardware at Exhaust Manifolds
1. Left Exhaust Tube
2. Exhaust Tube Bolt
4. Nut
2. Locate the reassembled exhaust inlet adapter

and tube assembly into position and secure
the exhaust tube assembly to the left and right
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62 TURBOCHARGER
exhaust manifolds. Finger tighten the mounting

hardware.
3. Remove all protective caps or duct tape from the
turbocharger, pedestal and crankcase openings.
Figure 70 Installing Turbocharger To Pedestal

(1998 and UP Model Years Shown)
Figure 69 Turbocharger Oil Supply O-Ring and
Oil Drain O-Ring
7. 1998 and UP Model Years:
2. Oil Drain O-Ring A. Place the turbocharger on the pedestal.
3. Turbocharger Mounting Pad Make sure the bolt holes in the
turbocharger are aligned with the bolt
holes in the pedestal.
4. Apply a light coat of grease to a new oil supply
B. Install and tighten the two turbocharger
O-ring and oil drain O-ring. Install the O-rings on
mounting bolts to the special torque
the turbocharger mounting pad.
value.
5. Late 1997 Model Year Only:
A. Place the turbocharger and pedestal
assembly onto the mounting pad.
B. Align the pedestal mounting holes with
the holes in the mounting pad.
C. Install the pedestal mounting bolts and
tighten to the special torque value.
6. 1998 and Up Model Years:
A. Place the pedestal on the mounting pad.
Make sure the bolt holes in the pedestal
are aligned with the bolt holes in the
mounting pad. Install and tighten the four
flange head mounting bolts to the special Figure 71 Connecting EBP Piston Rod (1998
torque value. and Up Model Years Shown)
B. Apply a light coat of grease to a new oil 1. EBP Piston Rod (Latch End)
supply O-ring and oil drain O-ring. Install 2. Control Arm
the O-rings onto the pedestal. 3. Slide Lock
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TURBOCHARGER 63
8. Connect the latch end of the EBP piston rod to the 10. Late 1997 Model Year, Engines With Exhaust
control arm. Move the slide lock forward to secure Bellows Tubes:
the latch end to the control arm.
A. Slide the turbocharger over the exhaust
inlet adapter and secure with four
retaining bolts. Finger tighten the bolts.
B. Tighten the bolts to the special torque
value.
C. Tighten the exhaust tube mounting
hardware at the exhaust manifolds to the
special torque value.
Figure 72 Installing Turbocharger To Exhaust

Inlet Adapter, Late 1997 Model Year Engine
Without Bellows Feature Shown)
1. Turbocharger Compressor Housing
2. Retaining Bolts (4 for engines with exhaust bellows
tubes) (2 for engines without exhaust bellows tubes)
3. Gasket
Figure 73 Installing the Exhaust Inlet Adapter
4. Exhaust Inlet Adapter
to the Turbocharger (1998 and Up Model Years
5. Studs On Inlet Adapter (Used on non exhaust
Shown)
bellows application
1. Exhaust Inlet Adapter
2. Clamp
9. Late 1997 Model Year, Engines Without
Exhaust Bellows Tubes:
11. 1998 and UP Model Years:
A. Slide the turbocharger over the two
mounting studs of the exhaust inlet A. Install the exhaust inlet adapter on the
adapter. turbocharger exhaust inlet. Make sure
the dowel on the adapter aligns with the
B. Secure with two nuts and two retaining
hole in the lip of the exhaust inlet.
bolts. Tighten to the special torque value.
B. Install and tighten the V-band clamp to
C. Tighten the exhaust tube mounting
the special torque value.
special torque value. C. Tighten the exhaust tube mounting
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64 TURBOCHARGER
13. Remove protective caps from the air intake

manifolds.
14. Lubricate a new compressor outlet seal with clean
oil. Install the seal in the turbocharger compressor
outlet.
15. Install the charge air cooling tube/crossover pipe
assembly as follows:
a. Install the charge air cooling tube/crossover
pipe assembly to the turbocharger
compressor housing and air intake hoses.
b. To secure the charge air cooling tube to the
Figure 74 Installing the EBP Wiring Harness turbocharger compressor housing, tighten the
Connector (1998 and Up Model Years Shown) turbocharger compressor outlet clamp.
1. Wiring Harness Clip c. Tighten the four hose clamps (two per side)
2. EBP Wiring Harness Connector to secure the hoses to the air intake manifold
covers.
12. Connect the wiring harness electrical connector to

the EBP solenoid.
Figure 76 Installing Air Inlet Elbow

1. Turbocharger
2. Air Inlet Elbow Clamp
3. Air Inlet Elbow
4. Crankcase Breather
5. Road Draft Tube
Figure 75 Installing the Charge Air Cooling
1. Turbocharger Compressor Outlet Seal 16. Install the air inlet elbow. Tighten the clamp.
2. Turbocharger Compressor Outlet Clamp 17. Install and secure the exhaust pipe connecting the
3. Charge Air Cooling Tube/Crossover Pipe Assembly turbocharger to the muffler.
4. Turbocharger Intake Manifold Hose (2)
5. Hose Clamp (4)
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TURBOCHARGER 65
Figure 78 Turbocharger Exhaust Tube Mounting

Hardware (Right Side Shown)
2. Exhaust Tube Mounting Bolt
3. Exhaust Tube Mounting Nut
Figure 77 Install Road Draft Tube Mounting

Bolts (Engine With Exhaust Bellows Feature 2. Locate the reassembled exhaust inlet adapter
Shown) and tube assembly into position and secure
the exhaust tube assembly to the left and right
1. Road Draft Tube Mounting Bolt
exhaust manifolds. Finger tighten the mounting
2. Road Draft Tube
hardware.
3. Remove all protective caps or duct tape from the
18. Move the road draft tube into the correct position. turbocharger, pedestal and crankcase openings.
19. Install road draft tube mounting bolts and secure
to crankcase. Tighten bolts to standard torque
value.
High Torque Turbocharger
NOTE: Use anti-sieze compound on the mounting

bolts and all other bolt threads used on the exhaust
system to prevent high temperature corrosion.
1. Pre-assemble the right and left side tube
assemblies to the exhaust inlet adapter with the
exhaust flange gasket (either side up) mounted
between the exhaust tube flange and the exhaust Figure 79 Turbocharger Oil Supply O-Ring and
inlet adapter. Torque the exhaust inlet adapter Oil Drain O-Ring
flange bolts that secure the exhaust tubes to the
exhaust inlet adapter to the special torque value.
2. Oil Drain O-Ring
3. Turbocharger Mounting Pad
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66 TURBOCHARGER
4. Apply a light coat of grease to a new oil drain 10. Use clean engine oil to lubricate a new
O-ring and oil supply O-ring. Install the O-rings turbocharger compressor outlet seal. Install
into the turbocharger mounting pad. the seal into the compressor housing.
5. Install the turbocharger pedestal on the 11. Install the charge air cooling tube/crossover pipe
crankcase. Make sure the bolt holes in the assembly as follows:
pedestal align with the bolt holes in the crankcase.
a. Install the charge air cooling tube/crossover
Install and tighten the flange head mounting bolts
pipe assembly to the turbocharger
to the standard torque value.
compressor housing and intake manifold
6. Install new oil supply and oil drain O-rings on the hoses.
top of the pedestal.
b. To secure the charge air cooling tube to the
7. Align oil supply and drain ports and place turbocharger compressor housing, tighten the
turbocharger on the pedestal. Install the two turbocharger compressor outlet clamp.
mounting bolts and tighten them to the special
c. Tighten the four hose clamps (two per side)
torque valve.
to secure the intake manifold hoses to the air
8. Install the seal and align the exhaust inlet adapter intake manifold covers.
with the turbine inlet. Install the V-band clamp and
12. Install the air inlet elbow and clamp. Tighten the
tighten to the special torque value.
clamp.
9. Tighten the exhaust tube mounting hardware at
the exhaust manifolds to the special torque value.
Figure 80 Installing Charge Air Cooling

1. Crossover Pipe
2. Charge Air Cooling Tube
3. Hose Clamps (4)
4. Turbocharger Intake Manifold Hoses (2)
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TURBOCHARGER 67
13. Place the road draft tube into the correct position.
14. Install the road draft tube mounting bolts in the
crankcase. Tighten the bolts to the standard
torque value.
Figure 81 Installing Road Draft Tube

1. Road Draft Tube Mounting Bolts
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68 TURBOCHARGER
SPECIFICATIONS
Table 4 Turbocharger Specifications

EBP Control Rod Spring Preload 13.5 3 N (10 2 lbf)
Turbine Shaft Axial End Play 0.02 - 0.10 mm (0.001 - 0.004 in)
Turbine Shaft Radial Movement (Play) 0.08 - 0.15 mm (0.003 - 0.006 in)
Wastegate Actuator Movement (Standard
1.016 mm @ 101.35 3.45 kPa (0.04 in @ 14.7 0.5 psi)
Torque Model)
Wastegate Actuator Movement (High Torque
0.369 mm @ 131 kPa (0.015 in @ 19 psi)
Model)
Special Torque
Table 5 Turbocharger Special Torques

Air Inlet Hose Clamps 4 Nm (36 lbfin)
Compressor Outlet Clamp 2 Nm (19 lbfin)
Exhaust Back Pressure Valve to Turbine Housing Mounting Bolts 21-24 Nm (15-18 lbfft)
Exhaust Inlet Clamp 12 Nm (9 lbfft)
Exhaust Tube to Exhaust Inlet Adapter Flange Bolts 28 Nm (21 lbfft)
Exhaust Tube to Exhaust Manifold Flange Bolts 26 Nm (19 lbfft)
Intake Manifold Hose Clamps 3 Nm (30 lbf-in)
Turbocharger Pedestal to Crankcase Mounting Bolts 24 Nm (18 lbfft)
Turbocharger to Pedestal Mounting Bolts (Standard Torque Model) 4751 Nm (3437 lbfft)
Turbocharger to Pedestal Mounting Bolts (High Torque Model) 49 Nm (36 lbfft)
Table 6 Turbocharger Special Service Tools

OEM1028 Dial Indicator with Magnetic Base
ZTSE4293 Turbocharger Intake Shield
ZTSE4296 Turbocharger Intake Cap Set
ZTSE4230 Spring Tension Scale 034 Nm (0-25 lbf)
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MANIFOLDS 69
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Left Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Right Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Left Intake Manifold Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Right Intake Manifold Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Right Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Left Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Right Intake Manifold Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Left Intake Manifold Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
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70 MANIFOLDS
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MANIFOLDS 71
Figure 82 Intake Manifold Component Locations

1. Turbocharger Charge Air 2. Hose Clamp (4) 4. Right Air Intake Cover
Manifold (Crossover Pipe) 3. Turbocharger Manifold Hose (2) 5. Left Air Intake Cover
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72 MANIFOLDS
Figure 83 Exhaust Manifold Components

1. Exhaust Manifold (Right) 3. Exhaust Manifold (Left)
2. Exhaust Manifold Gasket (For 4. EBP Tube Access Hole
Service Only)
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MANIFOLDS 73
Removal
Left Exhaust Manifold
1. Remove two bolts securing turbocharger exhaust
tube to exhaust manifold.
Figure 84 Removing the Left Exhaust Manifold

1. Exhaust Manifold
2. Mounting Bolts
2. Remove eight mounting bolts securing exhaust Figure 86 Removing the Oil Level Gauge
manifold to cylinder head. Remove exhaust 1. Oil Level Gauge
manifold and gasket, if equipped. 2. Nut
Right Exhaust Manifold
1. Remove two bolts securing turbocharger exhaust 3. Remove nut securing oil level gauge bracket to
tube to exhaust manifold. stud bolt. Remove oil level gauge.
Figure 87 Removing the Right Exhaust Manifold

1. Exhaust Manifold
2. Mounting Stud Bolt (1)
Figure 85 Removing the EBP Sensor Tube 3. Mounting Bolt (7)
1. EBP Sensor Tube
2. EBP Sensor Tube Nut
4. Remove seven mounting bolts and one stud
3. Exhaust Manifold
bolt that secure exhaust manifold to cylinder
head. Remove exhaust manifold and gasket, if
2. If equipped, loosen EBP sensor tube nut and pull equipped.
tube away from exhaust manifold.
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74 MANIFOLDS
Left Intake Manifold Cover Right Intake Manifold Cover
NOTE: When removing the left or right intake manifold NOTE: If it is necessary to disconnect and remove
cover be sure to do the following steps: the fuel filter, refer to Fuel Filter Piping, in the Fuel
System section.
Loosen compressor outlet clamp on charge air
cooling and crossover pipe. 1. Remove three bolts securing the fuel filter
mounting bracket to the manifold cover.
Loosen the four turbocharger manifold hose
clamps on the left and right intake manifolds and
slide turbocharger manifold hoses away from
manifold cover inlets.
Remove charge air cooling and crossover pipe
and turbocharger manifold hoses as an assembly.
Remove turbocharger compressor outlet seal
from turbocharger.
Figure 89 Right Intake Manifold Cover Slotted
Bolt Hole
2. Loosen but do not remove last bolt at the slotted

bolt hole.
3. Loosen and remove remaining intake manifold
cover bolts.
Figure 88 Left Intake Manifold Cover Bolts
4. Using a RTV sealant cutting tool, cut around the
intake manifold cover.
1. Remove ten bolts securing intake manifold cover
5. Slide intake manifold cover off cylinder head.
to cylinder head.
2. Using a RTV sealant cutting tool, cut around
intake manifold cover.
3. Remove intake manifold cover from cylinder head. Cleaning
NOTE: Be sure to clean all RTV sealant from cylinder
head and manifold cover.
Manifolds may be cleaned with a suitable non-caustic
solvent or steam cleaned.
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MANIFOLDS 75
Inspection Installation
Exhaust Manifold
NOTE: When installing exhaust manifolds, only use
1. Inspect cleaned exhaust manifolds for cracks. prevailing torque flanged-head bolts with interference
Replace the exhaust manifold as required. thread.
Right Exhaust Manifold
Figure 90 Inspecting Exhaust Manifold for

Figure 91 Installing the Right Exhaust Manifold
Warpage
1. Exhaust Manifold
1. Exhaust Manifold
2. Straight Edge
3. Mounting Bolt (7)
3. Feeler Gauge
1. Apply Never-Seez to the threads of the bolts.

2. To inspect exhaust manifold for warpage, place
a straight edge against mounting surface and 2. Install right exhaust manifold (with gasket if
try passing a 0.13 mm (0.005 in) feeler gauge required). Secure with seven mounting bolts
between straight edge and mounting surface. and one stud bolt. Tighten bolts in the specified
sequence to the special torque value.
If feeler gauge passes through, exhaust manifold
requires a gasket. Attach a gasket to the
exhaust manifold and proceed to the installation
procedure.
If a gasket was previously used on the exhaust
manifold, the manifold may be machined to
compensate for warpage. A maximum of 0.25
mm (0.010 in) material can be machined off to
correct warpage.
EGES-205
76 MANIFOLDS
4. If equipped, install EBP sensor tube to exhaust

manifold and tighten nut.
5. Connect exhaust manifold to turbocharger
exhaust tube. Tighten bolts to the special torque
value.
Left Exhaust Manifold
Figure 94 Installing the Left Exhaust Manifold

1. Exhaust Manifold
Figure 92 Installing the Oil Level Gauge
2. Bolt
1. Oil Level Gauge
2. Nut
3. Right Exhaust Manifold 1. Apply Never-Seez to the threads of the manifold
bolts.
2. Install exhaust manifold (with gasket, if required).
3. Install oil level gauge. Secure oil level gauge
Secure with eight mounting bolts. Tighten bolts
bracket to stud bolt with nut.
in the specified sequence to the special torque
value.
3. Connect exhaust manifold to the turbocharger
exhaust tube. Tighten bolts to the special torque
value.
Figure 93 Installing the EBP Sensor Tube

1. EBP Sensor Tube
3. Exhaust Manifold
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MANIFOLDS 77
Right Intake Manifold Cover Left Intake Manifold Cover
NOTE: After the left or right intake manifold covers

have been installed, be sure to do the following steps:
Inspect and if necessary replace, compressor
outlet seal.
Install the compressor outlet seal.
Align and install charge air cooling and crossover
pipe and turbocharger manifold hoses as an Figure 96 Left Intake Manifold Cover Bolts
assembly.
Secure charge air cooling and crossover pipe to 1. Apply RTV sealant to mating surfaces of the intake
turbocharger by tightening the compressor outlet manifold cover.
clamp.
2. Install intake manifold cover onto the cylinder
Secure turbocharger manifold hoses to left, right head. Install ten manifold cover bolts and tighten
or both intake manifold covers by tightening the all bolts in the specified sequence to the special
four clamps (two per each hose). torque value.
Figure 95 Right Intake Manifold Cover Bolts
1. Apply RTV sealant to mating surfaces of the intake

manifold cover.
2. Install intake manifold cover onto the cylinder
head. Make sure the slotted bolt hole slides
under the installed bolt.
3. Place fuel filter mounting bracket onto intake
manifold cover. Secure with three mounting bolts
and finger tighten.
NOTE: If the fuel filter needs to be installed and

connected to the fuel lines, refer to Fuel Filter and
Piping, in the Fuel System section.
4. Install remaining manifold cover bolts and tighten
all bolts in the specified sequence to the special
torque value.
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78 MANIFOLDS
SPECIFICATIONS
Table 7 Manifolds
Between ports: 0.13 mm (0.005 in)
Maximum Allowable Warpage
Total: 0.25 mm (0.010 in)
Maximum Allowable Removal of Material 0.25 mm (0.010 in)
Special Torque
Table 8 Manifolds Special Torques

Intake Manifold Cover Bolts 24 Nm (18 lbfft)
Exhaust Manifold Mounting Bolts 61 Nm (45 lbfft)
Exhaust Manifold Flanges 28 Nm (21 lbfft)
Figure 97 Exhaust Manifold Mounting Bolt Torque Sequence
1. Start all exhaust manifold mounting bolts 2. Tighten all exhaust manifold mounting bolts to
into the holes by hand. Tighten all exhaust 61 Nm (45 lbfft) again in an inline sequence
manifold mounting bolts to 61 Nm (45 lbfft) from the rear to the front. Start at the arrow.
in the numerical sequence shown.
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MANIFOLDS 79
Figure 98 Intake Manifold Mounting Bolt Torque Sequence
Start all intake manifold mounting bolts into the holes

by hand. Tighten the mounting bolts to 24 Nm (18
lbfft) in the numerical sequence shown.
Table 9 Manifolds Special Service Tools

OEM1028 Straightedge
ZTS4385 Intake Manifold Cover Removal Tool
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80 MANIFOLDS
EGES-205
CYLINDER HEAD AND VALVES 81
Table of Contents
Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Remove Left Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Remove Right Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Disconnect Under Valve Cover Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Remove Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Remove Oil Director Spout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Remove Valve Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Remove Push Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Drain Fuel Gallery and Oil Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Remove Fuel Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Remove EBP and ICP Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Remove Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Check For Warp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Check Cylinder Head Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Check Valve Recession. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Surface Height Gauge Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Straightedge and Feeler Gauge Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Check for Valve Leakage (Using Mineral Spirits). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Check for Cracks (Using Dye Penetrant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Cylinder Head Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Refacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Valve Face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Valve Stem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Valve Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Valve Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Resurfacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
EGES-205
82 CYLINDER HEAD AND VALVES
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Valve Rotators And Retainer Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Cleaning And Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Testing Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Fuel Injector Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Cleaning Bores, Fuel Galleries and Oil Galleries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Install Valve Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Install Oil and Fuel Rail Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Oil Rail End Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Drain Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Oil Gallery Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Valve Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Fuel Injector O-rings And Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Cylinder Head Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Install Fuel Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Install Oil Director Spout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Install Push Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Install Valve Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Install Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Connecting Under Valve Cover Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Installing Valve Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
EGES-205
Figure 99 Exploded View of Cylinder Head, Valves and Valve Cover Components
1. Oil Filler Standpipe 10. Valve Retainer Key (32) 21. O-Ring (6)
2. Right Valve Cover 11. Valve Rotator (16) 22. Oil Gallery Plug (6)
3. Under Valve Cover (UVC) 12. Valve Spring (16) 23. Oil Rail Drain Plug (4)
Gasket (2) 13. Valve Seal (16) 24. O-Ring (4)
4. Right Intake Cover 14. Intake Valve (8) 25. O-Ring (4)
5. Lifting Eye (2) 15. Exhaust Valve (8) 26. Oil Rail End Plug (4)
6. Left Valve Cover 16. Pipe Plug (4) 27. O-Ring (4)
7. Valve Lever Assembly Mounting 17. Cylinder Head (2) 28. Fuel Gallery Drain Plug (4)
Bolt (32) 18. Cylinder Head Mounting Bolt 29. Coolant Expansion Cup Plug (4)
8. Intake Valve Lever Assembly (8) (36) 30. Steel Ball (8)
9. Exhaust Valve Lever Assembly 19. Cylinder Head Plug (8) 31. Cylinder Head Gasket (2)
(8) 20. Fuel Injector Sleeve (8)
EGES-205
Cylinder Head Disassembly Remove Right Valve Cover

Before removing the cylinder head, remove the 1. Disconnect the wiring harness from the UVC
following items. Refer to the appropriate section for gasket.
the correct removal procedure:
2. Remove the ECM and support bracket. See
Fuel lines and filter assembly Engine Electrical section for the procedure.
High pressure hydraulic lines
Engine harness connections
Remove Left Valve Cover
CAUTION: To avoid damage to the engine,

cover the turbocharger inlet port to eliminate
induction of debris.
1. Remove the crankcase breather elbow and road

draft tube.
2. Disconnect the wiring harness from the Under
Valve Cover (UVC) gasket. Figure 101 Removing the Oil Filler Standpipe
3. Remove the oil filler standpipe from the valve

cover.
Figure 100 Removing the Left Valve Cover

2. Valve Cover
Figure 102 Removing the Right Valve Cover
3. Remove valve cover mounting bolts. Remove the
valve cover from the cylinder head.
3. Valve Cover
NOTE: The breather does not need to be removed at
this point.
4. Remove the valve cover mounting bolts. Note the
location of the stud bolts. Remove the valve cover
from the cylinder head.
EGES-205
Disconnect Under Valve Cover Harness 2. Disconnect the solenoid connectors from the fuel
injectors by pushing the metal wire bail off the
solenoid and pulling the connector down.
Figure 103 Glow Plug Lead Connectors Figure 105 Removing the Valve Cover Gasket
1. Glow Plug Lead 1. Gasket With UVC Harness
2. Glow Plug Lead Connector 2. Fuel Injector Solenoid Harness Connectors
3. Glow Plug Leads
CAUTION: To avoid damage to the wiring 3. Remove valve cover gasket and the UVC wiring
harness DO NOT pull on the wire leads when harness from the cylinder head.
disconnecting the connectors from the glow
plugs and injectors. NOTE: The valve cover gasket is reusable.
1. Disconnect four glow plugs by pulling the Remove Glow Plug

connectors away from the glow plugs. DO
NOT pull on the wire leads.
Figure 104 Disconnecting the Connector From

the Fuel Injector Solenoid Figure 106 Removing the Glow Plug
1. Connector
2. Gasket Surface
Use a 10 mm (3/8 in.) deep socket, remove four glow
plugs from each cylinder head.
EGES-205
Remove Oil Director Spout Remove Valve Lever
CAUTION: To avoid engine damage, mark

the location of each intake and exhaust
valve lever assembly. The assemblies are
different and can be installed incorrectly if
not properly marked.
Figure 107 Removing Oil Director Spout

1. Mounting Bolt
2. Oil Director Spout
3. Fuel Injector
Figure 108 Removing the Valve Lever Assembly
1. Valve Lever Assembly
Remove the mounting bolt and oil director spout from 2. Mounting Bolt
each of the fuel injector hold down clamps.
Remove the valve lever mounting bolts. Lift the valve

lever assemblies from the cylinder head.
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Remove Push Rod Drain Fuel Gallery and Oil Rail
NOTE: BE SURE to mark each push rod so they can

be installed in their original position.
Figure 110 Front Fuel Gallery Drain Port

1. Fuel Gallery Drain Port
2. Fuel Gallery Drain Plug
Figure 109 Removing Push Rods
Remove the push rods from the cylinder head.
Figure 111 Rear Fuel Gallery Drain Port

1. Drain the fuel gallery by removing the fuel gallery

drain plugs located at the front and rear of the
cylinder head.
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Remove Fuel Injector
NOTE: Make sure the fuel rails and oil rails have been
drained before removing the fuel injectors.
Figure 112 Oil Rail Drain Ports (two per head)

1. Oil Rail Drain Plug
2. Oil Rail Drain Port
2. Drain the oil rail by removing the oil rail drain plugs
located under the valve cover in the high pressure Figure 113 Removing the Mounting Bolt for the
oil rail. Fuel Injector Hold Down Clamp
1. Fuel Inboard Shoulder Bolt
2. Fuel Injector Solenoid
3. Mounting Bolt
4. Fuel Injector Hold Down Clamp
1. Remove all mounting bolts from the outboard

(exhaust manifold side) fuel injector hold down
clamps.
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Figure 114 Disengaging the Fuel Injector Hold Down Clamp

1. Shoulder Bolt 2. Fuel Injector Hold Down Clamp
CAUTION: To prevent damage to the

shoulder bolt, make sure the fuel injector
hold down clamp is free of the shoulder bolt
when prying up on the clamp.
NOTE: The shoulder bolts on the inboard side are not

accessible and do not require removal.
2. Disengage the fuel injector hold down clamp from
the inboard shoulder bolt by sliding the clamp up
and away from the valve springs, then up and over
the head of shoulder bolt.
3. Use a fuel injector removal tool to remove the fuel
injector from the cylinder head bore. Install the "T"
screw into the hold down clamp. Insert the fulcrum Figure 115 Installing the "T" Screw Into the Hold
under the outboard side of the hold down clamp. Down Clamp
Turn the screw until the fuel injector is unseated. 1. "T" Screw
2. Hold Down Clamp
3. Fuel Injector
4. Fulcrum
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Remove EBP and ICP Sensors
NOTE: Before removing the left or right cylinder head

do the following:
RIGHT CYLINDER HEAD Disconnect and
remove the EBP sensor and tube from the right
hand exhaust manifold
LEFT CYLINDER HEAD Disconnect and
remove the ICP sensor from the cylinder head.
1. Disconnect EBP sensor from wiring harness.
Figure 116 Removing the Fuel Injector From the

Cylinder Head
1. Hold Down Clamp
2. Fuel Injector
3. Shoulder Bolt
4. Remove the fuel injector from the cylinder head

bore by lifting the fuel injector straight up and out.
Place the fuel injector in a fuel injector holder rack.
5. Remove the shoulder bolt (one per injector).
CAUTION: To avoid damage to the engine,

always replace the O-rings and seals
whenever a fuel injector is removed. Refer
to the Fuel Injector O-Rings and Seals
procedure in this section.
Figure 117 Removing the EBP Sensor

1. Bracket Mounting Bolt
2. EBP Sensor
3. EBP Sensor Tube
2. Loosen EBP sensor tube nut at front of right

exhaust manifold. Disconnect tube from manifold.
3. Remove two mounting bolts that secure the EBP
sensor bracket to the high pressure pump oil
reservoir.
4. Remove EBP sensor, bracket, and tube as a unit.
5. Disconnect ICP sensor from the wiring harness.
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Figure 118 Removing ICP Sensor Figure 120 Attaching the Lifting Bracket
1. Lifting Bracket
1. ICP Sensor
2. Lifting Bracket Mounting Bolts (4)
2. O-Ring
2. Use four lifting bracket mounting bolts, secure

6. Remove ICP sensor from left cylinder head. lifting bracket to the center of the cylinder head.
Discard O-ring.
Remove Cylinder Head
NOTE: Leave one mounting bolt installed at each end

of the cylinder head. Remove the other mounting
bolts. Cylinder head mounting bolts are flange head
type that do not require washers. All cylinder head
mounting bolts are the same length.
Figure 121 Removing Cylinder Head

1. Crankcase
2. Lifting Bracket
3. Cylinder Head
Figure 119 Removing Cylinder Head Mounting 3. Attach a suitable lifting hook to the lifting bracket.
Bolts Remove remaining two cylinder head mounting
bolts.
4. Lift cylinder head squarely from the crankcase
1. Loosen the mounting bolts evenly. Begin at each
and place it on a workbench.
end of the cylinder head and work toward the
middle. 5. Remove cylinder head gasket.
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Cleaning Inspection
Crankcase Cylinder head condition must be evaluated by
checking all of the following conditions.
1. Clean the crankcase to cylinder head mating
surface of any gasket material, dirt, grease and
any other foreign deposits.
Check For Warp
CAUTION:
To avoid damage to the engine, clean dirt

in threads or replace any damaged bolts
with equivalent sized, phosphate coated
bolts with a 10.9 hardness grade. Damaged
threads may cause binding and result in a
false torque reading.
2. Use a bottoming hand tap (M12 x 1.75) to clear the

cylinder head mounting bolt threads of all grease,
dirt, and other deposits.
3. Wash all cylinder head bolts with a suitable
solvent and dry them thoroughly.
Cylinder Head
Figure 122 Checking for Cylinder Head Warp
1. Remove lifting bracket from the cylinder head.
1. Straightedge
NOTE: When cleaning BE CAREFUL not to damage 2. Cylinder Head
the cylinder head gasket surface. 3. Feeler Gauge
2. With valves installed to protect the seats, use a

rotary wire brush or gasket scraper with mineral
Use a straightedge and feeler gauge to check the
spirits to remove any deposits and gasket material
cylinder head gasket surface for warp.
from the gasket surface of the cylinder head.
If specifications are not met, check thickness of the
3. Use a suitable solvent and brush to remove any
cylinder head before resurfacing. The minimum
dirt, grease and other deposits from all of the bolt
deck-to-deck dimension must be maintained after
holes, oil return holes, water passages and fuel
resurfacing.
galleries. Rinse thoroughly with hot water and dry
the cylinder heads with filtered compressed air.
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Check Cylinder Head Thickness Check Valve Recession

Surface Height Gauge Method
Figure 124 Checking for Valve Recession Using

a Surface Height Gauge
Figure 123 Checking the Cylinder Head
Thickness
1. Outside Micrometer 1. Set a surface height gauge on the cylinder head
2. Cylinder Head deck. Zero dial indicator.
2. Move dial indicator onto the valve face. Record
reading. If specification is not met, valve or
1. Refer to the left and right hand intake manifold cylinder head may require repair or replacement.
cover removal procedures, in the MANIFOLDS
section.
2. Use a 56 inch outside micrometer, measure
cylinder head thickness at six locations (four
corners and two central points). If minimum
deck-to-deck dimension is not met, replace
cylinder head.
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Straightedge and Feeler Gauge Method Check for Cracks (Using Dye Penetrant)
Figure 125 Checking for Valve Recession Using

a Straight Edge and Feeler Gauge
1. Straightedge
2. Feeler Gauge
Figure 126 Checking the Cylinder Head For
Cracks Using the Dye Penetrant Method
1. Place straightedge across valve.
1. Gasket Surface of the Cylinder Head
2. Insert a feeler gauge of proper size between
straightedge and valve face. Record reading. If
specification is not met, valve or cylinder head 1. Spray commercially available brake cleaner onto
may require repair or replacement. gasket surface of cylinder head. Wipe dry.
2. Spray on dye penetrant. Allow dye to remain for
130 minutes.
Check for Valve Leakage (Using Mineral Spirits)
3. Wipe dye off gasket surface. Dye will remain in
1. Position cylinder head on wood blocks with the cracks.
gasket surface facing down.
4. Spray on developer. Let dry for 515 minutes.
2. Squirt mineral spirits into intake and exhaust
ports.
3. Wait five minutes. Use an inspection mirror
to inspect valve seat area for any indication of
mineral spirits leakage.
There should be no leakage. Reconditioning is not
required if the cylinder head passes this valve leakage
check. If leakage is observed, the valves and seats
require reconditioning.
Figure 127 Crack in Cylinder Head
5. Cracks show up as purple lines against white

developer. If cracks are present, replace cylinder
head.
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Cylinder Head Pressure Test

Pressure testing the cylinder head will reveal cracks
in ports or sleeve leakage which cannot be observed
using the dye penetrant method.
1. Remove the valves. Refer to Valves, Removal for
the procedure.
Figure 129 Installing the Cylinder Head Pressure

Test Plate
1. Pressure Plate Mounting Bolts (18)
2. Pressure Plate
3. Pressure Gauge and Regulator
4. Remove the fitting or plug from the cylinder

head. Install the pressure test regulator/gauge
Figure 128 Installing the Fuel Injector Shoulder assembly.
Bolts 5. Fasten the pressure plate and plate gasket to the
1. Shoulder Bolt cylinder head gasket surface with the mounting
2. Cylinder Head bolts and nuts supplied with the kit.
6. Spray a soapy water solution into all of the valve
bores. Apply air pressure and adjust to 124-138
2. If removed, install the inboard injector shoulder kPa (18-20 psi). Check for leaks at the following
bolts into the cylinder head. Tighten the bolts to locations:
the special torque value
Ports
NOTE: Be careful not to damage the fuel injector tips Upper cylinder head deck
during this procedure.
Lower cylinder head deck
3. Install the fuel injectors into the cylinder
head injector bores. Refer to Cylinder Head Nozzle sleeve area
Assembly, Install Fuel Injectors for the
procedure.
CAUTION: To avoid engine damage, replace
the cylinder head if leakage is observed at
any port or at the upper or lower cylinder
head deck.
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Valves
Removal
Figure 132 Removing the Valve Seal From the

Valve Stem
1. Valve Seal
2. Valve Stem
Figure 130 Removing the Valve Retainer Keys
1. Valve Spring Compressor Tool
2. Valve Spring 5. Remove the valve seal from the valve stem and
3. Valve Assembly Retainer Keys discard.
6. Remove the valve from the cylinder head.
1. Use a valve spring compression tool to compress
the valve spring. Cleaning
2. Use a small magnet to remove the valve assembly Use a suitable solvent and a fine brass wire brush to
retainer keys. remove all carbon deposits from the valve stems and
valve heads.
Inspection
1. Inspect each valve. Replace any valves that show
evidence of burn marks, warp, scuffing, bending
or tip pitting.
2. Measure the valve stem diameter at three
locations at 120 intervals. Replace any valves
that do not meet the specification.
3. Use the measurements from Step 2 to determine
the valve stem-to-guide running clearance.
Figure 131 Removing the Valve Rotor and Subtract the valve stem diameter from the valve
Spring guide inside diameter. Refer to Inspection,
1. Valve Spring
Valve Guides for the procedure to determine the
2. Valve Rotator
valve guide inside diameter. Replace the valves
that exceed the specification.
3. Remove the valve rotator.

4. Remove the valve spring.
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Refacing
Valve Face
NOTE: Intake and exhaust valves have the same stem

length and diameter. However, the exhaust valve has
a dimple on the bottom of the valve.
Figure 134 Measuring the Valve Face Margin

Figure 133 Intake and Exhaust Valve
Comparison
4. Use a caliper to measure the valve face margin at
1. Exhaust Valve (With Dimple) four locations. Replace the valve if the margin is
2. Intake Valve less than the specification after grinding.
Valve Stem
1. Use a dressing stud attachment or grinder to
dress the cutting stone.
NOTE: Refacing the valve stem tip provides a new
2. Place the valve in the grinder collet set to the wear surface for the valve lever and compensates for
specified angle. Turn on the cutting oil. material that was removed during the valve refacing.
1. Dress the cutting stone by moving the dressing
stud attachment across the face of the cutting
CAUTION: To avoid engine damage, the stone until a uniform grinding surface is achieved.
minimum valve face margin must be
maintained across the entire valve face. 2. Place the intake or exhaust valve into the valve
An insufficient margin will not provide stem clamping "V. Turn on the cutting oil.
proper heat dissipation and will lead to valve
warp or breakage.
CAUTION: To avoid engine damage when
resurfacing the valve stem tip, leave
NOTE: Intake and exhaust valve margins and valve sufficient material so the valve lever does
face angles are different. See the Specifications for not contact the valve spring, retainers, or
the correct measurements for each. rotators during operation.
3. Grind the valve face. Remove only the minimum

amount of material that is necessary to true 3. Touch the valve stem tip to the cutting stone.
the valve face. Record the amount of material Remove only a minimum amount of material. Do
removed for later reference during valve stem not remove more material than was removed at
resurfacing. the valve face.
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Valve Guides Valve Seats

Cleaning Cleaning
With the valves removed from the cylinder head, clean Clean the valve seat area with a suitable solvent.
all valve guides in a soap and water solution with a
nylon brush. Blow out any remaining residue with
Inspection
filtered compressed air.
Inspect the exhaust valve seats for wear or burned
spots. Either of these conditions require valve seat
Inspection resurfacing. If a crack is found, the cylinder head must
be replaced.
1. Position an inspection light at the bottom of the
valve guide bores and examine the walls for
burning or cracking. Replace the cylinder head if Resurfacing
it does not pass inspection.
Figure 135 Measuring the Valve Guide Inside

Diameter
2. Measure each valve guide for wear. Use an

appropriate sized small hole gauge to check
the inside diameter of the valve guide at three
locations at the upper end and at the lower end.
Measure the small hole gauge with a 0-1inch
micrometer. Record the readings.
Figure 136 Installing a Pilot in the Valve Guide
If any valve guide inside diameter is over the
specification, replace the cylinder head. 1. Pilot
1. Lightly lubricate and install the correct size pilot

into the valve guide bore.
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NOTE: If a new valve does not correct an excessive

recession condition, replace the cylinder head. If the
valve face protrudes above the deck, the valve seat
must be ground deeper into the cylinder head. After
grinding a valve seat, check the seat width and confirm
valve seat contact by using Prussian Blue.
8. After grinding the valve seat, use a depth gauge
and micrometer to check the valve recession.
Valve recession should not exceed specifications.
9. After the valves have been resurfaced and the
valve guides have been cleaned, insert the valves
into the clean valve guide. Check the contact
between the valve face and valve seat using
Prussian Blue or equivalent as follows:
a. Spread a thin film of Prussian Blue on the
valve face. Insert the valve into its guide.
b. Apply pressure on the center of the valve
head while making a quarter turn into the
valve seat.
c. Remove the valve. Inspect the impression
made on the valve seat and the valve face.
d. A blue line should appear around the entire
Figure 137 Using a Grinding Stone contact surface of the valve seat and an
impression on the blue film of the valve face
should be centered. Check several times to
2. Choose the correct angle grinding stone and prevent error. If acceptable, proceed with
dress the stone. valve installation.
3. Install the grinding stone over the pilot. 10. For proof of results of refacing and to test seating
operations, recheck the valve recession. Refer
4. Lower the grinding head over the pilot shank until to Inspection, Check Valve Recession in this
the wheel contacts the valve seat. Turn on the section.
power and gently apply the wheel to the valve seat
with hardly any pressure other than weight of the A poor quality grind cannot be corrected by
grinding wheel itself. lapping. Inspect each valve for seat dimensions
and make any necessary corrections. Corrections
5. Raise the wheel frequently to prevent overheating. should always be made on the seat, not the valve
6. Grind the seat to a smooth even finish. face. If the recession is excessive, install a new
cylinder head. If the valve protrudes above the
7. After grinding, use a caliper to check the width deck, grind the valve seat.
of the valve seat. If the valve seat widths are
excessive, they may be corrected by grinding with
a 15 or less angled stone.
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Valve Springs
Cleaning
Clean all valve springs and valve retainer keys in a
suitable solvent.
Inspection
1. Inspect the inside and outside of the valve retainer
keys for wear. Replace any worn retainer keys.
2. Inspect the valve springs for rust, pitting and
cracks. Look for spring distortion.
Figure 139 Checking the Valve Spring Tension

1. Linear Scale
2. Valve Spring
3. Load Indicator
4. Use a valve spring tester to measure the valve

spring tension. Apply the appropriate test load
to each spring and refer to the specifications.
Measure maximum spring length in use (valve
closed) and the minimum spring length in use
Figure 138 Checking Free Length and Flatness (valve open).
of the Valve Spring
5. Replace any valve spring that is rusted, pitted,
cracked, bent or incapable of meeting the
specifications.
3. Check the free length and flatness of the valve
springs. The spring ends must be flat and square.
Springs that are out-of-square place a lateral load
on the stem, causing accelerated valve guide
wear.
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Valve Rotators And Retainer Keys 1. Place valve spring and rotator in spring tester.
Place a ball bearing between rotator and ram of
Cleaning And Inspection
the spring tester. The ball bearing must be large
1. Clean all rotators and retainer keys in a suitable enough to prevent the ram from touching any part
cleaning solvent. of the rotator.
2. Inspect retainer keys for any damage or extrusion. 2. Paint a reference line on the rotator.
Replace as sets if required.
3. Compress the valve spring rapidly with even
pressure and observe the rotator as it turns.
Replace any rotator that does not turn.
Testing Operation
CAUTION: To avoid damage, lubricate the

rotator with clean engine oil before testing
and reuse in the engine.
Figure 140 Testing Operation of Valve Rotators
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Fuel Injector Sleeve

Removal
CAUTION: To avoid engine damage, when

removing the fuel injector sleeve without
removing the cylinder head, place a cork
plug into the bore before performing the
following procedure. This will prevent debris
from entering the cylinder bore.
Figure 142 Removing the Fuel Injector Sleeve

1. Slide Hammer
2. Fuel Injector Sleeve Puller Tool
3. Install the fuel injector sleeve puller tool into the

fuel injector sleeve and tighten the tool. Make sure
the tool has been completely threaded into the fuel
injector sleeve.
Figure 141 Removing the Fuel Injector Sleeve

1. Fuel Injector Sleeve
2. Fuel Injector Bore
3. Fuel Injector Sleeve Removal Tool
4. Centering Collar
1. Install the fuel injector removal tool into the fuel

injector sleeve. Figure 143 Fuel Injector Sleeve Removed From
2. Turn the removal tool to cut threads into the fuel Bore
injector sleeve. Remove the tool from the bore. 1. Fuel Injector Sleeve Removal Tool
4. Thread the slide hammer into the fuel injector

sleeve removal tool. Remove the fuel injector
sleeve from the fuel injector bore.
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Cleaning Bores, Fuel Galleries and Oil Galleries
Figure 146 Cleaning the Oil Galleries

Figure 144 Cleaning the Fuel Injector Bore
1. Small Nylon Brush In Oil Gallery Port
1. Injector Sleeve Bottom Brush 2. Oil Galley Port
2. Fuel Injector Bore 3. Fuel Injector Bore
4. Remove the three oil gallery plugs and the high

1. Insert the injector sleeve bottom brush into the fuel
pressure oil supply fitting. Insert a small stiff nylon
injector bore to remove deposits and hardened
brush into each oil gallery.
sealant from the bore.
Figure 145 Oil Rail End Plugs

1. Oil Rail End Plug (two per cylinder head) Figure 147 Cleaning the Fuel Galleries
1. Small Nylon Brush In Fuel Gallery Port
2. Remove the two oil rail end plugs (one located at
each end of the cylinder head).
5. Remove the two fuel gallery plugs. Insert a small
3. Insert a stiff nylon brush into the oil gallery. stiff nylon brush into each fuel gallery.
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Figure 148 Cleaning the Fuel and Oil Galleries

With Compressed Air
1. Oil Gallery
3. Air Nozzle
6. Use filtered compressed air to clean out all debris

from the fuel and oil gallery ports.
Figure 150 Inserting the Fuel Injector Sleeve

Installation 1. Installation Tool
3. Hammer
3. Use a hammer to drive the fuel injector sleeve into

the fuel injector bore. Remove installation tool
when fuel injector sleeve is in place.
4. Inspect the fuel injector sleeve after installation.
Use a shop rag to remove any debris caused by
installation.
Figure 149 Preparing the Fuel Injector Sleeve The following cutaway shows fuel injector sleeve
for Installation installed into the fuel injector bore. Note areas where
fuel injector sleeve lands contact the cylinder head.
1. Installation Tool
3. Loctite Application Area
1. Attach a new fuel injector sleeve to the installation

tool. Apply Loctite #262 to the fuel injector sleeve
at the end and top.
2. Use installation tool to insert fuel injector sleeve
into fuel injector bore.
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1. Lubricate the valves with clean engine oil. Insert

the valve stems into their respective valve guide
bores in the cylinder head.
Figure 153 Installing the Valve Seal

Figure 151 Fuel Injector Sleeve Installed in 1. Valve Seal
Cylinder Head 2. Valve Stem
1. Fuel Injector
2. Cylinder Head
3. Loctite Application Area 2. Lubricate the inner diameter of the new valve stem
4. Fuel Injector Sleeve seals with clean engine oil. Install the seals over
each valve stem. Make sure the seal assembly is
seated against the cylinder head spring pockets.
Cylinder Head Assembly

Install Valve Assemblies
NOTE: The exhaust valve stems have a dimple on the

valve head.
Figure 154 Installing the Valve Rotators

1. Valve Spring
2. Valve Rotator
3. Install the valve spring over the stem seal

assembly.
Figure 152 Lubricating the Valve Stems
4. Install the valve rotators.
1. Oil Can
2. Exhaust Valve
3. Intake Valve
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1. Check the oil rail end plug for an identification

groove. New style oil rail end plugs feature an
identification groove. Replace old style end plug
with new style end plug.
Figure 155 Installing the Valve Assembly

Retainer Keys
1. Valve Spring Compression Tool
2. Valve Spring
3. Valve Assembly Retainer Key
5. Attach the valve spring compression tool and

compress the valve spring. Install the valve Figure 157 Oil Rail End Plugs
assembly retainer keys and release valve spring
compression tool. Make sure the retainer keys 1. Oil Rail End Plug (two per head)
are correctly seated on all valve stems.
6. After valve inspection, reconditioning and 2. Use a clean dry cloth and brake cleaner to
replacement/installation, measure the valve clean the cylinder head internal threads. Dry the
head recession relative to deck to confirm a good threads before installing the plug.
reconditioning job. Refer to the specifications.
CAUTION: To avoid engine damage, make

Install Oil and Fuel Rail Plugs
sure the threads of the oil rail end plugs are
Oil Rail End Plug free of any oily residue. Failure to do so may
result in leakage past the plugs.
3. Apply clean engine oil to the seals. Install the

seals onto the oil rail end plugs without getting oil
on the clean threads.
4. Apply a small bead of Loctite #277 around the
threads of the oil rail end plugs. Install the plugs.
Tighten oil rail end plugs to the special torque
value.
NOTE: Before engine operation, wait at least one hour

for the Loctite to cure.
Figure 156 New and Old Style Oil Rail End Plug
1. New Style Oil Rail End Plug With ID Groove
2. Old Style Oil Rail End Plug Without ID Groove
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Drain Plugs
CAUTION: To prevent engine damage, do

not apply sealant to threads of the oil drain
plugs. DO NOT use anti-sieze compounds,
grease, or any other lubricant except engine
oil. Other lubricants have an adverse effect
on torque values.
Figure 159 Location of Front Fuel Rail Drain

Plug
1. Fuel Gallery Drain Port
Figure 158 High Pressure Oil Rail Drain Plug

1. Oil Rail Drain Plug (two per head)
2. Torque Wrench
3. Oil Rail End Plug
1. Apply clean engine oil to a new O-ring for each of

the oil rail drain plugs (two per head).
2. Install the oil rail drain plugs into the cylinder head
ports. Tighten the oil rail drain plugs to the special
torque value.
Figure 160 Location of Rear Fuel Rail Drain Plug

3. Apply clean oil to a new O-ring for both of the fuel

rail drain plugs.
4. Install the two fuel rail drain plugs into the cylinder
head ports. Tighten the fuel rail drain plugs to the
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Oil Gallery Plugs Valve Lever

Disassembly
Figure 161 Installing the Oil Gallery Plugs

1. High Pressure Oil Supply Fitting
2. Oil Gallery Plugs (three per head)
3. Torque Wrench
Figure 162 Disassemble the Valve Lever

1. Install new O-rings on the three oil gallery plugs. 1. Valve Lever Clip
2. Valve Lever Post
2. Apply Loctite #262 onto the threads of the three
3. Chrome Ball
oil gallery plugs and the one high pressure oil
4. Valve Lever
supply fitting. Install the plugs and fitting into the
oil gallery ports located above each of the fuel
injector bores. Tighten the plugs and fitting to the
NOTE: BE SURE to keep all items of each rocker lever
together for installation in their original locations.
1. Carefully remove the valve lever clip that secures
the valve lever, valve lever post, and the 10 mm
(3/8 in) chrome ball.
2. Remove the chrome ball from the cup on the valve
lever.
3. Separate the valve lever from valve lever post.
Cleaning
Clean all parts with a suitable solvent and dry parts
using filtered compressed air.
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Inspection Assembly
Figure 164 Lubricating the Chrome Ball
1. Place the chrome ball on the valve lever cup.

Lubricate the chrome ball with clean engine oil.
Figure 163 Valve Lever Component Relationship
1. Retaining Clip
2. Valve Lever Post
3. Chrome Ball
4. Valve Lever
1. Inspect the valve stem ends and corresponding

valve lever pads for pitting or scuffing. Inspect
the chrome ball and ball socket in valve lever for Figure 165 Installing the Valve Lever Post
scuffing. Replace the levers as required.
2. Inspect the valve lever post ball socket for
excessive wear. Inspect the bolts for thread 2. Place the valve lever post on the chrome ball.
damage. Replace worn components as required.
Figure 166 Installing the Retaining Clip
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Fuel Injector O-rings And Seals

CAUTION: To avoid engine damage, install Removal
the retaining clip correctly. Failure to do so
could result in valve lever assembly coming
apart in the running engine. CAUTION: To avoid engine damage, all of
the O-rings and seals on the fuel injector
3. Snap the retaining clip over the valve lever post should be replaced anytime the fuel injector
groove. is removed. When removing or installing the
O-rings and seals, be careful not to scratch
the seal grooves of the fuel injector body.
Use a non-metallic tool (wood or plastic) to
remove the seals away from the grooves.
Failure to do so could result in fuel or oil
dilutions.
1. Remove the copper gasket from the bottom of the

fuel injector.
2. Lift the lower O-ring out of its groove. Cut and
remove the seal.
3. Lift the middle seal out of its groove. Cut and
remove the seal.
4. Lift the upper O-ring out of its groove. Cut and
Figure 167 Valve Lever Retaining Clip Position remove the seal.
1. Retaining Clip 5. Lift the upper cushion ring out of its groove. Cut
2. Valve Lever and remove the seal.
3. Valve Lever Post
6. Lift one corner of the backup ring from its groove.
4. Pivot Ball
Slide the rest of the backup ring from its groove
and over the tip of the fuel injector.
7. Make sure the fuel injector is clean and free of
debris. Place the fuel injector into a holder rack
where it will be protected from debris and damage.
EGES-205
Installation Upper Groove

1. Locate the upper grove seals.
2. Lightly lubricate the new upper groove seal with
clean engine oil.
CAUTION: The backup rings acts like a

spring. Be careful when installing this
part. Do not twist the ring. Ring flatness is
important or a tight seal will not be formed.
This could result in fuel or oil dilution.
3. Gently expand the ring. Slide the backup ring over

the body of the fuel injector and into the upper
groove.
4. Slide the cushion ring over the body of the fuel
injector. Push the cushion ring into the upper
groove. Make sure the cushion ring is against the
backup ring.
5. Slide the O-ring over the body of the fuel injector
and push it into the groove. Make sure the O-ring
is against the cushion ring.
Middle Groove
6. Locate the middle groove seal.
Figure 168 Fuel Injector O-Ring and Seal 7. Lightly lubricate the seal with clean engine oil.
1. Backup ring (Steel) 8. Slide the middle seal over the fuel injector body
2. Upper Cushion Ring and push into middle groove. Make sure the
3. Upper O-Ring Seal middle fuel injector seal is against the groove.
4. Middle Seal
5. Lower O-Ring Seal Lower Groove
6. Copper Gasket 9. Locate the lower groove seal.
10. Lightly lubricate the lower O-ring seal with clean
engine oil.
CAUTION: To avoid engine damage, when 11. Slide the lower O-ring seal over the fuel injector
installing the O-rings and seals onto the fuel body and into the lower groove. Make sure the
injectors, make sure all O-rings and seals are lower O-ring seal is against the groove.
located at the top of the grooves to prevent
them from rolling during installation. Also, 12. Apply a light coat of grease to a new copper
make sure the O-rings and seals do not twist gasket. Place the gasket over the fuel injector tip.
during installation. Failure to do so could 13. Place fuel injector back into the holder rack for
result in fuel or oil dilution. protection from damage and dirt.
EGES-205
Cylinder Head Installation

CAUTION: To avoid engine damage, DO
NOTE: Valve lifters cannot be replaced or removed NOT slide or drop the cylinder head on the
when the cylinder head is bolted onto the crankcase. cylinder head gasket. Either action could
Complete any required work to the valve lifters before damage the gasket and dowel sleeves and
installing the cylinder head. may result in a loss of compression or fluid
leakage.
NOTE: When installing the cylinder head, align the

dowel sleeves on both sides of the crankcase with the
mounting holes in the cylinder head.
4. Attach a lifting hook to the lifting bracket. Raise
the cylinder head and install it on the crankcase.
CAUTION: To avoid engine damage, DO NOT

use anti-seize compounds, grease, or any
other lubricant except engine oil. Other
lubricants have an adverse effect on torque
values.
Do not install painted cylinder head bolts in

a position under the valve cover. Paint chips
may contaminate the engine oil.
Figure 169 Installing the Cylinder Head Onto the

Crankcase
1. Crankcase
2. Lifting Bracket
3. Cylinder Head
4. Dowel Sleeve Figure 170 Lubricating the Cylinder Head
5. Piston Mounting Bolts
1. Cylinder Head Mounting Bolts (18)
2. Oil Can
1. If removed, install the two dowel sleeves (one at
the front and one at the rear of crankcase).
2. Place a new cylinder head gasket with the "UP" 5. Lightly lubricate all cylinder head mounting bolts
stamp facing towards the cylinder head. Do not (the threads and under the flange head) with clean
apply sealant to the head gasket surfaces. engine oil.
3. Install the cylinder head lifting bracket in the 6. Install the cylinder head mounting bolts. Tighten
center of the cylinder head. Tighten the bracket the mounting bolts in the special tightening
mounting bolts. sequences and to the special torque values.
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Install Fuel Injector
Figure 172 Open End Wrench Method

1. Hold Down Clamp
2. Wrench
Figure 171 Installing the Shoulder Bolt 3. Fuel Injector
1. Shoulder Bolt
2. Cylinder Head
Method One: Place the hold down clamp over the
shoulder bolt. Use a 16 mm (5/8 in) open end wrench
on the lower edge of the hold down clamp to seat the
1. Install the shoulder bolt and tighten it to the special
fuel injector.
torque value.
2. Lubricate the fuel injector O-rings. Insert the fuel
injector in the cylinder head bore.
3. Do not strike the top of the fuel injector to seat it.
Use one of the following methods to seat the fuel
injector in the bore.
Figure 173 Installation Tool Method

2. Fuel Injector
3. Hold Down Clamp
Method Two: Place a fuel injector installation tool

onto the fuel injector. Slide the forks between the hold
down clamp and the fuel injector head and rest the lip
of the tool on the cylinder head. Turn the bolt on the
installation tool to seat the fuel injector.
EGES-205
Install the oil director spout and secure it with an Allen

head bolt. Tighten the bolt to the special torque value.
Install Push Rods
NOTE: Clean push rods so the copper color ball end

of the push rod can be identified.
Figure 174 Installing the Fuel Injector Hold

Down Clamp Mounting Bolt
1. Hold Down Clamp
2. Fuel Injector
3. Mounting Bolt
4. Install the mounting bolt for the hold down clamp. Figure 176 Installing the Push Rods
Tighten the bolt to the special torque value. 1. Push Rod
Install Oil Director Spout Insert the push rods into their respective positions with
the copper color ball end up.
Figure 175 Installing the Oil Director Spout

1. Hold Down Clamp
2. Oil Director Spout
3. Allen Head Bolt
4. Fuel Injector
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Install Valve Lever Install Glow Plug
CAUTION: To prevent engine damage, make

sure the copper end of the push rods are
up before proceeding. Then insert the other
end into the hydraulic roller lifter seats before
installing the valve lever assemblies.
1. Rotate the crankshaft until the vibration damper

notch is 15 from vertical (1 oclock position
when viewed from the front of the engine). This
positions all pistons below TDC so the valves
cannot contact the pistons when tightening the
valve lever assemblies.
Figure 178 Installing the Glow Plugs
1. Glow Plug
2. Torque Wrench
Apply Never-Seez to the threads of the glow plugs.

Install the glow plugs into the cylinder head. Tighten
the glow plugs to the special torque value.
Connecting Under Valve Cover Harness
Figure 177 Installing the Valve Lever Assembly

1. Push Rod Assembly
3. Valve Lever Mounting Bolt Figure 179 Installing the Valve Cover Gasket
1. Gasket With UVC Harness
2. Lubricate the valve lever assemblies and bolts 2. Fuel Injector Solenoid Harness Connectors
with clean engine oil. 3. Glow Plug Leads
3. Place the valve lever assemblies in their original

locations over the cylinder head mounting pads. 1. Position the valve cover gasket with the UVC
Install retaining bolts finger tight. harness onto the cylinder head.
4. Tighten the valve lever mounting bolts to the 2. Connect the electrical leads to the glow plugs by
special torque value. pressing the connector onto the glow plugs.
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Installing Valve Covers
Figure 180 Connecting the Connector to the Figure 181 Installing the Left Valve Cover
Fuel Injector Solenoid 1. Mounting Bolt (10)
1. Connector 2. Valve Cover
2. Gasket Surface
3. Connect the fuel injector electrical connector by

inserting the connector into the socket. Push the
connector up and secure it with the metal wire bail.
4. Make sure all UVC wiring is free and clear of any
moving parts and free of possible entrapment by
the valve cover.
Figure 182 Installing the Right Valve Cover

2. Mounting Studs Bolt (6)
3. Valve Cover
1. Place the valve cover onto the gasket. Be careful

to avoid pinching any UVC wires.
2. Install the mounting bolts finger tight. Make sure
that the stud bolts on the right valve cover are
installed in the correct locations.
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Crankcase Breather
Removal
Figure 183 Valve Cover Torque Sequence
3. Tighten the mounting bolts in the specified

sequence and to the special torque value.
Figure 185 Removing the Crankcase Breather

1. Mounting Screws
2. Crankcase Breather Assembly
3. Left Valve Cover
1. Loosen the hose clamps that secure the road draft

tube to the crankcase breather. Remove road
draft tube from crankcase breather.
Figure 184 Installing the Oil Filler Standpipe 2. Remove the two screws that secure the crankcase
breather to the valve cover. Remove the
crankcase breather.
4. On the right valve cover, install the oil filler
standpipe.
Cleaning
5. Connect the wiring harness connector to the UVC
gasket. Clean the breather element in solvent. Dry the
breather element with filtered compressed air.
6. After the valve cover is installed, refer to the
appropriate procedures about installing the glow
plug relay, turbocharger air inlet elbow, road draft
tube, and ECM.
EGES-205
Installation
CAUTION: To avoid damage to the engine BE
SURE the large O-ring seals are located on
the valve cover and the small O-ring seals are
under the mounting screw head. Failure to
do so can result in the O-rings falling into the
cylinder head causing damage to the engine.
1. Install the large O-rings onto the crankcase

breather and the small O-rings onto the mounting
screws.
2. Insert the mounting screws into the crankcase
breather.
3. Align the crankcase breather assembly with the
two mounting holes on left valve cover. Tighten
the screws to the special torque value.
Figure 186 Installing the Crankcase Breather 4. Install the road draft tube to the crankcase
1. Mounting Screws
breather. Tighten the hose clamps that secure
2. Large O-Ring Seals
the tube to the crankcase breather.
3. Crankcase Breather Assemble the following after the cylinder head is
4. Left Valve Cover installed. Refer to the appropriate section for correct
installation procedures.
Fuel lines and filter assembly
High pressure hydraulic lines
Engine harness connections
ECM
EGES-205
SPECIFICATIONS
Table 10 Cylinder Head

Exhaust Valves
Stem Diameter 7.9210-7.9388 mm (0.31185-0.31255 in)
Stem To Guide Clearance (Max. Allowable Before
0.140 mm (0.0055 in)
Replacement)
Face To Stem Runout (T.I.R. Max.) 0.05 mm (0.002 in)
Valve Face Angle 37.5
Valve Face Margin (Min.) 1.37 mm (0.054 in)
Intake Valves
0.140 mm (0.0055 in)
Replacement)
Valve Face Angle 30
Cylinder Heads
Inside Diameter Of Valve Guide 7.978-8.004 mm (0.3141-0.3151 in)
Valve Guide Taper (Max.) 0.10 mm (0.004 in)
Valve Seat Width (intake and exhaust) 1.65-2.41 mm (0.065-0.095 in)
Valve Seat Angle (intake) 30
Valve Seat Angle (exhaust) 37.5
Valve Seat Run Out (T.I.R. Max.) 0.05 mm (0.002 in)
Gasket Surface Flatness 0.025 mm in 0.5 mm (0.001 in. in 2 inches) 0.10 mm (0.004 in) overall
Gasket Surface Finish (Micro Inches) 63-125
Deck To Deck Dimension (Head Thickness
129.41-129.67 mm (5.095-5.105 in)
Overall)
Valve Head Recession Relative To Deck (Head Gasket) Surface On Cylinder Head
Intake 1.17-1.47 mm (0.046-0.058 in)
Exhaust 1.32-1.63 mm (0.052-0.064 in)
Valve Spring
Free Length 52.70 3.8 mm (2.075 0.150 in)
Test Length 34.34 mm (1.352 in)
Load at Test Length 102-113 kg (225-249 lbf)
Push Rod Runout/Straightness (Max. T.I.R.) 0.518 mm (0.02 in)
EGES-205
Special Torque
Table 11 Cylinder Head Special Torques

Crankcase Breather Screws 2 Nm (18 lbfin)
Initial: 54 Nm (40 lbfft)
Cylinder Head Mounting Bolts (special torque
Second: 95 Nm (70 lbfft)
sequences)
Final: 129 Nm (95 lbfft)
Fuel Injector Hold Down Clamp Mounting Bolt 14 Nm (120 lbfin)
Fuel Injector Shoulder Bolt 14 Nm (120 lbfin)
Fuel Rail End Plugs 16.3 Nm (12 lbfft)
Glow Plugs 19 Nm (14 lbfft)
ICP Sensor 29 2 Nm (21.5 1.5 lbfft)
Oil Deflector Mounting Bolt 12 Nm (106 lbfin)
Oil Fill Deflector 1116 Nm (812 lbf-ft)
Oil Rail Drain Plugs 6.8 1 Nm (60 10 lbfin)
Oil Rail End Plugs 81 Nm (60 lbfft)
Oil Rail Plugs 29 2 Nm (21.5 1.5 lbfft)
Valve Cover Bolts (special torque sequence) 11 Nm (8 lbfft)
Valve Lever Mounting Bolt 27 Nm (20 lbfft)
Figure 187 Valve Cover Bolt Special Torque Sequence
1. Start all bolts by hand and finger-tighten.
EGES-205
2. Torque bolts to the special torque value in the

sequence shown.
Figure 188 Cylinder Head Mounting Bolt Special Torque Sequence
1. Tighten to 54 Nm (40 lbfft) in numbered 3. Tighten to 129 Nm (95 lbfft) in line sequence.
sequence.
4. Tighten to 129 Nm (95 lbfft) again in line
2. Tighten to 95 Nm (70 lbfft) in numbered sequence.
sequence.
EGES-205
Table 12 Cylinder Head Special Service Tools

OEM1004 Outside Micrometer (56 inch)
OEM1014 Dial Caliper
OEM1023 Small Hole Gauge Set
OEM1272 Defect Detection Kit (Dye Penetrant)
OEM6343 Cleaning Brush
OEM6459 Surface Height Gauge Tool
ZTSE1631A Eccentric Valve Seat Grinder
ZTSE1846 Valve Spring Compressor
ZTSE1879 Slide Hammer Puller Kit
ZTSE2241 Valve and Clutch Spring Tester
ZTSE4297 Cylinder Head Lifting Bracket
ZTSE4299 Fuel Injector Holder Rack
ZTSE4300 Fuel Injector Removal Tool
ZTSE4301 Fuel Injector Tip Cleaning Brush
ZTSE4302A Fuel Injector Sleeve Removal Tool
ZTSE4303 Fuel Injector Sleeve (Adapter) Replacer
ZTSE4304 Fuel Injector Sleeve Cleaning Brush Set
ZTSE43042 Injector Sleeve Bottom Brush
ZTSE4308 Cylinder Head Pressure Test Plate
ZTSE4320 Oil and Fuel Gallery Brush Cleaning Set (Consists of 4 brushes)
ZTSE4353 Fuel Injector Installation Tool
ZTSE43862 Hand Tap (Bottoming M12 X 1.75)
ZTSE43021A Injector Sleeve Tap
EGES-205
OIL PAN, VIBRATION DAMPER, OIL PUMP WATER PUMP, AND 123
FRONT COVER
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Oil Pick-Up Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Vibration Damper Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Front Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Oil Pick-Up Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Vibration Damper Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Front Cover and Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Front Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Oil Pick-Up Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
EGES-205
124 OIL PAN, VIBRATION DAMPER, OIL PUMP WATER PUMP, AND
FRONT COVER
EGES-205
FRONT COVER
Figure 189 Oil Pump and Pick-Up Assembly

1. Vibration Damper 8. Front Cover
2. Front Seal 9. Front Cover Gasket (2)
3. Oil Pump Housing 10. Oil Pick-Up Tube Bracket
4. Oil Pump Gerotor Assembly 11. Oil Pan
5. Outer Oil Pump Gerotor 12. Oil Pick-Up Tube Gasket
6. Inner Oil Pump Gerotor 13. Oil Pick-Up Tube
7. Oil Pump Housing Gasket
EGES-205
FRONT COVER
Removal
Oil Pan
NOTE: BE SURE oil pan has been drained before

removing.
Figure 192 Removing the Oil Pan From the

Crankcase
4. Pry the oil pan down on one side to break the RTV
sealant at the front cover and rear plate. Roll the
oil pan off to the side to free it from the engine.
Figure 190 Removing Oil Pan Mounting Bolts

Oil Pick-Up Tube
1. Remove the oil filter.
2. Remove the oil pan mounting bolts.
Figure 193 Removing the Oil Pick-Up Tube

Figure 191 Cutting the RTV Sealant on the Oil 2. Oil Pick-Up Tube
Pan 3. Support Bracket
1. Hammer 4. Bracket Nut
2. RTV Sealant Cutting Tool
3. Oil Pan
Remove the two mounting bolts and the bracket nut
from the oil pick-up tube. Remove the oil pick-up tube.
3. Use a cutting tool to cut through the RTV sealant
on both oil pan rails.
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FRONT COVER
Vibration Damper
Figure 195 Removing the Vibration Damper

Figure 194 Checking the Vibration Damper Mounting Bolt
Runout 1. Vibration Damper
1. Paint Removal Areas (4 locations at 90 intervals) 2. Washer
2. Dial Indicator 3. Mounting Bolt
2. Remove the vibration damper mounting bolt.

1. Before removing the vibration damper, check the
Remove the washer and loosely install the
vibration damper runout as follows:
mounting bolt so the puller does not damage the
bolt threads during removal.
NOTE: Pry only in one direction to eliminate any
possible error induced by crankshaft end play.
a. Remove any paint from the face of the
vibration damper at four points 90 apart.
b. Attach a magnetic base dial indicator to the
front of the crankcase or oil pan. Position the
indicator point on the unpainted surface.
c. Pry the crankshaft forward and zero the
indicator. The zero point is now the baseline.
d. Turn the crankshaft 90 and pry the crankshaft
forward. Record the reading.
Assembly
e. Repeat Step d at each unpainted surface.
1. Vibration Damper
If the runout exceeds specifications, replace
2. Puller
vibration damper.
3. Forcing Screw
4. Removal Bolts (3)
3. Mount the vibration damper removal tool to the

damper with the three bolts that are provided.
4. Insert the forcing screw and turn it in against the
mounting bolt. The vibration damper will be pulled
off the crankshaft. Remove the mounting bolt and
the damper.
EGES-205
FRONT COVER
Vibration Damper Wear Sleeve Front Oil Seal
NOTE: Whenever the vibration damper is removed,

the vibration damper wear sleeve must be replaced.
Make sure the vibration damper has been cleaned
and inspected before proceeding with the wear sleeve
removal.
Figure 198 Removing the Front Oil Seal

1. Oil Pump Housing
2. Front Oil Seal
3. Oil Seal Removal Tool
Use the oil seal removal tool to pry the front oil seal
from the oil pump housing.
Oil Pump

Wear Sleeve
1. Vibration Damper Figure 199 Removing Oil Pump Housing
2. Wear Sleeve Removal Tool Mounting Bolts
3. Wear Sleeve
1. Retainer Bolts (4)
2. Oil Pump Housing
1. Install the wear sleeve removal tool on the

vibration damper.
1. Remove the four mounting bolts for the oil pump
2. Turn the forcing screw to remove the wear sleeve. housing.
EGES-205
FRONT COVER
3. Remove inner gerotor gear by sliding it off

crankshaft.
Water Pump
1. Remove the coolant filter from the water pump
housing.
2. Remove the mounting bolts that secure the water
pump to the front cover.
Figure 200 Removing Oil Pump Housing and

Outer Gerotor Gear
1. Oil Pump Housing
2. Seal Ring
3. Outer Gerotor
2. Remove the oil pump housing with seal ring and

the outer gerotor. Discard the seal ring.
NOTE: The crankshaft woodruff key can remain in Figure 202 Water Pump Mounting Bolts
place when removing the inner gerotor.
1. 30 mm (11/4 in)
2. 60 mm (21/2 in)
3. 100 mm (4 in)
3. Remove and discard the water pump gasket.
Figure 201 Removing Inner Gerotor From

Crankshaft
1. Inner Gerotor
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FRONT COVER
Front Cover 1. Remove the four front cover mounting bolts and
four water pump mounting bolts that secure the
front cover to the crankcase.
Figure 205 Removing the Front Cover From the

Crankcase
1. Front Cover
Figure 203 Front Cover and Mounting Bolts 2. Front Cover Gaskets
1. Front Cover
2. Mounting Bolts
2. Remove the front cover from the crankcase.
3. Remove and discard the gaskets from the front
NOTE: Refer to Water Pump Removal if removing the cover.
water pump.
Cleaning
Oil Pan
Thoroughly clean the RTV sealant from the oil pan and
crankcase mating surfaces and from the bolt holes in
the crankcase and oil pan.
Vibration Damper
CAUTION: Do not immerse the vibration

damper in a petroleum based solvent.
Damage to the rubber damping element may
result.
Clean the vibration damper with soap and water. Dry

Figure 204 Water Pump and Mounting Bolts it with filtered compressed air.
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FRONT COVER
Oil Pump Use a protractor to measure the angle between the

timing mark and the center of the key way. If the angle
Wash all parts thoroughly in a suitable solvent. Dry
is not 164 , replace the vibration damper.
the parts with filtered compressed air.
Oil Pump
Water Pump
1. Inspect the gerotors and housing for nicks, burrs
Wash the water pump thoroughly in a suitable cleaning
or scoring. Replace any damaged components.
solvent. Dry the pump with filtered compressed air.
Front Cover CAUTION: When placing the inner and outer

gerotors into the oil pump housing, make
Clean the RTV sealant and gasket material from the sure the word "damper" is facing the oil
front cover, crankcase and mating surfaces. pump housing. Failure to do so will result in
engine damage.
Inspection NOTE: The inner and outer gerotors are a matched

Oil Pick-Up Tube set. They cannot be replaced separately.
Inspect the pick-up tube for cracks at the seams and 2. Place the inner and outer gerotors in the oil pump
brazed connections. Replace the tube if required. housing.
Vibration Damper
Figure 207 Inspecting Gerotors For Wear

1. Outer Gerotor
2. Oil Pump Housing
3. Feeler Gauge
Figure 206 Vibration Damper Components

1. Keyway 3. To check for wear, use a feeler gauge to measure
2. Inner Member the radial clearance between the outer gerotor
3. Rubber Member and the pump housing.
4. Outer Member
5. Timing Mark
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FRONT COVER
Water Pump
Inspect the water pump for cracks and damage.
Replace the pump if necessary.
Front Cover
1. Inspect the front cover for cracks and damage.
2. Place the mounting surface of the front cover on
a smooth flat surface and check for warp.
3. Replace the front cover if cracked, damaged or
warped.
Figure 208 Checking the Oil Pump End

Clearance
1. Oil Pump Housing
2. Gerotors
3. Feeler Gauge
4. Straightedge
4. Check the oil pump end clearance as follows:

a. With the O-ring removed and the gerotors
in place in the oil pump housing, place a
straightedge across the housing.
b. Insert a feeler gauge under the straightedge
at the inner and outer gerotors and compare
the end clearance with the specification.
5. If the measurements are not within the
specifications, replace the components as
required.
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FRONT COVER
Installation NOTE: Make sure the vibration damper is clean and

free of oil before installing the wear sleeve.
Vibration Damper Wear Sleeve
1. Apply Loctite #271 around the inside diameter of
the wear sleeve. Place the wear sleeve onto the
wear sleeve installation tool.
2. Position the wear sleeve in the installation tool so
the outer chamfer is facing toward the tool.
3. Place the installation tool on a press table.
Position the vibration damper over the wear
sleeve installation tool and lower the damper onto
the wear sleeve installation tool.
4. Use a press to apply pressure to the inner member
of the vibration damper until the installation tool
bottoms out or seats.
Figure 209 Installing the Vibration Damper Wear

Sleeve
1. Wear Sleeve Installation Tool
2. Wear Sleeve
3. Loctite #271
4. Vibration Damper
5. Press
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FRONT COVER
Front Cover and Water Pump
CAUTION: Failure to properly install the

front cover may result in engine damage.
To properly install the front cover, the water
pump must be installed before tightening
the front cover mounting bolts. Four of the
water pump mounting bolts also secure the
front cover.
Figure 211 Installing the Front Cover to the

Crankcase
1. Front Cover
2. Front Cover Mounting Bolts
2. Fasten the front cover to the crankcase. Install the

front cover mounting bolts finger tight.
Figure 210 Installing the Gaskets and Applying
3. Place a new gasket in the water pump gasket
RTV to the Front Cover
groove.
1. New Gaskets
2. Sealant Locations
3. Front Cover CAUTION: Failure to properly mount the
water pump and obtain a correct seal may
result in engine damage. To properly mount
1. Position two new gaskets on the front cover. Apply the water pump and obtain a correct seal,
RTV sealant in the remaining grooves of the front install the water pump mounting bolts into
cover and around the front cover dowel pins. their proper locations.
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FRONT COVER
6. Apply a thin coat of new coolant to the coolant

filter gasket. Thread the coolant filter onto the filter
header.
7. Tighten the filter until the gasket touches the
header. Tighten it by hand an additional 1/2 turn.
8. Open the coolant filter shutoff valve on the water
pump.
Oil Pump
Figure 212 Water Pump Mounting Bolts

CAUTION: When installing the inner and
1. 30 mm (11/4 in) outer gerotor, make sure the word "damper"
2. 60 mm (21/2 in) is facing towards the front of the engine.
3. 100 mm (4 in) Failure to do so will result in engine damage.
4. Install the water pump on the front cover. Install

the water pump mounting bolts and tighten the
bolts to the standard torque values.
5. Tighten the front cover mounting bolts to the
standard torque value.
Figure 214 Installing the Inner Gerotor

1. Inner Gerotor
1. Install the inner gerotor over the crankshaft

nose with the word damper facing the oil pump
housing.
Figure 213 Installing Coolant Filter

1. Front Cover
2. Water Pump
3. Coolant Filter
4. Coolant Filter Shutoff Valve (ON Position)
5. Coolant Filter Shutoff Valve (OFF Position)
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FRONT COVER
Figure 215 Installing Outer Gerotor and Square

Cut Ring
Figure 216 Installing the Oil Pump Housing
1. Oil Pump Housing
2. Outer Gerotor
3. Seal Ring 5. Align dowel pins and install oil pump housing with
seal ring and large gerotor gear onto crankshaft.
2. Lubricate the outer gerotor with clean engine oil. 6. Install four oil pump housing mounting bolts.
Install the gerotor in the oil pump housing with the Tighten bolts to standard torque value.
word damper facing the oil pump housing.
3. Pack cavities between and around the gerotor with
an all purpose assembly grease to insure proper
priming at engine startup.
4. Install square cut seal ring in the oil pump housing
groove.
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FRONT COVER
Front Oil Seal
Figure 218 Seating the Front Oil Seal

1. Forcing Nut
Figure 217 Installing Front Oil Seal 2. Installation Tool
3. Oil Seal
1. Damper/Crankshaft Oil Seal Installation Tool
2. Oil Seal
3. Oil Pump Housing 2. Position the installation tool over the forcing screw
4. Crankshaft and tighten the forcing nut. Make sure the tool
5. Forcing Screw bottoms out against the housing so the oil seal is
fully seated in the housing.
1. Place front oil seal onto the installation tool. Apply

a thin coat of Aviation Permatex No. 3 to the
outside diameter of the seal.
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FRONT COVER
Vibration Damper
1. Apply RTV sealant to the vibration damper
keyway. This prevents oil seepage through
damper keyway. Align the keyway in the damper
with the key on the crankshaft and install the
damper.
Figure 220 Securing the Vibration Damper to

the Crankshaft
1. Vibration Damper
Figure 219 Installing the Vibration Damper
Installation Tool
1. Installer Plate 5. Apply RTV sealant to the washer and underside
2. Vibration Damper of the bolt head. Install the washer and mounting
3. Forcing Nut bolt. Tighten the bolt to the special torque value.
NOTE: ZTSE4310 is a combination tool. One side is Oil Pick-Up Tube

used to install the front oil seal while the other side is
used to install the vibration damper.
2. Assemble the puller screw, installer plate, thrust
washer and nut.
3. Turn nut to draw the vibration damper onto the
crankshaft.
4. Remove the installation tool.
Figure 221 Installing the Oil Pick-Up Tube

O-Ring
1. Install the O-ring on the oil pick-up tube mounting

flange. If necessary, use a small amount of RTV
sealant to hold the O-ring in place.
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FRONT COVER
Figure 223 Apply RTV Sealant to the Crankcase

Rails
Figure 222 Installing the Oil Pick-Up Tube 2. Apply RTV sealant to the entire crankcase
mounting surface to prevent leaks. Apply more
at the front and rear mating surfaces. Apply the
2. Oil Pick-Up Tube
sealant between and around the bolt holes.
3. Support Bracket
4. Bracket Nut 3. Install guide studs at two places on the crankcase
to ensure proper oil pan alignment. Install the oil
pan.
2. Install the oil pick-up tube and mounting bolts.
Tighten the bolts finger tight.
3. Adjust the bracket at the main bearing cap stud
and install the nut. Tighten the mounting bolts
to the standard torque value after alignment.
Tighten the bracket nut at the main bearing cap
stud last.
Oil Pan
CAUTION: Do not apply excessive amounts

of RTV sealant. Some could end up in the oil
pick-up screen and restrict oil flow. Such a
restriction may result in engine damage. To Figure 224 Oil Pan Bolt Hole Locations
avoid damaging the crankcase, make sure no
sealant gets in the bolt holes.
4. Install mounting bolts finger tight. Remove the
guide studs. Replace them with mounting bolts.
1. Wipe excess oil and foreign matter from all oil pan Tighten all mounting bolts to the standard torque
sealing surfaces. Use brake cleaner to thoroughly value.
degrease all sealing surfaces before applying
RTV sealant.
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FRONT COVER
SPECIFICATIONS
Table 13 Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tube and Front Cover
Lubricating Oil Pump
Type Gerotor
End Clearance - inner and outer rotor to housing 0.02-0.08 mm (0.001-0.003 in)
Radial clearance between outer rotor housing 0.71-0.81 mm (0.028-0.032 in)
Engine Lube Oil Pressure at Operating Temperature
At low idle speed (700 rpm) minimum 69 kPa (10 psi)
At high idle speed 241-483 kPa (35-70 psi)
Engine Oil Capacity
Without filter 17 liters (18 quarts)
With filter 18.5 liters (19.5 quarts)
Vibration Damper
Vibration damper mounting area runout (maximum) 0.13 mm (0.005 in)
Special Torque
Table 14 Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tube and Front Cover Special
Torques
Oil Pan Mounting Bolts 34 Nm (25 lbfft)
Oil Pick-Up Tube Flange Mounting Bolts 24 Nm (18 lbfft)
Vibration Damper Mounting Bolt 287 Nm (212 lbfft)
Water Pump Pulley Mounting Screw 41 7 Nm (30 5 lbfft)
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FRONT COVER
Service Tools
OEM1028 Magnetic Base Dial Indicator
ZTSE229569 Vibration Damper Removal Tool
ZTSE4300 Fuel Injector/Front Oil Seal Removal Tool
ZTSE4310 Front Oil Seal/Vibration Damper Installation Tool
ZTSE4314 Vibration Damper Wear Ring Removal Tool
ZTSE4315 Vibration Damper Wear Ring Installation Tool
ZTSE4385 Oil Pan Removal Tool
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FRONT COVER
EGES-205
VALVE TRAIN: PUSH RODS, HYDRAULIC VALVE LIFTERS AND 143
CAMSHAFT
Table of Contents
Push Rods and Hydraulic Valve Lifters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Leak Down Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Camshaft and Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

Check Gear Backlash and Camshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Assembling Cam Gear to Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Installation of Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
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144 VALVE TRAIN: PUSH RODS, HYDRAULIC VALVE LIFTERS AND
CAMSHAFT
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CAMSHAFT
Figure 225 Valve Train Components

1. Camshaft Gear 5. Valve Push Rod
2. Thrust Plate 6. Copper Colored End
3. Camshaft 7. Valve Lever
4. Hydraulic Valve Lifter 8. Valve
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CAMSHAFT
Push Rods and Hydraulic Valve Lube oil from the oil gallery is supplied to the lifters
Lifters through a hole in the side of the lifter body that indexes
with a groove and hole in the lifter plunger. Oil is then
Operation metered past the oil metering valve, up through the
push rods and onto the valve levers.
NOTE: As a general rule, hydraulic valve lifters should
not require any service if they are operating quietly When the lifter begins to roll up the cam lobe, the
and functioning satisfactorily. metering valve is held against its seat in the plunger
body by the spring. This action traps the oil in the base
of the lifter body below the plunger. The plunger body
and lifter body then rise as a unit, pushing the push
rod up in order to open the valve. The spring force
exerted on the plunger through the valve lever and
push rod causes a slight amount of leakage between
the plunger and lifter body.
"Leak down" is the term used to describe this leakage.
Leak down allows a slow escape of trapped oil in the
base of the lifter body. As the lifter rides down the
other side of the cam lobe and reaches the base circle
Figure 226 Valve Lifter Components or "valve closed" position, the plunger spring quickly
1. Lifter Body with Roller
moves the plunger back up to its original position. This
2. Spring
movement causes the check valve to open against the
3. Plunger
check valve spring and allows oil to be replenished
4. Plunger Body
from the oil gallery. This restores the lifter to zero lash.
5. Metering Valve
6. Push Rod Seat
7. Retainer
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CAMSHAFT
Removal
CAUTION: To avoid engine damage, the

valve lifters and push rods must be kept in
order so they can be installed in their original
positions.
Figure 229 Removing the Valve Lifter

1. Valve Lifter
3. Remove the hydraulic valve lifters from the

crankcase. Note the orientation of the lifters
within the bore so they can be installed later in
their original positions.
Disassembly
Figure 227 Removing the Push Rods
1. Push Rod
1. Remove the push rods from the crankcase.
Figure 230 Disassembling the Valve Lifter

1. Lifter Body with Roller
2. Plunger Spring
3. Plunger
4. Plunger Body
5. Metering Valve
6. Push Rod Seat
7. Retainer
Figure 228 Removing the Valve Lifter Guide
1. Valve Lifter Guide
2. Valve Lifter 1. Use a small screwdriver to remove the push rod
seat retainer.
2. Remove the push rod seat and metering valve.
2. Remove the retaining bolt from the center of each
valve lifter guide. Remove the valve lifter guides 3. Remove the plunger, plunger body, and plunger
from the crankcase. spring.
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CAMSHAFT
Cleaning NOTE: the valve lifter roller is crowned by design.

Therefore, a normal wear pattern will typically be
Clean the push rods and all the parts of the hydraulic
centered on the roller contact surface.
valve lifters with a suitable cleaning solvent. Dry the
parts with filtered compressed air. 5. Inspect the roller for pitting or roughness.
Inspection Assembly
1. Inspect all disassembled parts for nicks, burrs or
scoring. If signs of damage are evident, replace
the entire hydraulic valve lifter. CAUTION: To avoid engine damage after
assembly, perform a leak down test to
2. Inspect each push rod for wear and deposits that ensure that leakage past the plunger and
may restrict the flow of oil into the valve lever lifter body is correct. This assures that the
assemblies. Replace the push rods as required. check valve is functioning properly.
Figure 231 Checking the Push Rod Flatness

Figure 232 Assembling the Valve Lifter
3. Check all cleaned push rods by rolling them 1. Lifter Body with Roller
on a flat surface. If they are not straight or are 2. Plunger Spring
questionable, refer to the specifications for push 3. Plunger
rod runout. If the specifications are exceeded, 4. Plunger Body
replace the push rod. 5. Metering Valve
6. Push Rod Seat
7. Retainer
CAUTION: If the roller fails any one of the
following inspection criteria, the camshaft
lobes must be inspected for damage. Failure 1. Coat all hydraulic valve lifter parts with clean
to do so may result in damage to the engine. engine oil.
2. Install the plunger spring and plunger into the
plunger body, then into the lifter body.
4. While pushing on the valve lifter roller in a normal
direction of load, check for free rotation of the 3. Install the metering valve and push rod seat into
roller. Check the axial movement between the pin the valve lifter body. Secure the components with
and roller. a retaining ring.
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CAMSHAFT
Leak Down Test Installation
Figure 234 Installing the Valve Lifters Into the

Crankcase
1. Hydraulic Valve Lifters
Figure 233 Valve Lifter Tester
2. Piston
This test is used to determine whether leakage past

1. Lubricate the valve lifters with clean engine
the plunger and lifter body is correct and whether the
oil. Install the valve lifters into their respective
check valve is functioning properly.
bores within the crankcase. Maintain the original
direction of rotation.
NOTE: Use a test fluid specified by the tool
manufacturer. Make sure that the fluid is at room
temperature.
Use a hydraulic valve lifter tester to check the leak
down rate. Follow the instructions that come with the
testing unit.
The leak down rate is how many seconds it takes for
the plunger to move a specified portion of the distance
it will travel while under a 23 kg (50 lb) load. Refer to
the specifications.
Figure 235 Installing the Valve Lifter Guide

1. Valve Lifter Guide
2. Valve Lifter
2. Install the valve lifter guides over the hydraulic

valve lifters. Secure each guide to the crankcase
with a retaining bolt and tighten the bolts to the
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CAMSHAFT
Camshaft and Gear

CAUTION: To ensure the compatibility of the Check Gear Backlash and Camshaft End Play
metallic mating surfaces of the valve lever,
push rod, and valve lifter, the copper colored
end must face up when installed. Be aware
that the two rounded ends of each push rod
are made of different materials.
Figure 237 Checking the

Camshaft-to-Crankshaft Gear Backlash
1. Dial Indicator
2. Camshaft Gear
Figure 236 Installing the Push Rods

1. Before removing the camshaft, check and record
1. Push Rod the camshaft gear-to-crankshaft gear backlash as
follows:
3. Make sure the copper colored ball end is facing a. Mount a dial indicator on the front of the
up. Insert the push rods into their respective engine.
positions. b. Position the dial indicator tip on a gear tooth
and remove all lash.
c. Place a small pry bar between the camshaft
and crankcase. Lightly pry the camshaft
forward.
d. Zero the dial indicator while lightly prying the
camshaft forward.
e. Rotate the gear by hand while lightly prying
the camshaft forward. Record the amount of
backlash.
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CAMSHAFT
Removal
NOTE: Check the valve lifters for wear prior to any

camshaft replacement. Remove the valve lifters and
push rods before camshaft removal.
NOTE: If the engine is mounted on a turn over stand,

rotate the engine so that the front of engine is facing
up to a vertical position. This position allows for easy
removal of the camshaft assembly.
Figure 238 Checking the Camshaft End Play

1. Dial Indicator
2. Reposition the dial indicator and check the

camshaft end play as follows:
a. Push the camshaft toward rear of engine. Figure 239 Removing the Cam Gear Thrust Plate
Mounting Bolts
b. Zero the dial indicator.
1. Cam Gear Thrust Plate Bolts
c. Place a small pry bar between the camshaft 2. Camshaft Gear
gear and crankcase. Lightly pry the camshaft
forward. Compare the dial indicator reading
with the specifications. 1. Remove the two cam gear thrust plate mounting
d. If the end play exceeds the specifications, bolts.
replace the camshaft.
e. Remove the dial indicator.
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CAMSHAFT
Cleaning
Wash the camshaft in cleaning solvent with a soft
brush. Dry it with filtered compressed air.
Inspection
NOTE: This engine uses hydraulic valve lifters with

roller followers. Therefore, a lifter guide is needed
to maintain proper roller-to-cam lobe orientation.
Normal clearance between hydraulic valve lifter and
guide allows slight tracking of the roller across the
cam lobe.
The tracking of a hydraulic valve lifter roller is

a normal characteristic as the roller accelerates
and decelerates during typical engine operation.
Consequently, a typical wear pattern on the cam
lobes will exhibit tracks from side to side and will
have wide and narrow areas from the loading and
unloading of the follower. The visual wear pattern
(tracking) is normal. It does not require camshaft
replacement.
Figure 240 Removing the Camshaft Assembly
1. Inspect camshaft. If any lobes are scuffed, scored
1. Camshaft Assembly
or cracked, replace the camshaft.
2. Use a micrometer to measure camshaft journal
2. Remove the camshaft from the crankcase by diameter. If the journals are worn beyond
lifting the assembly straight up. specifications, replace camshaft.
3. Use a hydraulic press to remove the camshaft
gear from the camshaft, if necessary.
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CAMSHAFT
Assembling Cam Gear to Camshaft

injury or possibly death, use welding gloves
for this procedure.
CAUTION: The replacement cam gear and

timing disk assembly have been accurately
timed at the factory. Because accurate
timing upon reassembly cannot be assured,
do not disassemble these components.
Disassembly may consequently result in
engine damage.
Figure 241 Checking Camshaft Lobes
1. Camshaft
2. Micrometer
3. Use a micrometer to check camshaft lobe wear.

Measure across lobes (A-C and B-D). Subtract
dimension B-D from dimension A-C. This is the
cam lobe lift. Replace camshaft if cam lobe wear
exceeds specifications.
4. Inspect the thrust plate for wear, cracks and
distortion. Use a micrometer to measure thrust
plate thickness. Replace the thrust plate if it is
damaged or worn beyond the specification.
5. Inspect the camshaft drive gear for worn or
damaged teeth. Inspect the CMP sensor timing
disk attached to the front face of the cam gear. If
either of these components is worn or damaged,
replace the gear and timing disk as an assembly. Figure 242 Assembling the Cam Gear Onto the
Camshaft
1. Gear Teeth
2. Timing Disk
1. Heat the cam gear and timing disk assembly in an

oven to 260 C (500 F).
2. While the assembly is heating, position the
camshaft vertically near the oven. Clean the nose
of the camshaft.
3. Install the thrust plate on its journal and place the
cam gear key in its slot.
EGES-205
CAMSHAFT
4. Wear welding gloves to remove the cam gear

assembly from the oven. Quickly align the
gear keyway with the key and position the gear
assembly over the nose of the camshaft until
the gear is seated against the retaining flange
shoulder.
5. Allow the assembly to cool before installing the
camshaft in the engine. Do not quench.
Installation of Camshaft
NOTE: If new parts are installed, make sure the gear

backlash and end play are within specifications.
1. Coat the camshaft lobes and bushing journals
with clean engine oil.
NOTE: Avoid nicking or scratching the camshaft

bushings by the cam lobes.
Figure 244 Indexing the Cam Gear and
Crankshaft
1. Cam Gear
2. Crankshaft Gear
3. Crankshaft Gear Timing Mark
4. Cam Gear and Timing Disk Marks
3. Index the cam gear and crankshaft gear so timing

marks are aligned when the camshaft is in place.
Figure 243 Installing the Camshaft Assembly

1. Camshaft
2. Position the crankcase on engine the stand with Figure 245 Installing the Thrust Plate Bolts
the front facing up. Carefully install the camshaft 1. Crankshaft
assembly. 2. Camshaft Gear
3. Crankcase
4. Install two thrust plate mounting bolts. Tighten the

bolts to the special torque value.
EGES-205
CAMSHAFT
SPECIFICATIONS
Table 16 Valve Train

Camshaft
Bearing Journal Diameter (All Journals) 53.31-53.34 mm (2.099-2.100 in)
Bearing (Bushing) Inside Diameter 53.39-53.48 mm (2.102-2.105 in)
Journal/Bushing Running Clearance 0.051-0.165 mm (0.002-0.006 in)
Camshaft End Play 0.051-0.203 mm (0.002-0.008 in)
Timing Gear Backlash 0.140-0.2794 mm (0.0055-0.0110 in)
Maximum Permissible Cam Lobe Wear 0.51 mm (0.020 in)
Journal Surface Finish (microinches) 16 in
Camshaft Thrust Plate Thickness 3.910-3.960 mm (0.154-0.156 in)
Camshaft Lobe Lift
Intake 6.44 mm (0.2535 in) max.
Exhaust 6.43 mm (0.2531 in) max.
Valve Timing No. 1 Cylinder (Top of Ramp)
Intake Open 17.2 BTDC
Closed 34.8 ABDC
Exhaust Open 51.2 BBDC
Closed 20.8 ATDC
Hydraulic Valve Lifters
Diameter 23.391-23.411 mm (0.9209-0.9217 in)
Bore Diameter In Crankcase 23.439-23.477 mm (0.9228-0.9243 in)
Clearance In Bore 0.027-0.086 mm (0.0011-0.0034 in)
Bleed Down Rate Time required for plunger to move
3.175 mm (0.125 in) under a 50 lb load using test 18-90 seconds
fluid at room temperature
Special Torque
Table 17 Valve Train Special Torques

Cam Follower Guide Mounting Bolt 20 Nm (15 lbfft)
EGES-205
CAMSHAFT
Table 18 Valve Train Special Service Tools

OEM1000 Micrometer
ZTSE1893 Hydraulic Valve Lifter Tester
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CRANKCASE, CRANKSHAFT, CONNECTING RODS, AND PISTONS 157
Table of Contents
Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Resurfacing (Manual Transmissions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Installation of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Check Flywheel Housing Bore Concentricity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Check Flywheel Housing Face Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Check Flywheel Surface Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Check Crankshaft Pilot Concentricity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Installation of Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Rear Oil Seal and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Rear Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Connecting Rods, Pistons and Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

Check Piston Protrusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Checking Connecting Rod Side Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Check Width of Top Compression Ring Groove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Checking Side Clearance Of Oil Control Ring And Intermediate Compression Ring Groove. . .175
Piston Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Check Piston Ring End Clearance in Cylinder Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Check Inside Diameter of Piston Pin Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Check Connecting Rod Bearing Bore for Out-of-Round and Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Check Connecting Rod for Bend or Twist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Check Piston Pin Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Bearing Fitting Procedure For Old Style Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Assembly Old Style Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Assembly New Style Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Installation Old Style Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Installation New Style Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Crankshaft and Main Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
EGES-205
158 CRANKCASE, CRANKSHAFT, CONNECTING RODS, AND PISTONS
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Check Crankshaft Journals for Out-of-Round and Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Installation of Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Main Bearing Fitting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Installation of Main Bearing Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Check Crankshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Crankcase Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Inspect Short Circuit Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Replace Crankcase Cup Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Check Crankcase Surface for Flatness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Check Cylinder Bore for Out-of-Round and Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Deglazing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Camshaft Bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200

Check for Wear and Proper Running Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
EGES-205
Figure 246 Crankcase, Flywheel Housing And Related Parts

1. Front Camshaft Bushing 11. Valve Lifter Guide Retainer 20. Main Bearing Cap Stud (1)
2. Camshaft Bushing (2nd 5th) 12. Valve Lifter Guide Bolt 21. Short Mounting Bolt (10)
3. Crankcase 13. RTV, Liquid Gasket 22. Long Mounting Bolt (9)
4. Short Circuit Oil Plug 14. Rear Crankcase Cover 23. Pipe Plug (4)
5. Short Circuit O-Ring 15. Rear Oil Seal 24. Piston Cooling Tube (8)
6. Short Circuit Spring 16. Flywheel Housing 25. Pipe Plug (2)
7. Short Circuit Ball 17. Flywheel Housing Plate Cover 26. Dowel Pin (2)
8. Seat, Ball 18. Flywheel Housing Baffle (If 27. Pipe Plug (5)
9. Cup Plug (7) Equipped) 28. Plug (3)
10. Dowel Sleeve (4) 19. Main Bearing Cap (5) 29. Dowel Pin (2)
EGES-205
Figure 247 Crankshaft, Flywheel Or Flexplate, And Related Components

1. Crankshaft Gear 8. Flywheel (Manual transmission)
2. Crankshaft Key (2) 9. Flywheel Adapter (Automatic
3. Crankshaft Bearings (Nos. 1, 2, Transmission)
3 and 4) 10. Flexplate (Automatic
4. Thrust Bearing No. 5 Transmission)
5. Crankshaft 11. Reinforcement Ring (Automatic
6. Coiled Spring Pin Transmission)
7. Flywheel Ring Gear
EGES-205
Flywheel and Flywheel Housing

Removal
Figure 248 Connecting Rods, Pistons and Rings

1. Piston Ring Set
2. Piston
3. Piston Pin Figure 249 Removing the Flywheel
4. Retainer Rings 1. Flywheel and Ring Gear Assembly
5. Piston Assembly 2. Flywheel Mounting Bolts (10)
6. Pin Bushing 3. Guide Studs
7. Connecting Rod
8. Connecting Rod Bearings
9. Connecting Rod Bolts (2) NOTE: For automatic transmissions with the older
10. Connecting Rod Nuts (2) style flexplate: remove the reinforcement ring,
flexplate, and adapter before removing the flywheel.
For automatic transmissions with the newer style
flexplate, there is no flywheel. The ring gear is
installed directly onto the flexplate.
1. Remove two flywheel mounting bolts, one at the 3
oclock position and one at the 9 oclock position.
Install two guide studs in their place.
2. Remove the remaining flywheel mounting bolts.
Slide the flywheel out of housing and off the guide
studs. With the flywheel removed, the guide studs
can be removed.
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Resurfacing (Manual Transmissions)
Figure 250 Removing the Flywheel Housing

Flange Bolts
3. Remove six flywheel housing flange mounting

bolts and slide the flywheel housing off the
crankcase dowels. Figure 251 Flywheel Reconditioning
1. Flywheel Dimensions (NEW 45.822 mm 0.254
mm (1.804 0.010 in)) (Minimum Permissible After
Cleaning Resurfacing 36 mm (1.430 in))
Clean the flywheel with a non-caustic solvent. Dry the 2. Clutch Disc and Cover Plate Mounting Face
flywheel with filtered compressed air. 3. Crankshaft Flange Mounting Face
Inspection Flywheel machining information is provided for

guidance only. International Truck and Engine
Corporation assumes no responsibility for the results
of any work performed in accordance with this
WARNING: A crack or heat check in the information or for the ability of service personnel to
flywheel could cause it to separate and injure detect heat cracks.
the operator or bystanders. If any damage is
found, discard the flywheel.
1. Inspect the flywheel for cracks, heat checks, and

extensive scoring which would make it unfit for
further use. Replace the flywheel if any of these
defects are found or suspected.
2. Inspect the ring gear for worn, chipped or cracked
teeth. If the teeth are damaged, replace the ring
gear or flexplate depending on vintage.
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Installation of Flywheel Housing
WARNING: To avoid personal injury

and possible death, observe the following
warnings:
Resurfacing should be carried out by
a skilled technician using specialized
equipment for this function.
The flywheel may be ground to correct
minor wear and scoring. New flywheels
have a thickness of 45.822 mm 0.254
mm (1.804 0.010 in). DO NOT grind
beyond the minimum permissible
thickness of 44.907 mm (1.768 in).
Replace the flywheel if it is not repairable
by surface grinding. Figure 252 Installing the Flywheel Housing
Remove material from clutch face only. 1. Flywheel Housing Mounting Bolts
2. Torque Wrench
After resurfacing, check the flywheel for cracks
and heat checks. If any cracks or heat checks are
detected, replace the resurfaced flywheel with a new 1. Slide the flywheel housing onto the guide pins.
one. 2. Install six flywheel housing mounting bolts finger
tight to secure the housing to the crankcase.
3. Tighten the mounting bolts to the standard torque
value.
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Check Flywheel Housing Bore Concentricity Check Flywheel Housing Face Runout
CAUTION: Bore concentricity and face

runout checks are performed to ensure
proper engine to transmission alignment.
Improper bore concentricity and face runout
may result in reduced transmission life.
Figure 254 Checking the Flywheel Housing Face

Runout
Keep crankshaft end play at zero in the same direction

for all measurements.
1. Attach a dial indicator magnetic base to the
flywheel and place the indicator tip against
housing face.
2. Measure at four points 90 apart for a total
Figure 253 Checking the Flywheel Housing Bore
face variation. Compare the average to the
Concentricity
specification for the flywheel housing face runout
1. Dial Indicator tolerance.
2. Indicator Tip
3. Magnetic Base

crankshaft and place the indicator tip against the
flywheel housing bore.
2. Zero the dial indicator.
3. Rotate the crankshaft slowly and record the
total indicator variation. Compare the result
to the specification for flywheel housing bore
concentricity.
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Check Flywheel Surface Runout Installation of Flywheel
Figure 255 Checking Flywheel Surface Runout

flywheel housing and place the indicator tip Figure 256 Installing the Flywheel
against the flywheel surface.
1. Flywheel and Ring Gear
2. Rotate the crankshaft slowly and record the total 2. Flywheel Mounting Bolts
indicator variation. Refer to the specification for 3. Guide Studs
the tolerance.
1. Install a flywheel guide stud into the 3 oclock and

Check Crankshaft Pilot Concentricity 9 oclock positions of the crankshaft.
1. Attach a dial indicator magnetic base to the 2. Install the flywheel over the guide studs. Secure
flywheel housing and place the indicator tip the flywheel to the crankshaft with eight mounting
against the flywheel pilot. bolts finger tight.
2. Rotate the crankshaft slowly and record the total
indicator variation. Refer to the specification for NOTE: For automatic transmissions with the older
concentricity tolerance. style flexplate, install the flywheel adapter, flexplate,
and reinforcement ring onto the flywheel. Make sure
the lip of the reinforcement ring is facing outward.
Then install the eight mounting bolts.
For automatic transmissions with the newer style

flexplate, there is no flywheel. The ring gear is
installed directly onto the flexplate.
3. Remove the two guide studs and install the
remaining two mounting bolts. Tighten all ten
bolts to the special torque value.
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Rear Oil Seal and Wear Sleeve

Removal
Rear Oil Seal
Figure 258 Rear Oil Seal Mounting Bolts

1. Rear Oil Seal/Retainer
Figure 257 Flywheel Housing Baffle (if equipped) 4. Remove five bolts that secure the rear oil seal to
the rear crankcase cover.
2. Flywheel Housing Baffle
1. If not already done, remove the flywheel from

the housing. Refer to Flywheel and Housing
Removal in this section.
2. If equipped, remove the three mounting bolts
securing the flywheel housing baffle to the
flywheel housing.
3. Remove the flywheel housing baffle.
Figure 259 Cutting Through RTV Sealant

1. Hammer
2. Rear Crankcase Cover
3. RTV Cutting Tool
4. Seal/Retainer
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5. Use a cutting tool to cut through the RTV sealant

on the rear oil seal.
6. Remove the rear oil seal from the crankshaft and
rear cover plate.
Wear Sleeve
Figure 261 Removing the Wear Sleeve

1. Wear Sleeve Removal Tool
2. Wear Sleeve
3. Crankshaft
3. Discard the wear sleeve and inspect the

crankshaft flange for damage.
Installation
Figure 260 Installing the Wear Sleeve Removal
Tool NOTE: If the rear cover is going to be removed, do not
install the rear oil seal until the rear cover is installed.
1. Wear Sleeve Removal Tool
2. Forcing Screw
1. Mount the wear sleeve removal tool around the

wear sleeve on the crankshaft flange.
2. Turn the forcing screw to remove the wear sleeve.
Figure 262 Installing the Rear Oil Seal

Installation Tool
1. Alignment Dowels
3. Rear Crankcase Cover
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1. Install the rear oil seal installation tool onto the

crankshaft flange. Install two rear seal alignment
dowels.
2. Apply RTV sealant to the outer diameter of the
crankshaft seal flange. Also apply a bead of RTV
sealant around each bolt hole and the inside
diameter of the bolt hole pattern to the crankshaft
seal flange.
Figure 264 Installing the Rear Oil Seal Driver

1. Seal/Retainer
4. Install the driver over the centering tool. Tighten

the forcing screw to drive the wear sleeve and rear
seal into position.

1. Alignment Dowel
2. Crankshaft Seal Flange
3. Pilot Or Centering Tool
3. Place the seal and wear sleeve assembly over the

centering tool and position the seal retainer over
the alignment dowels. Make sure the seal retainer
and crankcase dowels align as the seal is being
installed.

1. Seal/Retainer
2. Rear Oil Seal Retainer Bolts (5)
5. Install the retainer bolts. Tighten the bolts to the

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Rear Cover Installation

Removal
CAUTION: If the rear cover is bent, replace it.
Failure to do so may result in engine damage.
CAUTION: To avoid damage to the rear cover,
make sure the rear oil seal is removed. Refer
to Rear Oil Seal and Wear Sleeve in this 1. Replace any missing or damaged dowel pins.
section.
Figure 267 Applying RTV to the Rear Cover

1. Rear Cover
2. RTV Sealant
3. Rear Cover Groove
Figure 266 Removing the Rear Cover

2. Apply RTV sealant to the groove in the rear cover
1. Dowel Pins and around the bolt and dowel pin holes.
2. Rear Cover Bolt Locations (8)
3. Place the rear cover over alignment dowels and
against the crankcase and install the mounting
1. Remove rear cover mounting bolts. bolts. Tighten the mounting bolts to the standard
torque value.
2. Gently pry the rear cover away from crankcase,
breaking the RTV sealant bond in the process. Do 4. Install the rear oil seal.
not bend the rear cover.
Cleaning Connecting Rods, Pistons and

1. Use a scraper or wire brush to remove the RTV Piston Rings
sealant and any foreign material from the rear
Check Piston Protrusion
cover/oil pan mating surfaces.
2. Use a commercially available brake cleaner
to clean the crankcase and rear cover gasket CAUTION: Lack of protrusion could indicate
surfaces. The surfaces must be free of oil for a damaged rod or a rod bearing out of
good adhesion of RTV sealant during installation. position. Excessive protrusion may require
replacement of rods or crankshaft. To avoid
3. Wipe and dry the surfaces with a clean shop cloth.
engine damage correct as required.
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NOTE: Before removing any piston and connecting 1. Use a razor knife or emery board to scrape carbon
rod assemblies, it is recommended that piston ridge from top of cylinder bore.
protrusion be evaluated. This will help identify bent
or twisted connecting rods.
1. Check piston protrusion above crankcase as CAUTION: For newer style connecting rods,
follows: keep the fractured mating surfaces clean
and free of lint and debris. Do not allow
2. Turn the crankshaft so the piston is just below the mating surfaces to rest on any surface.
crankcase deck surface. Do not bump the mating surfaces or drop
3. Place and zero a dial indicator gauge on the connecting rod or cap. This could
crankcase deck surface. cause chipping and wear on the mating
surface, resulting in improper mating during
4. Position tip of dial indicator gauge onto the piston installation and possible engine damage.
head at the 3 oclock position. (Positioning the dial
indicator tip at 12 oclock or 6 oclock will not yield
an accurate measurement).
5. Turn the crankshaft so the piston is at the highest
point of its stroke and record the reading.
6. Turn the crankshaft to reposition the piston to just
below the crankcase surface.
7. Reposition dial indicator tip onto piston head at the
9 oclock position.
8. Turn the crankshaft so the piston is at the highest
point of its stroke and record the reading. Then
average the two readings.
Figure 268 Connecting Rod Locations

Checking Connecting Rod Side Clearance 1. Connecting Rod Nuts or Bolts (16)
Use a feeler gauge to check connecting rod side 2. Connecting Rod (8)
clearance as follows: 3. Crankshaft
4. Connecting Rod Location Mark
1. Pry apart a pair of connecting rods on a crankshaft 5. Connecting Rod Cap (8)
rod journal. Insert largest feeler gauge to check
clearance.
2. Repeat for each pair of connecting rods on 2. Rotate crankshaft to position journals for removal
each crankshaft rod journal and compare with of connecting rod assemblies.
specifications. 3. Mark each connecting rod and its respective rod
cap with the cylinder number before removing
them from the engine. Also mark the rod caps for
Removal correct orientation to each rod.
CAUTION: To avoid piston damage, if a

carbon ridge is evident at the top of the
cylinder bore, remove carbon ridge prior
to removing the connecting rod and piston
assemblies. This reduces the chance of
piston ring land damage during removal.
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Figure 269 Removing the Connecting Rod Cap

1. Connecting Rod Cap Figure 270 Installing the Connecting Rod Guide
2. Connecting Rod Nut or Bolt Protector Caps (Old Style Connecting Rod)
1. Connecting Rod Nut (16)
2. Connecting Rod Cap (8)
CAUTION: There are two style connecting 3. Connecting Rod (8)
rods being used: 4. Connecting Rod Guide Protector Caps (2)
5. Crankshaft
Older style connecting rods use
mounting nuts. The mounting nuts
should turn freely off the connecting b. Old style connecting rods: install aluminum
rod studs. If binding exists, check for connecting rod guide protector caps over the
bent or damaged threads to avoid engine connecting rod studs to prevent damage to
damage. the crankshaft rod journals.
Newer style connecting rods use
self-retained bolts. Connecting rod bolts
should turn freely. If binding exists,
check thread condition carefully during
inspection to avoid engine damage.
4. Unscrew the two connecting rod mounting nuts or

bolts. Remove the connecting rod cap.
5. Remove the piston and connecting rod
assemblies from the crankcase as follows:
a. Rotate the engine into a vertical position (front
end up).
Figure 271 Pushing the Old Style Connecting
Rod and Piston Out Of the Cylinder Bore
1. Wooden Handle
2. Protector Cap
3. Connecting Rod
4. Crankcase
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Figure 272 Pushing the New Style Connecting Figure 274 Removing Piston and Connecting
Rod and Piston Out Of the Cylinder Bore Rod Assembly from Crankcase
d. Once the piston rings are free of the cylinder

c. Use a wooden or plastic handle to push the
bore, remove the assembly from the top of the
connecting rod and piston assembly out of the
crankcase.
cylinder bore.
6. Mark each connecting rod and its respective
bearing cap with the cylinder number from which
they were removed.
CAUTION: On engines using fractured

connecting rods: DO NOT alter or damage
the fractured mating surfaces of the
connecting rod and cap.
Figure 273 Removing Old Style Piston and

Connecting Rod Assembly from Crankcase
Figure 275 Matching Cap and Connecting Rod

Numbers
7. Upon removal, make sure matching connecting

rod and cap remain together as a set. A cap from
one connecting rod is not interchangable with any
other connecting rod.
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Disassembly 1. Use a piston ring expansion pliers to remove the

piston rings. Remove the top ring first, then the
intermediate ring, and finally the oil control ring.
CAUTION: To avoid engine damage, mark
the pistons with the cylinder number from
which each was removed. Each piston must
be reinstalled into its original cylinder bore WARNING: To avoid personal injury,
if the pistons are being reused. wear safety glasses when removing retaining
rings.
CAUTION: To avoid engine damage, make a

note of the engine serial number (stamped
on the crankcase pad, left side rear of the
crankcase) and piston part number (stamped
on the piston crown). There are multiple
pistons available for service applications.
Do not install any pistons unless they all
have matching part numbers.
Replacement of the flywheel / flexplate and

vibration damper may also be necessary
depending on engine serial number. Some
engines have pistons with a greater mass,
resulting in the need for a flywheel / flexplate Figure 277 Removing the Piston Retaining Ring
and vibration damper with inertia values that (New Style Connecting Rod Shown)
compliment the additional mass. See your
International Dealer for details.
2. Separate the connecting rod from the piston as
follows:
a. Use piston retaining ring pliers to remove the
two piston pin retaining rings.
b. Remove the piston pin from the bore by hand.
c. Separate the connecting rod from the piston.
3. Repeat procedure for each piston / connecting rod
assembly which needs to be disassembled.
Cleaning
NOTE: Never use a caustic solution or a wire brush to

Figure 276 Removing the Piston Rings clean aluminum pistons. Never use a bead blaster on
pistons.
1. Piston Ring Expander Tool
2. Piston 1. Use a soap and water solution to clean the
3. Piston Ring aluminum pistons. Soak the pistons, then clean
4. Connecting Rod the piston with a nonmetallic brush.
2. Clean all piston ring grooves thoroughly.
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3. The following disassembled components may be

cleaned using a suitable solvent.
Piston pins
Piston pin retainers
Connecting rods
4. Thoroughly clean all connecting rod bolt holes and
threads.
Inspection
1. Inspect the pistons for scuffed or scored skirts,
cracked or worn ring lands, and cracked or scuffed
pin bores. Replace as required.
Figure 278 Measuring Top Compression Ring
NOTE: Faulty piston rings cannot always be detected Groove
by visual inspection. Therefore, whenever a piston is 1. Piston gauge pins
removed from a cylinder, it is recommended that the
piston rings be replaced.
2. Inspect the new piston rings for cleanliness. 1. Check top compression ring groove for wear as
follows:
3. Inspect the connecting rod studs or bolts for nicks
and damage.
4. Inspect the connecting rod and cap mating CAUTION: There are two different size
surfaces for fretting. The bore must be smooth gauge pins to be used as follows:
and free of scoring or nicks. Replace as required. On old style connecting rod and
5. Inspect the piston pins for corrosion or wear. piston assemblies use 3 mm (0.115
Replace as required. in.) gauge pins.
On new style connecting rod and
piston assemblies use 2 mm (0.082
Check Width of Top Compression Ring Groove in.) gauge pins.
NOTE: Top compression ring groove is a keystone
design which requires measurement over gauge pins A. Install a piston gauge pin from the piston
to determine ring groove wear. groove wear gauge pin set into the top
ring groove to be measured. Piston
gauge pin must be parallel.
B. Use an outside micrometer to measure
diameter over piston gauge pins.
C. If measurement over the gauge pin is not
within specifications, excessive piston
groove wear exists. Replace piston.
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Checking Side Clearance Of Oil Control Ring And Use a feeler gauge to check side clearance of
Intermediate Compression Ring Groove oil control ring in its respective groove.
A. Tight side clearance may indicate
carbon build up in the ring groove.
Ring should be cleaned.
B. Excessive side clearance indicates
ring groove wear and requires piston
replacement.
Piston Replacement
Figure 279 Checking Side Clearance Of The

Intermediate Ring And Oil Control Ring Grooves
1. Compression ring groove
2. Intermediate compression ring groove
3. Feeler gauge
1. Check side clearance of intermediate ring groove

as follows:
Place outer edge of new ring in the immediate Figure 280 Measuring Piston Skirt Diameter
ring groove.
1. Piston Skirt
Roll ring entirely around piston in its 2. 34 inch micrometer
respective groove. Make sure ring is able to
move freely in its groove.
When the piston requires replacement, check the
Use a feeler gauge to check side clearance of
cylinder bores. If they exceed the out-of-round or
each ring in its respective groove.
taper specifications, boring may be required. Such
2. Check side clearance of oil control ring groove as cylinder bore reconditioning will require the use of
follows: oversize service pistons. Verify the piston size by
measuring the skirt diameter. See the Specifications
Place outer edge of new ring in oil control ring
for the correct measurement location.
groove.
Roll ring entirely around piston in its
respective groove. Make sure ring is able to
move freely in groove.
EGES-205
Check Piston Ring End Clearance in Cylinder C. If the gap does not meet the specification,
Bore select another piston ring or check the
cylinder bore wear again.
Connecting Rods
CAUTION: On newer engines using the

fractured connecting rods keep mating
surfaces clean and free of debris.
DO NOT allow mating surfaces to rest on
any other surface.
DO NOT bump the mating surfaces or
Figure 281 Checking the Piston Ring End drop the connecting rod or cap.
Clearance in the Cylinder Bore
1. Piston Ring This could cause wear and chipping of the
2. Feeler Gauge fractured surface, resulting in improper
mating during installation and possible
engine damage.
NOTE: Faulty rings cannot always be detected by
visual inspection. Therefore, whenever a piston is If the connecting rod cap is reversed when
removed from a cylinder, replace the piston rings. assembled to the connecting rod or a
connecting rod cap is not installed in
1. Inspect piston rings for cleanliness. its original matching connecting rod, the
2. Before installing new piston rings on piston, check fractured mating surfaces will be useless.
gap for each ring as follows: The entire connecting rod assembly must be
replaced.
A. Push piston ring down into cylinder bore.
Make sure the piston ring is square to the
cylinder wall. An inverted piston head can 1. Inspect connecting rod bolts for nicks or damage.
be used to push piston ring to desired Replace as required.
location of measurement (usually at the
2. Inspect connecting rod and cap mating surfaces
top of the piston stroke).
and bearing bore for any indication of damage.
B. Use a feeler gauge to measure the gap Bore must be smooth and free of scoring or nicks.
between the ends of each piston ring. Replace as required.
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Check Inside Diameter of Piston Pin Bushing Check Connecting Rod Bearing Bore for
Out-of-Round and Taper
CAUTION: To avoid engine damage, check

the connecting rods as follows:
A. On engines equipped with the older
style connecting rod, be sure the
nuts on connecting rods thread onto
the connecting rod studs by hand. If
excessive resistance is felt, clean the
connecting rod studs and try a new
nut. If the new nut does not thread
on freely, the connecting rod must be
Figure 282 Measuring the Inside Diameter of the replaced. Failure to do so may result
Piston Pin Bushing in engine damage.
1. Piston Pin Bushing B. On engines equipped with the
2. Telescoping Gauge newer style connecting rod, the
connecting rod bolts should be
checked for binding. The bolts
1. Use a telescoping gauge and an outside should thread into the connecting
micrometer, measure the pin bore at two locations rod freely when lubricated with
90 apart. Record the readings. clean engine oil. If they do not the
connecting rod must be discarded.
2. If the inner diameter of the piston pin bushing
Connecting rod threads cannot be
exceeds the specification, replace the connecting
re-tapped if bonding exists. Check
rod.
thread condition carefully during
inspection. Failure to do so may
result in engine damage.
1. Lubricate the connecting rod nuts or bolts with

clean engine oil. Assemble the cap onto its
matching rod with the bearing insert removed.
Tighten the nuts or bolts to the special torque
value.
EGES-205
common examples of connecting rod wear patterns

include the following:
A shiny surface on the edge of the piston pin
bushing usually indicates that a connecting rod is
bent or a piston pin hole is not in proper position
to the piston shirt and ring grooves.
Abnormal connecting rod bearing wear can be
caused by a bent connecting rod, an improperly
machined journal or a tapered connecting rod
bore.
Figure 283 Measuring the Connecting Rod
Twisted connecting rods will not create an easily
Bearing Bore for Out-of-Round
identifiable wear pattern, but severely twisted
1. Inside Micrometer connecting rods will disturb the action of an entire
2. Connecting Rod Bearing Bore piston, ring and connecting rod assembly. It may
3. Nuts or Bolts also be the cause of excessive oil consumption.
If any of these conditions exist, use a suitable
alignment fixture to check the connecting rods for
2. Use an inside micrometer (telescoping gauge) to
bends or twists. Follow the instructions of the fixture
measure the connecting rod bearing bore at three
manufacturer. If bend or twist exceeds specifications,
locations approximately 120 apart. Label them
replace the connecting rod.
A, B and C.
3. If the difference between micrometer reading
"B" and the average of reading "A" and reading Check Piston Pin Clearance
"C" exceeds the out-of-round specification, the 1. Inspect piston pins for corrosion or wear. Replace
connecting rod must be replaced. as required.
[(A+C)2] B = actual reading (If the result is
negative, disregard the negative sign.)
4. Check the connecting rod bearing bore taper by
measuring the bore inner diameter near the large
chamfer. Record the reading. Then measure
the bore inner diameter near the small chamfer.
Record the reading.
The difference between the two readings is the
bore taper. If the connecting rod exceeds the
specification, replace the connecting rod.
5. With the connecting rod cap removed, inspect the
surface finish of the connecting rod bearing bore.
The bore must be smooth and free of scoring,
nicks and burrs. Replace the connecting rod as
required.
Figure 284 Checking for Piston Pin Wear
1. Piston pin
Check Connecting Rod for Bend or Twist 2. 12 inch micrometer
Often, engine component wear patterns can be
identified and used to diagnose a problem. Some
2. Use a 12 inch micrometer to measure piston
pin outside diameter at two locations 90 apart.
Measure each end of the pin. Record the
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range of readings. If piston pin wear exceeds

specifications, replace piston pin.
Figure 286 Effects of Bearing Crush

1. Diameter at Open Ends Before Bearing Crush Load
2. Diameter at Open Ends After Bearing Crush Load
Figure 285 Measuring Piston Pin Bore Inside
Diameter
Bearing shells must fit tightly in the bore. When
bearing shells are inserted into the connecting rod
3. Using a 12 inch telescoping gauge and and cap, they protrude slightly above the parting
micrometer, measure each piston pin bore surface. This protrusion is required to achieve a
inside diameter, at two locations 90 apart. bearing crush.
4. Check piston pin clearance, subtract piston pin Across the open ends, bearing shells are slightly
outside diameter from piston pin bore inside larger than the diameter of the connecting rod bore
diameter measurements. If clearance exceeds into which they are assembled. This condition is
specifications, replace piston pin. designed into the bearing shell, causing it to spread
outward at the parting line when a bearing crush load
is applied by tightening the nuts. Some snap may be
Bearing Fitting Procedure For Old Style lost in normal use, but bearing replacement is not
Connecting Rod required because of a nominal loss of snap.
When the assembly is drawn up tight, the bearing is
compressed, ensuring a positive contact between the
CAUTION: To avoid engine damage, do not backside of the bearing and the machined surface of
attempt to reduce journal-to-bearing running the connecting rod bore.
clearances by reworking the bearing cap
1. Install new bearing shells in the connecting rod
and/or the bearings. Regrind or replace the
and in the bearing cap. Lubricate each shell with
crankshaft only.
clean engine oil.
2. Install the connecting rod on the crankshaft.
3. Install the bearing cap on the connecting rod.
Tighten the nuts or bolts on the bearing cap
alternately and evenly to the special torque value.
EGES-205
NOTE: With the use of precision bearings, few

problems should be encountered. However, if proper
running clearance is not achieved, a problem with the
crankshaft may still exist. Regrinding the crankshaft
and using undersize bearings are probably necessary.
Also, the bearing cap bolt torque is very important.

Use a torque wrench that is known to be accurate.
Repeat the running clearance check procedure before
condemning the crankshaft.
Figure 287 Measuring Bearing Running

Clearance With Plastigage
1. Plastigage Wrapper/Scale
2. Connecting Rod Bearing Journal
3. Flattened Plastigage
4. Measure the bearing running clearance as

follows:
a. Remove the bearing cap. Wipe the oil from
the face of the bearing shell in the bearing cap
and the exposed portion of the crankshaft.
b. Place a piece of undamaged Plastigage Figure 288 Checking the Connecting Rod Side
across the full width of the bearing shell Clearance with a Feeler Gauge
about 6 mm (0.25 in) from the center of the
1. Crankshaft
bearing cap.
2. Feeler Gauge
c. Install the bearing cap and tighten the nuts 3. Connecting Rod Bearing Cap
or bolts alternately and evenly to the special
torque value.
5. Measure the connecting rod side clearance using
NOTE: Do not turn the crankshaft. This will one of the following tests:
smear the Plastigage.
Feeler Gauge Test
d. Remove the bearing cap. The Plastigage
material will adhere to either the bearing Pry two adjacent connecting rods apart and use
shell or the crankshaft. Do not remove the a feeler gauge to measure the clearance between
Plastigage. them. Refer to the specifications and repeat for all
connecting rods.
e. Use the Plastigage scale to measure the
widest point of the flattened material. The
Dial Indicator Test
numbers within the graduated marks on the
wrapper/scale indicate the running clearance a. Place the tip of the dial indicator on the
in thousandths of an inch or millimeters. See connecting rod bearing cap.
the specifications for the correct running
b. Pry the two connecting rods apart with a
clearance.
screwdriver or prying tool. Then zero the dial
f. Remove the Plastigage material. Repeat the indicator.
test for each connecting rod bearing.
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c. Pry the connecting rod in toward the dial

indicator while recording the connecting rod
side clearance. Refer to the specifications
and repeat for all connecting rods.
NOTE: Lack of side clearance could indicate a

damaged rod or a bearing that is out of position. Too
much clearance may require replacement of the rods
or crankshaft.
Assembly Old Style Connecting Rod
WARNING: To avoid personal injury or Figure 289 Assembly of the Piston and
possible death, wear safety glasses when Connecting Rod
installing piston pin retaining rings.
1. Piston Stamped Cam, Part Number, (Service
Pistons Include Oversize Designation)
2. Large Chamfer Side of Connecting Rod
CAUTION: Make sure the connecting rod
and piston are assembled correctly to avoid
engine damage. The large chamfer side of 1. Connect the piston to the connecting rod as
the connecting rod must be located next to follows:
the crankshaft fillet.
Make sure the lock slots and forging feature

on the connecting rod are opposite the
CAM marking found on the piston head.
Figure 290 Installing the Piston Pin

1. Piston
2. Piston Pin
3. Connecting Rod
4. Retaining Rings
a. Lubricate the piston pin bore in the connecting

rod, the piston bore and the piston pin with
clean engine oil.
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2. Use piston ring expansion pliers to install piston

rings onto piston.
3. Install the oil control ring into the bottom piston
groove.
NOTE: The intermediate ring is identified by the two

"OO" marks located on the top surface of the ring. The
top ring is identified by one single O mark located
on the top surface of the ring. Make sure the ring is
installed with the identifications marks facing up.
Figure 291 Installing the Piston Pin Retaining

Ring
1. Pliers
2. Retaining Ring
NOTE: The retaining ring has a smooth finish

side and a rough finish side. The smooth
finish side faces the piston pin.
b. Use piston pin retaining ring pliers to install
a piston pin retaining ring at one end of the
piston pin bore.
Figure 293 Piston Ring Identification Mark (top
c. Insert the connecting rod into the piston. ring shown)
Make sure the bored holes of the connecting
rod and piston are aligned. 1. Identification Mark
d. Slide the piston pin through the bored holes,

stopping at the previously installed retaining 4. Use the piston ring expansion tool to install the
ring. intermediate ring into the middle piston groove.
e. Install the second retaining ring. 5. Use the piston ring expansion tool to install the top
ring into the top piston groove.
6. Space ring gaps approximately 120 apart after
ring installation.
Assembly New Style Connecting Rod
WARNING: To avoid personal injury or

possible death, wear safety glasses when
installing piston pin retaining rings.
Figure 292 Installing Rings Onto Piston
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a. Lubricate the piston pin bore in the connecting

CAUTION: Make sure the connecting rod rod, piston pin bore, and piston pin with clean
and piston are assembled correctly to avoid engine oil.
engine damage. The large chamfer side of
the connecting rod must be located next to
the crankshaft fillet.
Figure 296 Installing Piston Pin Retaining Ring

1. Pliers
2. Retaining Ring
NOTE: The retaining ring has a smooth finish

Figure 294 Proper Assembly of the Piston and side and a rough finish side. The smooth
Connecting Rod finish side faces the piston pin.
1. Piston Stamped CAM Part Number, (Service b. Use pliers to install a piston pin retaining ring
Pistons Include Oversize Designation) at one end of piston pin bore.
2. Large Chamfer Side of Connecting Rod
c. Insert the connecting rod into the piston.
Make sure the bored holes of the connecting
1. Connect piston to connecting rod as follows: rod and piston are aligned.
d. Slide piston pin through bored holes, stopping
at the previously installed retaining ring.
e. Install the second retaining ring.
Figure 295 Installing the Piston Pin

1. Piston
2. Piston Pin
3. Connecting Rod
4. Retaining Rings
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Figure 297 Piston Ring Locations Figure 299 Piston Ring Identification Mark (top
ring shown)
1. Top compression ring
2. Intermediate compression ring
3. Oil control ring
b. Use the piston ring expansion tool to install
the intermediate ring into the middle piston
2. Use piston ring expansion pliers to install piston groove.
rings onto piston as follows: c. use the piston ring expansion tool to install the
to ring into the top piston groove.
3. Space ring gaps approximately 120 apart after
ring installation.
Installation Old Style Connecting Rod
CAUTION: To avoid engine damage:

DO NOT use any air powered tools when
installing and tightening connecting
Figure 298 Installing Rings Onto Piston (Typical) rod nuts. This can cause seizure of
1. Piston ring expander tool connecting rod bolts.
2. Piston When installing the connecting rod and
3. Piston ring (top compression shown) piston assembly into the cylinder bore
BE SURE TO:
a. Use the piston ring expansion tool to install Install the connecting rod and piston
the oil control ring into the bottom piston assemble into the cylinder bore from
groove. which it was removed.
NOTE: The intermediate ring is identified by Assemble each connecting rod to the
two OO marks located on the top surface original connecting rod cap.
of the ring. The top ring is identified by one
single O mark located on the top surface
of the ring. Make sure the ring is installed NOTE: Install the piston and connecting rod
with the identification mark facing up (top of assemblies after the piston cooling jets and crankshaft
piston). have been installed.
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1. Turn the crankshaft so the appropriate crankpin is sure the ring gaps are oriented approximately
at the bottom of its stroke. 120 apart.
2. Make sure the connecting rod bearing shells
are properly installed in the bearing cap and the
connecting rod.
Figure 300 Installing Protector Caps on the

Connecting Rod Studs Figure 301 Correct Orientation of a Properly
1. Piston and Connecting Rod Assembly Installed Piston
2. Protector Caps
1. Identification Marking
3. Connecting Rod Bearing Shell (16)
3. Install aluminum protector caps over the

CAUTION: To avoid engine damage, the
connecting rod studs to help prevent damage to
arrow located on top of the piston must face
the crankshaft journals.
the camshaft side of the crankcase and the
4. Coat the cylinder bore, crankshaft journals, large chamfer on the connecting rod must
pistons, piston rings and the piston installation be positioned next to the crankshaft fillet.
sleeve with clean engine oil.
5. Before installing the piston into the ring
compressor or the installation sleeve, make
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Figure 302 Proper Position of an Installed Connecting Rod

1. Piston Pin Bushing 5. Bearing 9. Large Chamfer Side (next to
2. Connecting Rod 6. Connecting Rod Bearing (upper) fillet)
3. Crankshaft 7. Connecting Rod Bearing (lower) 10. Small Chamfer Side
4. Crankshaft Fillet 8. Connecting Rod Bearing Cap
6. Install the piston installation sleeve onto the

CAUTION: To avoid engine damage, when piston. Make sure the rod bolts are seated.
installing connecting rod and piston into Carefully place the piston and connecting rod
cylinder bore, be careful not to damage the assembly into the crankcase bore.
piston cooling tube.
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NOTE: Make sure each connecting rod is matched

with the its original bearing cap on the same crankpin
from which they were removed.
Figure 303 Seating the Piston in the Cylinder

Bore
Figure 305 Installing the Bearing Caps
1. Piston Installation Sleeve
2. Piston 1. Crankshaft
2. Bearing Shell
3. Connecting Rod
7. Use the handle of a hammer and tap the piston
into the cylinder bore.
9. Coat the bearing shell surfaces and connecting
8. Remove the aluminum protector caps from rod threads with clean engine oil. Install the
connecting rod bolts. bearing cap on the connecting rod.
Figure 304 Connecting Rod and Cap

Identification Marks
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Installation New Style Connecting Rod
CAUTION: To avoid engine damage:

DO NOT use any air powered tools when
installing and tightening connecting
rod bolts. This can cause seizure of
connecting rod bolts.
When installing the connecting rod and
piston assembly into the cylinder bore
BE SURE TO:
Install the connecting rod and piston
assemble into the cylinder bore from
which it was removed.
Keep the fractured mating surfaces
Figure 306 Securing the Connecting Rod Cap
clean and free of lint and debris.
1. Connecting Rod Nuts (16) Do not allow the mating surfaces
2. Connecting Rod Bearing Cap (8) to rest on any surface. Do not
3. Crankshaft bump the mating surfaces or drop
4. Connecting Rod (8) the connecting rod or cap. This
could cause chipping and wear on
the mating surface, resulting in
10. Install and tighten the connecting rod mounting improper mating during installation
nuts to the special torque value. and possible engine damage.
11. Check the piston protrusion above the crankcase. If the rod cap is reversed when
assembled to the connecting rod
12. Repeat the installation procedure for the or a rod cap is NOT installed on its
remaining connecting rods and pistons. original matching connecting rod,
the fractured mating surfaces will
be ruined. This may cause the rod
cap to come loose and cause engine
damage. The entire connecting rod
must be replaced.
NOTE: Install the piston and connecting rod

assemblies after the piston cooling jets and crankshaft
have been installed.
1. Turn crankshaft so the appropriate crankpin is at
the bottom of its stroke.
2. Make sure the connecting rod bearing shells
are properly installed in the bearing cap and the
connecting rod.
3. Coat piston and piston rings with clean engine
oil. Coat cylinder walls, crankshaft journals, and
piston cope with clean engine oil. (The cope is
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a special tool designed to hold the piston rings in

place during installation.)
Figure 308 Installing the Piston and Connecting

Rod Into the Cylinder Bore
2. Piston
3. Connecting Rod
4. Place the piston with rings and connecting rod

installed, into the cope.
5. Install bearing shells into connecting rod and cap.
Figure 307 Correct Orientation of a Properly Coat bearing shell in connecting rod with clean
Installed Piston engine oil.
1. Identification Marking
CAUTION: To avoid engine damage, when

installing connecting rod and piston into
CAUTION: To avoid engine damage, the cylinder bore, be careful not to damage the
arrow located on top of the piston must face piston cooling tube.
the camshaft side of the crankcase and the
large chamfer on the connecting rod must
be positioned next to the crankshaft fillet. 6. Carefully insert connecting rod and piston into
cylinder bore.
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8. Coat the bearing shell and connecting rod

surfaces with clean engine oil. Install the bearing
cap on the connecting rod.
Figure 309 Seating the Piston in the Cylinder

Bore
2. Piston
Figure 311 Securing the Connecting Rod Cap

7. Once piston and connecting rod have been 1. Connecting Rod Nuts or Bolts (16)
inserted into the cylinder bore, use the handle 2. Connecting Rod Bearing Cap (8)
of a hammer to tap piston into crankcase bore. 3. Crankshaft
Guide connecting rod into place over crankshaft 4. Connecting Rod (8)
journal.
NOTE: Be sure each connecting rod is matched with 9. Install and tighten the connecting rod mounting
the original bearing cap on the same crankpin from nuts or bolts to the special torque value.
which they were removed.
10. Repeat installation procedure for remaining
connecting rod and piston assemblies.
11. Check connecting rod side clearance with feeler
gauge. Refer to REMOVAL in this section for the
correct procedure.
Crankshaft and Main Bearings

Removal
NOTE: Crankshaft bearing caps are numbered from

the front to identify their respective positions for
installation. The No. 5 bearing cap accommodates a
Figure 310 Installing the Connecting Rod Cap thrust flange to limit crankshaft end play.
1. Crankshaft
2. Bearing Shell
3. Connecting Rod
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Figure 312 Removing the Main Bearing Cap

Figure 313 Removing the Crankshaft From the
1. Main Bearing Cap Bolt
Crankcase
2. Main Bearing Cap
1. Lifting Sling
2. Crankshaft
1. Loosen the main bearing cap mounting bolts.
2. Grasp the main bearing cap mounting bolts and
4. Attach a lifting sling to the crankshaft. Lift the
rock them back and forth to loosen and remove
crankshaft straight up and out of the crankcase.
the cap.
5. Remove the upper main bearing inserts by
3. Remove the lower bearing shell from the main
pushing them out of the main bearing saddle.
bearing cap. Keep each shell with its original cap
Mark the upper shells and put them with the lower
for main bearing inspection.
shells for a proper inspection.
WARNING: To avoid engine damage, Cleaning

serious personal injury or possibly death, 1. Clean the crankshaft with a suitable solvent. Dry
use an appropriate lifting sling when the crankshaft with filtered compressed air.
removing the crankshaft from the crankcase.
2. Use a stiff nylon brush to clean all of the
internal oil passages of the crankshaft. Loosen
all dirt, sludge, and other deposits that may
have accumulated. Flush the oil passages with a
suitable non-caustic solvent. Dry the oil passages
with filtered compressed air.
3. Clean the bearing caps and inserts thoroughly in
solvent. Dry with filtered compressed air.
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Inspection b. Again, take the second set of measurements

taken in the other position (at 90 to the first
set, one measurement at each end of the
journal) and record the average.
c. Subtract the smaller averaged value from
the larger averaged value. This will yield the
amount of out-of-round.
2. To determine journal taper, use the
measurements taken in Step 1.
a. Record the average of two measurements
taken at one end of the journal.
b. Record the average of the other two
measurements at the other side of the
journal.
c. Subtract the smaller averaged value from
the larger averaged value. This will yield the
amount of taper from one end of the journal
to the other.
Figure 314 Measuring the Crankshaft Journals
1. Micrometer
CAUTION: If any journals exceed either
2. Crankshaft
the maximum out-of-round or maximum
taper specifications, the crankshaft must
be replaced or reground and undersize
1. Inspect the crankshaft journals (main and
bearings installed. Failure to do so may
connecting rod) for scratches, grooves and
result in engine damage.
scoring. Use the dye penetrant method when
checking for cracks.
2. Inspect all bearing inserts. Replace any main
bearings that are scored, chipped or worn. Installation of Crankshaft
3. Use a micrometer to measure the diameter of
each journal. NOTE: Make sure the crankcase has been inspected
before installation.
1. Use a lint-free cloth to wipe any oil off the
Check Crankshaft Journals for Out-of-Round and crankcase bearing supports.
Taper
2. Clean the bearing inserts and bearing caps
1. To check for an out-of-round condition, measure thoroughly in solvent. Dry them with filtered
each end of each journal at two points, 90 apart compressed air.
from each other (4 measurements total).
3. Inspect each bearing. Replace any bearings that
NOTE: When taking crankshaft measurements, it are scored, chipped or worn.
is important to keep the micrometer clear of the
crankshaft fillet radius.
a. Take the first two measurements taken in the
same position (one measurement at each end
of the journal) and record the average.
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Figure 315 Lubricating the Upper Main Bearing

Inserts
1. Crankcase Figure 316 Installing the Crankshaft Into the
2. Main Bearing Insert Crankcase
1. Lifting Sling
4. Lubricate the upper main bearing inserts with 2. Crankshaft
clean engine oil and insert them into the
crankcase main bearing supports.
5. Attach an appropriate lifting sling to the crankshaft
NOTE: Make sure the locking tabs on the bearings and carefully lower it onto the main bearing saddle
are aligned with the slots in the crankcase saddle. in the crankcase.
Also, the oil holes in the bearing shells must line
up with the oil holes in crankcase.
Main Bearing Fitting Procedure
1. Install all of the main bearing caps. Tighten the
mounting bolts to the special torque value.
WARNING: To avoid engine damage,
serious personal injury or possibly death, 2. Remove one bearing cap and insert. Leave the
use an appropriate lifting sling when remaining caps tight while checking the fit of the
installing the crankshaft into the crankcase. bearing with the cap removed.
3. Clean the bearing surface and the exposed half of
the crankshaft journal. Make sure these surfaces
are free of oil.
4. Place a piece of Plastigage across the full width
of the bearing surface on the crankshaft journal or
bearing cap insert approximately 6 mm (.250 in)
off center. Install the main bearing cap and tighten
mounting bolts to the special torque value.
NOTE: Do not turn the crankshaft while the

Plastigage is on the journal.
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7. If the bearing running oil clearance is not within

specifications, the crankshaft must be replaced
WARNING: In chassis service only, or machined and undersized bearings installed.
before checking for bearing oil clearance, Refer to Crankshaft in this section.
the crankshaft must be supported and held
8. Perform this procedure for each main bearing.
up against the upper main insert bearing
Then continue on to Installation of Main Bearing
halves. Failure to do so may result in
Cap.
incorrect oil clearance values and may
cause personal injury or engine damage.
Installation of Main Bearing Caps
Use a jack and a piece of wood around
the center of the crankshaft to provide
NOTE: Make sure the bearing oil clearance is
adequate support. The oil clearance
acceptable before installing the main bearing caps.
checking procedure is performed exactly
the same as an engine that is mounted on 1. Clean the Plastigage from the main bearing and
an engine stand. crankshaft journal surfaces.
2. Apply clean engine oil to the main bearing cap
5. Remove the main bearing cap and insert. Do not inserts, crankshaft journals and main bearing cap
disturb the Plastigage. mounting bolts.
CAUTION: To avoid engine damage, make

sure the main bearing caps are installed in
the proper order. Do not mix them. Caps
must be installed with the stamped arrow
facing the front of the engine. The No. 1
location is at the front of the engine.
3. Place the No. 1 through No. 4 bearing caps into

position. Install the mounting bolts finger tight.
4. Use a soft hammer to tap the bearing caps until
the rear machined faces of the caps are flush with
the machined faces of the crankcase.
Figure 317 Checking the Bearing Clearance of CAUTION: Make sure the rear thrust flanges
the Crankshaft Journal are flush with each other. Aligning the main
1. Oil Clearance Scale bearing caps in this manner will ensure
2. Main Bearing Journal proper cap location and may prevent engine
3. Flattened Plastigage damage.
5. Install the No. 5 rear thrust bearing cap into

6. Use the Plastigage scale located on the
position. Install the mounting bolts finger tight.
envelope/wrapper, measure the widest point of
the flattened Plastigage. This reading indicates
the bearing running oil clearance in thousandths
of an inch or millimeter.
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Figure 318 Tightening the Main Bearing Cap

Mounting Bolts
1. Mounting Bolt Figure 319 Checking the Crankshaft End Play
2. Main Bearing Cap
3. Crankshaft 1. Pry Bar
4. Crankcase 2. Dial Indicator
3. Crankshaft Gear
6. Tighten the mounting bolts for main bearing caps

No. 1 through No. 4 to the special torque value. 4. Pry the crankshaft forward and zero the dial
indicator. Check the end play by prying the
crankshaft backward and reading the dial
Check Crankshaft End Play indicator. Repeat the procedure to ensure
the accuracy of previous results.
NOTE: The main thrust bearing cap (No. 5 main 5. After checking the crankshaft end play, one of the
bearing) provides the initial location of the crankshaft following will occur:
end thrust in relation to the crankcase.
The crankshaft end play is within
1. Mount a dial indicator on the crankcase with the specifications, installation is complete.
indicator tip on the crankshaft gear.
The crankshaft end play exceeds
2. Use a pry bar or equivalent to pry the crankshaft specifications, replace the main thrust
back and forth. bearing and check the crankshaft end play
3. Tighten the mounting bolts of the No. 5 thrust again.
bearing cap to the special torque value. The crankshaft end play is less than the
minimum specified limit, the main thrust
bearing faces are damaged or dirty. Replace
or clean the main thrust bearing and check
crankshaft end play again.
If the main thrust bearing is not damaged or
dirty, it was probably misaligned. Remove
the main thrust bearing and repeat installation
procedure again.
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Piston Cooling Jets Installation

Removal
CAUTION: The piston cooling jets use a
special patch type mounting bolt. Do not
substitute or the mounting bolts will not
tighten properly. This can cause the cooling
jet tubes to become misaligned, or loosen
and fall into the crankcase, causing severe
engine damage.
If the original patch bolts are being installed,

make sure the bolts threads and bolt holes
are cleaned and apply Loctite to the bolts
threads. This will ensure that the patch bolts
will not come loose in the engine.
Figure 320 Piston Cooling Jet

1. Piston Cooling Jet
2. Mounting Bolt
Remove the mounting bolt that secures each piston

cooling jet to the crankcase. Remove the piston
cooling jets.
Cleaning and Inspection

1. Replace any piston cooling jets that are cracked
or bent.
2. With the piston cooling jets removed, run an Figure 321 Installing the Piston Cooling Jet
appropriate size wire through each tube to
ensure there is no blockage. 1. Piston Cooling Jet Tube
2. Patch Bolt
3. Use filtered dry compressed air to blow out any
debris from cleaning.
NOTE: Do not perform Step 1 if new patch bolts are
being installed.
1. If the original patch bolts are being reused, clean
the bolt hole and bolt threads so they are free of
oil residue. Apply Loctite #242 to the threads of
reused patch bolts.
2. Place the piston cooling jet tube onto the
crankcase mounting pad.
NOTE: The bolt-on piston cooling jet tubes are self

aligning.
3. Tighten the patch bolts to the standard torque
value.
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Crankcase Reconditioning 6. Apply Aviation Permatex No. 3 to the main oil

gallery plug and install it into the crankcase. Make
Cleaning
sure the top of main oil gallery plug is below the
The best way to clean the crankcase during an surface level of the crankcase.
engine overhaul is in a chemical bath or HOT TANK.
7. Apply Aviation Permatex No. 3 to the new valve
This procedure removes all carbonized material
lifter oil gallery plugs and install them into the
and mineral deposits which collect in the cooling
crankcase.
passages. However, when a HOT TANK is not
available, use the following.
Inspect Short Circuit Valve
NOTE: Thoroughly clean and inspect crankcase
before and after reconditioning.
1. Use a scraper and a sanding block to clean all old
gasket material from the machined surfaces of the
crankcase.
2. Clean the cylinder bores with soap, water and a
nylon brush.
3. Remove the pipe plugs on front of crankcase.
Thoroughly clean all of the oil passages and bolt
holes.
4. Remove the main oil gallery plugs. Use a nylon
brush to clean the main oil gallery.
Figure 323 Short Circuit Components

1. O-Ring
2. Plug
3. Spring
4. Check Ball
1. Use a hex head wrench to remove the plug located

in the top left front of the crankcase.
2. Inspect the plug, O-ring, spring, and the check ball
for wear. Also check the ball seat in the valve port
of the crankcase. Replace any worn items.
Figure 322 Valve Lifter and Main Oil Gallery Plug 3. Install the ball and spring into the valve port. Apply
Locations clean engine oil to the O-ring and place it onto the
plug.
1. Valve Lifter Oil Gallery Plugs
2. Main Oil Gallery Plug 4. Screw the plug into the crankcase. Tighten the
plug to the standard torque value.
5. Remove the valve lifter oil gallery plugs located in

Replace Crankcase Cup Plugs
the rear of the crankcase and discard them. Use
a nylon brush to clean to clean the valve lifter oil 1. Use a hammer and punch to drive a hole into the
galleries. side of the cup plug (near the edge). Then pry
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out the cup plug. Be careful not to damage the 2. Using a straightedge, check the top surface of
expansion bore. the crankcase for flatness by attempting to insert
a 0.10 mm (0.004 in) feeler gauge between the
2. Use a cup plug driver to install new cup plugs.
straightedge and the crankcase head surface.
Coat the edges of the plug with Aviation Permatex
If the gap exceeds 0.10 mm (0.004 in), the
No. 3. The driver installs the plug to the proper
crankcase must be replaced.
depth.
Check Cylinder Bore for Out-of-Round and Taper

Check Crankcase Surface for Flatness
CAUTION: The threads in the crankcase bolt

holes must be cleaned and blown dry with
filtered compressed air. Dirt or oil left in the
holes may cause binding or a false torque
reading during reassembly.
CAUTION: Do not resurface the crankcase.

Surface defects beyond those listed are
not correctable. To avoid engine damage, Figure 325 Checking the Cylinder Bore for
replace the crankcase. Out-Of-Round
1. After cleaning, inspect the crankcase for scoring,

roughness, cracking or wear at the cylinder bores. 1. Check for an out-of-round condition as follows:
a. Measure the diameter of each cylinder bore
at the top of the piston ring travel (Dimension
"A"). For each cylinder, measure Dimension
"A" at a right angle to the center line of the
crankshaft. Record each reading.
b. Measure each cylinder bore so the gauge
reading coincides with the centerline of the
crankshaft (Dimension "B"). Record the
reading.
c. Subtract the smaller value from the larger
value. The difference in measurements will
be the out-of-round condition at the top of the
cylinder bore.
d. Repeat the same procedure at the bottom of
Figure 324 Checking the Crankcase Deck for the ring travel to check for an out-of-round
Flatness condition.
1. Straightedge
2. Feeler Gauge
3. Crankcase
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Figure 327 Glaze Breaking Brush

1. Rubber Hose Over Shaft
2. Cylinder bore can be deglazed using a 120 grit

glaze breaking brush. Install a 50 mm (2 in)
section of rubber hose over the end of the shaft
(Figure 327).
This silicone carbide-tipped nylon flexible brush
Figure 326 Checking Cylinder Bore Taper quickly deglazes cylinder walls and produces a
1. Measurement at the top of the cylinder cross-hatch pattern on the cylinder wall surface
2. Measurement at the bottom of the cylinder in a single operation. The brush contours itself to
the cylinder wall and conditions the wall surface
without altering the cylinder bore.
2. Determine the taper of the cylinder bore by
calculating the difference between the diameters
of the top and bottom of the cylinder bore.
3. If the cylinder bore is within specifications,
standard size pistons and rings may be used.
If a cylinder bore is suitable for use without
reconditioning, deglaze the cylinder bore with a
glaze breaking brush and continue with assembly.
Refer to Deglazing in this section.
If the cylinder walls have minor surface damage,
but are otherwise within specifications, it may be
possible to remove such damage by honing.
If any of the cylinder bores are deeply scored
and exceed any of the out-of-round or taper Figure 328 Preparing Glaze Breaking Brush for
conditions, machining the cylinders to the next Deglazing
oversize is necessary.
3. Obtain a 355 ml (12 oz) can of PE-12 Solvent

Deglazing and Penetrating Fluid manufactured by AGS
(or equivalent), available at any well-stocked
1. Remove the piston cooling jets. Refer to Piston auto supply house. This spray contains colloidal
Cooling Jets, Removal for the procedure. graphite and works well for this application. Spray
both the cylinder to be deglazed and the glaze
breaking brush.
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Camshaft Bushings
Check for Wear and Proper Running Clearance
1. Use a micrometer to measure each camshaft
bearing journal diameter at two locations
90 apart. Record the average of these two
measurements.
2. With the camshaft bushings installed in the
crankcase, use a telescoping gauge and
micrometer to measure each camshaft bushing
inner diameter at two locations 90 apart. Record
the average of these two measurements.
3. Subtract the two averages to determine the
Figure 329 Deglazing the Cylinder Bore running oil clearance. If the result exceeds the
specification, replace the camshaft bushings.
4. Deglaze the cylinder as follows:

Removal
a. Attach the glaze breaking brush to a variable
speed electric or air powered drill motor.
b. Deglaze the cylinder wall for about 15 CAUTION: When servicing the camshaft
seconds while stroking the bore up and down bushings, the crankshaft and main bearings
at a rate of one complete up and down stroke must be removed from the crankcase to
per second. avoid contamination from debris. Such a
contamination may result in engine damage.
A speed of approximately 100-120 rpm is
required. Speed adjustment is required for
the procedure to be successful.
c. Withdraw the glaze breaking brush from
the cylinder bore while the brush is rotating.
Wipe a portion of the cylinder wall and inspect
the cross-hatch pattern. Compare it to an
untouched cylinder bore. The crosshatch
pattern should be approximately 45 .
d. If the pattern is "flatter" than required,
increase the up and down stroke speed or
slow down the drill rotation.
e. Continue deglazing the cylinder bore for
10-15 seconds or 20-25 strokes.
Figure 330 Assembling and Installing the
f. Wipe the cylinder bore clean and inspect the
Camshaft Bushing Removal Tool
bore for a proper 45 cross-hatch pattern.
1. Pulling Screw
5. After deglazing, thoroughly clean the cylinder
2. Expanding Collet
bores with a soft bristle brush, soap and water.
3. Backup Nut
Dry the bores with filtered compressed air and
lubricate the bores with clean engine oil.
6. Install the piston cooling jets before assembly. 1. Use the camshaft bushing removal tool and select
Refer to Piston Cooling Jets, Installation for the proper size expanding collet and backup nut.
the procedure. Assemble the parts onto the expanding mandrel.
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2. With the expanding collet collapsed, install thrust bearing and pulling plate to remove the
the collet assembly into the camshaft bushing. camshaft bushing. Hold a wrench on the end of
Tighten the backup nut on the expanding mandrel the puller screw to prevent it from turning.
until the collet fits on the camshaft bushing.
Inspection
1. Inspect each bushing bore in the crankcase for
burrs or debris that could damage new bushings
when they are installed.
2. Remove any burrs and clean bores thoroughly
before installing new camshaft bushings.
Installation
CAUTION: The bushings are interchangeable

Figure 331 Attaching the Puller Screw from one bore to another except for the No.
1 (front) bushing, which is wider than the
1. Expanding Mandrel
others. To avoid engine damage, identify
2. Puller Screw
the No. 1 (front) bushing from the Nos. 2 5
(intermediate and rear) bushings.
3. Assemble the puller screw onto the expanding
mandrel. Wrap a cloth around the threads of the
1. Lubricate the new camshaft bushings and the
puller screw to protect the front camshaft bushing.
crankcase bores with clean engine oil.
CAUTION: Failure to use the correct

expanding collet can cause severe bushing
damage.
2. Use the camshaft bushing installation tool to

install the new bushing onto the expanding collet.
Tighten the collet by turning the backup nut until
the bushing is held securely.
3. Mark the oil hole location on the backup nut of
the installation tool as an aid in aligning the oil
holes in the bushing and crankcase. This step
must be repeated for each camshaft bushing that
Figure 332 Installing the Pulling Plate and is installed.
Thrust Bearing
1. Puller Screw
2. Backup Nut CAUTION: To ensure proper oil circulation
3. Thrust Bearing throughout the crankcase, make sure all
4. Pulling Plate camshaft bushing oil holes are in alignment
with the oil holes in the crankcase. Failure
to do so may result in engine damage.
4. Attach the pulling plate, thrust bearing and backup
nut to puller screw. Tighten the nut against the
EGES-205
4. Install the intermediate and rear camshaft 5. After all of the camshaft bushings have been
bushings through the front of the crankcase. installed, use a wire to verify oil hole alignment.
Then pull them into place from the rear of the
6. Install the front camshaft bushing by pulling it into
crankcase by turning the pulling nut on the puller
place from the rear of the crankcase.
screw. Remove the installation tool and inspect
the oil hole alignment.
Figure 333 Checking the Camshaft Bushing /

Crankcase Oil Hole Alignment
1. Alignment Wire
2. Main Bearing Saddle
3. Camshaft Bushing Oil Hole
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SPECIFICATIONS
Table 19 Crankcase, Camshaft Bushing, Crankshaft and Main Bearing, Connecting Rod and Piston
CRANKSHAFT
Main Bearing Journal Diameter
Standard Size 79.3191 - 79.3394 mm (3.1228 - 3.1236 in)
0.254 mm (0.010 in) Undersize 79.0651 - 79.0854 mm (3.1128 - 3.1136 in)
Main Bearing Journal Maximum Out-of-Round 0.00559 mm (0.00022 in)
Main Bearing Thrust Face Runout (T.I.R. maximum) 0.0254 mm (0.001 in)
Main Bearing Journal Taper (max. per inch) 0.381 mm (0.0015 in)
Main Journal Fillet Radius, Journal No. 1, 2, 3 and 4 3.302 mm (0.130 in)
Main Journal Fillet Radius, Journal No. 5 3.99 - 4.14 mm (0.157 - 0.163 in)
Rod Journal Fillet Radius 3.68 mm (0.145 in)
Oil Seal Journal Runout (maximum) 0.05 mm (0.002 in)
Flywheel Housing Bore Concentricity (maximum) 0.20 mm (.008 in)
Flywheel Housing Face Runout (maximum) 0.51 mm (0.020 in)
Flywheel Surface Runout (maximum) 0.05 mm (0.002 in)
Flywheel Thickness (minimum) (See flywheel reconditioning
44.907 mm (1.768 in)
Figure 251.)
Thrust Taken By No. 5 Main
Thrust Bearing Journal Length 31.509 - 31.585 mm (1.2405 - 1.2435 in)
Main Bearing Inner Diameter (Installed) 79.385 - 79.436 mm (3.1254 - 3.1274 in)
Main Bearing to Crankshaft Running Clearance 0.046 - 0.117 mm (0.0018 - 0.0046 in)
Connecting Rod Journal Diameter
Connecting Rod Journal, Maximum Out-of-Round 0.0056 mm (0.00022 in)
Connecting Rod Journal Taper (max. per inch) 0.0066 mm (0.00026 in)
Connecting Rod Bearing to Crankshaft Running Clearance 0.038 - 0.114 mm (0.0015 - 0.0045 in)
Crankshaft Flange Outer Diameter 111.05 - 111.15 mm (4.372 - 4.376 in)
Crankshaft End Play 0.063 - 0.216 mm (0.0025 - 0.0085 in)
Crankshaft End Play Maximum Wear Limit 0.51 mm (0.020 in)
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(cont.)
Rod to Crankshaft Side Clearance 0.30 - 0.61 mm (0.012 - 0.024 in)
Crankshaft Straightness (T.I.R. Maximum) 0.10 mm (0.004 in)
Crankshaft Gear Backlash (0.1397 - 0.02794 mm (0.0055 - 0.0110 in)
CRANKCASE
0.025 mm per 50.8 mm, 0.10 mm Total (0.001
Crankcase Deck Flatness
in. per 2 inches, 0.004 in Total)
Crankcase Main Bearing Bore Diameter 84.206 - 84.231 mm (3.3152 - 3.3162 in)
Crankcase Cam Bearing Bore Diameter 56.655 - 56.693 mm (2.2305 - 2.2320 in)
Valve Lifter Bore Diameter 23.439 - 23.477 mm (0.9228 - 0.9243 in)
Valve Lifter Outer Diameter 23.391 - 23.411 mm (0.9209 - 0.9217 in)
Oil Jet Tube Bore Diameter (Spray Hole Diameter) 0.91 - 1.32 mm (0.036 - 0.052 in)
Cylinder Bore Taper (Top to Bottom) 0.076 mm (0.003 in)
Cylinder Bore Diameter 104.384 - 104.402 mm (4.1096 - 4.1103 in)
Cylinder Bore Maximum Out-of-Round 0.05 m (0.002 in)
Centerline of Main Bearing Bore to Head Deck 287.73 - 287.83 mm (11.328 - 11.332 in)
Oil Seals (Front and Rear Seal Face Runout With Plates Installed
0.38 mm (0.015 in) T.I.R. Max.
On Engine)
CONNECTING RODS
Connecting Rod Length Center to Center 181.10 mm (7.130 in)
Bushing Bore Diameter (Pin End) 33.235 - 33.243 mm (1.3085 - 1.3088 in)
Piston Pin Bushing Inner Diameter 32.83 - 32.84 mm (1.2924 - 1.2929 in)
Bearing Bore Diameter (Crankshaft End) 68.339 - 68.364 mm (2.6905 - 2.6915 in)
Bearing Bore Maximum Out-of-Round 0.013 mm (0.0005 in)
Bearing Bore Maximum Taper / Inch 0.013 mm (0.0005 in)
Connecting Rod Bearing Inner Diameter 63.513 - 63.564 mm (2.5005 - 2.5025 in)
Connecting Rod Bearing Running Clearance 0.038 - 0.114 mm (0.0015 - 0.0045 in)
Connecting Rod Side Clearance 0.30 - 0.61 mm (0.012 - 0.024 in)
Twist 0.05 mm/in (0.002 in/in)
Bend 0.025 mm/in (0.001 in/in)
Weight - Complete Rod Without Bearing (Old Style) 1.058 - 1.446 kg (1058 - 1446 g)
Weight - Complete Rod Without Bearing (New Style) 1.202 - 1.216 kg (1201.5 - 1215.5 g)
Pin to Bushing Clearance 0.010 - 0.023 mm (0.0004 - 0.0009 in)
PISTONS
EGES-205
(cont.)
Skirt Diameter Measure 43 mm (1.684 in) below oil groove, at
90 angle to the piston pin. Measure only at room temperature of 104.34 - 104.44 mm (4.108 - 4.112 in)
19-21 C (66-70 F).
Service Piston
0.254 mm (0.010 in) Oversize 104.50 - 104.52 mm (4.114 - 4.115 in)
Piston Protrusion Above Crankcase Deck 0.58 0.84 mm (0.023 0.033 in)
Clearance In Cylinder Bore No. 1 8 0.112 - 0.1491 mm (0.0044 - 0.00587 in)
Top compression ring groove width - Measure over 2.92 mm (0.1150 in) gauge pins:
Upper Limit 104.85 mm (4.128 in)
Replacement Limit 104.06 mm (4.097 in)
Piston Pins
Length 75.9 - 76.2 mm (2.99 - 3.00 in)
Diameter 33.220 - 33.226 mm (1.3079 - 1.3081 in)
Pin fit @ room temperature, 19-21 C (66-70 F):
Clearance In Rod 0.010 - 0.023 mm (0.0004 - 0.0009 in)
Clearance In Piston 0.007 - 0.018 mm (0.0003 - 0.0007 in)
End Clearance 0.10 - 0.76 mm (0.004 - 0.030 in)
Piston Rings
Ring Diameter (Standard)
Compression Top (Full Keystone (Barrel Face) Plasma Coated) 104.4 mm (4.11 in)
Compression 2nd (Rectangular Negative Twist - Tapered Face) 104.4 mm (4.11 in)
Oil Control (One Piece Conformable with Chrome Expander
104.4 mm (4.11 in)
Spring)
Fit in Groove (Side Clearance)
2nd 0.05 - 0.10 mm (0.002 - 0.004 in)
Oil Control 0.023 - 0.074 mm (0.0009 - 0.0029 in)
Ring Gap in Bore
Top 0.35 - 0.61 mm (0.014 - 0.024 in)
2nd 1.57 - 1.82 mm (0.062 - 0.072 in)
Oil Control 0.30 - 0.61 mm (0.012 - 0.024 in)
EGES-205
Special Torque
Table 20 Crankcase, Crankshaft, Connecting Rods and Piston Special Torques

First Step: 71 Nm (52 lbfft)
Connecting (4 lbf-ft) Rod Mounting Nuts (Old Style)
Final Step: 108 Nm (80 lbfft)
Connecting Rod Bearing Bolts (New Style)
Flywheel gear access cover bolts 5 Nm (4 lbf-ft)
Flywheel Mounting Bolts 121 Nm (89 lbfft)
Main Bearing Cap Mounting Bolts
Oil Pick up Tube Flange Bolts 24 Nm (18 lbfft)
Piston Cooling Jet Mounting Bolts 11 Nm (100 lbfin)
EGES-205
Table 21 Crankcase, Crankshaft, Connecting Rods and Piston Special Service Tools
D81L6002B Plastigage
OEM1000 Micrometer
OEM1022 Telescoping Gauge Set
OEM1023 Telescoping Gauge
OEM1032 Dial Bore Gauge
OEM1293 Straight Edge
OEM6270 120 Grit Glaze Breaker Brush
OEM6453 Piston Retaining Ring Pliers
ZTSE1897E Camshaft Bushing Removal/Installation Set
ZTSE1942A Crankshaft Rear Oil Seal Installation Tool
ZTSE3020 Piston Groove Wear Measuring Tool Set
ZTSE4155A Expansion Plug Replacement Tool
ZTSE4220 Piston Ring Expander
ZTSE4311 Connecting Rod Installation/Remover Guide Pins
ZTSE4317 Crankshaft Wear Ring Removal Tool
ZTSE4318 Rear Oil Seal Installation Tool
ZTSE4375 Flywheel Installation/Removal Guide Studs
ZTSE4385 Oil Pan/Rear Oil Seal Cutting Tool
ZTSE4389 Oil Galley Cleaning Brush
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EGES-205
THERMOSTAT AND COOLANT FILTER 209
Table of Contents
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Testing Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Coolant Filter and Header. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214

Removal (Front of Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Installation (Front of Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
EGES-205
210 THERMOSTAT AND COOLANT FILTER
EGES-205
Figure 334 Water Pump and Thermostat

1. Water Outlet Pipe 5. Plug, 3/4 NPTF (2) 9. Coolant Filter Shutoff Valve
2. Thermostat with integral seal 6. Coolant Filter 10. O-ring
3. Water Pump Gasket 7. Water Pump Pulley 11. Water Pump Assembly
4. Plug, 3/8 NPTF (2) 8. Retaining Ring 12. Plug, 1/2 NPTF
EGES-205
Thermostat Testing Operation

Removal

WARNING: To avoid personal injury injury or possibly death, use caution to avoid
or possibly death, always allow engine to burns when dealing with hot coolant and
cool first. Wrap a thick, heavy cloth around objects. Use heat resistant gloves and wear
radiator cap. Push down and loosen the cap appropriate eye protection.
slowly to its first notch position. Then pause
a moment. This will avoid possible scalding
by hot water or steam. Continue to turn the
cap to the left and remove it. CAUTION: When servicing the thermostat, it
is essential that the thermostat opens fully
at the specified temperature. A thermostat
that functions properly will reduce the risk of
engine damage caused by overheating.
NOTE: Only genuine INTERNATIONAL thermostats

ensure proper coolant flow and positive sealing
characteristics. INTERNATIONAL thermostats are
required to provide proper engine cooling. Make sure
the thermostat is a INTERNATIONAL thermostat
that has the correct temperature range.
Figure 335 Thermostat Outlet Tube

1. Coolant Outlet Tube
2. Thermostat
3. Thermostat Gasket (Square Cross Section)
Figure 336 Testing Thermostat Operation
1. Suspension Line
2. Ribbon
1. Remove the three bolts that secure the outlet tube
3. Thermometer
to the water pump housing.
4. Thermostat
5. Heat Source
NOTE: Some engines were equipped with a
thermostat having a separate gasket. Remove
and discard thermostat and thermostat gasket.
1. Manually open the thermostat just enough to
Replace with new thermostat with integral seal. Refer
insert a nylon ribbon under the valve seat.
to Installation.
Suspend the thermostat in a container so the
2. Remove thermostat with integral seal from the thermostat does not touch the bottom of the
water pump housing. container.
EGES-205
2. Heat the container filled with water to the Installation

START-TO-OPEN temperature. Observe the
thermometer and record the temperature as soon
as the thermostat drops from the nylon ribbon.
This is the actual START-TO-OPEN temperature.
Figure 338 Installing the Thermostat and Outlet

Tube
Figure 337 Thermostat Sleeve Travel
1. Coolant Outlet Tube
1. Typical Thermostat
2. Thermostat with integral seal
2. Minimum Sleeve Travel
1. Install thermostat with integral seal into the water

3. Continue to heat the water to the FULL-OPEN
pump housing. Make sure the arrow on the
temperature. Observe the thermometer and
thermostat is pointing toward rear of the engine
movement of the thermostat sleeve when the
or toward the rear flange bolt.
FULL-OPEN temperature is achieved. The
minimum sleeve travel at the FULL-OPEN 2. Put the coolant outlet tube on the water pump
temperature is 8.0 mm (0.315 in). housing. To ensure a tight fit, make sure the outlet
tube flange is not bent or distorted.
4. Remove the thermostat from the container.
Quickly inspect the seat area for pitting and 3. Install three mounting bolts finger tight. Then
foreign deposits before the thermostat closes. tighten the mounting bolts evenly to the standard
torque value.
5. Replace thermostat if it does not operate as
described or if it does not meet the inspection
criteria.
EGES-205
Coolant Filter and Header 3. Use a strap type wrench to remove the coolant
filter from the water pump housing.
Removal (Front of Engine)
Installation (Front of Engine)

injury or possibly death, always allow the
engine to cool first. Wrap a thick, heavy
cloth around the radiator cap. Push down
and loosen the cap slowly to its first notch
position to relieve any pressure. This will
avoid possible scalding by hot water or
steam.
Figure 340 Coolant Filter Located on the Front

of the Engine
1. Shut Off Valve (OFF Position)
2. Water Pump Housing
3. Coolant Filter
Figure 339 Coolant Filter Located on the Front 1. Apply coolant to the gasket of the coolant filter.
of the Engine 2. Install new coolant filter to front cover. Tighten
1. Shut Off Valve (OFF Position) filter one full turn after the gasket contacts the
2. Water Pump Housing water pump housing.
3. Coolant Filter 3. Turn coolant filter shut off valve to the OPEN,
allowing coolant to flow through the filter.
1. Loosen radiator cap. 4. Tighten radiator cap.
2. Turn coolant filter shut off valve to OFF.
EGES-205
SPECIFICATIONS
Table 22 Thermostat and Coolant Filter

Thermostat
Type Poppet Valve, Pellet Operated
Operating Start-to-Open Temperature 89 2 C (192 4 F)
Maximum Full-Open Temperature 104 C (219 F)
Sleeve Travel at Full-Open Temperature 8 mm (0.315 in)
Coolant Filter
Type Spin-On
Length of Filter 106 mm (4.18 in)
Table 23 Thermostat and Coolant Filter Special Service Tools

OEM6413 Strap Wrench
EGES-205
EGES-205
OIL COOLER AND FILTER 217
Table of Contents
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
Leakage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
Filling Crankcase With Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
EGES-205
218 OIL COOLER AND FILTER
EGES-205
Figure 341 Oil Cooler Assembly

1. Front Header Gasket 7. Rear Oil Cooler Header
2. Front Oil Cooler Header Assembly
3. O-Ring (Thin) 8. Valve, Pressure Regulating
4. O-Ring (Thick) 9. 6 mm (1/4 in) Hex Head Plug
5. Oil Cooler Bundle 10. Lube Oil Filter
6. Rear Filter Header Gasket
EGES-205
Oil Cooler Leakage Test

Removal Inspect oil cooler assembly for leaks by using the
following air pressure test:
1. Drain coolant from the engine.
Figure 342 Removing Oil Cooler Assembly

1. Oil Cooler Assembly
2. Remove and discard oil filter.

3. Remove oil cooler assembly from crankcase and
front cover mounting pads.
Figure 343 Air Pressure Test

1. Pressure Gauge and Regulator
2. Oil Cooler Front Header
3. Test Plate
4. Oil Cooler Filter Header
1. Remove heater and block the heater plug.

2. Install a new oil filter and all pipe plugs in the
headers.
3. Fasten oil cooler test plate to oil cooler.
4. Fasten pressure gauge and regulator to test plate.
EGES-205
e. Inspect header castings, O-rings and oil side

1/4 NPTF hole for moving or growing bubbles.
Replace components as required.
Disassembly
Gently tap headers to loosen the O-rings. Twist
headers and separate them from oil cooler bundle.
Cleaning
Figure 344 Oil Pressure Check CAUTION: To avoid engine damage, should
1. Test Plate a bearing failure occur, the oil cooler bundle
2. Oil Cooler Filter Header must be replaced because debris from a
3. Oil Cooler Front Header failed bearing cannot be removed from the
4. Pressure Gauge and Regulator cooler bundle.
1. Immerse oil cooler, front header and filter header

5. Perform oil pressure check as follows: in a suitable solvent. Flush and drain oil cooler to
a. Leave water side 1/4 NPTF hole in the test remove any residue.
plate open. 2. Dry all components thoroughly with filtered
b. Install an air pressure hose to the oil side of compressed air.
the 1/4 NPTF hole in the test plate.
c. Immerse the assembly in a container of clean Inspection
water.
1. Inspect oil cooler for blocked tubes and corrosion
d. Apply 276 414 kPa (40 60 psi) of air where the tubes are assembled to the oil cooler
pressure while the assembly is immersed. bundle. Replace the oil cooler bundle if required.
e. Inspect the header castings, O-rings and 2. Inspect filter header for blocked orifices and
water side 1/4 NPTF hole for moving or damaged threads at the oil filter threaded inserts.
growing bubbles. Replace components as
required. 3. Remove any debris that may be blocking the oil
flow passages.
6. Perform water side oil cooler check as follows:
4. If thread damage is apparent, replace the header.
a. Leave the oil side 1/4 NPTF hole in the test
plate open.
b. Install an air pressure hose to the water side Assembly
of 1/4 NPTF hole in the test plate. 1. Install new O-rings on the oil cooler bundle.
c. Immerse assembly in a container of clean 2. Lubricate the oil cooler bundle headers and
water. O-rings with clean engine oil.
d. Apply 276 414 kPa (40 60 psi) air pressure 3. Carefully press the assembly together. Make sure
while the assembly is immersed. the header is not cocked and the locating clip of
the oil cooler rear header is aligned in the slot of
the cooler bundle.
EGES-205
Installation NOTE: Do not overtighten the filter. A damaged filter

may fracture or leak.
2. Lubricate a new filter gasket with clean engine oil.
3. Spin the oil filter on the threaded adapter until the
gasket contacts the oil filter header. Tighten the
oil filter an additional 3/4 to 1 turn.
Filling Crankcase With Oil

1. Fill the crankcase with 18.5 L (19.5 qt.) of oil if the
oil filter has been changed or 17 L (18 qt.) of oil if
the oil filter has not been changed. If the oil cooler
was removed or drained of oil, add an extra 0.94
Figure 345 Installing the Oil Cooler
L (1 qt.) of oil.
1. Oil Cooler Assembly
2. Start the engine and check for leaks. Fix leaks as
needed.
1. With the oil cooler and headers assembled, install 3. Shut down the engine and check the oil level. Add
the assembly with a new gaskets to the left side oil or drain oil as needed to bring the oil level within
of the crankcase. Tighten the bolts to standard the FULL and ADD marks on the oil level gauge.
torque. Do not overfill past the FULL mark.
EGES-205
ENGINE ELECTRICAL 223
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Exhaust Back Pressure (EBP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Engine Coolant Temperature (ECT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Injection Control Pressure (ICP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Injection Pressure Regulator (IPR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
Manifold Absolute Pressure (MAP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
Intake Air Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
Electronic Control Module (ECM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
Main Engine Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235
Verifying CMP Sensor Clearance (Air Gap). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
Glow Plug Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
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224 ENGINE ELECTRICAL
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Description circuit. It responds to a rotating actuator positioned

on the camshaft gear. The actuator has 24 stamped
NOTE: Refer to the following for electrical system windows. This produces a rectangular wave pulse for
troubleshooting: each tooth as the actuator rotates past the sensor.
The pulses are used to indicate engine speed and
EGES190, T 444E Diesel Engine / Vehicle Diagnostic camshaft position for control of fuel quantity, injection
Manual timing, and overspeed shutdown. The sensor is
located above the vibration damper on the right side
EGED195, Hard Start / No Start Performance Engine of the engine front cover.
Diagnostics Form
EGED200, Electronic Control System Diagnostics EXHAUST BACK PRESSURE (EBP) SENSOR
Form
CAMSHAFT POSITION (CMP) SENSOR
Figure 347 EBP Sensor
The EBP sensor is a ceramic diaphragm sensor that

measures the exhaust back pressure. It provides
Figure 346 CMP Sensor feedback to the ECM for closed loop control of the
exhaust back pressure. The result is faster engine
warm-up at cold ambient temperatures. If equipped,
The CMP sensor is a Hall effect type sensor stacked in the sensor is mounted on a bracket located on the
front of a magnet with a signal conditioning integrated top right side of the hydraulic reservoir.
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ENGINE OIL PRESSURE (EOP) SENSOR sensor is located above the water pump on the right
side of the engine front cover.
ENGINE OIL TEMPERATURE (EOT) SENSOR
Figure 350 EOT Sensor
The EOT sensor is a thermistor type sensor that

detects the engine oil temperature and sends the
engine temperature signal to the ECM. The ECM
Figure 348 EOP Sensor then uses the information for fuel rate and timing
adjustments. The sensor is located on the rear left
side of the high pressure oil reservoir.
The EOP sensor is a ceramic diaphragm sensor that
detects engine oil pressure and sends the pressure
signal to the ECM. The sensor is located on top of the INJECTION CONTROL PRESSURE (ICP) SENSOR
high oil pressure pump reservoir.
ENGINE COOLANT TEMPERATURE (ECT)

SENSOR
Figure 351 ICP Sensor
The ICP sensor is a ceramic diaphragm sensor that

Figure 349 ECT Sensor measures the injection control pressure. It provides
gallery pressure feedback to the ECM for a closed
loop control of the injector oil pressure. The sensor
The ECT sensor is a thermistor type sensor that is located toward the front of the engine on the left
detects changes in engine coolant temperature. The cylinder head, in the high pressure oil rail.
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INJECTION PRESSURE REGULATOR (IPR) VALVE The MAP sensor is a ceramic diaphragm sensor
that indicates manifold boost pressure or vacuum
by receiving a signal from the ECM. The sensor is
located on the right side of the intake manifold pipe.
INTAKE AIR TEMPERATURE
Figure 352 IPR Valve
The IPR valve is a pulse width modulated valve that

regulates the injection control pressure by receiving a
signal from the ECM. The valve is located on the left
side of the high pressure oil pump.
Figure 354 IAT Sensor
MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR The Intake Air Temperature (IAT) sensor is
a thermistor type sensor that has a variable
resistance which changes when exposed to different
temperatures. The IAT sensor measures intake air
temperature in order to control timing and fuel rate
while starting the engine in cold weather to limit
smoke emissions.
Figure 353 MAP Sensor
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Figure 355 Engine Top View

1. Electronic Control Module 5. Injection Pressure Regulator
(ECM) (IPR) Valve
2. Glow Plug Relay 6. Engine Oil Temperature (EOT)
3. Manifold Absolute Pressure Sensor
(MAP) Sensor 7. Engine Oil Pressure (EOP)
4. Injection Control Pressure (ICP) Sensor
Sensor 8. Main Engine Wiring Harness
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Figure 356 Engine Front View

1. Engine Oil Pressure (EOP) 4. Exhaust Back Pressure (EBP)
Sensor Sensor
2. Camshaft Position (CMP) 5. Main Engine Wiring Harness
Sensor
3. Engine Coolant Temperature
(ECT) Sensor
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Electronic Control Module (ECM) 2. Use a square head driver to unscrew the
connector bolt. Disconnect the engine wiring
Removal
harness from the ECM.
3. To remove the ECM from the support assembly,
remove the four mounting bolts and lift the ECM
from the support bracket.
4. To remove the ECM and support assembly as one
unit, perform the following steps:
Figure 357 Glow Plug Relay

1. Glow Plug Connector Terminals
2. Battery Connection Terminal
Figure 359 ECM Support Assembly Lower

1. Disconnect the battery and glow plug connectors Mounting Bolts
from glow plug relay.
a. Remove the two lower mounting bolts for the

ECM support assembly.
Figure 358 ECM Wiring Harnesses and Mounting

Figure 360 ECM Support Assembly Upper
Bolts
Mounting Bolts
1. Connector Bolt
2. Engine Wiring Harness
3. ECM Mounting Bolt (4) b. Remove the two upper mounting bolts for the
ECM support assembly.
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Installation
1. To install the ECM and support assembly as one
unit, perform the following steps:
Figure 361 Bottom Mounting Bracket

1. Top Bushing
2. Bushing Pin
3. Bottom Bushing
4. Bottom Mounting Bracket Figure 363 ECM Support Assembly Bushings
and Pins
1. Top Bushing
c. If necessary, remove the bushings and pins 2. Bushing Pin
from the mounting brackets. 3. Bottom Bushing
4. Bottom Mounting Bracket
Inspection
a. If previously removed, install the bushings
and pins in the bolt holes of the support
assembly.
Figure 362 ECM Mounting Bushings and Pin

1. Bushings
2. Pin
Figure 364 ECM Support Assembly Upper

Mounting Bolts
1. Inspect ECM mounting bushings for wear and
damage. Replace as necessary.
2. Inspect the wiring harnesses, covers, and cover b. Install the ECM and support assembly on
shields for wear and damage. Replace as the engine. Install and tighten the two upper
necessary. mounting bolts to the special torque value.
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Figure 365 ECM Support Assembly Lower

Mounting Bolts
Figure 367 Glow Plug Relay
c. Install and tighten the two lower mounting 1. Glow Plug Connector Terminals
bolts to the special torque value. 2. Battery Connection Terminal
4. Connect the battery and glow plug connectors to

the glow plug relay terminals.
Main Engine Wiring Harness

Removal
1. Perform Steps 1 through 7 in the Engine Control
Module (ECM), Removal procedure in this
section.
Figure 366 ECM Wiring Harnesses and Mounting

Bolts
1. Connector Bolt
2. Engine Wiring Harness
3. ECM Mounting Bolt (4)
2. To install the support assembly and ECM

separately, first perform the procedure in Step
1 for the support assembly only. Then install the
ECM on the support assembly. Install and tighten Figure 368 9Pin Connector to the Valve Cover
the four mounting bolts to the special torque Gasket
value.
3. Connect the engine wiring harness to the ECM. 2. Carefully unlatch and disconnect the 9pin
Tighten the connector bolt to the special torque connectors from the valve cover gasket. There is
value. one connector for each valve cover.
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Figure 369 MAP Sensor Connector

Figure 371 EBP Sensor Connector
1. MAP Sensor
2. Sensor Connector 1. Sensor Connector
2. EBP Sensor
3. Carefully unlatch and disconnect the sensor

connector from the MAP sensor. 5. Carefully unlatch and disconnect the sensor
connector from the EBP sensor.
Figure 370 EOP Sensor Connector Figure 372 ECT Sensor Connector
1. Sensor Connector 1. ECT Sensor
2. EOP Sensor 2. Sensor Connector
4. Carefully unlatch and disconnect the sensor 6. Carefully unlatch and disconnect the sensor
connector from the EOP sensor. connector from the ECT sensor.
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Figure 375 ICP Sensor Connector

Figure 373 CMP Sensor Connector
1. Sensor Connector
1. Sensor Connector 2. ICP Sensor
2. CMP Sensor
9. Carefully unlatch and disconnect the sensor

7. Carefully unlatch and disconnect the sensor connector from the ICP sensor.
connector from the CMP sensor.
Figure 376 IPR Valve Connector

Figure 374 EOT Sensor Connector
1. EOT Sensor
2. Sensor Connector 10. Carefully unlatch and disconnect the valve
connector from the IPR valve.
8. Carefully unlatch and disconnect the sensor NOTE: For removal of the IPR valve, refer to the
connector from the EOT sensor. HIGH-PRESSURE OIL PUMP section.
11. Remove the wiring harness routing clips from the
cylinder heads and front cover.
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CAUTION: To avoid engine damage, if any

resistance is felt during removal, DO NOT tug
on the wiring harness to free it. This could
damage the wiring harness. Investigate the
source of resistance and free the wiring
harness carefully before continuing with the
removal.
12. Carefully lift the engine wiring harness from the

engine.
Inspection Figure 377 Installing the CMP Sensor

1. If any sensors are removed, clean off any thread 1. CMP Sensor
locking compound from the sensor threads. 2. Sensor Port
2. Check the connector pins on the sensors. If any 3. Bolt Hole
pins are bent or corroded, replace the sensor.
3. Carefully inspect the wiring harness for worn b. Put a new O-ring on the sensor and lubricate
conduit, frayed insulation, and heat damage. the O-ring with clean engine oil.
Repair as necessary.
c. Insert the sensor into the port. Secure the
4. Check each connector for: sensor with the mounting bolt.
corrosion (green or gray) or white deposits on 3. If removed, install the ICP sensor as follows:
metal terminals.
female connector sleeves that are spread
open.
terminals that are incorrectly latched into the
connector body or pushed back relative to
other terminals in the same connector.
5. Check the wiring harness connectors, connector
covers, foam inserts, and cover shields for cracks,
cuts, or worn areas. Replace as necessary.
Installation
Figure 378 ICP Sensor O-Ring
NOTE: For installation of the IPR valve, refer to the
HIGH PRESSURE OIL PUMP section.
a. Put a new O-ring on the sensor.
1. If removed, install the EOT, ECT, EBP, EOP, and
MAP sensors in their proper locations (Removal, b. Apply Loctite #277 to the threads of the
page 232). sensor. Install the sensor in the front left
cylinder head bank and tighten the sensor to
2. If removed, install the CMP sensor as follows:
the special torque value.
a. If necessary, check the clearance of the
CMP sensor. Refer to Verify CMP Sensor
Clearance (Air Gap) in this section.
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Verifying CMP Sensor Clearance (Air Gap)
NOTE: It is only necessary to verify the sensor

clearance if there has been erratic operation.
Engine misfiring may also be caused by a low diesel

fuel cetane number. Verify the fuel being used has a
cetane number of 42 or higher.
Figure 379 9Pin Connector to the Valve Cover

Gasket
NOTE: To ensure the electrical connection between

the wiring harness and the valve cover gasket, install
a new retainer clip from service kit P/N 1844193C91
on both wiring harness connectors.
4. Connect the two 9pin connectors to the valve
cover gaskets. There is one for each valve cover. Figure 380 Removing CMP Sensor
NOTE: Make sure that each connector has its ribbed

1. Disconnect CMP sensor wiring harness
seal in place before installation into sensor. In some
connector.
cases, a ribbed seal may pull off its connector during
removal and remain in the mating socket of a sensor 2. Remove CMP sensor mounting bolt from engine
or actuator. A connector that is installed without the front cover. Pull CMP sensor out.
appropriate ribbed seal may become contaminated
3. Clean the sensor mounting surface.
with moisture and corrode the terminals, resulting in
a poor electrical connection.
5. Install the wiring harness on the engine. Carefully
align the connectors with the sensors. Push each
connector into its mating socket until the locking
tabs are fully latched.
6. Install the wiring harness routing clips.
Figure 381 Camshaft Sensor Air Gap Tool In

CMP Sensor
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4. Insert camshaft sensor air gap tool in calibration OPTIONAL METHOD

cup of CMP sensor. Hold firm downward pressure
on tool and adjust indicator dial to zero. Tighten
lock tab on dial ring of air gap tool. The tool is now
calibrated for the length of the CMP sensor.
5. Install camshaft sensor air gap tool tip against the
camshaft gear trigger wheel tooth. Secure tool
to front cover by tightening mounting screw to 1.0
Nm (10 inlbf).
6. Crank the engine with starter or bar engine over by
hand. Turn over at least two complete revolutions
prior to recording any readings.
7. Observe needle sweep on dial indicator. The
range sweep is an indication of timing wheel
runout which should not exceed 0.20 mm (0.008 Figure 382 Measuring the Sensor Air Gap
in).
8. Crank engine long enough to get an average
reading of the camshaft sensor air gap tool dial 12. Manually rotate the crankshaft clockwise at least
indicator. If an interference condition is observed two complete revolutions while facing the front
during cranking, the CMP sensor may have been of the engine. Then knock the crankshaft back
damaged and must be replaced. gently. This ensures that the sensor air gap is at
its maximum with the camshaft gear in contact
9. Perform the math using the CMP Sensor with its rear thrust face.
Clearance Worksheet. Select the appropriate
combination of shims to achieve a measurement NOTE: When taking the following measurement,
as close to 0.026 inch as possible. Refer to the measure up to the gear tooth on the trigger wheel.
International Service Parts Dealer for the correct DO NOT measure into the window between the teeth.
shim kit.
13. Use a depth micrometer or a precision caliper to
10. Install the CMP sensor with the shims required. carefully measure the distance (to nearest one
Insure that the shims are centered on the CMP thousandth of an inch) from the sensor mounting
sensor flange. Use a small amount of grease to surface to the camshaft gear tooth on the trigger
hold them in place. wheel. Record the measurement (sensor air gap)
11. Reconnect sensor wiring harness and test engine. on the worksheet.
14. Manually rotate the crankshaft 180 clockwise
while facing the front of the engine. Repeat Steps
12 and 13. Continue this process two more times
so the distance from the cover to the trigger wheel
is measured at four different locations.
Variations in these measurements determine the
runout of the trigger wheel. The variation should
not exceed 0.20 mm (0.008 in).
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15. Use a depth micrometer or a precision caliper to

carefully measure the CMP sensor from the tip to
the surface of the mounting flange. Record the
measurement on the worksheet.
16. Perform the math as directed on the worksheet.
Then select the appropriate combination of shims
to achieve a measurement as close to 0.026 inch
as possible. Refer to your International Service
Parts Dealer for the correct shim kit.
17. Install the CMP sensor with the necessary shims.
Ensure that the shims are centered on the sensor
flange. If necessary, use a small amount of grease
to hold them in place.
18. Connect the sensor wiring harness. Test the
engine.
Figure 383 Measuring the CMP Sensor

1. CMP Sensor
2. Depth Micrometer
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Table 24 CMP Sensor Clearance Worksheet

STEP MEASUREMENT
1. Rotate crankshaft clockwise at least two revolutions. Measure distance from CMP
sensor mounting surface to gear tooth on trigger wheel.
2. Rotate crankshaft 180 clockwise. Repeat measurement. +
5. Add measurements from Step 1 through Step 4. =
6. Obtain average dimension by dividing Step 5 total by 4. 4
7. Measure CMP sensor length from tip to surface of mounting flange. -
8 Subtract Step 7 measurement from Step 6 average. =
9. Desired air gap (inches) - 0.026
10. Subtract Step 9 dimension from Step 8 total.
=
This is the necessary shim thickness.
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Glow Plug Relay 3. Disconnect the 12V power wire, glow plug wire
and relay control harness connector.
Removal
4. Remove the two mounting screws. Lift the glow
plug relay from the engine.
WARNING: To avoid engine damage,

serious personal injury or possibly death, Inspection
do not use a screwdriver or similar tool to
pry off the terminal cover. Disconnect the NOTE: The glow plug relay is not repairable beyond
batteries first due to the presence of battery being certain that all electrical connections to it are
voltage at the relay terminals. Disconnect clean and tight.
the ground terminal first. Always wear eye
protection when working around batteries. Inspect the base and relay housing for cracks.
Replace if cracks are found.
1. Disconnect the main negative cable from the

batteries. Installation
2. Remove the glow plug relay plastic terminal cover. 1. Install the glow plug relay onto its bracket. Tighten
the two mounting screws.
2. Connect the glow plug wire and 12V power wire to
the top of the glow plug relay. Tighten the terminal
nuts.
3. Connect the relay control harness connector to
the glow plug relay.
4. Snap the glow plug relay cover into place.
5. Connect the main negative cable to the batteries.
Figure 384 Glow Plug Relay Disconnection

Points
1. Glow Plug Relay Mounting Bolt
2. Glow Plug Relay Terminal Stud
3. Relay Control Harness Connector
4. 12 Volt Power Wire Terminal Stud
EGES-205
SPECIFICATIONS
Table 25 Engine Electrical

Glow Plugs:
Location Cylinder Head
Quantity 8
Injection Pressure Regulator (IPR) Valve:
Maximum Flow Rate 17.5 L/m (4.62 gpm)
Maximum Operating Pressure 20.7 MPa (3000 psi)
Camshaft Position Sensor (CMP)
Location Front Cover
Operating Actuator Speed 15 to 2000 RPM
Operating Temperature Range -40 C to +130 C (-40 F to +266 F)
Operating Air Gap Range 0.10 to 0.86 mm (0.004 to 0.034 inch)
Desired Air Gap Measurement 0.66 mm (0.026 inch)
Special Torque
Table 26 Electrical System Special Torques

Glow Plug 19 Nm (14 lbfft)
Glow Plug Relay Stud Nuts 8 Nm (70 lbfin)
Injection Control Pressure (ICP) Sensor 50 5 Nm (37 4 lbfft)
ECM Mounting Bolts 24 Nm (18 lbfft)
ECM Support Assembly Mounting Bolts 24 Nm (18 lbfft)
ECM Mounting Bracket Nuts 24 Nm (18 lbfft)
Wiring Harness Connector Mounting Bolt (Engine
3 5 Nm (30 45 lbfin)
and Chassis)
Table 27 Special Service Tools

ZTSE 4414 Camshaft Sensor Air Gap
OEM 1013 Depth Gage Micrometer
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HIGH-PRESSURE OIL PUMP 243
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
High-pressure Oil Pump Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
High-pressure Oil Pump and Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
High-pressure Oil Pump and Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
Check Drive Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
High-pressure Oil Pump Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
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244 HIGH-PRESSURE OIL PUMP
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Figure 385 Injector Oil System Flow

1. Engine Lube Oil Pump 7. Cylinder Head High Pressure
2. Check Valve Oil Rail
3. Reservoir (Located on the Top 8. Fuel Injector (8)
of Front Cover) 9. Gallery (Crankcase)
4. High-pressure Oil Pump 10. Oil Filter
5. High-pressure Lines 11. Oil Cooler
6. Injection Control Pressure (ICP) 12. Injection Pressure Regulator
Sensor (IPR) Valve
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Removal 2. Remove power steering pump.

High-pressure Oil Pump Reservoir
NOTE: A service kit for servicing the discharge fittings

and rear plug is available for the high-pressure pump.
Figure 387 EBP Sensor Location

1. EBP Sensor Bracket Bolts (2)
Figure 386 Removing Oil From High-pressure 2. EBP Sensor
Oil Pump Reservoir 3. EBP Sensor Tube
4. EBP Sensor Tube Nuts
1. Hand Operated Vacuum Pump
2. High-pressure Oil Pump Reservoir
3. Remove two bolts that secure the EBP sensor
bracket to the right side of the high-pressure oil
1. Remove pipe plug from top left side of
pump reservoir.
high-pressure oil pump reservoir. Use a hand
operated vacuum pump to extract oil from the 4. Disconnect the EBP sensor tube from the right
reservoir. exhaust manifold.
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1. Use the special removal tool to disconnect the

high-pressure oil supply hoses at the pump and
at each cylinder head. Cap the fittings.
2. Disconnect the electrical harness from the IPR
valve solenoid.
Figure 388 Removing Mounting Bolts From the

1. Mounting Bolts
Figure 390 Removing Drive Gear Access Cover
5. Remove the three remaining mounting bolts that 1. Drive Gear Access Cover
secure the high-pressure oil pump reservoir to the 2. Mounting Bolt (2)
front cover. Remove the high-pressure oil pump
reservoir and gasket.
3. Remove the two bolts and the drive gear access
cover from the front cover. Clean all RTV sealant
High-pressure Oil Pump and Drive Gear from the access cover and front cover mating
surface.
Figure 391 Removing Drive Gear Bolt
Figure 389 Removing High-pressure Oil Supply 1. Drive Gear

Hoses 2. Mounting Bolt and Washer
1. High-pressure Oil Pump

2. Supply Hoses 4. Remove bolt and washer that secure the drive
3. Clamp gear to the high-pressure oil pump.
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Injection Pressure Regulator (IPR) Valve
NOTE: The IPR valve can be removed before or after

the high-pressure oil pump is removed.
Figure 392 Removing High-pressure Oil Pump

Mounting Bolts
1. Drive Gear
3. Mounting Bolts
5. Remove two capscrews that secure high-pressure

oil pump to front cover. Remove pump and gasket
from front cover.
Figure 394 Removing the IPR Valve Solenoid
NOTE: The gasket is reusable.
2. IPR Valve
3. Solenoid
4. Tinnermann Nut
1. Remove the tinnermann nut that secures the IPR

valve solenoid. Remove the solenoid.
Figure 393 Removing Drive Gear

1. Front Cover
2. Drive Gear
6. Remove the drive gear through the top of the front Figure 395 Removing the IPR Valve
cover.
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2. Use a 28 mm (1-1/8 in) deep socket to unscrew High-pressure Oil Pump and Drive Gear
the IPR valve from the high-pressure oil pump.
Installation
Figure 397 Installing High-pressure Oil Pump

and Gasket
1. Gasket
2. Front Cover
Figure 396 Installing the IPR Valve

1. Insert the high-pressure oil pump drive gear into
the opening on top of the front cover.
1. Check the O-rings on the IPR valve. Replace the
O-rings if damaged. 2. Position the high-pressure oil pump with the
gasket against the front cover.
2. Install the IPR valve into the high-pressure oil
pump. Tighten the IPR valve to the special torque
value.
3. Install the solenoid and tinnermann nut. Tighten
the tinnermann nut to the special torque value.
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4. Install the drive gear bolt and washer to secure the

drive gear to the high-pressure oil pump. Tighten
bolt to the special torque value.
Figure 398 Installing High-pressure Oil Pump

Mounting Bolts
Figure 400 Applying RTV Sealant to the Drive
1. Front Cover
Gear Access Cover
3. High-pressure Oil Pump 1. Drive Gear
3. RTV Bead
3. Install and tighten the two mounting bolts to the 4. Front Cover
5. Apply RTV sealant to the drive gear access cover

mounting surface.
Figure 401 Install Drive Gear Access Cover

1. Drive Gear Access Cover
Figure 399 Installing the Drive Gear Bolt

6. Install the access cover and two mounting bolts.
1. Drive Gear Tighten the bolts to the standard torque value.
2. Front Cover
7. Connect the engine wiring harness connector to
3. Drive Gear Mounting Bolt
the IPR valve solenoid.
4. Washer
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1. Mount the dial indicator.

2. Place the measuring tip of the dial indicator on the
gear tooth, tangent to the gear tooth, if possible.
3. Move the gear in one direction and hold it in place.
4. Zero the dial indicator.
5. Move the drive gear by hand in the opposite
direction. Record the backlash.
6. If the backlash exceeds specifications, replace the
drive gear.
Figure 402 Installing High-pressure Oil Supply

Hoses
2. High-pressure Oil Supply Hoses
3. Hose Clamp
8. Remove the protective caps from the fittings.

Install both high-pressure oil supply hoses at the
high-pressure oil pump and cylinder head. Make
sure the hose fittings snap into place.
Check Drive Gear Backlash

Figure 404 Installing a Gasket to the Reservoir
Mating Surface
1. Reservoir Gasket
3. High-pressure Oil Pump Drive Gear
4. Front Cover
1. Install a new gasket onto the top of the reservoir

mating surface.
Figure 403 Measuring Drive Gear Backlash

1. Dial Indicator
2. Drive Gear
3. Front Cover
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Figure 405 Install High-pressure Oil Pump

Reservoir
1. Exhaust Back Pressure (EBP) Sensor
3. Reservoir Mounting Bolts (3)
2. Install the reservoir to the front cover. Secure the Figure 406 Installing EBP Sensor
reservoir with three mounting bolts. 1. EBP Sensor Bracket Bolts (2)
2. EBP Sensor
3. EBP Sensor Tube
4. EBP Sensor Tube Nuts
3. Use two bolts to secure the EBP sensor bracket

onto the right side of the high-pressure oil pump
reservoir.
4. Connect the EBP sensor tube to the right exhaust
manifold. Tighten the tube nut.
5. Connect the EBP sensor to the wiring harness.
6. Fill the reservoir with clean engine oil.
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SPECIFICATIONS
Table 28 High-pressure Lube Oil System

High-pressure Oil Pump
Gear Backlash 0.1400.256 mm (0.00550.0101 in)
End Play 0.451.22 mm (0.0180.048 in)
Operating Temperature Range -40 to 125 C (-40 to 257 F)
Maximum Flow Rate 17.5 L/min (4.62 gpm)
Special Torque
Table 29 High-pressure Lube Oil System Special Torques

High-pressure Oil Pump Drive Gear Bolt 129 Nm (95 lbfft)
IPR Valve Tinnermann Nut 5.5 1.5 Nm (49 13 lbfin)
IPR Valve 50 5 Nm (37 4 lbfft)
High-pressure Hose Fitting (37 Flare) 26 Nm (19 lbfft)
45 and 90 Elbow Locknut 28 Nm (21 lbfft)
Table 30 High-pressure Lube Oil System Special Service Tools

ZTSE2499 Hand Operated Vacuum Pump
ZTSE4295 High-pressure Oil System Cap Set
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FUEL SYSTEM 255
Table of Contents
Fuel Filter Tower, Bracket and Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Fuel Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
Fuel Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
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256 FUEL SYSTEM
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FUEL SYSTEM 257
Figure 407 Fuel System Components

1. Pump Flange Gasket 9. Fuel Supply Pipe (Right Side) 18. Fuel Filter Water Drain Tube
2. High-pressure Oil Pump and Inlet Check Fittings 19. Fuel Filter Water Drain Hose
Assembly 10. Transfer Pump 20. Fuel Hose
3. High-pressure Manifold Hose 11. Fuel Filter to Transfer Pump 21. Hose Clamp
(Right Side) 12. Fuel Pump Supply Tube 22. Fuel Filter to Transfer Pump
4. Fuel Injection Pressure 13. Fuel Supply Hose from Pump to Tube
Regulator Regulator 23. Cylinder Head (Right Side)
5. High-pressure Oil Pump Supply 14. Clamp 24. Fuel Filter Bracket
Hose (Left Side) 15. Fuel Pump Lines Retaining 25. Fuel Supply Hose (Left Side)
6. Fuel Supply Hose (Left Side) Clamp 26. Fuel Pressure Regulating Valve
and Inlet Check Fittings 16. Water Drain Tube Clamp 27. Fuel Filter Element
7. Cylinder Head (Left Side) Support 28. Fuel Filter Lid (Part of Assembly)
8. Fuel Injector Assembly 17. Clamp
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258 FUEL SYSTEM
Fuel Filter Tower, Bracket and

Piping
Removal

injury, possible death, or damage to the
engine or vehicle, do not smoke or work
near open flames and sparks when draining
fuel.
Figure 409 Removing the Fuel Lines

1. Fuel Supply to Fuel Transfer Pump Line
2. Fuel Transfer Pump to Fuel Filter Line
3. Retaining Clamp
4. Fuel Filter to Fuel Transfer Pump Line
5. Fuel Filter Drain Line
2. Remove the bolt for the retaining clamp that holds

three of the fuel lines together.
3. Loosen the hose clamps and remove all four fuel
lines.
Figure 408 Fuel Filter Lever Locations

1. Fuel Filter Assembly
2. Fuel Filter Shutoff Lever, CLOSED Position
3. Fuel Filter Shutoff Lever, DRAIN Position
1. Place a suitable container at the end of the fuel

filter drain line to catch the draining fuel. Move the
fuel filter drain lever to the DRAIN position. When Figure 410 Removing Hoses from the Regulating
the fuel is done draining, return the lever to the Valve
CLOSED position.
1. Fuel Pressure Regulating Valve
2. Fuel Supply Hoses
4. Remove two fuel supply hoses from the fuel

pressure regulating valve. Cap the fittings on the
cylinder head.
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FUEL SYSTEM 259
5. Remove the bolts that secure the fuel pressure

regulating valve to the fuel filter. Check for
damage or corrosion.
Figure 412 Removing the Fuel Filter Tower

(Model Years 1999 and Up)
1. Fuel Filter Tower
2. Fuel Filter Support Bracket
3. Fuel Filter Tower Mounting Bolts (2)
4. Support Bracket Mounting Nuts (3)
6. Remove the two mounting bolts that secure the

fuel filter tower to the fuel filter support bracket.
Figure 411 Removing the Fuel Filter Tower Remove the fuel filter tower from the support
(Model Year 19971998) bracket.
1. Fuel Filter Tower 7. If necessary, remove the mounting nuts that
2. Fuel Filter Support Bracket secure the fuel filter support bracket to the
3. Fuel Filter Tower Mounting Bolts (2) cylinder head. Remove the support bracket.
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260 FUEL SYSTEM
Installation
Figure 414 Removing the Fuel Filter Tower

(Model Years 1999 and Up)
1. Fuel Filter Tower
2. Fuel Filter Support Bracket
3. Fuel Filter Tower Mounting Bolts (2)
Figure 413 Installing the Fuel Filter Tower 1. If removed, install the support bracket on the
(Model Year 19971998) cylinder head. Install the four mounting nuts and
1. Fuel Filter Tower tighten them to the standard torque value.
2. Fuel Filter Support Bracket 2. Install the fuel filter tower on the support bracket.
3. Fuel Filter Tower Mounting Bolts (2) Install the two mounting bolts and tighten them to
4. Support Bracket Mounting Nuts (4) the standard torque value.
Figure 415 Installing Hoses to Regulating Valve

1. Fuel Pressure Regulating Valve
2. Fuel Hoses
3. Install a new O-ring onto the fuel pressure

regulating valve.
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FUEL SYSTEM 261
4. Secure the regulating valve to the fuel filter with Fuel Strainer
two mounting bolts. Tighten the bolts to the
Removal
5. Attach the fuel supply hoses to the fuel pressure
regulating valve. Tighten the hose fittings.
Figure 417 Removing the Fuel Strainer

Assembly
1. Remove the fuel strainer assembly from the fuel

Figure 416 Attaching the Fuel Lines filter housing.
1. Fuel Supply to Fuel Transfer Pump Line 2. Use a 29 mm or 1-1/8 inch socket to remove the
2. Fuel Transfer Pump to Fuel Filter Line plastic fuel strainer cover from the filter strainer
3. Retaining Clamp assembly. Clean or replace the fuel strainer.
4. Fuel Filter to Fuel Transfer Pump Line
5. Fuel Filter Drain Line
Installation
6. Attach the three fuel lines between the fuel

transfer pump and the fuel filter.
7. Install the retaining clip and bolt to hold the three
fuel lines together.
8. Attach the fuel filter drain line. Secure it to the fuel
filter with hose clamps.
Figure 418 Installing the Fuel Strainer

1. Fuel Strainer
2. O-Ring
EGES-205
262 FUEL SYSTEM
NOTE: Install the fuel strainer with the open end

toward the top.
1. Install a new O-ring. Lubricate the threads of
the fuel strainer cover and the O-ring with clean
engine oil.
2. Install the new fuel strainer into the cover. Hand
tighten the strainer into the fuel filter body.
Fuel Filter
Removal
Figure 420 Removing the Fuel Filter Element

Assembly
1. Fuel Filter Cap
2. Fuel Filter Element
3. Fuel Filter Locking Tab
4. Bevel-Cut Gasket
2. Remove and discard the bevel-cut gasket.

Figure 419 Removing the Fuel Filter Cap Carefully clean all mating surfaces.
3. Press in on the fuel filter element locking tabs and
separate the filter element from the cap.
1. Use a large screwdriver to remove the fuel filter
cap. The filter element will come out with the cap.
Installation
CAUTION: The engine will not run without

the filter element in place. Failure to secure
the fuel cap to the fuel filter may result in
engine damage because the filter element is
required to open the valve in the center stand
pipe. When the valve is open, fuel is allowed
to flow into the filter. This feature protects
the injectors from contaminants if the filter
element is left out.
NOTE: If the fuel system has been drained, prime

the fuel filter by filling the filter housing up to the cap
threads with clean diesel fuel.
EGES-205
FUEL SYSTEM 263
Fuel Transfer Pump

Removal
Figure 422 Removing the Fuel Transfer Pump

1. Lines from Pump to Filter
2. Fuel Transfer Pump
Figure 421 Installing a New Fuel Filter Element 3. Fuel Supply Tube (to Regulating Valve)
1. Fuel Filter Cap 4. Fuel Supply Tube (Right Side)
2. Fuel Filter Element
3. Bevel-Cut Gasket
4. Fuel Filter Housing 1. Disconnect the lines between the fuel transfer
pump and the fuel filter. Plug the lines.
2. Disconnect both fuel supply tubes from the fuel
1. Apply a coating of diesel fuel to the new bevel-cut transfer pump. Plug the tubes.
gasket and install it on the fuel filter housing gland.
3. Remove the two mounting bolts that secure the
2. Install a new fuel filter element on the cap. Place fuel transfer pump to the base of the crankcase.
the new fuel filter element and cap into the fuel
filter housing. Tighten the cap onto the fuel filter 4. Rotate the engine by hand until the pump is
housing until the cap contracts the aluminum pushed up approximately 1/2 inch. This places
housing. the cam lobe at the top. In this position, if the
tappet falls out of the pump during removal, it will
not enter the crankcase.
5. Remove the fuel transfer pump.
6. If required, retrieve the tappet from the fuel
transfer pump bore located in the crankcase.
Insert the tappet into the base of the fuel transfer
pump.
Inspection
Inspect the fuel transfer pump tappet for wear.
EGES-205
264 FUEL SYSTEM
Installation 1. Install a new O-ring onto the fuel transfer pump.

2. Rotate the engine by hand until the fuel transfer
pump is pushed nearly flush with the crankcase.
Install the mounting bolts to the standard torque
value.
3. Remove the plugs from the fuel supply tubes.
Place new O-rings onto the tube fittings. Connect
the fuel supply tubes to the pump.
4. Connect the lines between the fuel transfer pump
and the fuel filter.
Fuel Injectors
NOTE: Refer to the CYLINDER HEAD AND VALVES

section, for fuel injector removal and installation
Figure 423 Installing a New O-Ring Onto the instructions.
Fuel Transfer Pump
1. Fuel Transfer Pump
2. O-Ring
3. Tappet
EGES-205
FUEL SYSTEM 265
SPECIFICATIONS
Table 31 Fuel System Specifications

Fuel Filter
Type Spin-On with Fuel Strainer
Fuel Pressure Regulating Valve
Valve open 496 kPa (72 psi)
Heater element activates 7 14 C (45 6.5 F)
Heater element deactivates 24 13 C (75 8.5 F)
Special Torque
Table 32 Fuel System Special Torques

Fuel Return Hose Fitting 16 Nm (12 lbfft)
Fuel Supply Tube Bolt (Lift Pump Banjo Fitting) 54 Nm (40 lbfft)
Table 33 Fuel System Special Service Tools

ZTSE4294 Fuel System Cap Set
EGES-205
266 FUEL SYSTEM
EGES-205
APPENDIX A SPECIFICATIONS 267
Table of Contents
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
EGES-205
268 APPENDIX A SPECIFICATIONS
EGES-205
NOTE: MOUNTING ENGINE ON STAND, and

OIL COOLER AND FILTER sections, have no
specifications that are necessary for service work.
SPECIFICATIONS
Table 34 Turbocharger
EBP Control Rod Spring Preload 13.5 3 Nm (10 2 lbf)
Turbine Shaft Axial End Play 0.02 - 0.10 mm (0.001 - 0.004 in.)
Turbine Shaft Radial Movement (Play) 0.08 - 0.15 mm (0.003 - 0.006 in)
Wastegate Actuator Movement (Standard Torque Model) 1.016 mm @ 101.35 3.45 kPa (0.4 in @ 14.7 0.5 psi)
Wastegate Actuator Movement (High Torque Model) 0.369 mm @ 131 kPa (0.015 in @ 19 psi)
Table 35 Manifolds
Between ports: 0.13 mm (0.005 in)
Maximum Allowable Warpage
Total: 0.25 mm (0.010 in)
Maximum Allowable Removal of Material 0.25 mm (0.010 in)
EGES-205
Table 36 Cylinder Head

Exhaust Valves
0.140 mm (0.0055 in)
Replacement)
Valve Face Angle 37.5
Intake Valves
0.140 mm (0.0055 in)
Replacement)
Valve Face Angle 30
Cylinder Heads
Inside Diameter Of Valve Guide 7.978-8.004 mm (0.3141-0.3151 in)
Valve Guide Taper (Max.) 0.10 mm (0.004 in)
Valve Seat Width (intake and exhaust) 1.65-2.41 mm (0.065-0.095 in)
Valve Seat Angle (intake) 30
Valve Seat Angle (exhaust) 37.5
Valve Seat Run Out (T.I.R. Max.) 0.05 mm (0.002 in)
Gasket Surface Flatness 0.025 mm in 0.5 mm (0.001 in. in 2 inches) 0.10 mm (0.004 in) overall
Gasket Surface Finish (Micro Inches) 63-125
Deck To Deck Dimension (Head Thickness
129.41-129.67 mm (5.095-5.105 in)
Overall)
Valve Head Recession Relative To Deck (Head Gasket) Surface On Cylinder Head
Intake 1.17-1.47 mm (0.046-0.058 in)
Exhaust 1.32-1.63 mm (0.052-0.064 in)
Valve Spring
Free Length 52.70 3.8 mm (2.075 0.150 in)
Test Length 34.34 mm (1.352 in)
Load at Test Length 102-113 kg (225-249 lbf)
Push Rod Runout/Straightness (Max. T.I.R.) 0.518 mm (0.02 in)
EGES-205
Table 37 Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tube and Front Cover
Lubricating Oil Pump
Type Gerotor
End Clearance - inner and outer rotor to housing 0.02-0.08 mm (0.001-0.003 in)
Radial clearance between outer rotor housing 0.71-0.81 mm (0.028-0.032 in)
Engine Lube Oil Pressure at Operating Temperature
At low idle speed (700 rpm) minimum 69 kPa (10 psi)
At high idle speed 241-483 kPa (35-70 psi)
Engine Oil Capacity
Without filter 17 liters (18 quarts)
With filter 18.5 liters (19.5 quarts)
Vibration Damper
Vibration damper mounting area runout (maximum) 0.13 mm (0.005 in)
EGES-205
Table 38 Valve Train

Camshaft
Bearing Journal Diameter (All Journals) 53.31-53.34 mm (2.099-2.100 in)
Bearing (Bushing) Inside Diameter 53.39-53.48 mm (2.102-2.105 in)
Journal/Bushing Running Clearance 0.051-0.165 mm (0.002-0.006 in)
Camshaft End Play 0.051-0.203 mm (0.002-0.008 in)
Timing Gear Backlash 0.140-0.2794 mm (0.0055-0.0110 in)
Maximum Permissible Cam Lobe Wear 0.51 mm (0.020 in)
Journal Surface Finish (microinches) 16 in
Camshaft Thrust Plate Thickness 3.910-3.960 mm (0.154-0.156 in)
Camshaft Lobe Lift
Intake 6.44 mm (0.2535 in) max.
Exhaust 6.43 mm (0.2531 in) max.
Valve Timing No. 1 Cylinder (Top of Ramp)
Intake Open 17.2 BTDC
Closed 34.8 ABDC
Exhaust Open 51.2 BBDC
Closed 20.8 ATDC
Hydraulic Valve Lifters
Diameter 23.391-23.411 mm (0.9209-0.9217 in)
Bore Diameter In Crankcase 23.439-23.477 mm (0.9228-0.9243 in)
Clearance In Bore 0.027-0.086 mm (0.0011-0.0034 in)
Bleed Down Rate Time required for plunger to move
3.175 mm (0.125 in) under a 50 lb load using test 18-90 seconds
fluid at room temperature
CRANKSHAFT
Main Bearing Journal Diameter
Main Bearing Journal Maximum Out-of-Round 0.00559 mm (0.00022 in)
Main Bearing Thrust Face Runout (T.I.R. maximum) 0.0254 mm (0.001 in)
Main Bearing Journal Taper (max. per inch) 0.381 mm (0.0015 in)
EGES-205
(cont.)
Main Journal Fillet Radius, Journal No. 1, 2, 3 and 4 3.302 mm (0.130 in)
Main Journal Fillet Radius, Journal No. 5 3.99 - 4.14 mm (0.157 - 0.163 in)
Rod Journal Fillet Radius 3.68 mm (0.145 in)
Oil Seal Journal Runout (maximum) 0.05 mm (0.002 in)
Flywheel Housing Bore Concentricity (maximum) 0.20 mm (.008 in)
Flywheel Housing Face Runout (maximum) 0.51 mm (0.020 in)
Flywheel Surface Runout (maximum) 0.05 mm (0.002 in)
Flywheel Thickness (minimum) (See flywheel reconditioning
44.907 mm (1.768 in)
Figure 251.)
Thrust Taken By No. 5 Main
Thrust Bearing Journal Length 31.509 - 31.585 mm (1.2405 - 1.2435 in)
Main Bearing Inner Diameter (Installed) 79.385 - 79.436 mm (3.1254 - 3.1274 in)
Main Bearing to Crankshaft Running Clearance 0.046 - 0.117 mm (0.0018 - 0.0046 in)
Connecting Rod Journal Diameter
Connecting Rod Journal, Maximum Out-of-Round 0.0056 mm (0.00022 in)
Connecting Rod Journal Taper (max. per inch) 0.0066 mm (0.00026 in)
Connecting Rod Bearing to Crankshaft Running Clearance 0.038 - 0.114 mm (0.0015 - 0.0045 in)
Crankshaft Flange Outer Diameter 111.05 - 111.15 mm (4.372 - 4.376 in)
Crankshaft End Play 0.063 - 0.216 mm (0.0025 - 0.0085 in)
Crankshaft End Play Maximum Wear Limit 0.51 mm (0.020 in)
Rod to Crankshaft Side Clearance 0.30 - 0.61 mm (0.012 - 0.024 in)
Crankshaft Straightness (T.I.R. Maximum) 0.10 mm (0.004 in)
Crankshaft Gear Backlash (0.1397 - 0.02794 mm (0.0055 - 0.0110 in)
CRANKCASE
0.025 mm per 50.8 mm, 0.10 mm Total (0.001
Crankcase Deck Flatness
in. per 2 inches, 0.004 in Total)
Crankcase Main Bearing Bore Diameter 84.206 - 84.231 mm (3.3152 - 3.3162 in)
Crankcase Cam Bearing Bore Diameter 56.655 - 56.693 mm (2.2305 - 2.2320 in)
Valve Lifter Bore Diameter 23.439 - 23.477 mm (0.9228 - 0.9243 in)
Valve Lifter Outer Diameter 23.391 - 23.411 mm (0.9209 - 0.9217 in)
EGES-205
(cont.)
Oil Jet Tube Bore Diameter (Spray Hole Diameter) 0.91 - 1.32 mm (0.036 - 0.052 in)
Cylinder Bore Taper (Top to Bottom) 0.076 mm (0.003 in)
Cylinder Bore Diameter 104.384 - 104.402 mm (4.1096 - 4.1103 in)
Cylinder Bore Maximum Out-of-Round 0.05 m (0.002 in)
Centerline of Main Bearing Bore to Head Deck 287.73 - 287.83 mm (11.328 - 11.332 in)
Oil Seals (Front and Rear Seal Face Runout With Plates Installed
0.38 mm (0.015 in) T.I.R. Max.
On Engine)
CONNECTING RODS
Connecting Rod Length Center to Center 181.10 mm (7.130 in)
Bushing Bore Diameter (Pin End) 33.235 - 33.243 mm (1.3085 - 1.3088 in)
Piston Pin Bushing Inner Diameter 32.83 - 32.84 mm (1.2924 - 1.2929 in)
Bearing Bore Diameter (Crankshaft End) 68.339 - 68.364 mm (2.6905 - 2.6915 in)
Bearing Bore Maximum Out-of-Round 0.013 mm (0.0005 in)
Bearing Bore Maximum Taper / Inch 0.013 mm (0.0005 in)
Connecting Rod Bearing Inner Diameter 63.513 - 63.564 mm (2.5005 - 2.5025 in)
Connecting Rod Bearing Running Clearance 0.038 - 0.114 mm (0.0015 - 0.0045 in)
Connecting Rod Side Clearance 0.30 - 0.61 mm (0.012 - 0.024 in)
Twist 0.05 mm/in (0.002 in/in)
Bend 0.025 mm/in (0.001 in/in)
Weight - Complete Rod Without Bearing (Old Style) 1.058 - 1.446 kg (1058 - 1446 g)
Weight - Complete Rod Without Bearing (New Style) 1.202 - 1.216 kg (1201.5 - 1215.5 g)
Pin to Bushing Clearance 0.010 - 0.023 mm (0.0004 - 0.0009 in)
PISTONS
Skirt Diameter Measure 43 mm (1.684 in) below oil groove, at
90 angle to the piston pin. Measure only at room temperature of 104.34 - 104.44 mm (4.108 - 4.112 in)
19-21 C (66-70 F).
Service Piston
Piston Protrusion Above Crankcase Deck 0.58 0.84 mm (0.023 0.033 in)
Clearance In Cylinder Bore No. 1 8 0.112 - 0.1491 mm (0.0044 - 0.00587 in)
Top compression ring groove width - Measure over 2.92 mm (0.1150 in) gauge pins:
EGES-205
(cont.)
Upper Limit 104.85 mm (4.128 in)
Replacement Limit 104.06 mm (4.097 in)
Piston Pins
Length 75.9 - 76.2 mm (2.99 - 3.00 in)
Diameter 33.220 - 33.226 mm (1.3079 - 1.3081 in)
Pin fit @ room temperature, 19-21 C (66-70 F):
Clearance In Rod 0.010 - 0.023 mm (0.0004 - 0.0009 in)
Clearance In Piston 0.007 - 0.018 mm (0.0003 - 0.0007 in)
End Clearance 0.10 - 0.76 mm (0.004 - 0.030 in)
Piston Rings
Ring Diameter (Standard)
Compression Top (Full Keystone (Barrel Face) Plasma Coated) 104.4 mm (4.11 in)
Compression 2nd (Rectangular Negative Twist - Tapered Face) 104.4 mm (4.11 in)
Oil Control (One Piece Conformable with Chrome Expander
104.4 mm (4.11 in)
Spring)
Fit in Groove (Side Clearance)
2nd 0.05 - 0.10 mm (0.002 - 0.004 in)
Oil Control 0.023 - 0.074 mm (0.0009 - 0.0029 in)
Ring Gap in Bore
Top 0.35 - 0.61 mm (0.014 - 0.024 in)
2nd 1.57 - 1.82 mm (0.062 - 0.072 in)
Oil Control 0.30 - 0.61 mm (0.012 - 0.024 in)
Table 40 Thermostat and Coolant Filter

Thermostat
Type Poppet Valve, Pellet Operated
Operating Start-to-Open Temperature 89 2 C (192 4 F)
Maximum Full-Open Temperature 104 C (219 F)
Sleeve Travel at Full-Open Temperature 8 mm (0.315 in)
Coolant Filter
Type Spin-On
Length of Filter 106 mm (4.18 in)
EGES-205
Table 41 Engine Electrical

Glow Plugs
Location Cylinder Head
Quantity 8
Maximum Flow Rate 17.5 L/m (4.62 gpm)
Camshaft Position Sensor (CMP)
Location Front Cover
Operating Actuator Speed 15 to 2000 RPM
Operating Temperature Range -40 C to +130 C (-40 F to +266 F)
Table 42 High-pressure Lube Oil System

High-pressure Oil Pump
Gear Backlash 0.1400.256 mm (0.00550.0101 in)
End Play 0.451.22 mm (0.0180.048 in)
Operating Temperature Range -40 to 125 C (-40 to 257 F)
Maximum Flow Rate 17.5 L/min (4.62 gpm)
Table 43 Fuel System

Fuel Filter
Type Spin-on with fuel strainer
Fuel Pressure Regulating Valve
Valve open 496 kPa (72 psi)
Heater element activates 7 14 C (45 6.5 F)
Heater element deactivates 24 13 C (75 8.5 F)
EGES-205
APPENDIX B TORQUES 277
Table of Contents
General Torque Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
EGES-205
278 APPENDIX B TORQUES
EGES-205
General Torque Guidelines Table 45 Standard Torques Class 10.9 Metric

Bolts and Studs
Thread
CAUTION: To avoid engine damage, do not Thread 1
Pitch Torque
substitute fasteners. Original equipment Diameter
(mm/thread)
standard hardware is defined as Class 10.9
metric or Type 8 standard coarse thread 6 mm 1 13 Nm (115 lbfin)
bolts and nuts and hardened flat washers
(Rockwell C" 38-45), all phosphate coated. 8 mm 1.25 31 Nm (23 lbfft)
10 mm 1.5 62 Nm (45 lbfft)

The standard torque charts provide the tightening 12 mm 1.75 107 Nm (79 lbfft)
torque for general purpose applications using original
equipment standard hardware as listed in the Parts 14 mm 2 172 Nm (127 lbfft)
Catalog for the application involved. 15 mm 2 216 Nm (159 lbfft)
Table 44 Standard Torques Pipe Thread 16 mm 2 266 Nm (196 lbfft)
Thread Size Torque

1 18 mm 2.5 368 Nm (272 lbfft)
1/8 in NPT 11 Nm (90 lbfin) 20 mm 2.5 520 Nm (384 lbfft)

1
1/4 in NPT 14 Nm (120 lbfin) Tolerances are 10% of nominal value.
3/8 in NPT 20 Nm (180 lbfin)
Table 46 Standard Torques Class 12.9 Metric
1/2 in NPT 34 Nm (25 lbfft) Bolts and Studs
3/4 in NPT 41 Nm (30 lbfft) Thread
Thread 1
1 Pitch Torque
Tolerances are 10% of nominal value. Diameter
(mm/thread)
6 mm 1 15 Nm (132 lbfin)
8 mm 1.25 36 Nm (27 lbfft)
10 mm 1.5 72 Nm (53 lbfft)
12 mm 1.75 126 Nm (93 lbfft)
14 mm 2 201 Nm (148 lbfft)
15 mm 2 252 Nm (186 lbfft)
16 mm 2 311 Nm (230 lbfft)
18 mm 2.5 430 Nm (317 lbfft)
20 mm 2.5 608 Nm (448 lbfft)
1
Tolerances are 10% of nominal value.
EGES-205
Figure 424 Classification and Identification Metric Fasteners
Figure 425 Classification and Identification Special Use Fasteners
Many conditions affect torque and the results of New phosphate coated fasteners do not require oil
torque applications. The major purpose in tightening lubrication during assembly and torque application.
a fastener to a specified torque is to obtain tension in Reused fasteners (even if originally phosphate
the fastener (i.e., bolt, nut, etc.), which in turn develops coated) do require oil lubrication to the threads and
a clamping load which exceeds any possible loading under head area for proper torque application.
imposed on parts due to engine rpm or vibration.
EGES-205
Threads that are dry, excessively rough, battered or

filled with dirt require considerable effort just to rotate.
Then when the clamping load is developed or the bolt
tension is applied, the torque reading mounts rapidly
(due to thread friction) to the specified torque value.
However, the desired bolt tension and maximum
clamping effect is not achieved. This condition can
lead to failure of the fastener to maintain component
integrity. The proper bolt tension and clamping effect
can never be attained if the fastener is dry. The
fastener threads must have a film of clean lubricant
(engine oil) to be considered lubricated.
Special Torque
NOTE: The THERMOSTAT AND COOLANT FILTER

and OIL COOLER AND FILTER sections, have no
special torques that are necessary for service work.
Table 47 Engine Mounting Special Torques

Table 48 Turbocharger Special Torques

Air Inlet Hose Clamps 4 Nm (36 lbfin)
Compressor Outlet Clamp 2 Nm (19 lbfin)
Exhaust Back Pressure Valve to Turbine Housing Mounting
21-24 Nm (15-18 lbfft)
Bolts
Exhaust Inlet Clamp 5.6 Nm (50 lbfin)
Exhaust Tube to Exhaust Inlet Adapter Flange Bolts 28 Nm (21 lbfft)
Exhaust Tube to Exhaust Manifold Flange Bolts 26 Nm (19 lbfft)
Turbocharger Pedestal to Crankcase Mounting Bolts 24 Nm (18 lbfft)
Turbocharger to Pedestal Mounting Bolts (Standard Torque
4751 Nm (3437 lbfft)
Model)
Turbocharger to Pedestal Mounting Bolts (High Torque Model) 49 Nm (36 lbfft)
Table 49 Manifolds Special Torques

Intake Manifold Cover Bolts 24 Nm (18 lbfft)
Exhaust Manifold Mounting Bolts 61 Nm (45 lbfft)
Exhaust Manifold Flanges 28 Nm (21 lbfft)
EGES-205
Figure 426 Exhaust Manifold Mounting Bolt Torque Sequence
1. Start all exhaust manifold mounting bolts 2. Tighten all exhaust manifold mounting bolts to
into the holes by hand. Tighten all exhaust 61 Nm (45 lbfft) again in an inline sequence
manifold mounting bolts to 61 Nm (45 lbfft) from the rear to the front. Start at the arrow.
in the numerical sequence shown.
EGES-205
Figure 427 Intake Manifold Mounting Bolt Torque Sequence
Start all intake manifold mounting bolts into the holes

by hand. Tighten the mounting bolts to 24 Nm (18
lbfft) in the numerical sequence shown.
EGES-205
Table 50 Cylinder Head Special Torques

Crankcase Breather Screws 2 Nm (18 lbfin)
Initial: 54 Nm (40 lbfft)
Cylinder Head Mounting Bolts (special torque
Second: 95 Nm (70 lbfft)
sequences)
Final: 129 Nm (95 lbfft)
Fuel Injector Hold Down Clamp Mounting Bolt 14 Nm (120 lbfin)
Fuel Injector Shoulder Bolt 14 Nm (120 lbfin)
Fuel Rail End Plugs 16.3 Nm (12 lbfft)
Glow Plugs 19 Nm (14 lbfft)
ICP Sensor 29 2 Nm (21.5 1.5 lbfft)
Oil Deflector Mounting Bolt 12 Nm (106 lbfin)
Oil Rail Drain Plugs 6.8 1 Nm (60 10 lbfin)
Oil Rail End Plugs 81 Nm (60 lbfft)
Oil Rail Plugs 29 2 Nm (21.5 1.5 lbfft)
Valve Cover Bolts (special torque sequence) 11 Nm (8 lbfft)
Valve Lever Mounting Bolt 27 Nm (20 lbfft)
Figure 428 Valve Cover Bolt Special Torque Sequence
EGES-205
Figure 429 Cylinder Head Mounting Bolt Special Torque Sequence
1. Tighten to 54 Nm (40 lbfft) in numbered

sequence.
2. Tighten to 95 Nm (70 lbfft) in numbered
sequence.
3. Tighten to 129 Nm (95 lbfft) in line sequence.
4. Tighten to 129 Nm (95 lbfft) again in line
sequence.
Torques
Oil Pan Mounting Bolts 34 Nm (25 lbfft)
Oil Pick-Up Tube Flange Mounting Bolts 24 Nm (18 lbfft)
Vibration Damper Mounting Bolt 287 Nm (212 lbfft)
Water Pump Pulley Mounting Screw 41 7 Nm (30 5 lbfft)
Table 52 Valve Train Special Torques

Cam Follower Guide Mounting Bolt 20 Nm (15 lbfft)
EGES-205
Table 53 Crankcase, Crankshaft, Connecting Rods and Piston Special Torques

Connecting (4 lbf-ft) Rod Mounting Nuts (Old Style)
Connecting Rod Bearing Bolts (New Style)
Flywheel gear access cover bolts 5 Nm (4 lbf-ft)
Flywheel Mounting Bolts 121 Nm (89 lbfft)
Main Bearing Cap Mounting Bolts
Oil Pick up Tube Flange Bolts 24 Nm (18 lbfft)
Piston Cooling Jet Mounting Bolts 11 Nm (100 lbfin)
Table 54 Electrical System Special Torques

Glow Plug 19 Nm (14 lbfft)
Glow Plug Relay Stud Nuts 8 Nm (70 lbfin)
Injection Control Pressure (ICP) Sensor 50 5 Nm (37 4 lbfft)
ECM Mounting Bolts 24 Nm (18 lbfft)
ECM Support Assembly Mounting Bolts 24 Nm (18 lbfft)
ECM Mounting Bracket Nuts 24 Nm (18 lbfft)
Wiring Harness Connector Mounting Bolt (Engine
3 5 Nm (30 45 lbfin)
and Chassis)
Table 55 High-pressure Lube Oil System Special Torques

High-pressure Oil Pump Drive Gear Bolt 129 Nm (95 lbfft)
IPR Valve Tinnermann Nut 5.5 1.5 Nm (49 13 lbfin)
IPR Valve 50 5 Nm (37 4 lbfft)
High-pressure Hose Fitting (37 Flare) 26 Nm (19 lbfft)
45 and 90 Elbow Locknut 28 Nm (21 lbfft)
Table 56 Fuel System Special Torques

Fuel Return Hose Fitting 16 Nm (12 lbfft)
Fuel Supply Tube Bolt (Lift Pump Banjo Fitting) 54 Nm (40 lbfft)
EGES-205
APPENDIX C SPECIAL SERVICE TOOLS 287
Table of Contents
EGES-205
288 APPENDIX C SPECIAL SERVICE TOOLS
EGES-205
NOTE: The MANIFOLDS, OIL COOLER AND

FILTER, and ELECTRICAL SYSTEM sections have
no special service tools that are necessary for service
work.
Table 57 Engine Mounting Special Service Tools

ZTSE4151A Rear Mounted Engine Bracket (Keine Stand) (Not shown)
ZTSE4348 Side Mounted Engine Bracket (OTC Stand)
OEM4137 Engine Turn-Over Stand
Table 58 Turbocharger Special Service Tools

OEM1028 Dial Indicator with Magnetic Base
ZTSE4293 Turbocharger Intake Shield
ZTSE4230 Spring Tension Scale 034 Nm (0-25 lbf)
EGES-205
Table 59 Cylinder Head Special Service Tools

OEM1004 Outside Micrometer (56 inch)
OEM1014 Dial Caliper
OEM1023 Small Hole Gauge Set
OEM1272 Defect Detection Kit (Dye Penetrant)
OEM6343 Cleaning Brush
OEM6459 Surface Height Gauge Tool
ZTSE1631A Eccentric Valve Seat Grinder
ZTSE1879 Slide Hammer Puller Kit
ZTSE2241 Valve and Clutch Spring Tester
ZTSE4297 Cylinder Head Lifting Bracket
ZTSE4299 Fuel Injector Holder Rack
ZTSE4301 Fuel Injector Tip Cleaning Brush
ZTSE4302A Fuel Injector Sleeve Removal Tool
ZTSE4303 Fuel Injector Sleeve (Adapter) Replacer
ZTSE4304 Fuel Injector Sleeve Cleaning Brush Set
ZTSE43042 Injector Sleeve Bottom Brush
ZTSE4308 Cylinder Head Pressure Test Plate
ZTSE4320 Oil and Fuel Gallery Brush Cleaning Set (Consists of 4 brushes)
ZTSE4353 Fuel Injector Installation Tool
ZTSE43862 Hand Tap (Bottoming M12 X 1.75)
ZTSE43021A Injector Sleeve Tap
EGES-205
Service Tools
ZTSE229569 Vibration Damper Removal Tool
ZTSE4300 Fuel Injector/Front Oil Seal Removal Tool
ZTSE4310 Front Oil Seal/Vibration Damper Installation Tool
ZTSE4314 Vibration Damper Wear Ring Removal Tool
ZTSE4315 Vibration Damper Wear Ring Installation Tool
ZTSE4385 Oil Pan Removal Tool
Table 61 Valve Train Special Service Tools

OEM1000 Micrometer
ZTSE1893 Hydraulic Valve Lifter Tester
EGES-205
Table 62 Crankcase, Crankshaft, Connecting Rods and Piston Special Service Tools
D81L6002B Plastigage
OEM1000 Micrometer
OEM1022 Telescoping Gauge Set
OEM1023 Telescoping Gauge
OEM1032 Dial Bore Gauge
OEM1293 Straight Edge
OEM6270 120 Grit Glaze Breaker Brush
OEM6453 Piston Retaining Ring Pliers
ZTSE1897E Camshaft Bushing Removal/Installation Set
ZTSE1942A Crankshaft Rear Oil Seal Installation Tool
ZTSE3020 Piston Groove Wear Measuring Tool Set
ZTSE4155A Expansion Plug Replacement Tool
ZTSE4220 Piston Ring Expander
ZTSE4311 Connecting Rod Installation/Remover Guide Pins
ZTSE4317 Crankshaft Wear Ring Removal Tool
ZTSE4318 Rear Oil Seal Installation Tool
ZTSE4375 Flywheel Installation/Removal Guide Studs
ZTSE4385 Oil Pan/Rear Oil Seal Cutting Tool
ZTSE4389 Oil Galley Cleaning Brush
Table 63 Thermostat and Coolant Filter Special Service Tools

OEM6413 Strap Wrench
Table 64 High-pressure Lube Oil System Special Service Tools

ZTSE2499 Hand Operated Vacuum Pump
ZTSE4295 High-pressure Oil System Cap Set
Table 65 Fuel System Special Service Tools

ZTSE4294 Fuel System Cap Set
EGES-205
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SERVICE MANUAL

2003 International Truck and Engine Corporation

Mounting Engine On Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Cylinder Head And Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Crankcase, Crankshaft, Connecting Rods, And Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

Thermostat And Coolant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209

Oil Cooler And Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217

Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223

High-pressure Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255

Appendix A Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267

Appendix B Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277

Appendix C Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287

Foreword The following literature supporting International

Service Diagnosis It is also very important that specific diagnostic tests

Safety Information SAFETY INSTRUCTIONS

This manual provides general and specific service Vehicle

Fire prevention Tools

Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Engine Identification Emission Label

Figure 2 Emission Label Location

The emission label is located on the left valve cover.

Explanation of the Engine Serial Number

Engine Component Location

Figure 3 Component Location, (Front View)

Figure 4 Component Location, (Left Side View)

Figure 5 Component Location, (Rear View)

Figure 6 Component Location (Right Side View)

Figure 7 Component Location, (Top View)

Figure 8 Engine Coolant Flow Diagram

Description Thermostat Operation

Figure 9 Lubrication System Diagram

Description drilled passages within the crankshaft. The camshaft

Air Induction and Exhaust System

Figure 10 Air Induction/Exhaust System Diagram

Description Some engines are equipped with an optional exhaust

Figure 11 Major Fuel System Component Locations

Description The fuel system consists of the following components:

NOTE: The fuel filter element is attached to the

Figure 13 Split Shot Injector Fuel System Schematic

Injection Control Pressure System

Figure 14 Injector Oil System Diagram (Left Side)

Figure 15 ECM And IPR Configuration

Operation The reservoir makes available a constant supply of

Injection Pressure Control

Figure 16 Closed Loop Operation Diagram

Figure 17 IPR Higher Injection Pressure Diagram

Figure 18 IPR Lower Injection Pressure Diagram

Figure 20 Stages of Injector Operation

Glow Plug Controller System

Figure 21 Glow Plug Controller System Diagram

Mounting Engine On Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Mounting Engine On Stand

Figure 23 Location of Oil Drain Plug

4. Remove the oil drain plug. Allow the oil to drain

Figure 22 Location of Coolant Drain Plugs

1. Drain the coolant from the crankcase by removing