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    173 views764 pages

    Manual de Armado NTA 855

    Uploaded by

    Fabian Niño
    Bueno

    Copyright:

    © All Rights Reserved
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    ADMINISTRATIVE PROCEDURES SPECIFIC FAILURES Oil Consumption, In addition to the information that follows, a service publication entitled Technical Overview of Oil Consumption is available, Bulletin 8379214, Cummins defines “Acceptable Oil Usage” as outlined in the following table: RECEPIABLE OW, USAGE "ANY TIME DURING COVERAGE PERIOD “T wes 1 “KLOM HOURS wes muss “pen |kuom Kom” "PER |uAS HRS PER enone See “Pea owpenial |'PER. “PER IMPERIAL | PER PER HIPERIAL Fawily —louatr_ ure "Guarr”[oUART wien QUART | OT fer QUART Taam er ee ec io A 425 Ea [ss 675, 775 [wo 06 i290 | BASE Yas eo e~«CTCP WO HS 120 vara = = ~ ~ [seas 48 [unr ooe [ae 88 vnrsss | 280 404848 Crs] 0 “fre | waist 300) To 74 8e Nant 300 774 84 isx ‘500 wo 74 ea | [sienarune [00 VivTiVTA-903 | 250 77a 8 ‘40 Krnctais [206 30 vivintwes |= 20 KITA = _| 48 KTASO = 1 QSK 19 = a0 82) 38 ‘ost 30 = te 20 OSK 46 = T1818 askea = 09 098 tt Introduction NT 855, Generai Safety Instructions Important Safety Notice Read and understand all safety precautions and wamings before performing repelrs. A Read and understand all of the safety precautions and wamings before performing any repait. This list 2 | , the gonoral safety precautions that must be followed to provide personel safety. Special safety precautions * ineluded in the procedures when they apply. : 4 > PPP 7 Generat ingtruc ineral Satety aor ‘This symbol appears in the manual when a potential safety hazard exists that can cause personal injury. These hazards are not always apparent to @ trained mechanic. It Is not possibie for Cummins Engine Company, Inc, te anticipste every possible circum- i stance that can inveive 2 potential hazard, Warning: Cummins Engine Company, ine. des not recommend of authorize any modifica Hons of epaics te engines of components except those detailed in CUMMINS SERVICE FORMATION. fn particular, unauthorized repair to safety-related components can cause personal injury. Components classified as safety-related include the following: / Air Compressor Air Conireis: Air Shutoff Assemblies: Balance Weights Cooling Fan Fan Hub Assembly Fan Mounting Brackst(s) Fan Mounting Capacrews: Fan Hub Spindie Flywheel Flywheel Crankghaft Adaptor Flywheel Mounting Capsorews Fuel Shutoff Assemblies Lifting Brackets Throttle, Controls ‘Turbocharger Compressor Casing . Turbocharger Oil Drain Tubes: ‘Turbocharger Oil Supply Tubes ‘Turbocharger Turbine Casing Vibration Damper Mounting Capscrews . i Make sure the work area surrounding the product is safe. Be aware of hazardous coneiions that can exist. : ia Always wear protective glasses and protective shoes when working. Do not wear loose-fitting or torn clothing. Remove all jewelry such as rings, watehes, when working. eee Disconnect the battery and di: ny capacitors before beginning any repair work,” Disconnect the air starting motor if equipped to prevent accidental engine starting. Puta "Do Not Operate” tag in the operator's ent or on the controls. Sis Introduction Manual jog Usados En Este section +6 ‘Simbolos Usados En Este Manual simbalos siguientes son usados en esto manual pare clariicay of procesc de fas instrucciones. Cuande eaaetno de estoe simbolas, SU significado 36 especifica on Ie parte intesior. ADVERTENCIA- Serios daitos personales odaito ala propiedad puede sesuttar silas instrucciones: de Adveriencia no se consideran. PRECAUCION - Dehos menores pueden resutiar, 0 de piezas del conjunta © el motor puede: averiarse at las insiracciones do Precaucion ne 8 siquen. Indica un paso de REMOCION o DESMONTAJE. indica un pase de INSTALAGION © MORTAIE. Se requiere INSPECSION. LIMPIESE {2 pieza 0 st monisie. EJECUTESE una MEDICION mecénica & det tempo, LUBRIQUESE {a pieza o ef montajo. Indica que se dara una LLAVE DE TUERCAS o 2! TAMANO O& HERRAMIENTA. APRIETESE hasta un par toreer especifico. EVECUTESE una MEDICION eléctrisa. Para informacion adicional rafierase a otro emplazamiento de este manual o a ole publicacion anterior. x Elcomponente pesa 23 kg {50ib] o mas. Paraeviter dano corporalempleen una cabriauobtengan ayuda para elevar el componente, introduction ‘Symboles Ulilises Dans Ce Mi NT 859 Page t-7 Syinboles Utilises Dans Ce Manuel Les symbotes suivants sont uilisés dane ce manust pour alder & communiquer te bul des instructions, Quand l'un de cs sytaboles apparsit, Il 4voque le sens daiini ci-dessous: AVERTISSEMENT - De graves lesions corporeiles ou des dommages matériels considérables he peuvent survenir si fes instructions données sous les rubriques “Avertissement” ne sont pas sues. ' ATTENTION - De petites lesions corporelles peuvent survenir, ou bien une piece, un ensemble AX ollle motour peuvent etre endommages si les instructions données sous les rubriques "Alten nN" ne sont pas sulvies. indique une operation de BEPOSE. andique uns opersiion oe MONTAGE, LHHSPECTION ast nécessaive. NETTOVER 1 piboe ner Fensartbls, ie EFFECTUER une MESURE mécanique cu de temps. GRAISSER la piece ou l'ensembie. * : Indique qu'une DIMENSION DE CLE ou D’QUTIL sera donnée. SERRER a un couple spécifiqua. EFFECTUER une MESURE électrique. Se reporter & un autre endroit dans ce manuel ou a une autre publication pour obtenir de: informations plus completes. Le compesant pese 23 kg {60 Ih] ou davantage. Pour eviter toute blessure, employer un appari de levage ou demander de l'aide pour le soulever. Introduction: NT 855 symbole verwendet, dio wesentliche Funktionen hervotheben. Die WARNUNG - Wird die Wamung nicht beachtel dann besteht erhonte Unfall- und Beschadigungsgetanr. VORSICHT - Werden dis Vorsichterassnahmen fight beachtet, dann besteht Unfall- und Beschadigungsgetaht. AUSBAU bzw. ZERLEGEN. EINBAU bzw. ZUSAMBEHBAL, INSPEKTION erforderlich, Toil oder Baugrupne REINIGEN. DIMENSION - oder ZEFTMESSUNG. Toit oder Baugruppe OLEN- WERKZEUGGROSSE wird angegeben. ANZUG auf vorgeschriebenes Drehmoment erforderticn. Elektrische MESSUNG DURCHPUHREN. Weitere Informationen an anderer Stelle baw. in anderen Handbichern. Das teil weigt 23 kg [50 Ib] oder meh, Zur vormeidung von koerperverietzung winde benutzen oer fe beim heben des tells in ansprueh nehmen. introduction liustratio; Page NT 855 Hiustvations “The illustrations used in this manual are intended to give an example of how to perform the action or the rep: being described. Many of the illustrations are common and will not look exactly like the engine or the parts us in your application. Most of the illustrations contain symbols to indicate an action required or to Indicate acceptable (OK) or unacceptable (not OK) condition. Gitgumierentiai Direction: Concentricity: PL: Cummins Sealant: D.C: Dye Penetrant Method: End Clearance: ESN: Hammer: Loctite 200: Loctite 608: » Lubriplate 105: intraduciion NT 688 Glossary Of Terms Atternating Current ir Eve! Gontrok & device in the fuel pume that fete Me fuel detivery until A Eue allen intake mantels pressure 10 allow fer complete combustion. After Top Dead Genter; refers io the position of the BISON the crankshaft fo jourkal. The piston ts Teaving dawnrwend on the power stroke oF intake sake. potion bea Centers refera to the pozaton of she gles OF Te orankshalt 10d journal. The pisien & at its lowes! postion the cylinder. peatiion nf the piston oF the cranks! ig the a the cormpemesion sfrake OF GH es goiore Top Dead Cenist: 12fe od runnin, The pisies 15 OME hnaust sto tn the direction of & cirale in vaspect € te cermterting OF surei Bert OF & bore. ipekyneshs the qanters of CHER HWE OF THE A meseuremen: a Je 3 jpans oF Ihe Bors His ORE par Contyol Parts Liat; this listing identifies the > ports dsat armat BS Jnstaled on the engine te meet agency Ca This is a one par Flom Temperature Vuloanizing (FTV) silicone rubber, adhe- This iG seatant material having figh heat and ol resistance, and low com pression set. ‘Some of the equivalent products are. Marston Lubricants, Hylosil, Dow Corr ing. Silastic 732. Loctite Superfiex, General Blectric 1473, and General Elec tric 1470. Direct Current ‘A method used to check for cracks in & par 2. using a dye penetrant and a A mgoper. Use crack detection Kit, Part No, SS7B436, oF fis equivalent. “The clearance in an agsemiy determined by pushing (Pe shaft in an axial dh Tee iene way and than pushing the Shafi the ether WaY- Engine Serial Number ‘A hand toot consisting of a hard steel head on a handle. Inside Diameter Asingle component, anaorobie, polyaster resin, uid sealant compound that hardens between sioeely fitted metal sureces lucing a tough, frard bond Mtn good characteristics. An equivalent product IS PermacLok HL 126. A single component anaerobic, liquie aghesive that mosis or exceeds the re- Gurorments of HIL-P-46082A (MR) TYPE 1 eine of the equivatent products are Loctite 694 and Permabond HL 188. ‘A minerot oil base grease with calcium soap (2 percent to 6 percent), and zine ‘Oxide (2 percent to 4 percent) edditives. introduetion AT 855, AG: Magnetic Particle Inspec tion: Mallet: MAX: ‘MIN: Protruston: ate Te: ‘To: TAR: ‘Water Pump Grease: ‘Glossary Of Terms: Page iti Allernating Current ‘A method of checking fer cracks in either ste} or iron parts, This method re- quires a Magnailux machine, or ar equivalent machine that imperts a rag- netic field on the part being checked. A hand toot consisting of a soft head, stier wood, plastic, lead, brass. or rawhide, on 3 handle. Maximum allowed Minimum allowed Number ‘Quiside Diameter Oversize “The differance in the height! between two parts in the assembled state. “ ‘Shaner ‘Torque Converter; used when refeiting to the forque converter cooler. ‘Top Dead Center; refers to the position of the piston or the crankshaft rod joumal. The piston is at its highest position in the eylinder. The rod journal is pointing straight up toward the piston. Total indicator Runout; used when measuring the goncentricity or the runout. ‘The TLR. refers io the total movement of the needie on a dial indicator, from the most negative reading to the most positive reading. A premium high temperature grease that will lubricate antifriction bearings continually from minus 40°C [minus 40°F] to plus 180°C [plus 350°F]. Same ofthe greases mooting thls requirement are Aeroshell No, & Chevron. ‘SRI, Amoco Fiykon Premium No. 2, Texaco Premium RB, and Sheit Dolium R. ‘Aetoshell No. 5 is not compatible with the other greases and must not be mixed. Curnmins Engine Company, Inc., uses Aeroshell No. § on new engines and components. inrockctiort WT 885 Bngine tdentification The engine ciataplais provides ‘and other important information engine dais available when commu sloating ‘Cumnintins Authorized Flapair Location. eatermatian on the daigplele 3 mandatory where fing serves GETS 3 Setiat Nuinber Have tho: a8) The model name provides the following engine date: N Tt G 400 Lo Maximum Rated Horsepower [____ Custom Rated __ Turbocharged Four Valve Heat antroduetion Engine Giagrar RT 855. Page i- Engine Diagrams “The following drawings contain information shout engine componenis, tilier locations, drain points, and acce locations for Instrumentation and engine costrals. The information and configuration of companents shown in these drawings are of a general nature. Son component locations will vary depending on applications and installations. Sih ales Fn HOTEUNEQR TAS oi tle Pressure fuel Pune ‘Starting Motor 1 Step Fin Put Per ur ewlbdge introduction: wT 885 ‘wanes Temperature and 21 Olher Hemapotsinre OM Fin Gut Le RTE Hower SemOR S, Pressure aging Sater ets 28 Dia Sane Watse NCS a omen 18.8 Dia = couian hee ‘Baten oben aplent Fier Combination Lube ‘Ou Fiter ewibdgd introduction Gonoral Cleaning Instruction NT BBS age M1 General Cleaning instrucilons Soiveni And Acid Cleaning 57] Several solvent and acid-ype cleaners can be used to clean the engine patts, Cummins Engine Con pany, Inc. does not recommend any epecitic cleaners. Always foliow the cleaner manufacturer instructions. Experience has shown thai the besi results can he cbiained using a cleaner that can be heated to 90% te 86°C [120°F to 260°F]. A cleaning tank thet provides 9 conatent mixing and filtering of the cleanin solution will give the best resalis, Remove ail the gasket material, cringe, and ihe deposits of sludge, carbon, ets., wilh 2 wire brush ¢ scraper before puting the paris in a clsaning tank, Be careful not to daniage any gasket surfaces, Whe possible, steam clean the parts before puting them in the cleaning tank, & Warning: The use of ack! can be extremely dangerous fo personnel and can damage the machinery Siways provide 9 iank of strong soda water an o nemiralizing agent. fre pita in hot wake after cleaning, Diy compievely with compressed air, Blow the rinse water fron ail 61 the capserem holes ane the oil eetings It pons fe net mo ne oseel mmediatey xear rear. cp them 9 8 sutable rustprooting compound. Th rustpionfing compouncl snest be removed from ‘he party belate inetaltation on the engine. Steam Cleaning Sieam cleaning can bo used to remove al types of dirt ihal can conteminate the cleaning tank, Itls a goo way fo clean the off deitings. i Warning: Wear protective clothing to prevent personal injury from the high pressure and extreme heat Do not steam clean the following parts: 1. Electrical Components 2. Wiring 3. Injectors 4, Fuel Pump. 6. Belts and Hoses 6. Bearings Glass Bead Cieaning Glass bead cleaning can be used on many engine components to remove carbon deposits. The cleanin process is controlled by the size of the glass beads, the operating pressure, and the cleaning time, ‘Caution: Bo not use glass bead cleaning on aluminum piston skirts o ring grooves, Small particles o glass will embed is ths aluminum ard reault in premature wear, Valves, turbocharger shafts, etc., can als be damaged, Follow the cleaning directions listed in the procedures. Plastic Bead Cleaning A new plastic bead media, Part No. 3824738, has been released for piston cleaning, This media can b used to clean the piston dome or crown, the ni-resist ring grooves, and the aluminum ring grooves. As wit! walnut shell or glags bead blasting, plastic bead blasting must be done at the minimum pressure thal i effective. Maximum pressure must not exceed 345 kPa [60 psij. The spray must not be concentrated | any one area for an extended period of time. Intrarigotion Several Repair Instewctions duction Follow the equipment manufacturer's cleaning instructions. The follwing guidelines oan be used to adapt to the manufacturer's instructions: 4. Bead size: Use U.S. size Ho. 70 for piston domes. Use U.S. size No. 60 for general purpose cleantfg, 2. Operating Presgure: Not to exosed 945 KP [59 stl lags beads afles ish solvent to remove atl ofthe foreign material and gi compressed al. laatic beads. 3, Sleam clean or wasti the paris wi Gleaning. Fine with hot water, Tiny with De not contaminate the wash tanks with glass or Pl General Repalr instructions ine audivona lacoste ey else Read the safety section ln this manual iound on page 1, Faltons alt" in the procedures. Provide a clean environment. Follow tie general cleaning g ‘are included ia the procedures. sor the inspections specified in the procedures. The inspections will result in a minimal number of parts ing replacemant. The cost of the rebuild will a * duced more than the cast of he additional inspection time. low the order of assembly and disassembly as described in the procedures to avoid causing damage fo the ings excapt where specific cleaning instructions Engine Disassembly anc Assembly - Group 0 Group Inde NTS55 Page 0. Pag Exhavet Maniiot ‘snetallation: Removal... Fen and Fan Hub Spacer Installation. Removal... Fen Drive Belts. installation Removal . Fen Hub Support Bracket and Fan Hub installation Removal Fiywheet installation Fiywheei Bore Runoul ~ Fhrwhes! Case 8 Removal Flyemee! Housing uszallation Bore Alignment - Check! Face alignment - Checking pubes: Housing Alzsiners Piston Ring End Gap hiessuroment ReRnOVA orn Front Crankshaft Seat installation ceneeeceenntnnenenenneeeese Removal. Front Engine Support. Installation Removal Fuel Crossovers Installation Rernoval .. Fuel Filter Installation Removal ...cicccncnrmnnnnanen Fuel Pum Installation Removal... Fuel Tubi Installaten Removal .... Gear Cover Insteltation Removal Group index. Hand Hole Cover Installat Removal. Injection Timing General Information ispeciton Inanection: Timing Tool installation ... Injectors Installation PTD - STC Injector. PTD - Top Stop Injector. Eniging Disaaseenioly and Ansemninly - Cras BE 4 Group Index Page 4 Powe Remove. - oe 59 1 $39 PTD STC Injector PID Ton Stop lnjocter [ injectors and Yateos Adiustrent ‘Genoia} istorii : jajscter Pretood Aduestinent «PID Fp. ‘Slop injectors (eter Pretoad Adtestrsent Pronedkares - FRO STC inje Valve » Ackustnient . Fi and Fixed Time Engines) «. tos Sas (Siep Ting ‘Contrei Engines) Lubricating OF Drainage ere ors, P Lubriaating O# Sinere Hnstallation wwe - oa Removal... : cone . a8 Lubricating OH Pome . installation Retnoval f Lubricating 0% Trumster Tribe Instalition won os wo wos 5 Reraxat . . CEI ce pad Main Bearing Snes CPPS Insiallation B Removal... E Oi Cooler Azsembly Installation. 0 188 189 168 ‘88 Big Carn IV. Big Cam WY are | Rew Removal. . O19 0.20 049 ‘88 Big Cam Big Gam V and iiow Big Oil Pan Installation Removal i Piston and onnectig Red 4 Assemblies Installation . Piston Ri Piston Cooling Nozzles Installation... Removal Pistons Installation on the Connecting Rods ~ Removal from the Gonnecting Ri f Push Rods astallation Removal in Cover installation Removal Rear Crankshaft Ot Seal Installation Removal... os Rocker Housing Covers Installation Removal .. 70 a7 34 Engine Disassembly and Assembly « Group 06 Group index AT B68 Page 0-5 Page Recker Lover Housings etaitation Bemova .. Starting Motor Installation coc. ssenensneneeneneee - Removal... STC Exteinat OW tani MgtaHASOR sare en Removal STC hegernal OH Misco iretallaiion.... Removal STC ON Gontrel Yaiwe installation, Freeza sevremness miei istallatier, pceetnaneeen tt S Bi Oe ‘Theemostat Hloweive Flow Cooking RPE } Srsiaiiations. Big Canr WV, Slew Big Cam IV. and NTE 44a Only Removal. sear Big Cam WV, New Big Cam iv, and NTC 444 Only. Thrust Bearings, Lower Bearing Sholts, and Main Bostiag Caps installation .. Removal... Turbocharger Insiatation Removal .... Vibration Damper {astallation Removal Water Bypass Tube Installation... Big Cam Removal. . Big Com Water Fil Tube installation... 88 Big Cam IV Only Reniovel 88 Big Cam iV Oniy ‘Water Honder Covers Installation. Removal Water Stanifold Assembly Instatlation Removal... Water Pump Installation .... 88 Big Cam IV. Big Cam IV and New Gi Removal .. and Engine Disassembly ond Asvembly ~ Sto wo WT ASS § Groug index Page O-8 . age Water Pump Belt instalfation. 158 0-459 0-188 . 928 ont G472 Water Treaster Twos OATE Installation... a6 Big Cam IV. os Big Cam ly and New Big fs Removal a . : oe a Dae Engine Disessemily and Assaabiy - Group 02 RT MRS Riyine Ghesmmeminly act Avsecrishy - Engine Disessembly end Assembly . Service Tools The following special tools ere recommended (o perform procedurss in Group 86. The uss of these iools is shawn in the appropriate procedure. These tools can be purchased from your Isat Cummins Authorized Repair Location ‘Tou! Oeacripiion oll HANH engines exaemt 5 “inch bors LeDTICHALgE [Eagine Suppoet Stand Yeo Hiusivation } i [Suppert engine when not weehassie or on the snying rebud i h erie: sland Standard Puller Use to remove drive pulleys, impellers, ete. 87-647 Torque Wrench Adapter - Tighten crosshead and rocker lever adjusting screws. i ST-669 tt Pision Ring Expander ~ Remove arte install pision rings on pisions. 1-763 f o-ring Assembly Toot ~ Use to install the ovings on piston cooling nozzles. oF ST-835 a | oe | Engine Disassembly and Assembiy - Servite Tools Engine Disassembly andi Assembly - Group OG Page 0-8 WTARS « Toot No. ___ Tool Beseription Foot Shusaeatbon Crankehalt Oil Seal Installer i [Use to drive the crankshaft oil seat into the rear cover. This too! 5 | 4 groggy [2l80 aligns the rear caver to the crankehatt i - set Fuel Purp Drive OH Seat Mandel sete drive the accessory drive oll seal into the gear cover wee) sreizs [mounted j Main Bearing Cap Fuller Remeve main Seating Sape. ST-H178 Rocker Lever Actuator Required to adjust injector travel ST-1193 Top Plate Included in oil seal puller/installer, Part No. ST-1259. Use to pull 9 : st-1260-1 |" install the front crankshaft oll seal. Wo 8 ssc i | Belt Tension Gauge i Use to check the belt tension on 3/s-inch to 1/2-inch top width! stare [Pats 5 : “ea Tension Gauge : Measure drive belt tension. 1 87-1203 : [Dial Gauge Attachment “Ty ae Attaches to crankshaft o provide measuring of flywhee! housing) 7 runout with a dial indicator. =o ‘: ST-1925 oy a seouge | | Engine Disassembly ana Assemialy « Group (it NTRS Foo! No, 3376013 7 Adapter Plate Use the sdapier plate to mount the engine to engine rebuild) stand, Pari No. 3375794, Engine Disassembly ant Accembly « Service Tools: Sage &9 ‘igo! liustration aR75049 Olt Filter Wrench Use to remove or tighten spin-on lubricating il filters, I i i SE78162 S375194 Piston Fling Compressor Use to compress ihe piston sings when insialling the pistons in| che cylinder Sner, Engine Rebuild Stand [Support oylindsr block curing engine rebuilt, Use with adapter} plate, Part No, 8875018. 3375268 Camshatt Installation Pilots se to guide the camshaft through the block camshaft bushings, Four are required per operation. 3375622 Injection Timing Fixture Used to determine the injector push tube travel in relation to the| piston travel, 3375601 [Connecting fod Guide Pins Guide connecting rods over crankshaft during removal or in- stallation of connecting rods. exten 3375629 [Universal Cylinder i.iner Pulter Remove cylinder liners from cylinder block. Requires eylinder| liner puller plate, Part No. ST-1202-1, Page 0-10 Tool Ne. fylon Litting Sting [Aid in removal and installation of crankshalt, flywheel, and other| neavy components. 8375987 Universal Gylindor Linse Putler Remove aybinder tinese trom ihe cylinder blot 9978015 | be Required to assemble and acuei tha mee! devics, Variakie Tang Fhaure Required to assenible and adjust the mechanical variable Sming, sareozs [tM Engine Disaeeombly and Assembly - Service Toole Engine Disassemdiy and Asxombly - Group Ue se ecm 7 855 ‘Geel iluswation th ol Dial Indicator and Sleeve Assembly [Use with dial gauge attachment, Part No. ST-1825, to measure} gazeosa —_ |fvwhoe! and fiawheel housing runout, Bracket and Stub Variable Timing Required toassemble andadjusttne mechanical variable timing} gavenoe [22% eva Gauge Block Measure cylinder liner protrusion above the cylinder block, Gear} garezny —_ [eever protrusion below the cylinder block, and intake and ex] aust valve protrusion above the cylinder head. Pulley instalation Toot install drive pulleys. 3976326 Engine Disassembly and Assenbiy - Group 6b NP 88S, Too! Deacsiption Engine Piesseombly and Aseanbly - Ser, ot e Toot ittratration. inch Pound Torque Wrench . \ [Requied to make consistent settings of the top stop injectors, Screwdriver socket, Part No. ST-669-13, must be usad with thi savess2 | EX Cylinder Liner Clamp Set Use te hold the cylinder finer in the block when checking liner zaveeeg —_ [Proitusion. nest i jeter aru Fut Bitter Wrench i i [Use to remave she coolant filer end the fuel fitter ; s97ee07 | wn Lubricating Suction Tube O-ring Expander - [Use to instell the lubricating oil transfer tube. 3976844 an od ftajector Puller [Use to pull ait non-step timing contro! injectors on Cummins sa7es72__ [engines. Engine Brake Feeler Gauge Use to set clearance between the brake piston and thel sarzage —_|etesshead. STC Tappet Adjusting Teal Use to lock and hold the top step injector. 3822648 Top Stop Injector Setting Fixture Required to set the top stop injactor. 3822696 Enging Disasvemily and Assembly « Service Toots Engine Dissesembly and Assembly - Group 80 Page 9.92 MT 63s, Toot No. _Toot Description F008 Hustration STG Injector Pulier Use to ramove step timing contrat (STC) injoctors. ——_ [cylinder Liner Installation Toot Lise to install the eyhinder liners. 4 Engine Disassembly and Seeombiy - Group 30 Engine Meascembly and Assembly - Genecal infosmation RY 865 Page 0-19 Engine Disassembly and Assembly - General information These procedures apply to ail NT engines. The dilferences belween engine models due to the application, the optional equipment on an engine, and the year an engine wes buill are included in the instructions, Omit the steps that do net apply to ihe engine being rebuilt, ‘ 1, Awaring statement i included for eny component or assembiy that weighs more than 23 kg [50 Ib}. To avoid personal injury, use @ hoist or yet assistance from more than one person when removing oF installing these parts 2. All capscrows used on the NT engine are U.S, customary. Disassembly The instructions in this procedure are organized in a iogical sequence to disassemble an engine. This is not the only sequence to disagsemble an engine. Certain parts must be removed in the sequence indicated. Use this sequence until you become familiar with the engine. Discard all gaskets, seals, hoses, fillers, and o-rings. Keep these parts if hey are needed for a lallute analysis. Lakel, lay, of mark the parts tor tention as the parts ary removedt in order (© saaily find all of the parts that can be involved in a failure anc to simplify ihe assemity procedure. # pnoisgraph ail segcial equipinent prior to the removal front an engine. This engine assembly procedure does nel include the installation of special! optiona’ equipment Force must be used to remove 0. Prust be ramoved Int iin paris, & wails must no used when ite ie required, alt of the fasteners rofen, Avoid as much dir ae possible during disassembly. The enctmulation ot additional diet wilt make it more difficult fo ciean the componsnts, Assembly Mako sure ail the components and assemblies have been cleaned, reptaced or rebuilt, and are ready to be installed on the engine before begining the assembly process Torque values are listed in each step. Ifa torque value is nat specified, use the chart listed in Specifications, Group 18, fo determine the correct torque value. Many of the gaskets and the o-rings are manufactured from a material designed to absorb oll. These gaskets will enlarge and provide a tight seat aiter coming in contact with oil, Use ONLY a recommended contact adhesive or @ vegetable-based oil te install these paris. Always use a capscrew of the same system (metric or U.S. customary), the same dimension, and the same grade as the capscrew removed. The use of 4 fonger capscrew than the capscrew that is listed can resuit in damage to the engine. Engine - Preparation tor Cleening Engine Dizagseinbly (06-08 Page G14 Hr ase Engine Disassembly (00-07) Engine - Preparation for Cleaning fe the engine weighs approximately warning: Becaus ‘ase 8 hiolat to litt the engine (© avait 1276 kg [2210 to}, feeroonal injury. Use liiting fieture, Part Ni rrinimurt titing capacity oF 4.5 Mm tor engine. Io, ST-125, and 2 holst with & 15.6 tons} to Hit he remove all electtical wiring and controls. Re Label and snaialt caps or tape on the following openings to prevent Tnoisture and ditt from entering the engine: . & 4. Both sides of the turbocharger (1) and (2). 2, Coolant outiet connection (8). 3, Alloit, air, water, and fuel openings. Engine - Cleaning & warning: When using o steam cleaner, wear protective Trothing and safety glasses oF a face shield. Het sieam can cause serious personal injury. Steam clean and dry with compressed ait. ant tive eam Engine Gwexseorsisly (B03) NY 856. Lubricating Oi - Drainage NOTE: The maximum oil pan capac is 34 fters [9.0 U.S gattonsi, Bemave the drain plugs and the copper washars. Check the copper washers for wear. Drain the oil. Replace the washers and the plugs. ‘Torque Value: 136 Nem [100 flb} Coolant - Orainage Remove ths plage trom the iollewing points: 5 Sper sist Spee fie angie Sper the 98 ooeler ot se @ suneDlo comainer to arin aauch ihe oaotant as i is Coolant Filter - Removal Use @ water and fuel filter wrench, Part No. 3376807, to remove the coolant filter. Fuel Fliter - Removal Use a water and fuel filter wrench, Part No. 3376807, to remove the fuel filter. & Lubstesting Oi. Grains Page 6 fly od Engine Disassembly (03) NT a55 Lubricating Oil Filters - Removal Yq sean oi fer wrench, Part No. 987504, to remove the bypass filter, the fullflow filter, of the corabination fubr- cating oil filter. Turbocharger - Removal && a Remove the of supply and the off drain vabes from the 2 turbocharger Loosen the hose clamps at the turbocharger and the Gee Rorcooler, Remove the support clamp and the air cross- over tube. Remove the four turbocharger mounting nuts. NOTE: Tag the turbocharger mounting nuts for future iden tification. The racunting nuts are designed for high stiength. Waring: Because this part weighs more than 23 ka (50 Ib}, two people of @ holst will be required to lif the turbocharger to avoid personal Injury. Ge Remove the turbocharger and the mounting gasket 49 Engine Dicassembly (00-01) NY S55 Exhaust Manifold - Removal Remove one mounting capscrew trom each end of the ‘exhaust manifold, and install two guide studs Warning: Because this eesembly weighs more than 23 Kg 150 Ib], two people or a hoist witl be required to lift the exhaust manifold assembly to avoid personal injury. Remove the remaining ten capscrews, the exhous! man- ifold assembly, and the manifold gaskets. Fan and Fan Hub Spacer - Removal Gautron: A tan hub spacer can be behind the tan, a wilt Srop as the tan is removed. Make sure to remove the faa and the fan hub spacer tagether. Remove the six capsorews snd ihe fan, ROTE: Cio net discal the tan spacers, The the thickness neecied 60 insiell the fan inthe Alternator Belts - Removal Loosen the alternator to alternator support nut and capserew. Loosen the adjusting link capscrew. Push the alternator toward the engine to release tension on the alternator belt, and remove the belts), Alternator - Removal Remove the adjusting link capscrew and the adjusting tink. Remove the alternator to attemator support bracket, nut, washer, capscrew, and the alternator. Alternator Mounting Bracket » Removal Engine Diewusembty (00-01) Page G18 Alternator Mounting Bracket - Re~ , moval Remove the three aternator mounting bracket capscrews and the mounting bracket. Starting Motor - Remaval Worntsg: Because tins part weighs more than 23 Ke [56 fb], two people or Aoist will be required to BA the starting motor to avoid personal injury, 9 motor eapserews, the starting cased) Remove the three sist moter, ond he BpScer Water Transfer Tube - Removal 1 Big Cam !V and New Big Gam IV Remove the four capscrews which hold the water transfer Cover to the thermostat housing. Remove the cover and the water transfer tube. 88 Big Cam 1V Loosen the hase clamps at the front of the oll cooler, and work the tront transfer hose away from the oll cooler. senocna Engine Disassembly (00.613 NT ASS Reniove the off cooler iranster tubs clamp capscrew, the clamp, and the transter tube. ‘Ol Cooler Assembly ~ Removal Big Cam IV and New Big Cam iv ‘On engines equipped with the une pase vit cooler design, remove the hose from the reer of the olf cocler Remove the turbocharger cil supply tube and the bypass. filter return tube, Remove the two capscrews which hold the oil cooler brace to the cylinder block. Remove one of the capscrews which holds the oil cooler ‘support to the cylinder block. Install a guide stud in the hole. ee Ra Ra ao ap Gil Cooler Assembly - Remove Page 0-46 il Cooler Assembly - Removal Engine Dissssambly (00-401 Page 0-25 wr see five capscrews from the off ca0let . fhe cooler assembly. Remove the rernaining support, and remove t ’ $8 Sig Sam ¥ 4 Remove tre capscrew whi % ich holds the oil costes SUPROT TS bracket 10 the ovfinder Sloe! kt the rear af tne ail COMET oil cooler the capserews which holds the ud in the Femove one of wylinder block. Install a guide st support to the ©} hole. Remove the remaining five capscrews from the oft cooler ‘cooler assembly. 29 support, and remave the Engine Disassembly (00.01) NTs Piston Cooling Nozzles - Ramoval Romove the piston cooling noxzies ar Remove and diseard the o-vings. Hand Hole Cover - Removal Remove the tur capsorews and the nand hole cover. &ea Thermostat Reserve Flow Cooling (RFC ) - Removal Bia Cam WV, New Big Cam IV, and NTC 444 Only Remove the capscrew from the rear reserve flew cooling &Ro I (RFC) tube brace. Remove the capscrew from the front REC tube brace. aR {Loosen the clamp on the REC tube inte the thermostat housing. Disconnect the hose from the thermostat hous- ing. Piston Cacling Nozles - phemevat Page 0.21 Ug ey ee @ Es Aftercoater Vent Tuba ~ Removal Page 0-22 Re Ge ee Engine Cisassembly (00-07) « NY 288 Remove the REC thermostat Housieg bofts: Remove the REC tube and the thermostat from fe er" gine. . Avtercooler Vent Tube - Removal Big Cam SV and New Big Cam IV Bemove ine aftercooler veri ibe. 88 Big Cam IV Remove the aftercooler vent tube. Aftercooler Coolant inlet and Outlet ! Tubes - Removal ; Big Cam IV and New Big Cam IV Remove the capscrew from the cootant inlet and outlet tube support clamp. Engine Disassembly (09-01) BTSs ¥ Loosen the hase clamps (1) and (2), and remove ihe coolant intel anid cultel tubes, Flemove the sereen fram the thermostat housing cover, 88 Big Cam IV Remove the capscrew from the coolant inlet tube support clamp. Loosen the hose clamps (1) and (2), and remove the coolant inlet and outlet tubes. Atteroooler Gosient inlet anc Ouligt Tubes - Remov. Page 6.2 a we ary Thermostat Housing - Femovel Engine Disassembly (00-01) NT 855 een irom the thermovist housing cover. , Ramove the soi ey ‘Thermostat Housing - Removal Big Cam I¥ and New Big Cam Ww tour capssrews tat hold the thermostat Hemove the the ther Agusing %@ he waier pump Inlet, and remove mosiat housing assembly. 88 Big Cam IV Remove the three capscrews that hold the thermostat housirig to the water pump. Carefully remove the thermostat housing by pulling & &Re forward away from the upper water manifold, -— Engine Disassembly (00-64) AT 85S, Water Header Covers < Removal Remove the six capscrews from each of the two water headsr covers, Remove the covers, and discard the gaskets. Ge Engine - installation on ihe Rebuild Stand NGTE: Use engine repuild stand, Part Ne. 3075194, andthe adapter plate, Pari Ne. 2375015. Use six 8/8-11 X 1 3/4-inch grade § capscraws to Install the adapter plate ts the rebuild stand ‘Forque Value: 100 Nem 175 aby Water Header Govars - Remova Page 0-25 ‘The engine stand adapter plate attaches to the cylinder block at the capscrew locations shown, Check the conditicn of the threads in the cylinder block before attempting to mount the engine on the engine stand. Clean the threads in the cylinder block and repair any damaged threads, Engine Oisssserisly (00-01) NT 888 Engine - installation on the Rebate Sten Page 0-29 install ine mouniing plate adapter on tne rear Waist ineader. \ Use five 4/420 X 1 14-inch capscrews 10 mount the adapter. Tighten the capscrews. Torque Value: 10 Nem [7 fe1b] Install four 1248 KF BRinch cepecraws through He adapter plate ae shown, install the tour adapter plate spacers over the capscrews. Use a litting fixture, Part No. ST-125, to lift the engine. : Put the exhaust side of the engine to the adapter plate of the rebuild stand. Align the mounting hote in the adapter plate (4) with the capscrew hole (2) in the mounting plate adapter. Use a §/9-11 X 1 3/4-inch grade § capscrew lo mount the adapter plate to the mounting plate adapter. Use your fingers to tighten the capscrews. Engine Disansembiy (oO) NT8ss Adjust ihe position of the engine so that the remaining mounting holes in the adapter plate (2) and (9) atign with the capseraw holes in the eytinder block. Use your fingere lo lighten the four 1/220 X 3 Si&Inch sepectows (2) Install four SETH X 3 Sf&inoh capacraws in the location shown (8), Lise your fmigers te bghian ine eapscrows, ‘Tighten all the adapter plate mounting capscrews in the sequence shown. Torque Values: 1. 4/2 Inch capscrews: 100 Nem [75 ft4b] 2. 3i8inch capserews: 40 Nem [39 ft-lb] 3. 5/8-inch capscrews: 100 Nem [76 ftlb} Flywheel - Removai Install two 1/2-13 X 1 1/2.inch puller capscrews which have a minimum of 1 1/4-inch threaded areas at points (1) and (2). Remove capscrews (3) and (4), and instail two 5/8-18 X 6-inch guide studs. © a 5, Fiymheot - Removal Page 0.27 VED | Flywheel Housing - Removal E) Page 0-28 @ Engine Disassembly (00-03) i NT es Determine the sapsorew thread size, end install lwe ¢ handles in the flywheel al points (4) and (5) Remove the remaining four flywhesl mounting capsorews. ‘raring: seaugs thia pant weighs more than 23 kg {0 fo]. two people or = Kelsx wil be required to OR the fiywhae! te avoid personel injury. Tighten sepsorens (3) and (2) in alternating sequenes 7% loosen the Hywhee Flywheel Housing - Removal Remove capscrews (¢) and (2), and install two 5/8-18 X 4-ineh guide studs. Warning: Because this part weighs more than 23 kg [50 tb}, two people of a hoist will be required to Tift the flywheel housing to avoid personal injury. Remove the remaining capscrews and the flywheel hous: ing. NOTE: Use a mallot to foosen the housing from the dowols in the cylinder block if necess2ry. Remove the guide studs. Engine Disassembly (00-09) HY'855 Water Bypass Tube - Removal Big Cam IV and New Big Cam 1V Only Loosen the hose clamps ai the front water manifold, Remove the retaining clamp and the water bypass tube. Fan Drive Belts - Removal Loosen the four capscrewe which secure the fan hub shalt 16 the bracket lemove the fan hub adjusting capscrew, and remove the fan belts. Water Pump Belt - Removal Loosen the idler pulley shaft lock nut, Turn the adjusting screw counterclockwise to release tension, and remove the water pump belt. Water Bypass Tube ~ Removal Page 0-28 ws Ge ca Fen Hub Support Gracket and Fan Hub - Removal Engine Disveserntsly (00-01) 5S 1 Page 0-30 Fan Hab Support Bracket and Fan hub - Removal Remove the four capsorews that ailacti the fats bub shaft tothe suppart bracket, and remove the fan hub assembly. Bamove the Tour cepscraws thai attah the Srace the supper bracket ane rocker housing. Rem oe Remove the two capscrews that attach the support bracket to the water pump or to the cylinder block, and remove the support bracket. Air Compressor Coolant Inlet and Outlet Tubes and Air Inlet Tube - Removal Big Cam IV and New Big Cam IV Remove ihe coviant tubes to the air compressor. the eylinder block, and the water manifold or water bypass tubs, we Engine Disaesembly (06.97) ar ess 88 Big Cam IV Remove the coolant tubes to the air compressor, the cylinder block, and the water pump, Remove the PYEESOF atid the ir comprossor air inlet tube to the com aferooaler. Coolant Filter Head - Removal 88 Big Cam IV Only Remove the capecrews and the coolant filter head. Water Fill Tube - Removal 88 Big Cam IV Only Remove the water fill tube. Ga a eee Goctant Fitter Head - Flemoval Page 0-31 ‘Water Sump - Rentovel Page O32 Engine Disassembly (60-01) NT 855 Water Pump - Removal Remove the six mounting capserews from the water pump. Caution: The water pump must de removed carefully to prevent damage to the impeller. Remove the water pump irom the engine. Accessory Drive Pulley - Removal Remove the pivley retaining nul aution: The gear cover will b¢ damaged i the puller capsorews extend beyond the rear face af the accessory drive putley. oe & standart puis putley- Vibration Damper - Removal Caution: Do not use a hammer or a screwdriver to re move # viscous damper. These tools can damage the viscous damper. Remove one of the capscrewe which holds the vibration damper and the pulley to the crankshaft, and install a guide stud in the hole. Remove the remaining five capscrews, the damper, and the pulley. Front Engine Support. Removal 2q_Flemove the eight mounting capscrews and the front en- gine support irom the gear cover, pon tw. Engine Disassembly (00-01) NY 855 Cemebaft Beating Support - Removal Page 0-28 Camshaft Bearing Support - Removal j Remove the three capserews from the suppor. Use a mailet to rotate the bearing support approximately degrees. Use 2 suitable psy ber ia remove the beasing support trom Bue goer cover Ri | Remove the o-ring and the shims from the bearing sup- Port. Do net dispose of the shims. &Re Aftercooler - Removai Remove the air compressor air inlat, the AFC signat tube, Ware attached tothe SO and any other tubes or brackets that aftercooler. = Engine Disaveembly (80-01) NT 835 : Rocker Housing Covers - Removal + Page O34 Remove one mounting capecrew and washer aleach ng of the heusing. Install 4 guide stud in each capscrew mounting hole. NOTE: Two guide studs are required to support the aftercooler assembly during removal. Remave the cemaining seven mounting capscrews and wasiners. NOTE: The Big Cam 1¥ ana New Sig Gam aitersootst assemblies have thres iower mounting canscrews tat we supporting siemps. ‘Warning: Because this assembly weighs more than 23 kg [50 Ib], two people or a hoist will be required to lift the aftercooler assembly to avoid personal injury. Remove the aftercooler assembly. Rocker Housing Covers - Removal Ya, Remove he hose or tube from the crankcase breather (if equipped). Use a metal marker to mark the rocker housing cover location. Remove the five capscrews and washers from each of the rocker housing covers. Remove the covers. <7 3m in Engine Disassembly (0-01) NY S55 Engine Brake Housing - Removal Disconnect the brake harness wire irom the electrical connector on each brake housing. NOTE: On engines equipped with the Cummins C-Brake, disconnect the STC C-Brake sensing line (1) from the rear brake housing. Remove the hold down avis, the. titing brackets, the ry, epacer, and the brake housings eK Engine Brake Wiring Harness - Re- moval Remove the four wiring hamess mounting clips from the (3p water manifold mounting studs. Remove the wiring hamess mounting clip irom the cyi- inder block. Ro S| Engins Broke Housing - Removal Page 0-35 STC Exiernal Oi! Manifold ~ Remuval Page 6-36 . { | Engine Disassembly (00-01) NT BSS Remove the iuel pump switch and brackel assembly from the fuel pump. ‘ “he Cayetully pull the wiring harness [rem behind the taeh Oy gs! eunp. oe STC External Oil Manifold - Removal ‘On engines equipped with step timing contro! (STC), disconnect the external oil manifold supply hose from the rear of the external cll manifold, NOTE: The external oil manifold must be held in place with a wrench to prevent damage to the manifold. Remove the three external oil manifold holddown capscrews. Remove the extemal olf manitotd. Engine Disassembly (20-07) NT 955 Rocker Lever Housings - Removal Remove the engine lifting brackets. Re Lausen the rocker lever adjusting serew and the jock nut Turh the sojusting screws counterclockwise two full turns, If the engine is equipped with an engine brake, identify the location of each mounting stud as it is removed. Three different length mounting studs are used. The ar- Fangement of the mounting studs is determined by the original equipment manufacturer (OEM). Remove the rocker lever housing mounting capscrews. Ga NOTE; To prevent increased wear, mark each rocker lever housing as it is removed so it can be installed back in its original iocation, Remove the rocker lever housings. Rocker Lover Housings « Removal 7 STE Internal Ol Manifold - Removal Page 6-38 erg Engine Rignezemmly (00-01) WT ASS STC internal Oi Manifold - Removat Gn engines equipped with STC, tit both ends of the interna oll manifold out of the oil connection blacks at the same time. Puaeh Rods - Removat ahve Dust rods and the injector gush sods. OTE: To preven Increased wear, mark Bach push fo Be ie removed 491 oan be installed Back it ts orginal incawion, Crossheads - Removai Loosen the crosshead adjusting screw lock nuts, and remove the crossheads. Number each crosshead with the cylinger number and the position as it is removed Water Manifold Assembly - Removal Remove the mounting capscrews and the water mani fold. NOTE: The water manifold sealing sings used on Big Cam IV engines contain a balance orifice. an in In Engine Disassembly (00-01) MY 885 injectors - Removal PTD - Top Stop Injector Caution: Do not drop or damage the injector plungers. A Remove the injector link from each injector. Remove the two clamp capscrews and the injector hold Ge down clamp from each injector. Use injector puller, Part No. 3376872, to remove the p> uijectose, ys PTD - STC Injector Remove the injector holddown clamp capscrew and hold- &e down clamp. Use injector puller, Part No. 3822897, to remove the injector. Insert the threaded end of the puller into the tapped hole inthe STC tappet top stop lock nut. remove the injectors. injeators - Renewal Page 0-39 Fuel Crossovers - Removal &e & ® ee Engine Diseesembly (60-01) WT 885 Homave the STC oil connection block and gromesel, Fuel Crossovers - Hemoval Remove the tour capscrews from eaoh of the we fue! }) crossovers, and remove the fusi oresacvers. Fuel Tubing - Removal Remove the fuel supply tube trom the fuel pump to the cylinder heads. Fiemove the fuel drain tube from the cylinder head, Cylinder Heads - Removal Remove the 72 capscrews and washers from each cyt: . inder head. Warning: Because this part weighs more than 23 kg [50 Ib], two people or @ hoist will be required to lift the cylinder heads to avoid personal injury. Lift the cylinder heads from the block, and remove the cylinder head gaskets. NOTE: To preventinoreased wear, mark each oylindot head it ig removed so it can be installed back in its original as location. ee aan ne Engine Disassembly (00-015 HTa55 Caution: Yo prevent damage % ihe head gasket aus face, put the sylinder heads on wooden lacks when they ave removed. Cylinder Liners - Removal of Carbon Deposits Caution: Ge nat use att emery sloth ov sanépaper to yemove carnon irom the cytinier fines and the cylincier block cylinder eax mounting siatacs. Siurninum oxide orailicon perticies trom an emery cloth orsansipapercan Hae sprigs arising semage, Rotate the crankshail te expose the carbon ridge above: ibe ring travel area in the cylindor liner. Caution: Do not use any abrasives in the ring travel area of the cylinder liner. The liner can be damaged. Use a gasket seraper with an aluminum blade to remove the carbon ridge. Use a fine fibrous abrasive pad such as Scotch-Brite® 7448 or its equivalent to remove the remaining carbon. A Fuel Pump - Removal Remove the capscrew from the air compressor support bracket. Remove the four capscrews and the fuel pump. Remove the coupling spider. & ‘Oylinder Liners - Rereoval of Gathon Bepasits | Page 0-43 : ne ooo Engine Disussemisty (09-01 STG Olt Control Valeg - Removal Page G42 WT 255 STC ON Control Valve - Removal fromove the following hoses from the STC olf contrat vaive: Fuel pressure sensing hose (1) Oil oullat hose to tappets (2) C-Brake sensing hose (3) Fuat leakage return hose (4) Oi supply hose (5) ut a plug in all openings on the valve after removing the hoses. y papscrews which Noid the STC valve to 2 SFO contest vals Herove the gee mounting br Lubricating Oil Pump - Removal Remove the demand flow and cooling (DFC} signal line. Remove the capscrews and the lubricating oil transfer tube. Remove the five capscrews which hold the lubricating oif i) pump to the cylinder block. Caution: Bo not pry on the gear or the oll pump flange. ‘The oll pump can be damaged. Remove the lubricating oi! pump from the gear case. Re Discard the gasket. Bee Ca Wil NO’ posi * der On Ren Engine Hisacssmbly (60-01) HT 885. Air Compressor - Removal Remove the ait compressor coolant tubes from the air compressor and the cylinder block. Fiamave ihe tour capsorews, the ear comprasser, and the Accessory Drive - Removal Caution: If the accessory drive dowel pin has been in- correctly installed, the dowel pin must be removed be- fore attempting to remove the accessory drive to pre- vent damage to the accessory drive bushing. Remove the five capscrews and the accessory drive assembly. Cam Followers - Removal Without Mechanical Variable Timing NOTE: Cam follower lavers must be installed in the same position from which they were removed from the engine. . Mark the cam follower housings as they are removed to identify their location on the block. On fixed injection timing engines, remove the six capscrews from each cam follower housing. Remove the cam follower housings and the gaskets. &a ws R Ge Air Gompressar - Removat Page 0-43 Cam Foltowers - Removal Engine Disassembly (00-01) Page 044 RT 85: “Measure and record ihe thickness of the gackels used beiween each cam follower housing and the blow. NOTE: The thickress of the gaskets controls tne injection 1) 49 fiming. Discard the gaskets. Cam Followers - Removal With Mechanical Variable Timing Remove the wo center capeorews irom the irant and the rear housings of the assembly. Install the variable tring tuture, Part No, 3876028, 10 he Remove the six capscrews from the center housing, Remove the remaining four capscrews from the front and the rear housings of the assembly. Waring: Because this assembly weighs more than 23 kg [50 Ib], two people of a hoist are required to lift the cam follower and actuator assembly to avoid personal injury. Remove the cam follower housing and the actuator as- sembly, . Remove and discard the gasket, 6 eranradt Engine Disassembly (06-07) NT 856 Oi Pan - Removal Fiomove the ofl pan mounting capscrews and the oll pan. &Re Pision aad Connecting Red Assem- blies - Removal Rotate the crankshaii to put the CONMBCHRG Tod Caps at “BDO” bolton: dead cemar; tor rsmoval Loosen the connecting rod capscrews unt there is ap “proximately 44-inch between the capsorew head and tle $80 OBB, NOTE: Do not remove the capsorews irom the rods. Use a mallet to hit the connecting rod capscrews te loosen the cap from the dowel in the connecting rod. Remove the connecting rod capscrews. R Remove the rod caps. Remove the lower rad bearings. Mark the cylinder number and the letter ‘surface of the bearing tangs. the flat Olt Pan ~ Removal | Page O45 | etm Install two connecting rod guide pins, Part No. 3375601. Use a t-handle piston pusher to push the rod away from the crankshaft, Push the rod until the piston rings are outside of the top of the cylinder liner. hs Rap Engine Bissosembly (00-91) NT 85! | Caution: The piston and connecting rod assemblies i Caution inatafieg in ne game cylirder abinber from whieh: mast peara removes, the piston t= wel previously 4 +) wey ar mark the eylinder number on the top of each ie) piston as the aasembly is removed. Remove the piston and rod assembly. NOTE: The pistons must have the cylinder numbers aSinped on the piston top toward the camshaft side of the engine. | ‘ j ' Remove the upper rad bearing. fark tne ovinder number and the etter “U" in the Hal ‘ surface of ine bearing tangs. - i f A Caution; Put the piston and rod assembly in & rack to F prevent damage. Put tho rod and piston assemblies in a container t0 070 f tect them from damege. A A Rear Cover - Removal c Remove the capscrews from the rear cover, and remove in 29 tho cover from the crankshaft flange. in Remove the seal from the rear cover. Je vs T Engine Bioassembly (00-01) NT 855 Gear Cover - Removal Remove one capscrew on each side af the gear cover, eRe and instail a 7/16-29 X 4-inch guide siud in each location to suppor the cover during removal. Remove the remaining gear cover capserews, and re "AD move the gear cover, sarmshatt nd the ovankshetl gear Use a diel indiestor to chevk the backlash belween the ey we Beckiosh Between the Gamshati and the Grenkshatt Gears oe OE aie \ibacklast is ant witnin specifications, mark the gears for replacement. Front Crankshaft Seal - Removal Remove the front crankshaft seal. &a Accessory Drive Seal - Removal Remove the accessory drive seal. &Re Camshaft - Removal install four camshaft pilots, Part No, 3375268, over the

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