1. Position gasket on manifold. Then insert 1-2 bolts through manifold to hold gasket in place. 2. Install manifold attaching bolts finger tight. 3. Verify that gaskets are properly aligned. Tighten manifold bolts to 18-25 lb-ft (24-34 N•m) torque.
1. Apply Permatex #2 to crossover gaskets and position gaskets on cylinder heads (Figure 2-185). 2. If new crossover is being installed, transfer hose fittings to new crossover. Use Loctite PST on fitting threads. 3. Connect bypass hose to water pump (Figure 2-185). 4. Install crossover. Tighten cross-to-cylinder head bolts/studs to 25-37 lb-ft (34-50 N•m).… Read More »
1. Flush injector lines with fresh diesel fuel and compressed air. 2. Attach fuel lines to injectors and pump. Verify line routing and connection (Figures 2-183 and 2-184). 3. Tighten fuel line fittings at injectors and at pump to 19 lb- ft (25 N•m) torque. 4. Install clips on injector lines (if removed). 5. Attach… Read More »
1. Clean mounting flanges on both rocker covers and cylinder heads. Wipe flange sealing surfaces off with isopropyl alcohol to prepare surface for sealer application. 2. Apply RTV-type sealer to cover sealing surfaces. 3. Align and install covers on cylinder heads (Figure 2-182). 4. Install cover attaching bolts and studs and tighten to 13-25 lb-ft… Read More »
NOTE: The rocker arm end of each pushrod is identified with a paint stripe. In addition, the ball at this end of the pushrod is heat treated/coated giving it a distinctive color. Be sure the pushrods are installed with the correct end up and toward the rocker arm. 1. Insert pushrods in roller lifters. Verify… Read More »
1. Install glow plugs in each cylinder head (Figure 2-178). Tighten plugs to 8-12 lb-ft (11-16 N•m). 2. Install gasket on each injector nozzle (Figure 2-179). 3. Install injector nozzles in cylinder heads finger tight. 4. Tighten nozzles to 44-60 lb-ft (60-81 N•m) torque with installer tool J–29873. 5. Connect return hoses between nozzles and… Read More »
Important: • Make sure that the block and head gasket surfaces are clean. • The head gasket material is soft. Handle the gasket with care and make sure the gasket surface is not creased or dented. CAUTION: Do not apply any type of sealant to the head gaskets. The head gasket is made with sealant… Read More »
1. Prime valve lifters in kerosene then engine oil. Immerse lifter in kerosene first and oil last. Then pump plunger with pushrod to force solution through lifter. 2. Lubricate lifters with oil and install in cylinder block. 3. Position guide plates on lifters. Then install guide clamps and bolts. Tighten bolts to 15-20 lb-ft (20… Read More »
1. Apply Permatex #2 to both sides of gasket and install gasket and water pump on adapter plate (Figure 2-171). Tighten adapter plate bolts to 13-20 lb-ft (18-27 N•m). 2. Apply Loctite gasket maker or 510 to contact area of adapter plate as shown (Figure 2-172). 3. Install adapter plate and water pump on front… Read More »
1. Install injection pump gasket on front cover studs. 2. Mount injection pump on front cover studs (Figure 2-169). Install retaining nuts finger tighten. 3. Rotate crankshaft if necessary, to place timing mark on injection pump drive gear at 12 o’clock position. 4. Install pump driven gear into fron cover so the timing mark on… Read More »