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REPAIR INSTRUCTIONS
Air Inlet Manifold Installation
[214 HD]
Refer to Figure 303 and Figure 304.
1. For two-piece manifolds place the front air
inlet manifold section (8) into position on the
cylinder head and insert the 12-point
capscrews (9) and washers. Current
production one-piece manifolds are
positioned on the cylinder heads with all the
retaining 12-point capscrews inserted.
2. Torque capscrews to 40 lb-ft (54 N•m), using
torque wrench J 24407, or equivalent.
3. For two-piece manifolds, place the coupling
on the rear of the front air inlet section (8).
Assemble two clamps on the coupling and
install the rear air inlet section (6).
4. Continue assembling the two-piece manifold
by inserting the 12-point capscrews and
torque to 40 lb-ft (54 N•m), using torque
wrench J 24407, or equivalent.
5. Tighten the clamps on the coupling and
torque to 38 lb-in (4.3 N•m).
304
Figure 304 — One-Piece Air Inlet Manifold (Current
Production)
Thermostat, Housing and Seal
Installation
[215 NU, NG & LD]
Refer to Figure 305.
1. When replacing a seal for any reason,
examine the surface of the thermostat
sleeve, the bore area and the seal to prevent
premature failure of the new seal. A sealing
lip that has been turned back, cut or
otherwise damaged will leak and must be
replaced. The lip faces the front of the
engine.
2. Remove any surface nicks, burrs, sharp
edges and tool marks from the thermostat
sleeve and housing bore area using crocus
cloth.
3. Check to see that the replacement seals are
free from any contaminants such as chips,
grit, dust or any other debris that would
prevent the seal from properly seating in the
thermostat housing.
4. Press the seal into the housing bore with
smooth, uniform pressure, using seal
installation tool J 26637-A and driver handle
J 8092.
Tool J 26637-A is designed to regulate the
thermostat seal installation depth. The shoulder
on the tool bottoms on the thermostat bore of the
housing to prevent the seal from being installed
too far.
Wherever possible, an arbor press should be
used to apply assembly pressure. The use of a
hammer is not recommended since uneven
pressure would be applied directly to seal
surfaces. Precautions should be taken against
cocking the seal throughout the installation
operation. Make sure the seal is not cocked when
installed.
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