Table of Contents
Disassembly and Assembly Section
Fuel Priming Pump - Remove and Install ..... .... 5
Flow Control Valve - Remove and Install..... ..... 6
Fuel Filter Base - Remove and Install........ ....... 8
Water Separator and Fuel Filter (Primary) -
Remove and Install .................... ................... 12
Fuel Manifold (Rail) - Remove and Install.... ... 14
Fuel Injection Lines - Remove ............ ............ 17
Fuel Injection Lines - Install .............. .............. 20
Exhaust Cooler (NRS) - Remove and Install . . 22
Throttle Valve (Intake Air) - Remove and Install
(Rear Facing Inlet Elbow) ............... .............. 24
Throttle Valve (Intake Air) - Remove and Install
(Side Facing Inlet Elbow)............... ............... 26
Fuel Injection Pump - Remove ............ ........... 28
Fuel Injection Pump - Install .............. ............. 29
Fuel Injection Pump Gear - Remove ....... ....... 31
Fuel Injection Pump Gear - Install ......... ......... 32
Electronic Unit Injector - Remove .......... ......... 33
Electronic Unit Injector - Install ............ ........... 35
Turbocharger - Remove (Top Mounted
Turbocharger) ........................ ....................... 37
Turbocharger - Remove (Side Mounted
Turbochargers) ....................... ...................... 40
Turbocharger - Install (Top Mounted
Turbocharger) ........................ ....................... 42
Turbocharger - Install (Side Mounted
Turbocharger) ........................ ....................... 45
Wastegate Solenoid - Remove and Install... ... 47
Exhaust Gas Recirculation Valve - Remove and
Install............................... .............................. 49
Selective Catalytic Reduction (SCR) Canister -
Remove and Install .................... ................... 53
Clean Emissions Module - Remove and Install
(Top Mounted Diesel Oxidation Catalyst
(DOC)) ............................. ............................. 55
Clean Emissions Module - Remove and Install
(Flywheel Mounted Diesel Oxidation Catalyst
(DOC)) ............................. ............................. 56
Diesel Exhaust Fluid Lines - Remove and
Install............................... .............................. 58
Diesel Exhaust Fluid Pump - Remove and
Install............................... .............................. 63
DEF Injector and Mounting - Remove and
Install............................... .............................. 65
Diesel Exhaust Fluid Tank - Remove and
Install............................... .............................. 68
Manifold (DEF Heater) - Remove and Install. . 70
Solenoid Valve (DEF Heater Coolant) - Remove
and Install........................... ........................... 74
Flexible Exhaust Pipe - Remove and Install
(Flexible Exhaust Pipe from the Turbocharger
and the Diesel Oxidation Catalyst (DOC)) .. .. 75
Flexible Exhaust Pipe - Remove and Install
(Flexible Exhaust Pipe Between DOC and the
SCR) ............................... .............................. 76
Exhaust Manifold - Remove and Install (Side
Mounted Turbocharger Exhaust Manifold) .. . 80
Exhaust Manifold - Remove and Install (Top
Mounted Turbocharger Exhaust Manifold) .. . 83
Support and Mounting (CEM) - Remove and
Install (Flywheel Housing Mounted CEM)... .. 87
Support and Mounting (CEM) - Remove and
Install (Top Mounted DOC) .............. ............. 88
Inlet Manifold - Remove and Install ........ ........ 91
Inlet and Exhaust Valve Springs - Remove and
Install............................... .............................. 94
Inlet and Exhaust Valves - Remove and Install 96
Inlet and Exhaust Valve Guides - Remove and
Install............................... .............................. 99
Engine Oil Filter Base - Remove and Install . 100
Engine Oil Cooler - Remove ............. ............ 102
Engine Oil Cooler - Install ............... .............. 103
Engine Oil Relief Valve - Remove and Install 104
Engine Oil Pump - Remove ............. ............. 105
Engine Oil Pump - Install ............... ............... 106
Water Pump - Remove ................. ................ 107
Water Pump - Install ................... .................. 108
Water Temperature Regulator - Remove and
Install.............................. ............................. 109
Engine Lifting Bracket - Remove ......... ..........110
Engine Lifting Bracket - Install ........... ............111
Flywheel - Remove.................... ....................112
Flywheel - Install ...................... ......................113
Crankshaft Rear Seal - Remove and Install . .114
Flywheel Housing - Remove and Install
(Stressed Cylinder Block) .............. ..............116
Flywheel Housing - Remove and Install (Non-
Stressed Cylinder Block) .............. ...............118
Power Take-Off Drive - Remove and Install. . 121
Crankshaft Pulley - Remove and Install.... .... 123
Crankshaft Front Seal - Remove and Install. 124
Front Cover - Remove and Install......... ........ 126
Idler Gear - Remove ................... .................. 128
Idler Gear - Install ..................... .................... 130
Housing (Front) - Remove .............. .............. 132
Housing (Front) - Install ................ ................ 133
Accessory Drive - Remove and Install..... ..... 136
UENR4503
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Table of Contents
