EGES1602

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.
DT 466E AND THE INTERNATIONAL 530E

DIESEL ENGINE
SERVICE MANUAL
FORM EGES-160-2
DT-466E and THE INTERNATIONAL 530E

DIESEL ENGINE (MODEL YEAR 1995 through 1999)
MODEL YEAR 1995 through 1999
SERIAL NUMBER RANGE: 1075289 through 1194038
FORM EGES-160-2
© 2003 International Truck and Engine Corporation

Printed in the United States of America
SERVICE MANUAL
SECTION INDEX
INTRODUCTION SECTION
SECTION 1 – MOUNTING ENGINE ON STAND
SECTION 2 – TURBOCHARGER
SECTION 3 – MANIFOLDS
SECTION 4 – CYLINDER HEAD AND VALVES
SECTION 5 – ROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS
SECTION 6 – CONNECTING RODS, PISTONS, RINGS AND SLEEVES
SECTION 7 – VIBRATION DAMPER, CRANKSHAFT, MAIN BEARINGS, FLYWHEEL

& CRANKCASE
SECTION 8 – TIMING GEAR TRAIN AND FRONT COVER
SECTION 9 – LUBRICATING OIL PUMP, OIL FILTER AND COOLER
SECTION 10 – WATER PUMP AND THERMOSTAT
SECTION 11 – ENGINE ELECTRICAL
SECTION 12 – HIGH PRESSURE LUBE OIL SYSTEM
SECTION 13 – FUEL SYSTEM
APPENDIX
EGES 160 – 1
SERVICE MANUAL
MAIN INDEX
PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SERVICE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
PREREQUISITES FOR EFFECTIVE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
SAFETY
Safety Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TURBOCHARGER IDENTIFICATION (Non Wastegate Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TURBOCHARGER IDENTIFICATION (Wastegate Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHASSIS MOUNTED CHARGE AIR COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
THERMOSTAT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OIL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OIL PRESSURE REGULATOR VALVE AND OIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . 13
AIR INDUCTION AND EXHAUST SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
NEGATIVE PRESSURE (VACUUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FUEL SUPPLY PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel System With Front Mounted Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel System With Top Mounted Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INJECTION CONTROL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front Mounted ICP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mid Mounted ICP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL INJECTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FUEL INJECTOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
POPPET VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INTENSIFIER PISTON AND PLUNGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
NOZZLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FILL CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
END OF INJECTION – DRAIN CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Equipped With Chassis Mounted ECM and IDM Units . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Equipped With Engine Mounted ECM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LEFT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine Equipped With Chassis Mounted ECM and IDM Units &
Front Mounted Hand Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine Equipped With Chassis Mounted ECM and IDM Units and
Top Mounted Hand Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Engine Equipped With Engine Mounted ECM Unit and
Top Mounted Hand Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EGES 160 – 1
SERVICE MANUAL
MAIN INDEX – Continued

PAGE
INTRODUCTION – Continued
REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RIGHT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SECTION 1 – MOUNTING ENGINE ON STAND

SPECIAL TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REMOVING TURBOCHARGER OIL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVING COOLANT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVING OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVING ROAD DRAFT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MOUNTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 2 – TURBOCHARGER
TURBOCHARGER PIPING (NON WASTEGATE VERSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TURBOCHARGER PIPING (WASTEGATE VERSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger And Related Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TURBOCHARGER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PRE–DISASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHECK FOR FREE ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHECK FOR TURBINE/COMPRESSOR WHEEL HOUSING RUB . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CHECK AXIAL END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CHECK WASTEGATE ACTUATOR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EGES 160 – 1
SERVICE MANUAL

PAGE
SECTION 3 – MANIFOLDS
EXPLODED VIEW OF EXHAUST MANIFOLD AND GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VALVE COVER/INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Old Style Breather Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
New Style Breather Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHARGE AIR COOLER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MISCELLANEOUS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ROAD DRAFT TUBE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MISCELLANEOUS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 – CYLINDER HEAD AND VALVES

EXPLODED VIEW OF CYLINDER HEAD AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL INJECTOR WIRING HARNESS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DRAINING THE SUPPLY MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SUPPLY MANIFOLD DISCONNECT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engines Equipped With Old Three–Way Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engines Equipped With New Three–Way Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engines Equipped With Engine Mounted ECM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL INJECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
VALVE LEVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PUSH ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CYLINDER HEAD CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSPECT FOR WARPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHECK THICKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHECK FOR VALVE LEAKAGE (USING MINERAL SPIRITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSPECT FOR CRACKS (USING DYE PENETRANT METHOD OEM1272) . . . . . . . . . . . . . . . . . . . 18
PRESSURE CHECK CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EGES 160 – 1
SERVICE MANUAL

PAGE
SECTION 4 – CYLINDER HEAD AND VALVES – Continued
CYLINDER HEAD RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
VALVE AND VALVE GUIDE RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removing Valves From Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clean Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspect Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replace Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clean Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspect Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reface Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Valve Seat Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Valve Rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Valve Spring Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FUEL INJECTOR SLEEVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CLEANING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLING THE PUSH ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
VALVE LEVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
VALVE LASH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVING FUEL INJECTOR O–RINGS AND SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLING FUEL INJECTOR O–RINGS AND SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
UPPER GROVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
MIDDLE GROOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
LOWER GROOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FUEL INJECTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SUPPLY MANIFOLD CONNECTION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MISCELLANEOUS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
EGES 160 – 1
SERVICE MANUAL

PAGE
SECTION 5 – ROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS
EXPLODED VIEW OF ROCKER ARM ASSEMBLY, CAMSHAFT ASSEMBLY,
TAPPETS AND PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Valve Lever and Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tappets Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Push Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Valve Lever Shaft Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ROCKER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MISCELLANEOUS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MEASURE CAMSHAFT LOBE LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CAMSHAFT GEAR AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CAMSHAFT AND CAMSHAFT GEAR CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CAMSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY OF CAMGEAR ONTO CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CHECKING CAMSHAFT END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CAMSHAFT BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CAMSHAFT BUSHING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CRANKCASE BUSHING BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CAMSHAFT BUSHING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TAPPET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PUSH ROD CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CAMSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 – CONNECTING RODS, PISTONS, RINGS AND SLEEVES

EXPLODED VIEW OF CONNECTING RODS, PISTONS, RINGS AND SLEEVES . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Piston Rings – Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston Rings – Oil Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PISTON AND ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CYLINDER SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONNECTING ROD, PISTON & RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EGES 160 – 1
SERVICE MANUAL

PAGE
SECTION 6 – CONNECTING RODS, PISTONS, RINGS AND SLEEVES – Continued

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CYLINDER SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OUT–OF–ROUND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CYLINDER SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
METHOD ONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
METHOD TWO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
METHOD THREE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BEARING FITTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CYLINDER SLEEVE FITTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SURFACE GAUGE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DEPTH MICROMETER METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
METHOD ONE, USE GRADUATED MARKS ON TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
METHOD TWO, USE FEELER GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CONNECTING RODS, PISTONS & RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CYLINDER SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PISTON & CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CONNECTING ROD BEARING INSERTS AND CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 7 – VIBRATION DAMPER, CRANKSHAFT, MAIN BEARINGS,

FLYWHEEL & CRANKCASE
EXPLODED VIEW OF CRANKSHAFT, BEARINGS, FLYWHEEL
AND RELATED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EXPLODED VIEW OF CRANKCASE AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EXPLODED VIEW OF ENGINE MOUNTING, FLYWHEEL HOUSING
AND REAR POWER TAKE–OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLODED VIEW OF OIL PAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FLYWHEEL HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REAR OIL SEAL AND WEAR SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR OIL SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flywheel Housing Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR OIL SEAL AND CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flywheel Housing Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EGES 160 – 1
SERVICE MANUAL

PAGE
FLYWHEEL & CRANKCASE – Continued
WEAR SLEEVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REAR OIL SEAL AND WEAR SLEEVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REAR OIL SEAL AND CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLING FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CHECKING THE FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHECKING FLYWHEEL HOUSING BORE CONCENTRICITY
AND FACE RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHECKING CRANKSHAFT PILOT CONCENTRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLING THE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REAR PTO HOUSING ASSEMBLY REMOVAL (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REAR PTO HOUSING ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REAR OIL SEAL CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REAR PTO HOUSING ASSEMBLY INSTALLATION (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REAR OIL SEAL CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLING REAR PTO HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FLYWHEEL RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FLYWHEEL RESURFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
RING GEAR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OIL LEVEL GAUGE TUBE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
VIBRATION DAMPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OIL PICK–UP TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CRANKCASE (RECONDITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
BEARING FITTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
MAIN BEARING AND CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
EGES 160 – 1
SERVICE MANUAL

PAGE
FLYWHEEL & CRANKCASE – Continued
OIL PICKUP TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FRONT MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 8 – TIMING GEAR TRAIN AND FRONT COVER

EXPLODED VIEW OF CRANKCASE FRONT COVER AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . 1
TIMING GEAR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE GEAR TRAIN TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING ENGINE GEAR TRAIN TIMING WITHOUT REMOVING
FRONT COVER AND/OR ENGINE TEAR DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Method One – Using A Feeler Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Method Two – Using A Dial Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT COVER, FRONT HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GEAR TRAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IDLER GEAR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CAMSHAFT GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CRANKSHAFT GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT COVER, REAR HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Idler Gear Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GEAR TRAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
IDLER GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FRONT COVER, FRONT HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AIR COMPRESSOR/POWER STEERING PUMP (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FAN HUB AND PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ALTERNATOR BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AUTO BELT TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
EGES 160 – 1
SERVICE MANUAL

PAGE
SECTION 9 – LUBRICATING OIL PUMP, OIL FILTERS & COOLER
LUBRICATION SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EXPLODED VIEW OF LUBRICATING OIL PUMP AND PICK UP TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EXPLODED VIEW OF OIL COOLER, OIL FILTER AND COOLANT FILTER . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pressure Regulator Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OIL FILTER AND HEADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PRIME THE LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PREFERRED METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE RUN–IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 10 – WATER PUMP AND THERMOSTAT

EXPLODED VIEW OF FAN DRIVE, THERMOSTAT AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COOLANT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WATER INLET ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EGES 160 – 1
SERVICE MANUAL

PAGE
SECTION 11 – ENGINE ELECTRICAL
ENGINE SENSOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINES EQUIPPED WITH CHASSIS MOUNTED ECM AND IDM UNITS . . . . . . . . . . . . . . . . . . . . . 1
ENGINES EQUIPPED WITH ENGINE MOUNTED, FRONT ECM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINES EQUIPPED WITH ENGINE MOUNTED, REAR ECM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE MOUNTED ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing The ECM And Mounting Bracket As A Single Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing The Mounting Bracket And ECM As Separate Units . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAIN ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ENGINES EQUIPPED WITH CHASSIS MOUNTED ECM AND IDM UNITS . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINES EQUIPPED WITH ENGINE MOUNTED ECM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
VERIFYING CMP SENSOR CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CMP Sensor Clearance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE SENSORS AND CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Camshaft Position Sensor (CMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Coolant Temperature Sensor (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Oil Temperature Sensor (EOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Oil Pressure Sensor (EOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Injection Control Pressure Sensor (ICP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Injection Pressure Regulator Valve (IPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Manifold Absolute Pressure Sensor (MAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
EGES 160 – 1
SERVICE MANUAL

PAGE
SECTION 12 – HIGH PRESSURE LUBE OIL SYSTEM
HIGH PRESSURE LUBE OIL SYSTEM FLOW AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Injection Oil Pressure Control Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
High Pressure Pump Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING AND INSTALLING SUPPLY MANIFOLD END PLUG 3
SUPPLY MANIFOLD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISCONNECT LOCATIONS AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVING THE LUBE OIL SUPPLY HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engines Equipped With Old Three–Way Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engines Equipped With New Three–Way Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engines Equipped With Engine Mounted ECM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVING THE ICP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engines Equipped With The Old Three–Way Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSPECTION FOR WARPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HIGH PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVING THE INJECTION PRESSURE REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SUPPLY MANIFOLD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONNECTION LOCATIONS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLING THE ICP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engines Equipped With The Old Three–Way Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLING THE LUBE OIL SUPPLY HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 13 – FUEL SYSTEM

COMPONENT LOCATION FOR ENGINES EQUIPPED
WITH A FRONT MOUNTED PRIMER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WITH A TOP MOUNTED PRIMER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WITH ENGINE MOUNTED ECM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRIMING FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
EGES 160 – 1
SERVICE MANUAL

PAGE
APPENDIX
GENERAL ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DT 466E DIESEL ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
THE INTERNATIONAL® 530E DIESEL ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DT 466E AND THE INTERNATIONAL® 530E DIESEL ENGINE RATINGS . . . . . . . . . . . . . . . . . . . . . 3
POWER RATINGS AND SPEED SETTINGS, DT 466E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER RATINGS AND SPEED SETTINGS, INTERNATIONAL® 530E . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPONENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve Lever And Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tappets Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Push Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston Rings – Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston Rings – Oil Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Regulator Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Injection Control Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
High Pressure Pump Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuel Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TORQUE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GENERAL TORQUE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tension Values for Standard Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fastener Thread Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL NUT AND BOLT TORQUE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL SERVICE TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
EGES 160 – 1
SERVICE MANUAL
Foreword Technical Service Literature

International Truck and Engine Corporation is 1171681R1 Parts Catalog
committed to continuous research and development
1171683R1 DT 466E, 1995 & 1996 Model
to improve products and introduce technological
Year Operations Manual
advances. Procedures, specifications, and parts
defined in published technical service literature may 1171713R1 DT 466E, 1997 Model Year
be altered. Operations Manual
This Service Manual provides a general sequence 1171684R1 International® 530E, 1995 & 1996
of procedures for out-of-chassis engine overhaul Model Year Operations Manual
(removal, inspection, and installation). For in-chassis 1171714R1 International® 530E, 1997 Model
service of parts and assemblies, the sequence may Year Operations Manual
vary.
EGED 160 Service Manual
NOTE: Photo illustrations identify specific parts or
assemblies that support text and procedures; other EGES 145 Diagnostic Manual
areas in a photo illustration may not be exact. EGES 150 Hard Starting / No Starting
See vehicle manuals and Technical Service Diagnostic Form
Information (TSI) bulletins for additional information. EGED 155 Electronic Diagnostic Form
* Order latest Manual Available.
Technical Service Literature is revised periodically

and mailed automatically to “Revision Service”
subscribers. If a technical publication is ordered, the
latest revision will be supplied.
NOTE: To order technical service literature, contact
your International dealer.
EGES 160 – 1
SERVICE MANUAL
Service Diagnosis repeat failure occurs. This can be prevented if specific

diagnostic action is taken prior to, during and after
Service diagnosis is a systematic procedure of
engine disassembly and during engine reassembly.
investigation to be followed in order to locate
and correct an engine problem. The engine is It is also very important that specific diagnostic tests
first considered as a complete unit in its specific follow engine reassembly prior to and after the engine
application and then the problem is localized to is placed back into service.
components or systems; intake, exhaust, cooling,
Identification of the symptoms which lead to engine
lubrication or injection. Testing procedures will then
failure is the result of proper service diagnosis.
help analyze the source of the problem.
Effective service diagnosis requires use of the
PREREQUISITES FOR EFFECTIVE DIAGNOSIS: following references:
1. Knowledge of the principles of operation for 1. EGES 145 - DT 466E and International®
both the engine and application systems. 530E Diesel Engine Diagnostic Manual.
2. Knowledge to perform and understand all 2. EGED 150 - DT 466E and International®
procedures in the diagnostic and service 530E Hard Start/No Start Diagnostic Manual
manual.
3. EGED 155 - DT 466E and International®
3. Availability of and the ability to use 530E Electronic Diagnostic Form
mechanical and electronic diagnostic test
4. EGES 160 - DT 466E and International®
equipment.
530E Engine Service Manual
4. have available the current Guideline Data for
5. Components Specifications within this
the engine application. (Refer to Diagnostic
manual.
Publications).
6. Service Bulletins.
Although the cause of an engine failure may be
apparent, very often the real cause is not found until a
EGES 160 – 1
SERVICE MANUAL
INTRODUCTION
This manual is arranged in sections, with the pages numbered consecutively in each section. Any photos
or artist renderings are also numbered consecutively in each section. Included at the top of each page is the
Section Title. Section Number and Page Number. The bottom center of each page will show the Manual Form
Number (i.e. EGES 160–1).
NOTE: A dash one (–1) or two (–2) indicates the number of times the basic manual has been revised.
Section
No.
Section Section 1
Title GENERAL
Page 1
Page
No.
E
X
A
M
P
L
E
Form No. EGES 160–1
An index arranged according to sections will be found at the beginning of this manual.
EGES 160 – 1
SERVICE MANUAL
INTRODUCTION – Continued
This manual is divided into three basic parts:
INTRODUCTORY SECTION
COMPONENT SECTIONS
APPENDIX
INTRODUCTORY SECTION
This section addresses the following general subjects which should be read prior to engine repair or overhaul:
Safety Suggestions
Engine Identification
Engine Description
Engine Systems
COMPONENT SECTIONS
These sections address the actual service procedures for each engine component. Each component section
is arranged as follows:
Section Index
Explodes View(s)
Specifications
Special Torque Values
Special Tools
Removal and Reassembly (where applicable)
– Removal
– Cleaning
– Inspection
– Installation
Engine Component Identification (where applicable)
Removal and Reassembly (where applicable)
– Removal
– Cleaning
– Inspection
– Installation
Reconditioning
– Disassembly
– Cleaning
– Inspection
– Repair
– Reassembly
APPENDIX
The appendix is located at the end of the manual and consists of the following:
General Engine Specifications
Component Specifications
Torque Data
Special Service Tool List
English/Metric Conversion Chart
EGES 160 – 1
SERVICE MANUAL
SAFETY Page 1
SAFETY SUGGESTIONS
Keep work area organized and clean. Wipe up oil
spills of any kind. Keep tools and parts off floor.
Eliminate the possibility of a fall which could result
in a serious injury.
Be sure to reinstall safety devices, guards or shields

after adjusting and/or servicing the engine.
After servicing, be sure all tools, parts, or servicing

equipment are removed from the vehicle or engine.
Be sure to wear safe work clothing. It should be well

fitted and in good condition.
Do not wear rings, wrist watches or loose fitting

clothing, when working on machinery, they could
catch on moving parts causing serious injury. Wear
sturdy, rough–soled work shoes. Never adjust and/
or service a machine in bare feet, sandals or sneak-
ers.
Do not use defective portable power tools. Check

for frayed cords prior to using the tool. Be sure all
electric tools are grounded. Severe injury can occur
if electrical equipment is defective or not used prop-
erly.
Be careful when using compressed air. Never apply

compressed air to any part of the body or clothing,
severe injury can occur.
Use approved air blow guns, do not exceed recom-

mended pressure. Wear safety glasses or goggles
and use proper shielding to protect everyone in the
work area.
When refueling, keep the hose and nozzle or the

funnel and container in contact with the metal of the
fuel tank to avoid the possibility of an electric spark
igniting the fuel.
Do not over fill the fuel tank – overflow creates a fire

hazard.
Do not smoke when refueling and never refuel when

the engine is running.
Electric storage batteries give off highly flammable

hydrogen gas when charging and continue to do so
for some time after receiving a steady charge.
Do not under any circumstances allow an electric

spark or open flame near the battery or explosion
may occur.
EGES 160 – 1
SERVICE MANUAL
Page 2 SAFETY
SAFETY SUGGESTIONS – CONTINUED
Always disconnect a battery cable before working
on the electrical system.
Keep a “charged” fire extinguisher within reach

whenever you work in an area where fire may occur.
Also, be sure you have the correct type of extin-

guisher for the situation:
Type A: Wood, Paper, Textile and Rubbish
Type B: Flammable Liquids
Type C: Electrical Equipment
EGES 160 – 1
SERVICE MANUAL
INTRODUCTION SECTION
INTRODUCTION SECTION INDEX
Page
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TURBOCHARGER IDENTIFICATION (Non Wastegate Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TURBOCHARGER IDENTIFICATION (Wastegate Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHASSIS MOUNTED CHARGE AIR COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
THERMOSTAT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OIL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OIL PRESSURE REGULATOR VALVE AND OIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . 13
AIR INDUCTION AND EXHAUST SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
NEGATIVE PRESSURE (VACUUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FUEL SUPPLY PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel System With Front Mounted Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel System With Top Mounted Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INJECTION CONTROL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front Mounted ICP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mid Mounted ICP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL INJECTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FUEL INJECTOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
POPPET VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INTENSIFIER PISTON AND PLUNGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
NOZZLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FILL CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
END OF INJECTION – DRAIN CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Equipped With Chassis Mounted ECM and IDM Units . . . . . . . . . . . . . . . . . . . . . . 28
Engine Equipped With Engine Mounted ECM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LEFT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine Equipped With Chassis Mounted ECM and IDM Units &
Front Mounted Hand Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine Equipped With Chassis Mounted ECM and IDM Units and
Top Mounted Hand Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Engine Equipped With Engine Mounted ECM Unit and
Top Mounted Hand Primer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RIGHT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
EGES 160 – 1
SERVICE MANUAL
Introduction Section
INTRODUCTION Page 1
ENGINE IDENTIFICATION
When in need of parts, always specify the engine
model and serial number.
The permanent engine serial number is stamped on

the left side of engine (2, Figure i.1).
The Engine Emission Label identifies engine model

code and year manufactured. The Emission Label
is located on the top of the valve cover/intake man-
ifold (1, Figure i.1).
Other nameplates, are located, on the turbocharger

and starter. These nameplates, show manufacturer
and specifications and are important to assist oper-
ator or maintenance personnel as to what equip-
ment is on the engine and its operating conditions.
EG–6943
Figure i.1 Engine Serial Number and Emission Label Locations
1. Engine Emission Label 2. Engine Serial Number Stamp
EGES 160 – 1
SERVICE MANUAL
Page 2 INTRODUCTION
ENGINE IDENTIFICATION – CONTINUED
ENGINE SERIAL NUMBER CHART
Engine Identify- Variation Code End Use Code Country of Origin Serial Sequence
ing Code Number
530 H M2 U 0000000*
530 = Engine Identifying Code

H = Diesel, Turbocharged, Air Intercooled and Electronically Controlled
M2 = End Use Code
U = Country of Origin – U.S.A.
0000000* = Starting Sequence Number
EGES 160 – 1
SERVICE MANUAL
INTRODUCTION Page 3
TURBOCHARGER IDENTIFICATION (NON WASTEGATE VERSION)

Refer to Figure i.2.
9 1
10 3
7 6 5
EG–6944
Figure i.2 Non Wastegate Turbocharger Component Locations

1. Navistar Part Number 6. Oil Outlet
2. Turbocharger Serial Number 7. Compressor Housing
3. Turbine Housing 8. Air Intake
4. Exhaust Outlet 9. Compressed Air to Charge Air Cooler
5. Oil Cooled Center Housing 10. Oil Inlet
EGES 160 – 1
SERVICE MANUAL
Page 4 INTRODUCTION
TURBOCHARGER IDENTIFICATION (WASTEGATE VERSION)
10 11 1 2
9
3
5 4
8 7
EG–6945
Figure i.3 Wastegate Turbocharger Component Locations

1. Wastegate Actuator 7. Turbocharger Serial Number
2. Turbine Housing 8. Compressed Air to Charge Air Cooler
3. Exhaust Outlet 9. Air Intake
4. Oil Cooled Center Housing 10. Compressor Housing
5. Oil Outlet 11. Oil Inlet
6. Navistar Part Number
EGES 160 – 1
SERVICE MANUAL
INTRODUCTION Page 5
GENERAL FEATURES
The DT 466E and International® 530E (Figure i.4) RIGHT SIDE (OIL COOLER SIDE)
are inline six cylinder, four (4) cycle water cooled en-
gines. These engines are equipped with a FRONT
turbocharger, overhead valves, air–to–air inter-
cooled with replaceable valve guides and valve
seats for both intake and exhaust. The engine is REAR
fueled by a direct injection fuel system with Elec-
tronic sensors and Hydraulically actuated electroni-
cally controlled Unit Injectors (HEUI). The firing or-
der is 1–5–3–6–2–4.
The crankcase has been especially designed to
withstand the loads of diesel engine operation and
has cast water and oil passages. The crankcase
also has replaceable wet type cylinder sleeves. Ev-
ery main bearing web has angled, drilled holes LEFT SIDE (HIGH PRESSURE PUMP)
EG–6946
which are fitted with jet tubes that direct lube oil, un-
der pressure, to the underside of each piston to help
dissipate heat. Figure i.4 Engine Orientation
The crankshaft is forged steel with induction hard-
ened journals and undercut fillets. It is supported on
seven precision insert bearings. The camshaft is
supported on four pre–reamed bushings and is gear
driven from the crankshaft. The end thrust of the
camshaft is controlled by a thrust flange located be-
tween the front camshaft journal and the cam gear.
Valve lifters have roller followers which provide ex-
cellent camshaft and lifter durability. This helps
minimize engine noise.
The tee pee style connecting rod is constructed of
forged steel. It is attached to the crankshaft, one per
journal. The pistons are cast aluminum alloy and
are fitted with two compression rings and one oil
ring. The piston pin is a free floating type permitting
the pin to move or float freely in the piston and con-
necting rod and is held in place with pin retaining
rings.
A gerotor type lube oil pump is mounted to the front
cover. The pump is driven directly by the crankshaft
at engine speed. All models are equipped with an
oil cooler. The oil cooler has a single spin–on type
oil filter. There is also a spin–on type coolant filter.
The fuel system has a single spin–on type fuel filter
and a pre strainer assembly attached to the fuel filter
header. There is no external oil piping with the ex-
ception of the air compressor, turbocharger, and
high pressure pump piping to cylinder head.
EGES 160 – 1
SERVICE MANUAL
Page 6 INTRODUCTION
GENERAL FEATURES – CONTINUED
CHASSIS MOUNTED CHARGE AIR COOLER
The charge air cooler (Figure i.5) is chassis
mounted in front or next to the radiator. Air from the
turbocharger is pushed through a network of heat
exchanger tubes prior to entering the valve cover/in-
take manifold. Outside air flowing over the tubes
and fins serves to cool the charge air.
The resulting cooler intake air is denser than un-
cooled air, which results in additional air entering the
cylinders so that additional fuel may be injected to
increase output power.
COOLING SYSTEM
DESCRIPTION
The function of the cooling system is to keep the en- Figure i.5 Charge Air Cooler Mounting
gine within a designated temperature range. Major
components of most cooling systems include a ra-
diator and fan combination with a coolant (water)
pump, thermostat, oil cooler, and coolant filter. On
these engines, the water pump is a belt–driven cen-
trifugal type, which is set into the front cover.
This front cover incorporates two separate pas-
sages. One passage to channel coolant to the
crankcase from the water pump, the other is a by-
pass to route coolant back to the water pump when
the thermostat is closed. The thermostat starts to
open at 82° C (180° F) and is fully open at 94° C
(202° F).
Coolant flows from the bottom of the radiator into the
inlet tube of the front cover and onto the water
pump. The coolant is pushed by the impeller of the
water pump, through an internal passage in the front
cover and out to the crankcase.
An internal passageway located in the crankcase di-
rects coolant from front to rear, evenly distributing
coolant to the lower sections of the cylinder sleeves.
The coolant flow is directed toward each cylinder
sleeve on a tangent causing a swirling motion up-
ward towards the cylinder head. This swirling action
improves heat dissipation.
EGES 160 – 1
SERVICE MANUAL
INTRODUCTION Page 7
COOLING SYSTEM – CONTINUED

DESCRIPTION – CONTINUED
Coolant leaves the area around the cylinder sleeves

in the following two ways:
1. The coolant is directed to the oil cooler via an

exterior tube leading to the rear of the oil cooler
header. Coolant flows through passages in the
oil cooler and exits at the water pump to be re–
mixed with incoming coolant from the radiator.
Coolant is supplied to the rear of the air com-
pressor from the left side of the crankcase. Af-
ter the coolant exits at the front of the air com-
pressor, it is returned to the crankcase on the
left side.
EG–5886
Figure i.6 Coolant Flow
EGES 160 – 1
SERVICE MANUAL
Page 8 INTRODUCTION
COOLING SYSTEM – CONTINUED
DESCRIPTION – CONTINUED
2. Coolant exits from the crankcase, through two

cored holes at the top of each side of the cylin-
der sleeve bore and is metered for even dis-
tribution by holes in the head gasket. Coolant
then flows through the cylinder head to the ther-
mostat. The thermostat incorporates two out-
lets to direct coolant either to the radiator when
the engine is at operating temperature, or di-
rectly back to the water pump when the engine
has not yet reached operating temperature.
THERMOSTAT OPERATION
When the engine coolant temperature is below spe-

cified thermostat opening temperature, the coolant
flows through the bypass passage to the water
pump because the radiator outlet port is blocked.
As the engine reaches operating temperature, the
thermostat opens, directing coolant towards the ra-
diator; this also restricts the bypass opening.
LUBRICATION SYSTEM
DESCRIPTION
The lubrication system is pressure regulated,
cooled and full flow filtered. In addition to providing
engine lubrication, pressurized lube oil is used to
control fuel delivery in the hydraulically actuated
electronically controlled unit injectors. External oil
piping is kept to a minimum to avoid oil leakage.
LOCATION
The right side of the engine has an oil cooler, re-
placeable full flow oil filter, turbocharger oil supply EG–6150
line, and road draft tube. The left side of the engine
has the oil filler tube, oil level gauge, high pressure
pump and oil supply manifold. Figure i.7 Thermostat Operation
EGES 160 – 1
SERVICE MANUAL
INTRODUCTION Page 9
LUBRICATION SYSTEM – CONTINUED

OIL FLOW
Refer to Figures i.8 And i.9.
Lube oil is drawn from the oil sump through the pick–
up screen and tube into the oil pump. The oil pump
is of the gerotor type with the inner rotor portion driv-
en directly by the crankshaft. The pump housing is
bolted to the front cover. The pump inlet and outlet
passages are through ports in the pump plate and
front cover ports. Leaving the oil pump, the unfil-
tered oil travels (under pressure) back through the
front cover assembly, passing the high pressure oil
relief valve and into the crankcase unfiltered oil gal-
ley. The high oil pressure relief valve controls unfil-
tered oil pressure at 552 kPa (80 psi). When oil
pressure exceeds 552 kPa (80 psi), the oil pressure
relief valve opens and excess oil is dumped back to
the oil sump.
NOTE: The high pressure oil relief controls un-

filtered oil pressure at 552 kPa (80 psi) maxi-
mum.
There are two oil galleries in the crankcase. The un-

filtered oil travels down the unfiltered oil galley on
the lower right hand side of the crankcase and the
filtered oil galley runs above it. There are two exit
ports in the unfiltered oil galley. One exits to the front
header of the oil cooler and one exits to the rear
header of the oil cooler. The oil cooler thermostat,
located in the rear header, opens or closes by sens-
ing oil temperature in the unfiltered galley. Depend-
ing upon the position of the oil thermostat, hot oil
flows through the oil cooler core into the rear header
and cold unfiltered oil by–passes the oil cooler core
and goes directly to the oil filter.
Oil directed from the unfiltered galley to the filter,

enters from the outside of the element and exits
from the center. The oil filter by–pass valve is lo-
cated within the filter can and operates at a pressure
differential of 124–138 kPa (18–20 psi). The oil filter
element by–pass is effected from within the filter
can. Clean engine oil flows out of the filter and goes
back into the oil cooler header, then out the header
and into the crankcase clean oil galley. The clean
oil enters the crankcase, passes the oil pressure
regulator valve and is directed through various ports
of the crankcase. Excess oil is dumped back into
the crankcase by the regulator valve.
NOTE: The oil pressure regulator valve controls

filtered oil pressure at 345 kpa (50 psi).
EGES 160 – 1
SERVICE MANUAL
Page 10 ENGINE DESCRIPTION
OIL FLOW – CONTINUED
Connecting rod bearings are individually fed
through drilled passages in the crankshaft from
main to rod journals. The camshaft journals are fed
through passages drilled vertically through the main
bearing webs.
Oil is fed from the main bearing webs, through

angled drillings, providing pressurized lube oil to the
piston cooling jets. The valve lever rocker arms are
lubricated through an anulus on the inside of the
rear camshaft bushing bore of the crankcase. Oil
then travels up through the vertical galley in the rear
of the engine, through the banana slot in the head
gasket and up the cylinder head bolt bore into the
rocker arm shaft. Oil continues flowing through dril-
lings located in the shaft of each rocker arm. Oil
drains back to sump through push tube openings in
the cylinderhead.
EG–5889
Figure i.8 Oil Flow
EGES 160–1
SERVICE MANUAL
INTRODUCTION Page 11

Oil from the front of the main galley is routed through
a cast–in passage located in the front of the crank-
case, to the passage in the top of the high pressure
pump reservoir. Oil then flows to the oil reservoir
cast into the front cover, located in front of the high
pressure pump. Oil, as needed, is then drawn by
the high pressure pump through a passage found in
the pump housing. High pressure oil is delivered to
the high pressure supply manifold via an external
hose from the high pressure pump. The high pres-
sure oil reaches the fuel injectors through drillings
in the supply manifold which intersect with the injec-
tor bores.
The turbocharger receives filtered oil through an ex-

ternal tube connected at the rear oil cooler header.
The air compressor (if equipped) also receive oil
through external lines which are connected on the
left side of the crankcase main filtered oil gallery.
This fitting is supplied with oil directly from the main
gallery. The front gear train is splash lubricated by
oil draining from the high pressure reservoir and air
compressor (if equipped) and from a small bleed
slot at the top of the high pressure oil pump reservoir
on the outer front cover.
EGES 160 – 1
SERVICE MANUAL
EG–5891
Figure i.9 Oil Cooler Oil Flow
EGES 160–1
SERVICE MANUAL
ENGINE DESCRIPTION Page 13

OIL PRESSURE REGULATOR VALVE AND OIL
PRESSURE RELIEF VALVE
The unique design of the lubricating oil high pres-
sure relief valve, 552 kPa (80 psi) located in the front
cover (Figure i.10) and the oil pressure regulating
valve [345 kPa (50 psi)], located by the rear oil cool-
er header (Figure i.11), extends the life of the en-
gine because it controls the volume and pressure of
oil supplied to the engine. The volume of oil supplied
by the pump is always in excess of what is needed
to lubricate the engine. The oil high pressure relief
valve is located in the front cover and is used to pro-
tect the oil cooler and oil filter from extremely high
pressures encountered during cold starts in cold
weather. If oil pressure exceeds 552 kPa (80 psi) on
the valve face, it moves the valve inward allowing oil
to travel through the valve and back to the oil pan,
thus relieving pressure in the lubrication system.
The oil pressure regulator valve is located on the

right side of the crankcase, between the oil filter
header and crankcase. When all points of lubrica-
tion within the engine are satisfied, restriction to flow
causes pressure to build on the valve causing it to
move inward. This action allows excess oil to go di-
rectly back to the oil pan, through the ports uncov- EG–5329
ered by the movement of the valve.
Figure i.10 High Pressure Relief Valve Loca-
tion
1. Rear Half of Front Cover
2. Oil High Pressure Relief Valve
3. Crankcase
Figure i.11 Oil Pressure Regulating Valve

Location
1. Oil Cooler Rear Header
2. Oil Pressure Regulating Valve
3. Crankcase
EGES 160 – 1
SERVICE MANUAL
AIR INDUCTION AND EXHAUST SYSTEMS
DESCRIPTION
The intake and exhaust systems consist of those
components that flow filtered air to the engine cylin-
ders and exhaust gases to the atmosphere.
AIR FLOW
The intake system consists of an air cleaner, air to

air cooler, the compressor side of the turbocharger,
valve cover/intake manifold and intake valves. Dur-
ing start up, the air is forced through the air cleaner
by the atmospheric pressure.
The turbocharger is used to increase engine power

output by increasing air supply to the engine. It pro-
vides uniform performance at various operating alti-
tudes. It is an exhaust driven centrifugal air com-
pressor; that allows filtered air to enter at the center
of the compressor housing and forced under pres-
sure to the combustion chamber. After combustion,
hot and expanding exhaust gases move through the
turbine housing causing the turbine wheel to spin.
The turbine wheel drives the compressor wheel
through a common shaft. The turbocharger re-
sponds directly to engine loads. During heavy load,
increased flow of exhaust gases turn the turbine
wheel faster causing the compressor impeller to
turn faster and supply more air (greater boost) to the
intake manifold. Conversely, with light engine load,
flow of exhaust gases decrease and less air is
pumped into the intake manifold.
The air is cooled by a charge air cooler prior to enter-

ing the intake manifold. Air then flows into the com-
bustion chamber where the proper amount of fuel is
injected causing combustion to occur. Exhaust
gases leave the cylinders through exhaust ports
and the exhaust manifold. From the exhaust man-
ifold, the expansion of exhaust gases on the ex-
haust turbine drive the turbocharger and are re-
leased through the exhaust pipe to the atmosphere.
The exhaust system includes exhaust valves, ex-

haust manifold, muffler and exhaust piping. The
turbocharger compressor side is part of the intake
system and turbine side is part of the exhaust sys-
tem.
EGES 160 – 1
SERVICE MANUAL
AIR INDUCTION AND EXHAUST SYSTEMS – CONTINUED

AIR FLOW – CONTINUED
WASTEGATE (IF EQUIPPED)

CHARGE AIR COOLER
Figure i.12 Air Induction/Exhaust System
EGES 160 – 1
SERVICE MANUAL
FUEL SYSTEM
Refer to Figure i.13 or Figure i.14.
LOCATION
The fuel system consists of a chassis mounted fuel
tank, fuel filter strainer, hand primer pump, fuel filter,
fuel supply pump, supply manifold and fuel injec-
tors. All of these items are located on the left side
of engine.
The fuel system provides filtered fuel to the fuel in-

jectors at a regulated pressure. The system also re-
turns warm fuel to the fuel tank.
As fuel travels through the fuel system, it will be un-

der negative pressure (vacuum), supply pump pres-
sure and high pressure (injection pressure).
NEGATIVE PRESSURE (VACUUM)

When the priming pump is pushed down, the check
ball is seated onto the fuel strainer. Releasing the
priming pump unseats the check ball, draws fuel
from the fuel tank to the inlet port of the fuel filter
header and into the fuel strainer assembly. Fuel ex-
its the strainer, flows through the internal passage
of the fuel filter header, via a fuel line to the fuel sup-
ply pump.
Once the engine has been primed, the fuel supply

pump keeps the intermediate fuel system under
pressure and the fuel supply line under negative
pressure for a constant supply of fuel.
FUEL SUPPLY PUMP PRESSURE

The supply pump produces a regulated pressure of
fuel. Fuel now flows from the supply pump to the
fuel filter header. Fuel then travels through an inter-
nal passage into the fuel filter. Fuel passes through
the fuel filter, from the outside of the filter element
to the filter header spud,. Fuel then flows from the
filter header through an external hose or line to the
fuel supply manifold.
HIGH PRESSURE
Fuel in the supply manifold is delivered to drillings
in the cylinder head leading to the injector bores.
The fuel is then pressurized by the injectors. Any
excess fuel is piped from the rear of the supply man-
ifold to the fuel tank.
EGES 160 – 1
SERVICE MANUAL
FUEL SYSTEM – CONTINUED

Fuel System With Front Mounted Primer Pump
INJECTOR FUEL MANIFOLD
RETURN
TO TANK
SUPPLY PUMP
FUEL MANIFOLD INJECTOR
RETURN
FILTERED FUEL
BLEEDER VALVE
UNFILTERED FUEL
HAND PRIMER CHECK BALL

PUMP
SUPPLY PUMP
FUEL INLET
FUEL UNDER NEGATIVE STRAINER

PRESSURE (VACUUM)
FILTER
EG–3769
Figure i.13 Front Mounted Primer Pump Fuel System
EGES 160 – 1
SERVICE MANUAL
Fuel System With Top Mounted Primer Pump
INJECTOR FUEL MANIFOLD
SUPPLY PUMP
FUEL MANIFOLD INJECTOR

FUEL PRESSURE
RETURN VALVE
RETURN
TO TANK
FILTERED FUEL
BLEEDER VALVE
HAND PRIMER
UNFILTERED FUEL
CHECK BALL
SUPPLY PUMP FUEL

UNDER NEGATIVE FUEL INLET
PRESSURE (VACUUM)
STRAINER
FILTER
EG–3770
Figure i.14 Top Mounted Primer Pump Fuel System
EGES 160 – 1
SERVICE MANUAL
INJECTION CONTROL PRESSURE

Refer to Figure i.15 or Figure i.16.
The system utilizes hydraulically actuated, elec-

tronically controlled unit injectors to deliver fuel to
each cylinder. The hydraulic fluid used to actuate
the injectors is engine oil.
Oil is drawn from the oil pan thru the pickup tube by
the engine oil pump. The engine oil pump is a
gerotor type pump driven by the crankshaft. Oil is
fed through passages in the front cover to the oil res-
ervoir.
The reservoir makes available a constant supply of

oil to a high pressure hydraulic pump mounted to the
front cover. The high pressure pump is a gear driv-
en swash plate pump. High pressure oil is delivered
by the high pressure pump to the supply manifold
and into oil passages machined into the cylinder
head.
When an injector is energized, a poppet valve is

opened by an electronic solenoid mounted on the
injector. Oil pressure is allowed to flow into the in-
jector and act on the amplifier piston. When the so-
lenoid is denergized the oil pressure on top of the
amplifier piston is vented by the poppet valve thru
the top portion of the injector.
EGES 160 – 1
SERVICE MANUAL
INJECTION CONTROL PRESSURE – CONTINUED
Front Mounted ICP Sensor
EG–5890
Figure i.15 Front Mounted ICP Sensor
Mid Mounted ICP Sensor
INJECTOR
HIGH PRESSURE MANIFOLD
HIGH PRESSURE PUMP

HOSE
INJECTION PRESSURE
RESERVOIR REGULATOR VALVE EG–3771
Figure i.16 Mid Mounted ICP Sensor
EGES 160 – 1
SERVICE MANUAL

Pressure control in the Injection Control Pressure
System is a closed loop. It is controlled by the Injec-
tion Pressure Regulator (IPR) valve, the Injection
Control Pressure (ICP) sensor and the strategy in
the Electronic Control Module (ECM).
ICP pressure ranges from 3447.4 to 20684.2 kPa

(500 to 3000 psi). The regulator valve is mounted
in the high pressure pump and achieves injection
control pressure regulation by dumping excess oil
into the front cover and back to sump.
Refer to Figure i.17 for the chassis mounted ECM

system or Figure i.18 for the engine mounted ECM
system.
The ECM controls the IPR valve. Desired pressure

control is a variable function of the engine control
strategy and the calibration that has been pro-
grammed into the ECM.
The ICP sensor is mounted on the supply manifold

and provides the feedback signal for the closed loop
control system. The ICP sensor is a ceramic disk
type pressure sensor that converts pressure into a
0 to 5 volt analog signal that the ECM uses to deter-
mine ICP pressure.
A spring/piston pop–off valve is installed internal to

the high pressure pump and is set to dump oil pres-
sure into the front cover in the event ICP pressure
exceeds 27579 kPa (4000 psi).
EGES 160 – 1
SERVICE MANUAL
1 2
ECM IDM
5
ICP
EG–1114
Figure i.17 Chassis Mounted ECM System

1. Electronic Control Module (ECM)
2. Injector Driver Module (IDM)
3. Fuel Injector
4. Injection Pressure Regulator (IPR)
5. Injection Control Pressure Sensor (ICP)
EGES 160 – 1
SERVICE MANUAL
ECM
4
ICP
EG–6947
Figure i.18 Engine Mounted ECM System

1. Electronic Control Module (ECM)
2. Fuel Injector
3. Injection Pressure Regulator (IPR)
4. Injection Control Pressure Sensor (ICP
EGES 160 – 1
SERVICE MANUAL
FUEL INJECTOR ASSEMBLY
The fuel injector is a unitized fuel injector that is hy-

draulically actuated and electronically controlled.
Hydraulic actuation is accomplished when the injec-

tor solenoid is energized opening a poppet valve
and allowing ICP pressure to flow on top of the am-
plifier/accumulator piston.
Fuel is supplied to the injector by passages drilled

through the cylinder head that intersect with fill ports
in the injector. GALLERY
The area under the plunger is filled with fuel from

pressure supplied by the supply pump. As the
plunger moves down the increased pressure closes
the fuel inlet check ball. Pressure continues to rise
opening the nozzle valve, fuel is pressurized thru
the nozzle orifices and injected into the combustion
chamber.
Injection is terminated when the solenoid is dener-

gized and ICP pressure is released. Figure i.19 Fuel Injector Flow
EGES 160 – 1
SERVICE MANUAL
FUEL INJECTOR COMPONENTS

The fuel injector consists of four (4) major compo-
nents described in the following paragraphs:
1
1. Solenoid
2. Poppet Valve
3. Intensifier Piston and Plunger
4. Nozzle Assembly
SOLENOID
The solenoid is a very fast acting electro–magnet, 2
which when energized, pulls the poppet valve off its
seat (Figure i.20).
3
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. When 4
the solenoid is energized, the poppet is quickly lifted
off its seat. The path to drain is closed and the inlet
for high pressure oil is opened (Figure i.20).
5
INTENSIFIER PISTON AND PLUNGER 6
When the poppet valve opens the inlet port, high EG–1075
pressure oil enters the injector and acts on the top
of the intensifier piston. Pressure builds on the in-
Figure i.20 Fuel Injector Components
tensifier, pushing it and the plunger down. The in-
tensifier is seven (7) times larger on the DT 466E, 1. Solenoid
and six (6) times larger on the International) 530E, 2. Poppet Valve
in surface area than the plunger; providing an equal 3. Intensifier Piston
multiplication of force. The downward movement of 4. Check Ball
the plunger pressurizes the fuel in the plunger cav- 5. Nozzle Assembly
ity, causing the nozzle to open (Figure i.20). 6. Nozzle Valve
NOZZLE ASSEMBLY
The nozzle assembly is of conventional design with
the exception of the fill check. This check ball (4,
Figure i.20) seats and seals during the downward
stroke of the plunger to prevent leakage of the high
pressure fuel. During the return stroke, it unseats
allowing the plunger cavity to fill. The nozzle valve
is an inwardly opening type which lifts off its seat
when pressure overcomes the spring force. Fuel is
then atomized at high pressure through the nozzle
tip (6, Figure i.20).
EGES 160 – 1
SERVICE MANUAL
Introdection Section
FUEL INJECTOR OPERATION
Refer to Figures i.21 and i.22.
There are three stages the fuel injector goes
through during operation. They are:
1. Fill cycle
2. Injection
3. End of injection
FILL CYCLE
During pre–injection all internal components have
returned to their spring loaded positions. The pop-
pet valve is blocking high pressure oil from entering
the injector. The plunger and intensifier are at the
top of their bore and the plunger cavity is full of fuel.
Fuel pressure in the plunger cavity is the same as
fuel gallery pressure.
INJECTION
When the ECM determines that the injector should
be fired, the following sequence of events occurs:
1. Engines equipped with chassis mounted
ECM and IDM units: ECM sends a Fuel Deliv-
ery Command Signal (FCDS) to IDM, which
controls an electric current pulse sent to the in-
jector solenoid bank. At the correct time, the
IDM grounds the solenoid through a low–side
driver within the IDM. When the injector has de-
livered the proper amount of fuel, the low–side
driver is opened and the solenoid is denergized.
OR
1. Engines equipped with engine mounted
ECM unit: The ECM sends a FCDS signal to
the injector solenoid.
2. Solenoid is fully energized almost instantly
creating a strong magnetic pull on the armature.
3. Magnetic pull of solenoid overcomes spring
tension holding the poppet closed. EG–1076
4. Poppet is quickly raised off its seat.
5. Upper poppet land closes off path to drain.
6. Lower land opens poppet chamber to incoming
high pressure oil. Figure i.21 Fuel Injector Operation
7. High pressure oil flows around poppet to the top
of intensifier piston.
Pressure on top of intensifier forces it down along

with plunger. Downward movement of plunger
pressurizes fuel in the plunger cavity and nozzle.
When the fuel pressure reaches Valve Opening
Pressure (VOP) the nozzle valve lifts off its seat and
injection begins.
Injection pressures may be as high as 12,411 kPa
(18,000 psi) depending on engine requirements.
EGES 160 – 1
SERVICE MANUAL
FUEL INJECTOR OPERATION – CONTINUED

END OF INJECTION – DRAIN CYCLE
Refer to Figure i.21 and i.22.
Engines equipped with chassis mounted ECM

and IDM units: The end of the injection cycle be-
gins when the ECM terminates the fuel delivery
command signal to the IDM. The IDM then termi-
nates the electric pulse to the solenoid. The follow-
ing events occur:
OR
Engines equipped with engine mounted ECM

unit: The end of the injection cycle begins when the
ECM terminates the fuel delivery command signal
to the IDM solenoid. The following events occur:
1. The magnetic field of the solenoid collapses

and is no longer able to overcome poppet
spring tension to hold the poppet off its seat.
2. The poppet closes, shutting off high pressure oil
from entering the injector.
3. When the poppet is seated, the upper land of
the poppet opens the poppet cavity to drain.
4. Pressurized oil in the intensifier chamber and
poppet chamber flows upward around the pop-
pet seat, through the vent holes in the poppet
sleeve and out the adapter drain hole.
5. The pressure of the fuel and spring in the plung-
er cavity exerts an upward force on the plunger
and intensifier. As the pressure of the pressur-
ized oil above the intensifier drops, so does the
downward force on the intensifier.
6. The upward force from the pressurized fuel al-
most instantly becomes greater than the down-
ward force on the intensifier so the downward
motion of the intensifier and plunger stops.
7. When the plunger stops, fuel flow also stops. EG–1077
8. With the check still open, the remaining pres-
sure on the fuel pushes a tiny amount of addi-
tional fuel out the orifice holes. This causes a
large pressure drop and fuel nozzle pressure
dorps below the VOP. Spring tension on the
nozzle valve now reseats and injection stops. Figure i.22 Fuel Injector Drain Cycle
EGES 160 – 1
SERVICE MANUAL
Introdection Section
COMPONENT LOCATION
FRONT VIEW
Engine Equipped With Chassis Mounted ECM and IDM Units
Refer to Figure i.23 for a front view of an engine equipped with chassis mounted ECM and IDM units.
9
1
8 2
3
5
EG–5320
Figure i.23 Front View Component Location On Engines Equipped With Chassis Mounted ECM
And IDM
1. Fan Pulley 6. Auto Belt Tensioner
2. Front Cover 7. CMP Sensor
3. Vibration Damper 8. Coolant Temperature Sensor
4. Front Engine Mounting Bracket 9. Thermostat
5. Water Pump Pulley
EGES 160 – 1
SERVICE MANUAL
COMPONENT LOCATION – CONTINUED

FRONT VIEW – CONTINUED
Engine Equipped With Engine Mounted ECM Unit
Refer to Figure i.24 for a front view of an engine equipped with an engine mounted ECM unit.
9
1
8
2
4
EG–6948
Figure i.24 Front View Component Location On Engines Equipped With Engine Mounted ECM
1. Fan Pulley 6. Auto Belt Tensioner
2. Front Cover 7. CMP Sensor
3. Vibration Damper 8. Coolant Temperature Sensor
4. Front Engine Mounting Bracket 9. Thermostat
5. Water Pump Pulley
EGES 160 – 1
SERVICE MANUAL
LEFT SIDE VIEW
Engine Equipped With Chassis Mounted ECM and IDM Units & Front Mounted Hand Primer Pump
Refer to Figure i.25 for a left side view of an engine equipped with chassis mounted ECM and IDM units and
horizontal mounted hand primer pump.
16 17 1 2 3
15 4
14 5
13
12 11 10 9 EG–5043
Figure i.25 Left Side View Component Location On Engines Equipped With Chassis Mounted ECM
and IDM Units and Front Mounted Hand Primer Pump
1. 31 – Pin Connector 10. Oil Fill Tube and Oil Level Gauge
2. Valve Cover Wiring Harness Connector 11. Fuel Filter
3. Valve Cover/Intake Manifold 12. Air Compressor (If Equipped)
4. Lifting Eye 13. High Pressure Oil Pump
5. Supply Manifold 14. Engine Oil Temperature Sensor (EOT)
6. Fuel Filter Header 15. Fuel Supply Pump
7. Fuel Strainer 16. Injection Control Pressure Sensor (ICP)
8. Flywheel Housing 17. Wiring Harness
9. Oil Pan
EGES 160 – 1
SERVICE MANUAL

LEFT SIDE VIEW – CONTINUED
Engine Equipped With Chassis Mounted ECM and IDM Units and Top Mounted Hand Primer Pump
Refer to Figure i.26 for a left side view of an engine equipped with chassis mounted ECM and IDM units and
vertical mounted hand primer pump.
18 1 2 3 4
17 5
8
16
15
14
9
13 12 11 10
EG–6949
Figure i.26 Left Side View Component Location On Engines Equipped With Chassis Mounted ECM
and IDM Units and Top Mounted Hand Primer Pump
1. 31 – Pin Connector 10. Oil Pan
2. Valve Cover Wiring Harness Connector 11. Oil Fill Tube and Oil Level Gauge
3. Supply Manifold 12. Fuel Filter
4. Valve Cover/Intake Manifold 13. Air Compressor (If Equipped)
6. Hand Primer Pump 15. Fuel Supply Pump
7. Fuel Filter Header 16. Engine Oil Temperature Sensor (EOT)
8. Fuel Strainer 17. Injection Control Pressure Sensor (ICP)
9. Flywheel Housing 18. Wiring Harness
EGES 160 – 1
SERVICE MANUAL
LEFT SIDE VIEW – CONTINUED
Engine Equipped With Engine Mounted ECM Unit and Top Mounted Hand Primer Pump
Refer to Figure i.27 for a left side view of an engine equipped with an engine mounted ECM unit and vertical
mounted hand primer pump.
1 2 3 4 5 6 7
16
15
14 13 12 11 10
EG–6950
Figure i.27 Left Side View Component Location On Engines Equipped With Engine Mounted ECM
Unit and Top Mounted Hand Primer Pump
1. Electronic Control Module (ECM) 9. Fuel Filter Header
2. ECM Connector 10. Flywheel Housing
3. Manifold Absolute Pressure Sensor (MAP) 11. Oil Pan
4. Injection Control Pressure Sensor (ICP) 12. Oil Fill Tube and Oil Level Gauge
5. Supply Manifold 13. Fuel Filter
6. Valve Cover/Intake Manifold 14. Engine Oil Pressure Sensor (EOP)
8. Hand Primer Pump 16. Fuel Supply Pump
EGES 160 – 1
SERVICE MANUAL

REAR VIEW
Refer to Figure i.28 for a rear view of an engine equipped with chassis mounted ECM and IDM units.
6 1
4 3
EG–5005
Figure i.28 Rear View Component Location On Engines Equipped With Chassis Mounted ECM
and IDM Units
1. Road Draft Tube 4. Flywheel
2. Turbocharger Assembly 5. Oil Fill Tube and Oil Level Gauge
3. Flywheel Housing 6. Lifting Eye (2)
EGES 160 – 1
SERVICE MANUAL
REAR – CONTINUED
Refer to Figure i.29 for a rear view of an engine equipped with engine mounted ECM and unit.
6 1
4 3
EG–6951
Figure i.29 Rear View Component Location On Engines Equipped With Engine Mounted ECM Unit
1. Road Draft Tube 4. Flywheel
2. Turbocharger Assembly 5. Oil Fill Tube and Oil Level Gauge
3. Flywheel Housing 6. Lifting Eye (2)
EGES 160 – 1
SERVICE MANUAL

RIGHT SIDE VIEW
Refer to Figure i.30 for a right side view of an engine equipped with chassis mounted ECM and IDM units.
1
2
12
11
3
10
5
6
8
7
EG–5319
Figure i.30 Right View Component Location On Engines Equipped With Chassis Mounted ECM
and IDM Units
1. Valve Cover/Intake Manifold 7. Oil Pan

2. Lifting Eye (2) 8. Oil Filter
3. Alternator Bracket 9. Flywheel Housing
4. Coolant Filter 10. Road Draft Tube
5. Water Inlet 11. Exhaust Manifold
6. Oil Cooler 12. Turbocharger Assembly
EGES 160 – 1
SERVICE MANUAL
RIGHT SIDE VIEW – CONTINUED
Refer to Figure i.31 for a right side view of an engine equipped with engine mounted ECM unit.
13 1 2 3
12
11
6
10
9 8 7
EG–6952
Figure i.31 Right View Component Location On Engines Equipped With Engine Mounted ECM
Unit
1. Valve Cover/Intake Manifold 8. Oil Pan

2. Manifold Absolute Pressure Sensor (MAP) 9. Oil Filter
3. Lifting Eye (2) 10. Flywheel Housing
4. Alternator Bracket 11. Road Draft Tube
5. Coolant Filter 12. Exhaust Manifold
6. Water Inlet 13. Turbocharger Assembly
7. Oil Cooler
EGES 160 – 1
SERVICE MANUAL
MOUNTING ENGINE ON STAND
SECTION 1 INDEX
Page

REMOVING TURBOCHARGER OIL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVING COOLANT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVING OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVING ROAD DRAFT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MOUNTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EGES 160 – 1
SERVICE MANUAL
Section 1
MOUNTING ENGINE ON STAND Page 1
SPECIAL TORQUE VALUES

Oil Pan Drain Plug 68 Nm (50 lb–ft.)
SPECIAL SERVICE TOOLS
TOOL NUMBER DESCRIPTION

ZTSE4151 Adapter Plate
OEM4137 Engine Turn–Over Stand
ZTSE4296 Turbocharger Intake Cap Set
EGES 160 – 1
SERVICE MANUAL
Section 1
Page 2 MOUNTING ENGINE ON STAND
REMOVING TURBOCHARGER OIL
LINES
Perform the following steps before installing engine
to mounting stand:
1. Remove oil pan drain plug and plug gasket.
Drain all engine oil and discard gasket.
2. Reinstall oil pan drain plug together with new
plug gasket. Refer to the special torque value.
3. Using an open end wrench, loosen
turbocharger oil feed supply tube nut, located
on top of oil filter header. Remove and discard
tube nut sleeve (Figure 1.1).
4. Remove two (2) mounting bolts securing oil
feed supply tube to top of turbocharger center
housing. Remove oil feed supply tube and tube
EG–5026
flange gasket. Discard flange gasket (Figure
1.2). Figure 1.1 Loosen Oil Supply Tube Nut
EG–5027
Figure 1.2 Remove Oil Feed Supply Tube
EGES 160 – 1
SERVICE MANUAL
Section 1
REMOVING TURBOCHARGER OIL

LINES – CONTINUED
5. Remove turbocharger oil drain tube as follows:

(Refer to Figure 1.3)
a. Remove one bolt securing turbocharger oil

drain tube retaining plate to crankcase.
b. Remove two (2) capscrews securing turbo–

charger oil drain tube to bottom of
turbocharger housing.
c. Remove turbocharger oil drain tube retain-

ing plate together with turbocharger oil drain
tube, tube flange, two tube O–Rings and
tube flange gasket from bottom of
turbocharger assembly. Discard both drain
tube O–Rings (one on each end of drain
tube) and flange gasket.
d. Cap ALL openings on the turbocharger as-

sembly. Use ZTSE 4296 turbocharger in-
take cap set.
NOTE: If plastic caps are not available, use duct

tape to cover openings. EG–5028
Figure 1.3 Remove Oil Drain Tube
REMOVING TURBOCHARGER
Remove four nuts securing turbocharger assembly

to exhaust manifold flange (Figure 1.4).
Remove turbocharger assembly and gasket from

engine. Discard gasket.
EG–5029
IMPORTANT
SUPPORT TURBOCHARGER ASSEMBLY DUR-
ING REMOVAL OF MOUNTING HARDWARE TO Figure 1.4 Remove Turbocharger Mounting
PREVENT DAMAGE. Nuts
EGES 160 – 1
SERVICE MANUAL
Section 1
REMOVING OIL FILTER
Remove oil filter from oil cooler filter header. Dis-
card oil fiter (Figure 1.5).
REMOVING COOLANT FILTER

Remove coolant filter from header. Discard old
coolant filter (Figure 1.6).
EG–5035
Figure 1.5 Remove Oil Filter
EG–5033
Figure 1.6 Remove Coolant Filter
EGES 160 – 1
SERVICE MANUAL
Section 1
REMOVING OIL COOLER ASSEMBLY

NOTE: Remove oil cooler and water coolant
supply tube as an assembly.
1. Remove one (1) bolt and retainer plate securing

water coolant supply tube from crankcase (Fig-
ure 1.7).
2. Remove mounting hardware securing oil cooler
assembly to crankcase (Figure 1.7).
1
3
2
3
EG–5037
Figure 1.7 Remove Oil Cooler Mounting Hardware
1. Retainer Plate and Mounting Bolt

2. Oil Cooler
3. Oil Cooler Mounting Hardware
3. Remove oil cooler and water coolant supply

tube as an assembly from crankcase and dis-
card O–Rings (Figure 1.8).
EG–5039
Figure 1.8 Remove Oil Cooler
EGES 160 – 1
SERVICE MANUAL
Section 1
REMOVING OIL COOLER ASSEMBLY –
CONTINUED
4. Remove oil pressure regulating valve assembly
from the crankcase. Depress valve plunger and
insert a copper wire, release plunger to trap
wire in the valve. Pull out (Figure 1.9).
IMPORTANT
THE OIL PRESSURE REGULATING VALVE
SHOULD BE TAGGED UPON REMOVAL TO EN-
SURE IDENTIFICATION. DO NOT MIX OIL PRES-
SURE REGULATOR VALVE WITH HIGH OIL
PRESSURE RELIEF VALVE (FOUND IN FRONT
COVER). EG–5041
Figure 1.9 Remove Oil Pressure Regulating

Valve
REMOVING ROAD DRAFT TUBE

1. Remove two (2) bolts securing road draft tube
to crankcase (Figure 1.10).
2. Pull road draft tube out from valve cover/intake
manifold and away from crankcase.
EG–6808
Figure 1.10 Remove Road Draft Tube
EGES 160 – 1
SERVICE MANUAL
Section 1
MOUNTING ENGINE
1. Cap ALL openings to prevent debris from en-
tering.
CAUTION
WHENEVER MOUNTING AN ENGINE TO A RE-
PAIR STAND, REFER TO THE INSTRUCTIONS
INCLUDED WITH THE MOUNTING STAND AND
ITS CORRESPONDING ADAPTER PLATES FOR
SPECIFIC DIRECTIONS ON THEIR SAFE USE.
USE ONLY METRIC M–10/GRADE 8 BOLTS
WHEN MOUNTING THE ENGINE TO AN ENGINE
STAND.
EG–5044
2. Install recommended adapter plate ZTSE 4151

as directed. Refer to instructions included with
Figure 1.11 Attach Adapter Plate
engine stand OEM4137 and secure adapter
plate to side of engine (Figure 1.11).
SERVICE NOTE: Adapter plate must be
mounted to engine first before installing engine
stand. Locating guide pins (made locally) are
recommended to assist in aligning and holding
adapter plate.
CAUTION
CAUTION SHOULD BE USED WHEN HOISTING
THE ENGINE TO THE STAND TO AVOID DAM-
AGE TO VALVE COVER/INTAKE MANIFOLD.
USE A SAFETY CATCH ON THE HOIST HOOK
WHEN LIFTING THE ENGINE BY THE LIFTING
EYES.
EG–5047
3. Attach engine stand to adapter plate (Figure Figure 1.12 Attach Engine Stand To Adapter
1.12). Plate
EGES 160 – 1
SERVICE MANUAL
TURBOCHARGERS
SECTION 2 INDEX
Page
TURBOCHARGER PIPING (NON WASTEGATE VERSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TURBOCHARGER PIPING (WASTEGATE VERSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger And Related Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TURBOCHARGER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PRE–DISASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHECK FOR FREE ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHECK FOR TURBINE/COMPRESSOR WHEEL HOUSING RUB . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CHECK AXIAL END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CHECK WASTEGATE ACTUATOR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EGES 160 – 1
SERVICE MANUAL
Section 2
TURBOCHARGERS Page 1
TURBOCHARGER PIPING (NON WASTEGATE VERSION)

Refer to Figure 2.1 for non wastegate turbocharger and common parts.
15
EG–6162
Figure 2.1 Non Wastegate Turbocharger Piping

1. Turbocharger Assembly 9. Turbo Oil Drain Tube
2. Turbo Oil Inlet Tube Flange Gasket 10. Turbo Oil Drain Tube O–Ring
3. Turbo Oil Inlet Tube Flange Bolt (2) 11. Turbo Oil Drain Tube Retaining Bracket
4. Turbocharger Assembly Gasket 12. Turbo Oil Drain Tube Retaining Bracket
5. Turbocharger Assembly Mounting Nuts (4) Mounting Bolt
6. Turbo Oil Drain Tube Flange Gasket 13. Turbo Oil Drain Tube Flange Bolt (2)
7. Turbo Oil Drain Tube Flange 14. Turbo Oil Inlet Tube Assembly
8. Turbo Oil Drain Tube Flange O–Ring 15. Tube Mounting Nut
EGES 160 – 1
SERVICE MANUAL
Section 2
Page 2 TURBOCHARGERS
TURBOCHARGER PIPING (WASTEGATE VERSION)
Refer to Figure 2.2 for wastegate turbocharger and common parts.
15
EG–6163
Figure 2.2 Wastegate Turbocharger Piping

1. Turbocharger Assembly 9. Turbo Oil Drain Tube
2. Turbo Oil Inlet Tube Flange Gasket 10. Turbo Oil Drain Tube O–Ring
3. Turbo Oil Inlet Tube Flange Bolt (2) 11. Turbo Oil Drain Tube Retaining Bracket
4. Turbocharger Assembly Gasket 12. Turbo Oil Drain Tube Retaining Bracket
5. Turbocharger Assembly Mounting Nuts (4) Mounting Bolt
6. Turbo Oil Drain Tube Flange Gasket 13. Turbo Oil Drain Tube Flange Bolt (2)
7. Turbo Oil Drain Tube Flange 14. Turbo Oil Inlet Tube Assembly
8. Turbo Oil Drain Tube Flange O–Ring 15. Tube Mounting Nut
EGES 160 – 1
SERVICE MANUAL
Section 2
SPECIFICATIONS
Turbine Shaft Axial End Play 0.02–0.10 mm (0.001–0.004 in.)
Turbine Shaft Radial Shaft Movement (Play) 0.08–0.15 mm (0.003–0.006 in.)
Wastegate Actuator Movement 0.369 mm at 196 kPa (.015 in. at 28.5 psi)

Back Plate–to–Center Housing Capscrews 21–24 Nm (185–215 lb–in.)
Center Housing–to–Turbine Housing Capscrews 13.5 Nm (115 lb–in.)
Center Housing–to–Compressor Housing Capscrews 21–24 Nm (185–215 lb–in.)
Compressor Wheel (Non–Wastegate Turbocharger) (See NOTE) 13.5–15.2 Nm (115–135 lb–in.)
Compressor Wheel (Wastegate Turbocharger) (See NOTE) 10–12.5 Nm (90–111 lb–in.)
Turbocharger Mounting Nuts 66 Nm (49 lb–ft.)
NOTE: Apply clean engine oil to threads of bolt.

ZTSE4296 Turbocharger Intake Cap Set
EGES 160 – 1
SERVICE MANUAL
Section 2
GENERAL OPERATION
TURBOCHARGER
The turbocharger assembly is an exhaust–driven
centrifugal air compressor. Its purpose is to in-
crease power output by supplying compressed air
to the engine. The center housing is oil and air
cooled. Engine oil is circulated through the center
housing which acts as a heat barrier between the
“hot” turbine and the “cold” compressor. Bearings
are sleeve–type and are lubricated by engine oil. Oil
is pumped directly from the clean–oil side of the oil
filter, thru the turbocharger oil feed supply tube, then
circulated in the center housing of the turbocharger
and returned to the engine through an oil drain tube.
High velocity engine exhaust gases drive the tur-

bine shaft assembly to speeds over 100,000 revolu-
tions per minute. Filtered air entering the compres-
sor side of the turbocharger is compressed and
delivered to the engine valve cover/intake manifold
at a pressure higher than atmospheric pressure.
Because more air is delivered to the intake man-
ifold, the result is more power, fuel efficiency and the
ability to maintain power at altitude.
COMPONENT IDENTIFICATION
The turbine wheel is located in the turbine housing;
the compressor impeller is located at the opposite
end on a common shaft that connects the turbine
wheel and impeller.
EGES 160 – 1
SERVICE MANUAL
Section 2
GENERAL OPERATION – CONTINUED

COMPONENT IDENTIFICATION – CONTINUED
Turbocharger And Related Parts Location
Refer to Figure 2.3 for turbocharger and common parts location.
1
9 10 2
8 3
4
5
EG–5319
Figure 2.3 Turbocharger And Related Parts Location

1. Compressor Outlet 6. Oil Filter Header
2. Front Exhaust Manifold 7. Turbocharger Oil Supply Tube
3. Compressor Inlet 8. Turbocharger Exhaust Outlet
4. Turbocharger Oil Drain Tube 9. Rear Exhaust Manifold
5. Turbocharger Assembly 10. Center Exhaust Manifold
EGES 160 – 1
SERVICE MANUAL
Section 2
REMOVAL
TURBOCHARGER REMOVAL
1. Using an open end wrench, loosen and remove
oil feed supply tube nut located on top of oil filter
header. Remove and discard tube nut O–Ring
(Figure 2.4).
2. Remove two capcrews securing oil feed supply
tube to top of turbocharger housing (Figure
2.5).
3. Remove oil feed supply tube and tube flange
gasket from turbocharger assembly. Discard
flange gasket.
4. Cap oil feed supply tube fitting located on filter
header.
EG–5026
Figure 2.4 Loosen Oil Feed Supply Tube Nut
EG–5027
Figure 2.5 Remove Oil Feed Supply Tube

Capscrews
EGES 160 – 1
SERVICE MANUAL
Section 2
REMOVAL – CONTINUED
TURBOCHARGER REMOVAL – CONTINUED

5. Remove turbocharger oil drain tube as follows:
a. Loosen capscrew securing turbocharger oil
drain tube retaining plate to crankcase. Re-
move retaining plate and capscrew.
b. Remove two capscrews securing
turbocharger oil drain tube to bottom of
turbocharger housing.
c. Remove turbocharger oil drain tube retain-
ing plate together with turbo oil drain tube,
tube flange, two tube O–Rings and tube
flange gasket from bottom of turbocharger
assembly. Discard both drain tube O–Rings
(one on each end of drain tube) and flange
gasket.
6. Cap ALL openings on turbocharger assembly.
Use turbocharger intake cap set ZTSE4296.
NOTE: If plastic caps are not available, use duct
tape to cover openings.
7. Remove four nuts securing turbocharger as-

sembly to exhaust manifold flange. Refer to
Figure 2.7.
8. Remove turbocharger assembly and gasket
from engine. Discard gasket. EG–5028
IMPORTANT Figure 2.6 Remove Turbocharger Oil Drain

SUPPORT TURBOCHARGER ASSEMBLY DUR- Tube
ING REMOVAL OF MOUNTING HARDWARE TO
PREVENT DAMAGE.
EG–5029
Figure 2.7 Remove Turbocharger
EGES 160 – 1
SERVICE MANUAL
Section 2
INSPECTION
CLEANING
Clean these components as follows:
IMPORTANT
DO NOT USE A CAUSTIC SOLUTION ON
TURBOCHARGER OR TUBES.
1. Thoroughly clean the piping connecting the air

cleaner to the turbocharger with soap and wa-
ter. Dry with filtered compressed air.
2. Remove the vehicle mounted air cleaner and
clean inside the air cleaner element housing.
(Helps prevent turbocharger or engine failure.)
3. Clean air inlet piping and connecting hoses with
filtered compressed air.
4. Inspect oil inlet tube and oil drain tube for re-
strictions. Clean with a suitable solvent and a
nylon brush. Dry using filtered compressed air.
PRE–DISASSEMBLY INSPECTION
Make the following checks and if the turbocharger
meets these requirements, it can be considered sat-
isfactory and reinstalled on the engine. If it does not
meet the requirements, it must be replaced or re-
built. Refer to Reconditioning, in this section.
EGES 160 – 1
SERVICE MANUAL
Section 2
INSPECTION – CONTINUED
VISUAL INSPECTION
IMPORTANT
DO NOT ATTEMPT TO STRAIGHTEN BENT
WHEEL BLADES.
Visually inspect the compressor impeller and tur-

bine wheel for blade erosion, bending, breakage or
deposits. Replace as required.
NOTE: Compressor impeller and turbine wheel

deposits can be caused by the following:
HIGH AIR INLET RESTRICTION – which allows oil

to transfer from the turbocharger center housing, re-
sulting in oil deposits.
EXCESSIVE OIL CONSUMPTION – resulting in

turbine wheel carbon deposits.
ENGINE OVERFUELING – can result in excessive

operating temperatures which can cause aluminum
components to melt. Such deposits may be found
on the turbine wheel if such a failure occurs.
Visually inspect the turbine and compressor hous-

ings for evidence of wheel rubbing. Replace the
housing(s) as required.
CHECK FOR FREE ROTATION

1. Stand the turbocharger on bench with shaft in a
horizontal position.
2. Wheels must spin freely when turned by hand.
EGES 160 – 1
SERVICE MANUAL
Section 2
CHECK FOR TURBINE/COMPRESSOR WHEEL
HOUSING RUB
Refer to Figure 2.8.
1. Visually inspect the turbine and compressor

housing for any contact.
2. Rotate shaft and check for any rubbing within
the housings.
EG–5907
CHECK AXIAL END PLAY

Figure 2.8 Checking Turbine/Compressor
1. Clamp turbocharger mounting flange in a vise Wheel Housing Rub
and position a dial indicator with a magnetic
base on the frame of the vise. Place the tip of
the indicator on the turbine end of the shaft.
2. Move the shaft back and forth by hand and re-
cord the readings.
3. If the reading exceeds the specifications, the
turbocharger must be reconditioned.
5 1
CHECK WASTEGATE ACTUATOR (IF 6 3

EQUIPPED)
1. Clamp turbocharger mounting flange in a vise

and position a dial indicator with a magnetic
base on the frame of the vise. Place the tip of 4
the indicator onto the actuator lever.
2. Connect an air hose to a 207 kPa (30 psi) pres- EG–5908
sure regulator.
Figure 2.9 Checking Wastegate Actuator
3. Using a hose, connect the pressure regulator to
the wastegate actuator. Measure actuator rod 1. Wastegate Housing
travel. 2. Turbine Housing
3. Wastegate Actuator Shaft
4. Gradually apply air pressure to 197 kPa (28.5 4. Air Pressure Regulator
psi). Refer to Specifications for actuator move- 5. Dial Indicator
ment tolerance. 6. Magnetic Base Stand
EGES 160 – 1
SERVICE MANUAL
Section 2
DISASSEMBLY
Mark the compressor housing location to the back
plate to aid in reassembly (Figure 2.10).
CAUTION
REORIENTATION OF COMPRESSOR HOUSING
ON VEHICLE WILL DAMAGE COMPRESSOR
HOUSING O–RING.
NOTE: The disassembly procedure is the same

for the wastegate and non wastegate turbochar-
gers except where noted.
Disassemble turbocharger as follows:
1. Wastegate Turbocharger Only: Remove two EG–5425
(2) hose clamps on the hose connecting the tur- Figure 2.10 Mark Compressor/Backplate
bine side of the turbocharger to the wastegate Location
actuator. Remove hose (Figure 2.11).
2. Wastegate Turbocharger Only: Remove re-
taining clip to disengage wastegate actuator
arm (Figure 2.12).
EG–5421
Figure 2.11 Remove Hose Clamp
EG–5422
Figure 2.12 Remove Retaining Clip

1. Retaining Clip
EGES 160 – 1
SERVICE MANUAL
Section 2
DISASSEMBLY – CONTINUED
3. Wastegate Turbocharger Only: Remove
three (3) bolts securing wastegate actuator arm
bracket to center housing. Remove actuator
bracket arm (Figure 2.13).
4. Remove six (6) bolts securing compressor
housing to backplate. Remove clamps (Figure
2.14). Remove compressor housing.
5. Remove O–Ring from backplate (Figure 2.15).
EG–5424
Figure 2.13 Remove Wastegate Actuator

Arm
EG–5427
Figure 2.14 Remove Compressor Housing
EG–5428
Figure 2.15 Remove Backplate O–Ring

1. Backplate
2. O–Ring
EGES 160 – 1
SERVICE MANUAL
Section 2
6. Mark turbine and center housing (Figure 2.16).
7. Remove four (4) bolts securing center housing
to turbine housing (Figure 2.17).
8. Wastegate Turbocharger Only: Mark the
wastegate housing and the turbine housing.
Remove six (6) bolts securing wastegate hous-
ing to turbine housing. Remove housing (Fig-
ure 2.18).
EG–5429
Figure 2.16 Mark Turbine/Center Housing
EG–5430
Figure 2.17 Remove Turbine Housing
EG–5432
Figure 2.18 Remove Wastegate Housing
EGES 160 – 1
SERVICE MANUAL
Section 2
9. Flip actuator arm and observe check valves for
cracks or wear (Figure 2.19).
REASSEMBLY
1. Align marks of the compressor housing to back-
plate. Attach compressor housing to the back-
plate.
2. Install wastegate actuator bracket with actuator
EG–5433
arm and diaphragm attached to center housing.
Secure with three (3) bolts, if equipped. Tighten Figure 2.19 Checking Wastegate Valves
to standard torque (Figure 2.20).
3. Connect wastegate actuator arm to wastegate
and install retaining clip, if equipped.
4. Align marks of the wastegate and turbine hous-
ing. Attach wastegate housing to turbine hous-
ing and secure with six (6) bolts. Tighten bolts
(Figure 2.21).
EG–5423
Figure 2.20 Install Wastegate Actuator Brack-

et
EG–5431
Figure 2.21 Install Wastegate Cover
EGES 160 – 1
SERVICE MANUAL
Section 2
REASSEMBLY – CONTINUED
5. Align marks of the turbine and center housing.
Attach turbine housing to center housing. Se-
cure with four (4) bolts and tighten to special
torque value (Figure 2.22).
6. Using six (6) bolts and two (2) clamps secure
compressor housing to backplate. Tighten to
the special torque value (Figure 2.23).
IMPORTANT
WASTEGATE TURBOCHARGERS ONLY: USE A
NEW ACTUATOR HOSE WHEN REASSEMBL-
ING TURBOCHARGER.
EG–5430
7. Wastegate Turbocharger Only: Attach hose
from the compressor side of the turbocharger to Figure 2.22 Installing Turbine Housing
the wastegate actuator. Secure hose with two
(2) hose clamps (Figure 2.23).
EG–5426
Figure 2.23 Installing Compressor Housing
EGES 160 – 1
SERVICE MANUAL
Section 2
INSTALLATION
1. Install turbocharger assembly onto a clean ex-
haust manifold flange as follows:
a. Install a new gasket on the exhaust manifold
flange.
b. Attach turbocharger assembly over gasket
on exhaust manifold flange and tighten nuts
to the specified torque value (Figure 2.24).
2. Install the turbocharger oil feed supply tube as
follows (Figure 2.25):
a. Remove the protective caps from the oil in-
let port at the turbocharger and from oil feed
supply tube fitting located on oil filter head-
er.
b. Pour five ounces of clean engine oil into the
oil inlet opening of the turbocharger. This
will provide sufficient lubrication for the EG–5029
turbocharger bearings until engine oil pres-

sure is obtained. Figure 2.24 Installing Turbocharger
c. Position a new gasket at the turbocharger

oil inlet port.
d. Install oil feed supply tube to turbocharger
and secure using two mounting capscrews.
EG–5027
Figure 2.25 Installing Oil Feed Tube
EGES 160 – 1
SERVICE MANUAL
Section 2
INSTALLATION – CONTINUED
e. Install a new rubber seal ring at the oil feed
supply tube connector nut.
f. Install oil feed supply tube onto tube fitting
and secure with connector nut (Figure
2.26).
3. Install turbo oil drain tube as follows (Figure
2.27):
a. Remove protective cap from oil drain port on
turbocharger.
b. Lubricate two new O–Rings with engine oil
and install one on each end of turbo oil drain
tube.
c. Position turbo oil drain tube together with
new O–Rings, tube flange and flange gas- EG–5026
ket onto turbocharger oil drain port.
d. Secure turbo oil drain tube gasket to Figure 2.26 Securing Oil Feed Tube
turbocharger and tighten bolts.
4. Install loose end of turbocharger oil drain tube

into crankcase and secure with retaining plate
and one capscrew.
EG–5028
Figure 2.27 Installing Oil Drain Tube
EGES 160 – 1
SERVICE MANUAL
MANIFOLDS
SECTION 3 INDEX
Page
EXPLODED VIEW OF EXHAUST MANIFOLD AND GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHARGE AIR COOLER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VALVE COVER/INTAKE MANIFOLD IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Old Style And New Style Breather Element Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ROAD DRAFT TUBE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EGES 160 – 1
SERVICE MANUAL
Section 3
MANIFOLDS Page 1
EXPLODED VIEW OF EXHAUST MANIFOLD AND GASKET

Refer to Figure 3.1 for the components which make up the exhaust manifold.
Figure 3.1 Exhaust Manifold Components

1. Exhaust Manifold Gasket
2. Front Exhaust Manifold
3. Center Exhaust Manifold
4. Rear Exhaust Manifold
CHARGE AIR COOLER PIPING

Figure 3.2 Charge Air Cooler Piping

NOTE: Intercooler and connecting hardware is chassis mounted. Refer to the appropriate chassis
and parts publications for detailed information.
EGES 160 – 1
SERVICE MANUAL
Section 3
Page 2 MANIFOLDS
VALVE COVER/INTAKE MANIFOLD IDENTIFICATION
Old Style And New Style Breather Element Locations
Refer to Figure 3.3 for the location of the old style and new style breather elements.
NEW STYLE BREATHER ELEMENTS
BREATHER ELEMENTS
OLD STYLE BREATHER ELEMENTS EG–7218
Figure 3.3 Underside Of Old Style And New Style Valve Cover/Intake Manifolds
EGES 160 – 1
SERVICE MANUAL
Section 3
MANIFOLDS Page 3
SPECIFICATIONS
Intake Manifold
Maximum Allowable Warpage 0.254 mm (0.010 in.)
Exhaust Manifold
Maximum Allowable Removal of Material 0.635 mm (0.025 in.)
Flange Thickness (Minimum) 18.41 mm (0.725 in.)

Exhaust Manifold Bolts 81 Nm (60 lb–ft.)
Valve Cover/Intake Manifold Bolts 18 Nm (13 lb–ft or 156 lb–in.)

No special service tools required.
EGES 160 – 1
SERVICE MANUAL
Section 3
Page 4 MANIFOLDS
MISCELLANEOUS REMOVAL
Refer to the appropriate section for removal of these
components.
Turbocharger Oil Feed Supply Tube, if required
Turbocharger Oil Drain Tube, if required
Turbocharger, if required
Engine Mounted ECM Unit and Mounting Bracket,
if equipped
Engine Wiring Harness
ROAD DRAFT TUBE REMOVAL

1. Remove two (2) bolts securing road draft tube
to crankcase (Figure 3.4).
2. Pull road draft tube out from valve cover/intake
manifold and crankcase.
EG–6808
EXHAUST MANIFOLD
Figure 3.4 Road Draft Tube Removal
REMOVAL
1. Remove twelve (12) mounting bolts securing
the three piece exhaust manifold sections to
cylinder head (Figure 3.5).
2. Remove exhaust manifold and one piece gas-
ket.
CLEANING
1. The exhaust manifold is a three piece assembly
and may be cleaned with a suitable non–caustic
EG–6848
solvent or steam cleaned.
2. After cleaning, blow dry using filtered com-
pressed air. Figure 3.5 Exhaust Manifold Removal
EGES 160 – 1
SERVICE MANUAL
Section 3
MANIFOLDS Page 5
EXHAUST MANIFOLD – CONTINUED

INSPECTION
1. Visually inspect exhaust manifold for cracks.
Replace as required.
2. Inspect for warpage as follows (Figure 3.6):
a. Install exhaust manifold to cylinder head
WITHOUT GASKET. Tighten bolts to the
special torque value.
b. Using a 0.25 mm (.010 in.) feeler gauge,
measure gap between bolts at manifold
flange to cylinder head mating surface.
c. If feeler gauge will pass through, exhaust
manifold requires resurfacing.
IMPORTANT
A MAXIMUM OF 0.64 MM (0.025 IN.) MATERIAL EG–6841
CAN BE GROUND OFF TO CORRECT WARP-
AGE.
3. If warpage cannot be corrected by grinding, re-

place exhaust manifold. Figure 3.6 Checking Exhaust Manifold For
Cracks And Warpage
INSTALLATION
1. Install exhaust manifold as follows:
a. Apply “Never–Seez” to the bolts.
b. Install assembled exhaust manifold with
gasket to cylinder head.
c. Assure gasket alignment with bolt holes and
install twelve (12) “prevailing torque” bolts.
IMPORTANT
BE SURE EXHAUST MANIFOLD GASKET AND
EXHAUST MANIFOLD ARE ALIGNED BEFORE
EG–6847
TIGHTENING BOLTS.
d. Tighten bolts to the special torque value

(Figure 3.7). Figure 3.7 Installing Exhaust Manifold
EGES 160 – 1
SERVICE MANUAL
Section 3
Page 6 MANIFOLDS
VALVE COVER/INTAKE MANIFOLD
REMOVAL 1
IMPORTANT 2
BE SURE THE ROAD DRAFT TUBE HAS BEEN
REMOVED FROM THE VALVE COVER/INTAKE
MANIFOLD. IF IT HAS NOT, REFER TO “DRAFT
TUBE REMOVAL”.
3
NOTE: If engine is equipped with an engine
mounted Electronic Control Module (ECM), re-
fer to the “Electronic Section” for removal pro-
cedures. Remove the ECM and its mounting
bracket.
4
1. Disconnect the wiring harness connector from EG–5059
valve cover/intake manifold. Refer to Figure
3.8 for engines equipped with chassis mounted Figure 3.8 Disconnect Wiring Harness
ECM unit or Figure 3.9 for engines equipped 1. Main Wiring Harness
with engine mounted ECM unit. 2. 31–Pin Connector
2. Release the retaining tabs of the wiring harness 3. Wiring Harness Connector Tabs
connector (3, Figure 3.8 or 3, Figure 3.9). Push 4. Wiring Harness Connector
the connector body toward the inside of the
valve cover/intake manifold (Figure 3.10). Re-
move the valve cover/intake manifold and gas- 3
ket from the cylinder head. Leave the wiring
harness connected to the fuel injectors.
2
EG–6818
Figure 3.9 Disconnect Wiring Harness

1. ECM
2. Wiring Harness Connector
3. Wiring Harness Connector Tabs
EG–6850
Figure 3.10 Wiring Harness Connector
EGES 160 – 1
SERVICE MANUAL
Section 3
MANIFOLDS Page 7
VALVE COVER/INTAKE MANIFOLD –

CONTINUED
3. Remove the thirteen (13) valve cover/intake
manifold mounting capscrews (Figure 3.11).
Remove valve cover/intake manifold and gas-
ket from the cylinder head.
EG–6846
Figure 3.11 Valve Cover/Intake Manifold Removal
CLEANING
1. Clean valve cover/intake manifold using a suit-
able non–caustic solvent.
2. Throughly clean valve cover/intake manifold
breather and dry using filtered compressed air.
3. Visually inspect the valve cover/intake manifold
for any damages.
EGES 160 – 1
SERVICE MANUAL
Section 3
Page 8 MANIFOLDS
CONTINUED
INSTALLATION
NOTE: If valve cover/intake manifold gasket is
not damaged and in good condition, it can be re-
used.
1. Place gasket onto cylinder head.

2. Hold the valve cover/intake manifold over the
engine. Place a new O–ring into the wiring har-
ness connector port and push the connector in
until the tabs lock.
IMPORTANT
BE SURE THE VALVE COVER/INTAKE MAN-
IFOLD AND GASKET ALIGN PROPERLY.
3. Install the valve cover/intake manifold onto the

cylinder head.
4. Secure valve cover/intake manifold to the cylin-
der head using thirteen (13) mounting caps-
crews (Figure 3.12). Tighten to the special
torque value.
EG–6845
Figure 3.12 Valve Cover/Intake Manifold Installation
EGES 160 – 1
SERVICE MANUAL
Section 3
MANIFOLDS Page 9

CONTINUED
INSTALLATION – CONTINUED 1
5. Lubricate and install a new O–Ring onto the
road draft tube (Figure 3.13).
6. Insert the draft tube into the bore located on the
rear right hand side of the valve cover/intake
manifold. Secure the road draft tube to the
crankcase using two (2) mounting bolts and
tighten (Figure 3.14).
2
3
EG–6840
MISCELLANEOUS INSTALLATION
Figure 3.13 Installing Road Draft Tube To
Refer to the appropriate sections for the proper
Valve Cover/Intake Manifold
installation procedures for the following:
1. Valve Cover/Intake Manifold
Turbocharger, if removed 2. Road Draft Tube O–Ring
Turbocharger oil supply tube, if removed 3. Road Draft Tube
Turbocharger oil drain tube, if removed
Engine Mounted ECM Unit and Mounting Bracket,
if equipped
Engine Wiring Harness
EG–6808
Figure 3.14 Securing Road Draft Tube
EGES 160 – 1
SERVICE MANUAL
CYLINDER HEAD AND VALVES
SECTION 4 INDEX
Page
EXPLODED VIEW OF CYLINDER HEAD AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL INJECTOR WIRING HARNESS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DRAINING THE SUPPLY MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SUPPLY MANIFOLD DISCONNECT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL INJECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
VALVE LEVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PUSH ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CYLINDER HEAD CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSPECT FOR WARPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHECK THICKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHECK FOR VALVE LEAKAGE (USING MINERAL SPIRITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSPECT FOR CRACKS (USING DYE PENETRANT METHOD OEM1272) . . . . . . . . . . . . . . . . . . . 18
PRESSURE CHECK CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CYLINDER HEAD RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
VALVE AND VALVE GUIDE RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removing Valves From Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clean Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspect Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replace Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clean Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspect Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reface Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Valve Seat Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Valve Rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Valve Spring Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FUEL INJECTOR SLEEVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CLEANING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLING THE PUSH ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
VALVE LEVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
EGES 160 – 1
SERVICE MANUAL
CYLINDER HEAD AND VALVES
SECTION 4 INDEX
Page
VALVE LASH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

REMOVING FUEL INJECTOR O–RINGS AND SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLING FUEL INJECTOR O–RINGS AND SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
UPPER GROVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
MIDDLE GROOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
LOWER GROOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FUEL INJECTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SUPPLY MANIFOLD CONNECTION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEAD AND VALVES Page 1
EXPLODED VIEW OF CYLINDER HEAD AND RELATED PARTS
2 4
1
3 5
6
9 10 11
7 8
27
28 12
29
16 16
17 17 9
18 10
18 15
19 24
20 20 9 30
21 14 10
21 25
22 13
23 26
INTAKE EXHAUST EG–7002
Figure 4.1 Exploded View Of Cylinder Head And Related Parts

1. Front Lifting Eye 16. Valve Stem Key
2. Cylinder Head Short Bolt (20) 17. Valve Rotator With Seal
3. Cylinder Head Bolt Washer 18. Valve Rotator Seal
4. Fuel Injector Sleeve 19. Intake Valve Spring
5. Rear Lifting Eye 20. Valve Stem Seal With Retainer
6. Cylinder Head Assembly With Valves 21. Valve Guide
7. Oil & Fuel Supply Manifold Gasket 22. Intake Valve Seat Insert
8. High Pressure Oil and Fuel Supply Manifold 23. Intake Valve
9. Manifold End & Oil Supply Plug O–Ring 24. Exhaust Valve Spring
10. Manifold End & Oil Supply Plug Back–up Ring 25. Exhaust Valve Insert
11. Supply Manifold End Plug 26. Exhaust Valve
12. Flange Bolt 40mm (1.6 in.) 27. Pipe Plug 1/2 in. NPT
13. Cylinder Head Gasket 28. Pipe Plug 3/4 in. NPT
14. Supply Manifold Plug (End Mounted ICP) 29. Pipe Plug 1/8 inch NPT
15. Cup Plug 1–1/4 inch (32 mm) 30. Supply Manifold Plug (Mid Mounted ICP)
EGES 160 – 1
SERVICE MANUAL
Section 4
SPECIFICATIONS – CONTINUED
Cylinder Head – Continued
Exhaust Valve Seat O.D.:

0.05 mm (0.002 in.) Oversize 46.050 mm (1.813 in.)
0.38 mm (0.015 in.) Oversize 46.380 mm (1.826 in.)
Valve Seat Insert Cylinder Head Counterbore Diameter:
Intake: Standard Size 46.253 mm (1.821 in.)
0.05 mm (0.002 in.) 46.304 mm (1.813 in.)
0.381 mm (0.015 in.) 46.634 mm (1.836 in.)
Exhaust: Standard Size 46.0 mm (1.811 in.)
0.05 mm (0.002 in.) 46.050 mm (1.813 in.)
0.381 mm (0.015 in.) 46.380 mm (1.826 in.)
Valve Head Recession Relative to Deck 0.00 mm (0.000 in.)
Surface (Intake & Exhaust) 0.36 mm (0.014 in.)
Cylinder Head Surface Flatness 0.10 mm (0.004 in.) in 229 mm (9 in.)
Deck–to–Deck Dimension:
128.27 mm (5.050 in.)
(Head Thickness) (New) 128.78 mm (5.070 in.)
Minimum Deck–to–Deck Dimension After Rework 128.02 mm (5.040 in.)
Valve Springs
Intake:
Number of Springs per Valve 1
Identification Color Stripe Blue
Valve Spring Free Length 58 mm (2.292 in.)
Test Length (Valve Closed) 51 mm (2.007 in.)
Test Load (Valve Closed) 333–369 N (75–83 lbs.)
Test Length (Valve Open) 38 mm (1.497 in.)
Test Load (Valve Open) 921–965 N (207–217 lbs.)
Wire Diameter 5.26 mm (.207 in.)
Exhaust:
Identification Color Strip White
Valve Spring Free Length 62.18 mm (2.448 in.)
Test Length (Valve Closed) 50.29 mm (1.980 in.)
Test Length (Valve Open) 38.86 mm (1.530 in.)
EGES 160 – 1
SERVICE MANUAL
Section 4
Page 4 CYLINDER HEAD AND VALVES
Cylinder Head Bolts See Notes and Figure 4.2
Fuel Injector Hold Down Clamp Mounting Bolt 13 Nm (120 lb–in.)
Fuel Injector Hold Down Clamp Shoulder Bolt 13 Nm (120 lb–in.)
High Pressure Oil Hose Nut 26 Nm (19 lb–ft.)
Injection Control Pressure Sensor (Apply Loc- 26 Nm (19 lb–ft.)
tite® #277 To Threads Prior to Installation)
Supply Manifold Mounting Bolt 27 Nm (20 lb–ft.)
Supply Manifold End Plug 81 Nm (60 lb–ft.)
Supply Manifold 3–way Fitting Nut 35 Nm (26 lb–ft.)
Supply Manifold Fuel Return Nut 27 Nm (20 lb–ft.)
Valve Adjusting Screw Nut 27 Nm (20 lb–ft.)
NOTE 1: Tighten cylinder head bolts following the assembly steps listed:
1. Lubricate bolt threads, bolt head seating areas and washers with clean engine oil.
2. Tighten bolts in three (3) stages.
NOTE 2: + – Tighten in steps as shown in Figure 4.2.
EG–6152
Figure 4.2 Cylinder Head Bolts Special Torque Sequence
EGES 160 – 1
SERVICE MANUAL
Section 4

PS94–831–1 Cylinder Head Magnetic Intake Shield
OEM1293 Bevelled Edge Straightedge, 914 mm (36 in.) long
OEM1023 Small Hole Gauge Set
OEM6343 Valve Guide Brush
OEM1272 Defect Detector Kit, (Dye Penetrant)
ZTSE4289–1A Cylinder Head Pressure Test Hardware Kit
ZTSE4289–2A Cylinder Head Pressure Test Plate
ZTSE4302 Fuel Injector Sleeve Remover
ZTSE43023 Fuel Injector Sleeve Puller
ZTSE4300 Fuel Injector Removal Tool
ZTSE43024 Plastic Plug Set (6)
ZTSE4303 Fuel Injector Sleeve Installer
ZTSE4304 Fuel Injector Sleeve Brushes
ZTSE4305 Fuel Injector Sleeve Seat Brush
ZTSE4299 Fuel Injector Holder Rack and Caps
ZTSE1879–1 Slide Hammer Puller Set
ZTSE1951C Universal Valve Seat Extractor
ZTSE1951–20 Collet (Used With Universal Valve Seat Extractor,
ZTSE1951C)
ZTSE1846 Valve Spring Compressor
ZTSE1943 Valve Guide Installer
ZTSE4377 Valve Guide Removal Tool
ZTSE4164A Valve Seat Installer
ZTSE4393 Valve Guide Deburring Tool
ZTSE2241 Valve and Clutch Spring Tester
ZTSE4320 Cleaning Brush Set (Consists of 4 brushes)
EGES 160 – 1
SERVICE MANUAL
Section 4
Prior to the removal of the cylinder head, refer to the
appropriate sections of this publication and remove
the following items:
Turbocharger oil supply tube
Turbocharger oil drain tube
Turbocharger
Road Draft Tube
Exhaust manifold
ECM and Mounting Bracket, if Equipped
Main Wiring Harness
Fuel supply line to supply manifold from filter header
FUEL INJECTOR WIRING HARNESS

REMOVAL
Once the valve cover/intake manifold and gasket
have been removed, identify the fuel injectors and
solenoid connectors (Figure 4.3). Place the cylin-
der head magnetic intake shield (5, Figure 4.3)
(PS94–831–1) over the intake ports of the cylinder
head. This prevents any small loose parts from fal-
ling into the crankcase.
1 2 3 4 5
EG–7004
Figure 4.3 Fuel Injector And Cylinder Head Magnetic Intake Shield Locations
1. Fuel Injector
2. Main Wiring Harness Connector
3. Fuel Injector Solenoid Connector
4. Wiring Harness Channel
5. Cylinder Head Magnetic Intake Shield (PS94–831–1)
EGES 160 – 1
SERVICE MANUAL
Section 4

Remove the fuel injector wiring harness per the fol-
lowing steps.
IMPORTANT
DO NOT PULL ON WIRES OR SPREAD CLIPS
OUT TO FAR AS THEY MAY BEND.
1. Fuel Injectors With Plastic Connector Clip:

Disconnect the six (6) fuel injector solenoids
from the wiring harness by undoing the clips
and pushing down from the solenoid (Figure
4.4). EG–7003
OR Figure 4.4 Plastic Clip Connector Removal

1. Fuel Injectors With Wire Connector Clip:
Pull back on the six (6) fuel injector solenoid
connector wire clips (Figure 4.5). 1 2
2. Pull down on the solenoid connector to remove
the wiring harness from the fuel injector (Figure
4.6).
EG–6852
Figure 4.5 Wire Clip Connector Location

1. Fuel Injector Solenoid Connector
2. Fuel Injector Solenoid Connector Clip
EG–6854
Figure 4.6 Wire Clip Connector Removal
EGES 160 – 1
SERVICE MANUAL
Section 4
3. Fuel Injectors With Plastic Clip Connector:
Remove bolts securing the wiring harness
channel and oil deflectors to the fuel injector 3
hold down clamps (Figure 4.7). Remove oil de-
flectors and wiring harness channel.
OR
3. Fuel Injectors With Wire Clip Connector:
Remove bolts securing the wiring harness/oil 1 2
deflector assembly (Figure 4.8).
4. Remove wiring harness/oil deflector assembly
(Figure 4.9).
EG–5143
Figure 4.7 Wiring Harness Channel Removal

On Engines Equipped With Fuel Injectors With
Plastic Clip Connectors
1. Fuel Injector
2. Oil Deflector
EG–6855
Figure 4.8 Wiring Harness Channel Removal

On Engines Equipped With Fuel Injectors With
Wire Clip Connectors
EG–6856
Figure 4.9 Removing Wiring Harness
EGES 160 – 1
SERVICE MANUAL
Section 4
DRAINING THE SUPPLY MANIFOLD

Use the following steps to remove the supply man-
ifold end plug.
IMPORTANT
THE SUPPLY MANIFOLD OIL RAIL MUST BE
DRAINED PRIOR TO REMOVING THE FUEL IN-
JECTORS TO PREVENT LEAKAGE INTO THE
CYLINDER BORE.
1. Drain the supply manifold by removing the sup-

ply manifold end plug from the supply manifold
(Figure 4.10)
EG–5130
NOTE: Be sure to clean any and all old Loctite®
found on the threads of the plug prior to installa- Figure 4.10 Removing Supply Manifold End
tion. Plug
2. Install a new O–Ring and back–up ring onto the
end plug (Figure 4.11).
3. Apply Loctite® #277 to the end plug threads
and install into the supply manifold (Figure 1
4.11). Tighten plug to the special torque value
2
(Figure 4.12).
EG–5132
Figure 4.11 End Plug O–Ring And Back–Up

Ring Locations
1. End Plug
2. Back–up Ring
3. O–Ring
EG–5131
Figure 4.12 Installing Supply Manifold End

Plug
EGES 160 – 1
SERVICE MANUAL
Section 4
SUPPLY MANIFOLD DISCONNECT
POINTS
REMOVAL
Perform the following steps when removing the
three–way fitting.
Engines Equipped With Old Three–Way Fitting

2
Loosen the nuts (2, Figure 4.13) and disconnect
high pressure oil supply hose (3, Figure 4.13) from
the three–way fitting and the high pressure pump (1, 1
Figure 4.13). 3
OR
Engines Equipped With New Three–Way Fitting

the three–way fitting and the high pressure pump (3,
Figure 4.14).
2
OR EG–7005
Figure 4.13 Supply Manifold Disconnect

Points For Engines Equipped With Old Three–
Way Fitting
1. High Pressure Pump
2. Oil Supply Line Mounting Nuts
3. Oil Supply Line
1
2
EG–6873
Figure 4.14 Supply Manifold Disconnect

Points For Engines Equipped With New
Three–Way Fitting
2. Oil Supply Line
3. High Oil Pressure Pump
EGES 160 – 1
SERVICE MANUAL
Section 4
SUPPLY MANIFOLD DISCONNECT

POINTS – CONTINUED
REMOVAL – CONTINUED 3 1
Engines Equipped With Engine Mounted ECM
Unit 2
the three–way fitting and the high pressure pump (3,
Figure 4.15).
1 EG–6883
If not already done, disconnect the fuel supply line

from the fuel filter header to the supply manifold. Figure 4.15 Supply Manifold Disconnect
Points For Engines Equipped With Engine
Mounted ECM Unit & New Three–Way Fitting
NOTE: If it is necessary to remove the supply 1. Oil Supply Line Mounting Nuts
manifold from the cylinder head, refer to Section 2. Oil Supply Line
12, “High Pressure Lube Oil System” for proper 3. High Oil Pressure Pump
removal, maintenance and installation proce-
dures.
SENSOR REMOVAL
Use the following steps when removing the Injection

Control Pressure (ICP) sensor.
Remove ICP sensor, together with O–Ring, from the

three–way fitting of the supply manifold (Figure
4.16).
EG–5117

found on the threads of the sensor prior to Figure 4.16 Removing ICP Sensor From Old
installation. Three–Way Fitting
EGES 160 – 1
SERVICE MANUAL
Section 4
SUPPLY MANIFOLD REMOVAL – CON-
TINUED
SENSOR REMOVAL – CONTINUED
4.17).

found on the threads of the sensor prior to
installation.

Unit
supply manifold (Figure 4.18).
EG–6843
installation. Figure 4.17 Removing ICP Sensor From New
Three–Way Fitting
EG–6877
Figure 4.18 Removing ICP Sensor From Sup-

ply Manifold On Engines Equipped With En-
gine Mounted ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 4
FUEL INJECTOR REMOVAL

Perform the following steps when removing the fuel
injector from the cylinder head.
1. Remove all fuel injector hold down clamp

mounting bolts, located at the front of the fuel in-
jector (Figure 4.19).
NOTE: Shoulder bolt at the rear of the fuel injec-
tor DOES NOT require removal.
2. Disengage fuel injector hold down clamp from

shoulder bolt by sliding clamp toward rear of en-
EG–5146
gine, then, up and over head of shoulder bolt
(Figure 4.20). Figure 4.19 Removing Fuel Injector Hold
3. Remove fuel injector from cylinder head bore. Down Bolt
Either use fuel injector Removal Tool
ZTSE4300 or a pry bar. Insert pry bar under
hold down clamp and pry up (Figure 4.21).
IMPORTANT
BE SURE THE CLAMP IS FREE OF THE SHOUL-
DER BOLT WHEN PRYING UP ON THE CLAMP
TO PREVENT DAMAGE TO THE BOLT.
4. Lift fuel injector straight up and out of injector 2

bore of the cylinder head. O–Rings should be
replaced whenever the fuel injector is removed.
If required, remove six (6) shoulder bolts. 1
EG–5147
Figure 4.20 Fuel Injector Hold Down Clamp

1. Hold Down Clamp
2. Fuel Injector
1
2
EG–5151
Figure 4.21 Removing Fuel Injector

1. Fuel Injector
2. Hold Down Clamp
EGES 160 – 1
Printed in the United STates of america
SERVICE MANUAL
Section 4
VALVE LEVER REMOVAL
Use the following steps when removing the valve le-
ver assembly from the engine.
1. Loosen twelve (12) valve lever adjusting screw

nuts (Figure 4.22).
2. Loosen twelve (12) adjusting screws (Figure
4.22) one (1) full turn.
NOTE: Loosening valve lever adjusting screws
one (1) full turn will avoid possible valve train
damage during installation procedure.
3. Remove six (6) (long bolts) valve bracket bolt

(Figure 4.23).
NOTE: Shoulder bolt at the rear of the fuel injec-
tor DOES NOT require removal.
EG–5152
Figure 4.22 Loosening Valve Lever Adjusting

Screw
EG–5157
Figure 4.23 Removing Valve Lever Assembly

Mounting Bolts
EGES 160 – 1
SERVICE MANUAL
Section 4
VALVE LEVER REMOVAL – CONTIN-

UED
4. Remove valve lever assembly from cylinder
head (Figure 4.24).
EG–5158

PUSH ROD REMOVAL
IMPORTANT
NUMBER THE PUSH RODS SO THEY CAN BE
MATCHED TO THE SAME LOCATION AT
INSTALLATION. THIS HELPS TO ELIMINATE
PREMATURE WEAR OF THE PUSH ROD.
Remove all push rods (Figure 4.25) from cylinder

head.
EG–5159
Figure 4.25 Removing Push Rods
EGES 160 – 1
Printed in the United STates of america
SERVICE MANUAL
Section 4
CYLINDER HEAD REMOVAL
Perform the following steps when removing the cyl-
inder head from the crankcase.
1. Remove remaining twenty (20) cylinder head

bolts (short bolts) (Figure 4.26).
2. Using a small pry bar, carefully pry the cylinder
head loose from the gasket, so the cylinder
head will lift off easily (Figure 4.27).
NOTE: Only light force should be required on
the pry bar to break the cylinder head loose from
the gasket.
EG–5157
3. Lift the cylinder head from the crankcase using
appropriate lifting equipment (Figure 4.28). Figure 4.26 Removing The Cylinder Head
NOTE: Place the cylinder head on wood blocks Mounting Bolts
to protect the valves and bottom deck surface.
4. Remove cylinder head gasket from crankcase

(Figure 4.28).
EG–5164
Figure 4.27 Loosening The Cylinder Head And

Gasket From The Crankcase
EG–5165
Figure 4.28 Lifting The Cylinder Head
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEAD CLEANING

NOTE: Before proceeding any further, remove
the lifting eyes and there mounting hardware
from the cylinder head.
Perform the following steps to clean the cylinder

head.
1. With the valves installed to protect the seats, re-

move deposits and gasket material from the
gasket surface of the cylinder head using a
rotary wire brush or sanding block with mineral
spirits.
2. Clean all bolt holes with appropriate size tap.
Clear debris from bolt holes, oil return and water
passages, using filtered compressed air.
3. Clean the cylinder head bolt threads.
4. Wash all bolts and washers with a suitable sol-
vent and dry thoroughly.
NOTE: Dirt in threads or damaged threads may EG–5257
cause binding and result in a false torque read-
ing.
Figure 4.29 Checking Cylinder Head For

Warpage
CYLINDER HEAD INSPECTION

NOTE: Cylinder head condition must be evalu-
ated by inspecting for warpage, thickness,
cracks and/or valve leakage.
INSPECT FOR WARPAGE

Using a straightedge (OEM1293) and feeler gauge,
check the cylinder head gasket surface for warpage
utilizing the checking pattern shown in Figure 4.29.
If specifications are NOT met check head thickness
prior to resurfacing. The minimum deck–to–deck di-
mension must be maintained after resurfacing.
CHECK THICKNESS
EG–5258
Measure cylinder head deck thickness, using a mi-
crometer, at six locations (four corners and two cen-
ter points). Refer to “SPECIFICATIONS”. If the
minimum deck to deck dimension cannot be met, re-
place the cylinder head (Figure 4.30). Figure 4.30 Checking Cylinder Thickness
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEAD INSPECTION – CON-
TINUED
STEP ONE:
CHECK FOR VALVE LEAKAGE (USING MINER-
AL SPIRITS)
Visually inspect for valve leakage as follows:
1. Position the cylinder head on wood blocks with

the gasket surface facing down.
2. Squirt mineral spirits into the the intake and ex-

haust ports.
Wait five minutes, use an inspection mirror and visu-

ally inspect the valve seat area for leakage of the EG–5259
mineral spirits.
STEP TWO:
IMPORTANT
THERE SHOULD BE NO LEAKAGE. RECONDI-
TIONING IS NOT REQUIRED IF THE CYLINDER
HEAD PASSES THE MINERAL SPIRITS TEST. IF
LEAKAGE IS OBSERVED, THE VALVES RE-
QUIRE RECONDITIONING. REFER TO “CYL-
INDER HEAD RECONDITIONING” IN THIS SEC-
TION. THIS TEST DOES NOT CHECK FOR
CONDITION OF VALVE GUIDE OR VALVE EG–5260
STEM–TO–GUIDE CLEARANCE
STEP THREE:
INSPECT FOR CRACKS (USING DYE PENE-

TRANT METHOD OEM1272)
Visually inspect for cylinder head cracks using the

four step dye penetrant method as follows: (Refer to
Figure 4.31.) EG–5261
STEP FOUR:
STEP ONE – Spray the cleaner onto the lower deck
(gasket surface) of the head and wipe dry.
STEP TWO – Spray on the dye penetrant. Allow the

dye to remain on the surface from one (1) to ten (10)
minutes.
STEP THREE – Wipe the dye off the surface.
NOTE: Dye will remain in any cracks during the

EG–5262
“wipe off” step.
STEP FOUR – Spray on the developer and let dry Figure 4.31 Checking Cylinder Head For
for five to fifteen minutes. Cracks
EGES 160 – 1
SERVICE MANUAL
Section 4

TINUED
INSPECT FOR CRACKS (USING DYE PENE-
TRANT METHOD OEM1272) – CONTINUED
NOTE: Cracks will show up as purple lines

against the white developer. Refer to Figure
4.32.
IMPORTANT
IF ANY CRACKS ARE PRESENT, REPLACE THE
CYLINDER HEAD.
EG–5263
Figure 4.32 Identifying Cylinder Head Crack
PRESSURE CHECK CYLINDER HEAD
Pressure testing the cylinder head will reveal cracks

in ports or sleeve leakage which cannot be ob-
served using dye penetrant. Pressure–test the cyl-
inder head as follows:
1. If removed, install shoulder bolt into cylinder

head. Tighten to the special torque value (Fig-
ure 4.33).
2. Install fuel injectors into cylinder head injector

bores and secure, refer to “Fuel Injector Instal-
lation” in this section for instructions.
3. Remove the valves, using a valve spring com- EG–5148

pressor. Refer to “CYLINDER HEAD RE-
CONDITIONING”, in this section for valve re- Figure 4.33 Installing Fuel Injector Shoulder
moval instructions. Bolt
EGES 160 – 1
SERVICE MANUAL
Section 4
TINUED
PRESSURE CHECK CYLINDER HEAD – CON-
TINUED
4. Pressure test the cylinder head using the Cylin-
der Head Pressure Test Plate Kit
ZTSE4289–1A Hardware and Regulator and EG–6912
ZTSE4289–2A Plate. Refer to Figure 4.34. Figure 4.34 Cylinder Head Pressure Test Kit
5. Fasten the pressure plate and head gasket to Components
the cylinder head gasket surface using the 1. Pressure Test Plate
twenty–four (24) mounting bolts and nuts sup- 2. Air Regulator
plied with the kit. Refer to Figure 4.35. 3. Pressure Test Plate Mounting Bolts (24)
6. Remove thermostat and install air regulator.
Secure to cylinder head with two (2) mounting
bolts. Refer to Figure 4.36.
7. Remove the pipe plug next to the thermostat
opening. Fill cylinder head with hot water and
reinstall pipe plug.
8. Install a hose fitting to the cylinder head at the
removed plug. Apply 124–138 kPa (18–20 psi) EG–5399
air pressure and visually inspect for leaks at the:
Fuel injector nozzle sleeve area Figure 4.35 Mounting Cylinder Head Pressure
Ports Test Plate
Upper deck
Lower deck
IMPORTANT 1
IF LEAKAGE IS OBSERVED AT ANY PORT OR
THE UPPER AND LOWER DECK, REPLACE THE
CYLINDER HEAD.
2
EG–5400
Figure 4.36 Mounting Air Regulator To Cylin-

der Head
1. Cylinder Head
2. Air Regulator
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEAD RECONDITIONING
VALVE AND VALVE GUIDE RECONDITIONING
Removing Valves From Cylinder Head
Remove the intake and exhaust valves as follows:
1. Using a valve spring compressor tool

ZTSE1846, remove the valves.
2. Install the valve spring compressor over the

valve to be removed and compress the spring.
3. Remove the valve spring locks (keepers). Re- EG–5388
fer to Figure 4.37.

Figure 4.37 Removing Valve Spring Locks
4. Remove the valve spring compressor tool.
5. Remove the valve rotator, valve spring, valve

seal and valve as shown in Figure 4.38. If the
nylon rotator seal becomes dislodged from the
rotator and sticks to the valve stem, remove the
seal from the valve stem with your fingers. Dis-
card all 12 rotator seals.
IMPORTANT
SEPARATE THE INTAKE AND EXHAUST
SPRINGS AT TIME OF REMOVAL. THE SPRING
RATES ARE DIFFERENT AND CANNOT BE
MIXED ON CYLINDER HEAD REASSEMBLE.
EG–5389
Figure 4.38 Removing Valve Components

6. Remove valve stem seal assemblies and
valves. Discard all 12 stem seal assemblies
due to damage from removal across the valve
keeper grooves.
Clean Valve Guides
With valves removed, clean all valve guides using EG–5395

a nylon brush (OEM6343), soap and water. Refer
to Figure 4.39. Figure 4.39 Cleaning Valve Guides
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEAD RECONDITIONING –
CONTINUED
VALVE AND VALVE GUIDE RECONDITIONING –
CONTINUED
Inspect Valve Guides
Position an inspection light at the bottom of the
valve guide bores and visually examine the walls for
burning, cracking. Replace any guides which do not
pass the visual inspection.
Measure each valve guide using a ball gauge EG–5396

(OEM1023) and outside micrometer as shown in
Figures 4.40 and 4.41. Figure 4.40 Measuring Valve Guide
Measure the valve guides within 0.64 mm (0.025

inch) of each end of the guide and 90 degrees from
the crankshaft center–line. Record valve guide I.D.
readings so valve–to–guide running clearance may
be determined later (Figure 4.41). If valve guide ex-
ceeds specifications, replace the guide.
Replace Valve Guides

Remove any valve guides which do not pass the in-
spection criteria as follows:
1. Insert the valve guide remover ZTSE4377 into
the guide from the valve port side of the cylinder
head.
2. Press out the valve guide. Refer to Figure 4.42.
EG–5420
Figure 4.41 Measuring Valve Guide Gauge
Figure 4.42 Installing Valve Guide Remover

1. Valve Guide Remover Tool
2. Valve Guide
3. Cylinder Head
EGES 160 – 1
SERVICE MANUAL
Section 4

CONTINUED
CONTINUED
Install Valve Guides
IMPORTANT
INSTALL THE VALVE GUIDE INSERTS WITH
THE LARGE 15 DEGREE CHAMFER END
DOWN.
1. Lubricate valve guide insert using clean engine

oil and press into the cylinder head until installer
sleeve (ZTSE1943) bottoms against cylinder
head. Chilling guide may facilitate installation.
Refer to Figure 4.43. DO NOT hammer or
pound valve guide insert into cylinder head. EG–5393
2. Deburr the valve guide, after installation, using
ZTSE4393 valve guide deburring tool. Figure 4.43 Using Valve Guide Installer Tool
NOTE: DO NOT ream valve guide I.D. after
installation. Service guides are provided in a
finish reamed condition. Clean valve guides as
described in Figure 4.39.
Clean Valves
Remove all carbon from the valve stems and valve
heads.
Inspect Valves
1. Visually inspect each valve, replacing any that
show evidence of burn marks, warpage, scuf-
fing or bending.
2. Measure each valve stem for wear using a mi-
crometer to measure valve stem diameter. Re-
cord the readings.
NOTE: Measure valves at three locations 90°
apart. Refer to the “SPECIFICATIONS” and re-
place valves which exceed the minimum stem
diameter specification.
3. Using the valve stem diameter and valve guide
inside diameter measurements, recorded earli-
er (see “INSPECT VALVE GUIDES” in this sec-
tion), determine valve stem–to–guide running
clearance. Refer to “SPECIFICATIONS”. Re-
place the valve or valve guide as required.
EGES 160 – 1
SERVICE MANUAL
Section 4
CONTINUED
CONTINUED
Reface Valves
NOTE: If valves are in serviceable condition, re-
face the valve to the specified angle, as re-
quired. Refer to Figure 4.44.
1. Reface the valves as follows: Figure 4.44 Valve Angles Specifications

a. Dress the cutting stone, prior to refacing the
valves, using the dressing stud attachment
on the grinder.
b. Install the valve in the grinder and set to the
specified angle.
c. Grind the valve face. Remove only the
minimum amount of material necessary to
true up the valve face. Refer to Figure
4.45.
2. Measure valve face margin at four locations us-
ing a caliper. Refer to Figure 4.46.
NOTE: The minimum valve face margin (See
“SPECIFICATIONS”) must be maintained
across the entire valve face. An insufficient
margin will NOT provide proper heat dissipation EG–5368
and lead to valve warpage or breakage. Intake
and exhaust valve margins are different. Re- Figure 4.45 Grinding The Valve Face
place the valve if the margin is less than the spe-
cified minimum, after grinding.
EG–5199
Figure 4.46 Measuring The Valve Face
EGES 160 – 1
SERVICE MANUAL
Section 4

CONTINUED
CONTINUED
Reface Valves – Continued
3. Reface the valve stem tip as follows:
a. Dress the cutting stone using the dressing

stud on the grinder.
b. Install the valve in the grinder as shown in

Figure 4.47. EG–5367
IMPORTANT Figure 4.47 Placing Valve On Grinder

WHEN RESURFACING THE VALVE STEM TIP,
LEAVE SUFFICIENT MATERIAL SO THE VALVE
LEVER (ROCKER ARM) DOES NOT CONTACT
THE VALVE SPRING LOCKS OR ROTATORS,
DURING OPERATION.
c. Touch the valve stem tip to the cutting stone

removing only a minimum of material.
NOTE: Refacing the valve stem tip provides a

new wear surface for the rocker arm.
EG–5196
4. After refacing valves, insert valves in clean

valve guide and check valve face contact with Figure 4.48 Applying Prussian Blue On Valve
valve seat using Prussian Blue™ (or equivalent)
as follows:
a. Spread thin film of Prussian Blue™ on valve

face. Insert valve into its guide. Refer to
Figure 4.48.
b. Apply pressure on exact center of valve

head while making a quarter turn in the seat.
c. Remove valve, inspect impression made on

seat and on valve face.
d. Bluing should appear around entire contact

surface of valve face and valve seat to be
acceptable. CHECK SEVERAL TIMES TO EG–5197
PREVENT ERROR. If acceptable, proceed
with valve installation. Figure 4.49 Turning Valve In Cylinder Head
EGES 160 – 1
SERVICE MANUAL
Section 4
CONTINUED
CONTINUED
Valve Seat Grinding
1. If required, resurface the valve seat as follows:
a. Lightly lubricate and install the correct size
valve seat installer (ZTSE4164A) into the
valve guide.
b. Choose the correct angle grinding stone
and dress the stone. Refer to “SPECIFI-
CATIONS” for valve seat angles.
c. Install the grinding stone over the valve seat
installer.
d. Lower grinder head over valve seat installer
shank until wheel barely clears the valve
seat. Turn on power. GENTLY apply grind-
ing wheel to valve seat with little pressure
other than weight of the wheel.
e. Raise wheel frequently to prevent overheat-
EG–5398
ing.
f. Grind seat to a smooth even finish.
EG–5397
Figure 4.50 Using Valve Seat Installer

ZTSE4164A
EGES 160 – 1
SERVICE MANUAL
Section 4

CONTINUED
CONTINUED
Valve Seat Grinding – Continued
2. After resurfacing, check valve seat width using
a caliper as shown in Figure 4.51. Refer to
“SPECIFICATIONS” for seat width limits. If
seat widths are excessive, they may be cor-
rected by grinding with a 15 degree or smaller
angle stone.
3. Check valve recession using a straightedge
OEM1293 and feeler gauge or a surface gauge. EG–5198
Refer to Figures 4.52 and 4.53. Refer to

Figure 4.51 Checking Valve Seat After Resur-
“SPECIFICATIONS” for recession limits. If
facing
valve recession is excessive, install a new valve
or replace the valve seat. If the valve protrudes
above the deck, regrind the valve seat.
NOTE: Clean valve guides as described in Fig-
ure 4.39.
IMPORTANT
IF A NEW VALVE WILL NOT CORRECT AN EX-
CESSIVE RECESSION CONDITION, THE VALVE
SEAT MUST BE REPLACED AND REGROUND.
IF THE VALVE FACE PROTRUDES ABOVE THE
DECK, THE VALVE SEAT WILL HAVE TO BE RE-
GROUND DEEPER INTO THE HEAD. AFTER RE-
GRINDING ANY SEAT, RECHECK THE SEAT EG–5265
WIDTH (FIGURE 4.44) AND CONFIRM VALVE

Figure 4.52 Checking Valve Recession Using
SEAT CONTACT USING PRUSSIAN BLUE™
Straightedge And Feeler Gauge
(SEE FIGURES 4.43 AND 4.44.)
Figure 4.53 Checking Valve Recession Using

Surface Gauge
1. Dial Indicator
2. Cylinder Head
3. Valve
EGES 160 – 1
SERVICE MANUAL
Section 4
CONTINUED
CONTINUED
4. After resurfacing the valve seat, check the seat
for runout, using an appropriate dial indicator.
Valve seat runout should not exceed limits
shown in “SPECIFICATIONS”.
IMPORTANT
IF VALVE SEAT RUNOUT, CONCENTRICITY
AND/OR SEAT WIDTH CANNOT BE MAIN- EG–5271
TAINED, REPLACE AND RESURFACE THE

VALVE SEATS. Figure 4.54 Installing Collet Onto Handle
Valve Seat Replacement

1. USE A VALVE SEAT PULLER ZTSE1951C to
remove defective valve seat inserts as follows:
NOTE: These instructions are general in nature.
Follow the instructions that apply to the tool.
a. Cut groove in insert using stone.

b. Choose the appropriate size collet
(ZTSE1951–20). Position the collet in the
valve seat insert (Figure 4.54).
c. Expand the collet by threading the shaft into EG–5273
the collet until the collet is tight inside the
valve seat. Refer to Figure 4.55. Figure 4.55 Installing Collet Into Valve Seat
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEADS AND VALVES Page 29

CONTINUED
CONTINUED
d. Turn the large handle on the bridge assem-
bly to pull the valve seat insert from the cyl-
inder head. Refer to Figure 4.56.
e. Unlock the pin collet by loosening the
threaded shaft and discard the valve seat in-
sert.
2. Select the appropriate size valve seat insert.
Refer to “VALVE SEAT INSERT CHART”.
VALVE SEAT INSERT CHART
OVERSIZE DIAMETER OF CYLINDER HEAD COUNTERBORE
INSERT INTAKE EXHAUST
Standard* 46.253 mm (1.821 in.) 46.0 mm (1.811 in.)
0.05 mm (0.002 in.)* 46.304 mm (1.823 in.) 46.050 mm (1.813 in.)
0.381 mm (0.015 in.) 46.634 mm (1.836 in.) 46.380 mm (1.826 in.)
* Standard and 0.05 mm (0.002 in.) oversize service insert DOES NOT require insert counterbore
enlargement before installing.
EG–5274
Figure 4.56 Removing Valve Seat Insert
EGES 160 – 1
SERVICE MANUAL
Section 4
CONTINUED
CONTINUED
IMPORTANT
STANDARD SERVICE VALVE SEAT INSERTS
ARE AVAILABLE THRU SERVICE PARTS. IF
THE SEAT IS DAMAGED BEYOND THE STAN-
DARD OR 0.05MM (.002 IN.) DIAMETER, IT WILL
BE NECESSARY TO MACHINE THE INSERT
COUNTERBORE IN THE CYLINDER HEAD FOR
AN OVERSIZE SEAT INSERT. STANDARD SIZE 2
INSERTS DO NOT REQUIRE COUNTERBORE
ENLARGEMENT.
1
3. Install the valve seat insert as follows: EG–5194
Chill the valve seat insert in a freezer for 30 min-

utes before installing.
NOTE: Chilling the valve seat insert prevents
peeling of metal from the cylinder head counter- Figure 4.57 Installing Valve Seat Inserts
bore during installation.
Align the insert to avoid cocking. 1. Valve Seat Insert
2. Installation Tool
Press the insert into its counterbore using
ZTSE4164A for the intake and exhaust valve
seat inserts. Refer to Figure 4.57.
4. Grind the new valve seat(s) to the specified
angles and width. Refer to “VALVE SEAT
GRINDING” in this section.
VALVE SPRINGS
Cleaning
Clean all valve springs and seats in a suitable sol-
vent.
Inspection
1. Visually inspect valve springs for rust, pitting
and cracks. Look for spring distortion.
2. Spring ends must be flat and square to prevent EG–5201
lateral loads on valve stem. Refer to Figure

4.58.
NOTE: Out of square springs place a side load
on the stem causing rapid guide wear. Figure 4.58 Checking Valve Springs
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEADS AND VALVES Page 31

CONTINUED
VALVE SPRINGS – CONTINUED
3. Measure valve spring tension using valve
spring tester ZTSE2241. Refer to Figure 4.59
and “SPECIFICATIONS”.
Measure maximum spring length in use (valve
closed).
Measure minimum length in use (valve open).
NOTE: Apply the appropriate test load to each
spring and determine if test length is achieved.
4. Replace any valve spring which is rusted,

pitted, cracked, bent or incapable of meeting
tension requirements.
Valve Rotators
CLEANING
EG–5202
Clean rotators in a clean solvent.
INSPECTION Figure 4.59 Checking Valve Spring Tension

1. To properly test the rotator for function, a valve
spring load must be applied to the rotator.
IMPORTANT
THE ROTATOR MUST BE LUBRICATED WITH
CLEAN ENGINE OIL PRIOR TO TESTING.
2. Place the valve spring with the rotator in the

spring tester ZTSE2241. Place a ball bearing
between the rotator and ram of the spring tester.
The ball bearing must be large enough to pre-
vent ram from touching any part of the rotator.
3. Paint a reference line on the rotator.
4. Compress the valve spring rapidly with even
pressure and observe the rotator as it turns
(Figure 4.60).
5. Replace any rotator which does NOT turn.
Valve Spring Locks

CLEANING
Clean valve spring locks in a suitable solvent.
INSPECTION EG–5206
Visually inspect inside and outside of the valve

spring locks for wear. Replace any worn spring
locks, as required. Figure 4.60 Checking Valve Rotator
EGES 160 – 1
Section 4 SERVICE MANUAL
CYLINDER HEAD RECONDITIONING—

CONTINUED
FUEL INJECTOR SLEEVE REPLACEMENT
Removal
NOTE: If the injector sleeve is going to be removed

when In-chassis, place a cork plug into the bore
(to prevent debris entering bore or onto piston)
before performing procedure.
Use the following steps to remove fuel injector sleeves.

Figure 4.61 Installing Fuel Injector
1. Inser t fuel injector sleeve remover tool ZTSE4302A Remover Tool
into fuel injector sleeve (Figure 4.61).
2. Turn injector sleeve remover tool to cut threads

into fuel injector sleeve. Once threads have been
cut into fuel injector sleeve, remove tool from bore
(Figure 4.62)
3. Install fuel injector sleeve puller tool ZTSE43023

into bore and tighten. BE SURE puller tool
threads into fuel injector sleeve (Figure 4.63).
Figure 4.62 Threading The Fuel

Injector Sleeve

Sleeve Puller Tool
EGES 160-2
SERVICE MANUAL
Section 4

CONTINUED
FUEL INJECTOR SLEEVE REPLACEMENT –
CONTINUED
Removal – Continued
4. Screw slide hammer ZTSE1879–1 into fuel in-
jector sleeve puller tool. Remove fuel injector
sleeve from bore (Figure 4.64).
5. Insert a stiff wire brush ZTSE4305 into fuel in-
jector bore and remove deposits and hardened
sealant from bore (Figure 4.65).
EG–5900
6. Insert a small stiff nylon brush ZTSE4320 into
oil gallery for cleaning.
Figure 4.64 Removing Fuel Injector Sleeve
7. Using compressed air to clean out all fuel and oil
galleries of debris.
EG–5387
Figure 4.65 Cleaning Fuel Injector Bore
EGES 160 – 1
SERVICE MANUAL
Section 4
CONTINUED
FUEL INJECTOR SLEEVE REPLACEMENT – APPLY HERE
CONTINUED
Installation
Use the following steps to install a new fuel injector
sleeve:
1. Attach a new fuel injector sleeve to adapter
ZTSE4303 and apply Loctite® 262 to fuel injec-
tor sleeve at (Figure 4.66):
1. Wall (end) EG–5385
2. Upper Wall (top)

Figure 4.66 Preparing Fuel Injector Sleeve For
2. Insert sleeve into fuel injector bore (Figure Installation
4.67).
3. Using a hammer, drive sleeve into fuel injector
bore (Figure 4.68). Remove adapter tool once
fuel sleeve injector is in place.
4. Clean fuel injector sleeve after installation, us-
ing ZTSE4304 brush set.
EG–5902
Figure 4.67 Inserting Fuel Injector Sleeve Into

Bore
EG–5901
Figure 4.68 Installing Fuel Injector Sleeve
EGES 160 – 1
SERVICE MANUAL
Section 4

CONTINUED 2
1
FUEL INJECTOR SLEEVE REPLACEMENT –
CONTINUED
Installation – Continued
5. Figure 4.69 shows a cutaway with the fuel in-
jector sleeve installed into the fuel injector bore.
Note areas where injector sleeve lands contact
cylinder head.
3
CYLINDER HEAD ASSEMBLY
CLEANING CYLINDER HEAD
1. Clean valve faces and seats with a suitable
cleaning solvent to remove all dirt or foreign ma-
terial. Blow dry all new and used components
using filtered compressed air. Figure 4.69 Fuel Injector Installed Into Cylin-
2. Thoroughly clean all valve guides, prior to valve der Head Cutaway
installation, as follows: 1. Cylinder Head
a. Coat a brush OEM6343 with soap and wa- 2. Fuel Injector Sleeve
ter. 3. Contact Areas
NOTE: Brush must have a slightly larger diame-
ter than the I.D. of the valve guide.
b. Insert brush into valve guide bore and clean
with a turning motion to insure removal of
any deposits.
c. Dry with filtered compressed air.
IMPORTANT
PERFORM VALVE GUIDE BORE CLEANING ON:
1. NEW SERVICE VALVE GUIDES.
2. VALVE GUIDES INSTALLED IN NEW SER-
VICE CYLINDER HEADS (LESS VALVE).
3. VALVE GUIDES PRESENTLY INSTALLED IN
CYLINDER HEAD, WHICH MEET BORE
SPECIFICATIONS.
3. Insert a large nylon brush into rear of oil rail gal-

lery for cleaning.
4. Use compressed air to clean out the oil gallery.
5. Install a new O–Ring into the end plug and
install into the supply manifold. Tighten to the
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEAD ASSEMBLY – CON-
TINUED
CLEANING CYLINDER HEAD – CONTINUED
6. Insert a large nylon brush into rear of fuel rail
gallery for cleaning.
7. Use compressed air to clean out fuel rail gallery.
VALVE ASSEMBLY
1. Lubricate the valve stems with clean engine oil
and insert the valves into the valve guides.
2. Lubricate the I.D. of the new valve stem seal as-
EG–5391
semblies with clean engine oil and install them
over the valve and valve guide as shown in Fig-
ure 4.70. Be sure the seal assemblies are
seated down against the cylinder head spring Figure 4.70 Installing Valve Stem Seal Assem-
pockets. blies
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEAD ASSEMBLY – CON-

TINUED
VALVE ASSEMBLY – CONTINUED
3. Install the valve spring over the stem seal as-
sembly.
NOTE: Be sure to install proper valve spring at
proper valve location. Failure to properly locate
the springs could cause engine damage (Figure
4.71).
4. Install the rotator assembly over the valve

spring. Refer to Figure 4.72.
EG–5200
NOTE: Snap new rotator seals into bottom side
(rotator cone) of valve rotators before installing Figure 4.71 Intake/Exhaust Valve Spring Com-
rotator assembly on engine. parison
5. Compress the valve spring using valve spring

compressor tool (ZTSE1846) and install the
spring locks (keepers) as shown in Figure 4.73.
EG–5390
Figure 4.72 Installing Rotator Assembly
EG–5388
Figure 4.73 Install Valve Spring Locks
EGES 160 – 1
SERVICE MANUAL
Section 4
CYLINDER HEAD INSTALLATION
INSTALLATION
Install the cylinder head assembly as follows:
1. Clean and dry the cylinder head gasket sur-

faces.
2. Clean all cylinder head bolt holes using an ap-

propriate tap and blow out bolt holes with fil-
tered compressed air.
EG–5166
IMPORTANT Figure 4.74 Installing Dowel Rings Into Crank-

PRIOR TO CYLINDER HEAD INSTALLATION, case
CHECK CYLINDER SLEEVE PROTRUSION AS
DESCRIBED IN SECTION 7.
3. Install the dowel rings into the crankcase top

deck. Refer to Figure 4.74.
NOTE: The dowel rings are used to locate the

cylinder head gasket.
4. Install a new cylinder head gasket over the “lo-

EG–5165
cating” dowel rings.
Figure 4.75 Lower Cylinder Head Onto Crank-
5. Install the lifting eye on the rear of the cylinder case
head and tighten the mounting bolt. Install the
lifting eye on the front of the cylinder head, using
one washer (1) per mounting bolt. Tighten the
mounting bolts.
6. Carefully lower the cylinder head onto the gas-

ket. Refer to Figure 4.75.
7. Lubricate the cylinder head bolt threads, wash-

ers and under head seating area using clean
engine oil. Refer to Figure 4.76.
NOTE: Lubricate both long and short bolts.

EG–5163
8. Run twenty (20) cylinder head mounting bolts in Figure 4.76 Installing Cylinder Head Mounting
finger–tight. Bolts
EGES 160 – 1
SERVICE MANUAL
Section 4
INSTALLING THE PUSH ROD
Install the push rods with the cup end up as shown

in Figure 4.77.
IMPORTANT
BE SURE TO MATCH THE PUSH RODS TO THE
PROPER SLOTS AS NUMBERED DURING DIS-
ASSEMBLY.
EG–5159
Figure 4.77 Installing Push Rods
VALVE LEVER INSTALLATION
1. Install valve lever (rocker arm) assembly onto

the cylinder head using six (6) cylinder head
mounting bolts as follows: EG–5158
a. Insert the rocker arm and shaft assembly Figure 4.78 Installing Valve Lever Assembly
with the long cylinder head bolts into their
respective bolt holes. Refer to Figure 4.78.
b. Run the long cylinder head bolts in finger–

tight (except the two end bolts). Place a
0.013 mm (0.005 in.) feeler gauge between
the outside brackets and the rocker levers to
prevent binding. Finger–tighten the remain-
ing two end bolts (Figure 4.79).
2. Tighten the cylinder head bolts in three stages

as specified under special torque values.
NOTE: Check the two end rocker arms for free-

dom of movement after tightening the cylinder
head bolts.
EG–5155
3. Remove the two (2) 0.013mm (0.005 in.) feeler Figure 4.79 Installing Valve Lever Assembly
gauges. Mounting Bolts
EGES 160 – 1
SERVICE MANUAL
Section 4
VALVE LEVER INSTALLATION – CON-
TINUED
4. Adjust valve lash as follows:
NOTE: All valves are adjusted by rotating the
engine only twice.
a. Rotate the crankshaft until the #1 piston is

on the compression stroke and the timing
arrow on the front cover is in line with the
TDC mark on the vibration damper.
NOTE: Confirm that the #1 piston is on the com-
pression stroke by turning both push rods by
hand to verify that both valves are closed. The
valves are closed when the push rods are loose
and can be turned easily.
b. Set valve lash by loosening the lock nut and

turning the valve adjustment screw with the EG–5153
appropriate size feeler gauge inserted be-
tween the rocker arm and valve stem tip. Figure 4.80 Setting Valve Lash
Tighten the valve adjustment screw until the
valve lever can support the feeler gauge.
Refer to Figure 4.80 and “SPECIFI-
CATIONS” for valve lash.
c. Tighten the lock nut once the valve adjust-
ment is set. Remove the feeler gauge. Re-
fer to Figure 4.81.
EG–5152
Figure 4.81 Tightening Valve Lever Lock Nut
EGES 160 – 1
SERVICE MANUAL
Section 4
VALVE LEVER INSTALLATION – CON-

TINUED
VALVE LASH ADJUSTMENT
Six valves are adjusted when the #1 piston is at TDC
(compression) and the remaining six are adjusted
when the #6 piston is at TDC (compression). Refer
to Figure 4.82.
Figure 4.82 Valve Lash Adjustment Valve Lever Positions
EGES 160 – 1
SERVICE MANUAL
Section 4
REMOVING FUEL INJECTOR O–RINGS
AND SEALS
IMPORTANT
O–RINGS SHOULD BE REPLACED EACH TIME
THE FUEL INJECTOR IS REMOVED. IF ANY OF
THE FUEL INJECTORS HAVE DAMAGED O–
RINGS, ALL OF THE FUEL INJECTORS
SHOULD BE REMOVED AND HAVE THERE O–
RINGS REPLACED. CARE MUST BE TAKEN
NOT TO SCRATCH THE SEAL GROOVES ON
THE FUEL INJECTOR BODY WHILE REMOVING
THE SEALS.
REMOVAL PROCEDURE
Figure 4.83 shows the proper location of seals and
O–Rings when installed onto the fuel injector. Using
a non–metallic tool, i.e.; plastic or wood, remove the
old seals from the fuel injector as follows:
1. Remove the copper fuel injector gasket from
the bottom of the fuel injector.
2. Lift the lower O–Ring out of its groove with a
wooden or plastic tool. Cut the seal and remove
it. EG–3765
3. Lift the middle seal out of its groove with a wood-
en or plastic tool. Cut the seal and remove it. Figure 4.83 Fuel Injector Seal/Ring Groove ID
4. Lift the upper O–Ring out of its groove with a 1. Back–Up Ring (steel)
wooden or plastic tool. Cut the seal and remove 2. Upper Cushion Ring (black)
it. 3. Upper O–Ring (blue)
5. Lift the upper cushion ring out of its groove with 4. Middle Seal (blue and black)
a wooden or plastic tool. Cut the ring and re- 5. Lower O–Ring (orange)
move it. 6. Gasket (copper)
6. Lift one corner of the back up ring from its
groove, slide the rest of the back up ring from its
groove and over the tip of the fuel injector.
7. Make sure that the fuel injector is clean and free
of debris. Place the fuel injector into holder rack
ZTSE4299 where it will be protected from de-
bris and damage.
EGES 160 – 1
SERVICE MANUAL
Section 4
INSTALLING FUEL INJECTOR O–

RINGS AND SEALS
Figure 4.84 shows the proper location of seals and

O–Rings when installed onto the fuel injector. Refer
to the following instructions for the proper installa-
tion procedures.
IMPORTANT
INJECTOR O–RINGS MUST BE LUBRICATED
WITH CLEAN ENGINE OIL. WHEN INSTALLING
O–RINGS ONTO THE INJECTORS, BE SURE
ALL O–RINGS AND SEALS ARE LOCATED TO
THE TOP OF THE O–RING GROOVES. THIS AC-
TION WILL PREVENT THE O–RINGS AND
SEALS FROM TRYING TO ROLL IN THEIR RE-
SPECTIVE GROOVES DURING THE INSTALLA-
TION PROCEDURE.
EG–3765
Figure 4.84 Fuel Injector Seal/Ring Groove ID

1. Back–Up Ring (steel)
UPPER GROVE 2. Upper Cushion Ring (black)
3. Upper O–Ring (blue)
Install the fuel injector O–Rings as follows: 4. Middle Seal (blue and black)
5. Lower O–Ring (orange)
6. Gasket (copper)
1. Locate the upper groove seals.
2. Lightly lubricate each of the three seals with

new clean engine oil.
3. Gently spread the gap in the back up ring.

2
IMPORTANT
THE BACK UP RING ACTS LIKE A SPRING.
CARE MUST BE TAKEN WHEN INSTALLING
THIS PART. DO NOT TWIST THE RING. RING
FLATNESS IS IMPORTANT.
EG–1154
Figure 4.85 Installing Fuel Injector Back–Up

Ring
4. Slide the back up ring over the body of the fuel
injector and into the upper groove (Figure 1. Back–up Ring
4.85). 2. Fuel Injector
EGES 160 – 1
SERVICE MANUAL
Section 4
RINGS AND SEALS – CONTINUED
UPPER GROVE – CONTINUED
5. Slide the cushion ring over the body of the fuel
injector. Push the cushion ring into the groove.
Make sure the cushion ring is up against the
back up ring (Figure 4.86).
IMPORTANT
3
MAKE SURE THAT THE CUSHION RING DOES
NOT TWIST DURING INSTALLATION.
6. Slide the O–Ring over the body of the fuel injec-

tor. Push the O–Ring into the groove. Make
sure the O–Ring is up against the cushion ring
EG–1155
(Figure 4.87).
Figure 4.86 Upper Groove Back–up Ring and

Cushion Ring Installed
1. Back–Up Ring
2. Cushion Ring
3. Fuel Injector
EG–1156
Figure 4.87 Upper Groove Back–up Ring,

Cushion Ring And O–Ring Installed
1. Back–Up Ring
2. Cushion Ring
3. O–Ring Seal
4. Fuel Injector
EGES 160 – 1
SERVICE MANUAL
Section 4

RINGS AND SEALS – CONTINUED
MIDDLE GROOVE
Install the middle groove seal as follows (Figure
4.88):
1. Locate the middle groove seal.

2. Lightly lubricate the seal with clean engine oil.
3. Slide the middle seal over the fuel injector and
push into the middle groove. Make sure the
middle fuel injector seal is up against the
groove.
IMPORTANT
MAKE SURE THAT THE MIDDLE FUEL INJEC- Figure 4.88 Middle Groove Seal Installed
TOR SEAL DOES NOT TWIST DURING INSTAL- 1. Seal
LATION. 2. Fuel Injector
LOWER GROOVE
1. Locate the lower groove seal.
2. Lightly lubricate the seal with clean engine oil.
3. Slide the lower fuel injector seal over the fuel in-
jector body and into the lower groove. Make
sure the lower fuel injector seal is up against the
groove (Figure 4.89).
IMPORTANT
MAKE SURE THAT THE LOWER FUEL INJEC-
TOR SEAL DOES NOT TWIST DURING INSTAL-
LATION.
Figure 4.89 Lower Groove Seal Installed
4. Apply a light coat of grease to a new copper 1. Seal
gasket and place onto fuel injector (Figure 2. Fuel Injector
4.90).
Figure 4.90 Copper Gasket Installed

1. Copper Gasket
2. Fuel Injector
EGES 160 – 1
SERVICE MANUAL
Section 4
FUEL INJECTOR INSTALLATION
1. If removed install shoulder bolt and tighten to
the specified torque value (Figure 4.91).
2. Lubricate fuel injector and insert injector as-
sembly in bore of cylinder head.
NOTE: DO NOT STRIKE TOP OF FUEL INJEC-
TOR TO SEAT IT! USE HAND PRESSURE, AP-
PLIED TO THE TOP OF THE FUEL INJECTOR,
UNTIL HOLD DOWN CLAMP CAN BE ENGAGED
UNDER THE HEAD OF THE SHOULDER BOLT
(FIGURE 4.92).
3. Seat the fuel injector into the fuel injector bore

with the hold down clamp over the shoulder EG–5148
bolt. Use a 5/8 inch (16 mm) open end wrench

on lower edge of hold down clamp to further in- Figure 4.91 Installing Shoulder Bolt
sert fuel injector into bore of cylinder head, until
seated (Figure 4.93).
3
1
EG–5149

1. Fuel Injector
3. Shoulder Bolt
2. Hold Down Clamp
EG–5150
Figure 4.93 Securing Hold Down Clamp
EGES 160 – 1
SERVICE MANUAL
Section 4
FUEL INJECTOR INSTALLATION –

CONTINUED
4. Install fuel injector hold down clamp mounting
bolt and tighten to the special torque value (Fig-
ure 4.94).
CAUTION
IT IS IMPERATIVE THAT INJECTOR HOLD
DOWN CLAMP BOLT BE TIGHTENED TO THE
SPECIAL TORQUE VALUE.
5. Fuel Injectors With Plastic Clip Connector:

Install the oil deflector and wiring harness chan-
nel to the fuel injector. Secure with bolts (Fig-
ure 4.95). 2
OR
1
EG–5145
Figure 4.94 Tightening Hold Down Clamp

Mounting Bolt
1. Hold Down Clamp
2. Fuel Injector
2
1
EG–5142
Figure 4.95 Installing Wiring Harness Channel

And Oil Deflector To Fuel Injectors With Plas-
tic Clip Connectors
1. Fuel Injector
2. Oil Deflector
EGES 160 – 1
SERVICE MANUAL
Section 4
CONTINUED
Install the wiring harness/oil deflector assembly
(Figure 4.96).
6. Install the bolts securing the wiring harness/oil
deflector assembly to the fuel injector and tight-
en (Figure 4.97). EG–6856
7. Fuel Injectors With Plastic Clip Connector: Figure 4.96 Installing Wiring Channel/Oil De-
Connect the six (6) fuel injector solenoids to the flector Assembly To Fuel Injectors With Wire
wiring harness. Push the wiring harness clips Clip Connectors
up into the fuel injector solenoid. BE SURE the
clips lock onto the tabs of the fuel injector sole-
noid.
OR
Push the wiring harness connector into the fuel
injector solenoid connector (Figure 4.6).
EG–6855
Figure 4.97 Securing Wiring Channel/Oil De-

flector Assembly
EG–6854
Figure 4.98 Installing Wiring Harness To Fuel

Injector Solenoid
EGES 160 – 1
SERVICE MANUAL
Section 4

CONTINUED 1 2
Push the six (6) fuel injector solenoid connector
wire clips onto the fuel injector solenoids (Fig-
ure 4.99).
NOTE: If it was necessary to remove the supply

manifold from the cylinder head, refer to Section
12, “High Pressure Lube Oil System” for proper
maintenance and installation procedures.
EG–6852
SUPPLY MANIFOLD CONNECTION
Figure 4.99 Securing Solenoid Connector
POINTS With Wire Clip
1. Install the fuel supply line and connect it from 1. Fuel Injector Solenoid Connector
the fuel filter header to the supply manifold. 2. Fuel Injector Solenoid Connector Clip
Tighten fittings to the special torque value.

1. Install the supply oil hose (3, Figure 4.100) to
the three–way fitting and high pressure pump
(1, Figure 4.100). Tighten the nuts (2, Figure
4.100) to the special torque value. 2
OR
1
3
2
EG–7005
Figure 4.100 Installing Oil Supply Hose To En-

gines Equipped With The Old Three–Way Fit-
ting
2. Oil Supply Hose Mounting Nuts
3. Oil Supply Hose
EGES 160 – 1
SERVICE MANUAL
Section 4
1. Install the oil supply hose (2, Figure 4.101) to
the three–way fitting and the high pressure
pump (3, Figure 4.101). Tighten the nuts (1,
Figure 4.101) to the special torque value.
1
2
OR
Unit 1
1. Install the oil supply hose (2, Figure 4.102) to
the three–way fitting and the high pressure
pump (3, Figure 4.102). Tighten the nuts (1,
3
Figure 4.102) to the special torque value.
EG–6873

gines Equipped With The New Three–Way Fit-
ting
2. Oil Supply Hose
3 1
1 EG–6883

gines Equipped With Engine Mounted ECM
Unit
2. Oil Supply Hose
EGES 160 – 1
SERVICE MANUAL
Section 4

SENSOR REMOVAL

installation.
1. Apply Loctite #277 to the threads of the ICP

sensor.
2. Install ICP sensor, together with O–Ring, to the

4.103). EG–5117
Figure 4.103 Installing ICP Sensor To Old

Three–Way Fitting

installation.
1. Apply Loctite #277 to the threads of the ICP

sensor.
2. Install the ICP sensor, together with O–Ring, to

the three–way fitting of the supply manifold
(Figure 4.104). EG–6843
Figure 4.104 Installing ICP Sensor To New

Three–Way Fitting

Unit

installation.
1. Apply Loctite #277 to the threads of the ICP EG–6877

sensor.
Figure 4.105 Installing ICP Sensor To Supply
2. Install the ICP sensor, together with O–Ring, to Manifold On Engines Equipped With Engine
the supply manifold (Figure 4.105). Mounted ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 4
Complete the installation by attaching the following
items. Refer to the appropriate sections for the
proper installation procedures.
Turbocharger oil supply tube
Turbocharger oil drain tube
Turbocharger
Road Draft Tube
Exhaust manifold
ECM and Mounting Bracket, if Equipped
Main Wiring Harness
Fuel supply line to supply manifold from filter header
EGES 160 – 1
SERVICE MANUAL
ROCKER ARM ASSEMBLY CAMSHAFT,
TAPPETS AND PUSH RODS
SECTION 5 INDEX
Page
EXPLODED VIEW OF ROCKER ARM ASSEMBLY, CAMSHAFT ASSEMBLY,

TAPPETS AND PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Valve Lever and Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tappets Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Push Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ROCKER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MISCELLANEOUS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MEASURE CAMSHAFT LOBE LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CAMSHAFT GEAR AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CAMSHAFT AND CAMSHAFT GEAR CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CAMSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY OF CAMGEAR ONTO CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CHECKING CAMSHAFT END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CAMSHAFT BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CAMSHAFT BUSHING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CRANKCASE BUSHING BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CAMSHAFT BUSHING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TAPPET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PUSH ROD CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CAMSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
EGES 160 – 1
SERVICE MANUAL
ROCKER ARM ASSEMBLY, CAMSHAFT ASSEMBLY, Section 5
Page 1
EXPLODED VIEW OF ROCKER ARM ASSEMBLY, CAMSHAFT ASSEMBLY, TAPPETS
AND PUSH RODS
Figure 5.1 Exploded View of Rocker Arm Assembly, Camshaft Assembly, Tappets and Push Rods
1. Screw
2. Timing Sensor Disk
3. Dowel Pin
4. Camshaft Gear
5. Bolt
6. Camshaft Thrust Plate
7. Woodruff Key
8. Push Rod
9. Valve Roller Tappet
10. Roller Tappet Guide
11. Camshaft Assembly
12. Retainer Ring
13. Valve Adjusting Screw
14. Valve Lever (Rocker Arm)
15. Rocker Shaft Bracket
16. Rocker Arm Shaft Spring
17. Rocker Arm Shaft Plug
18. Rocker Arm Shaft
EGES 160 – 1
SERVICE MANUAL
Section 5 ROCKER ARM ASSEMBLY, CAMSHAFT ASSEMBLY,
Page 2
SPECIFICATIONS
Camshaft
Cam Lobe Lift (Total):

Intake 8.070 mm (0.3177 in.)
Exhaust 7.369 mm (0.2901 in.)
Maximum Permissible Cam Lobe Wear 0.51 mm (0.020 in.)
0.05 mm (0.002 in.)
Camshaft Running Clearance 0.18 mm (0.007 in.)
Maximum Permissible Camshaft Running Clearance 0.20 mm (0.008 in.)
58.026 mm (2.2845 in.)
Bushing I.D. (Installed in Crankcase) 58.115 mm (2.2880 in.)
57.948 mm (2.2814 in.)
Bushing Journal Diameter 57.976 mm (2.2825 in.)
Service Bushings Furnished to Size Yes
6.96 mm (0.274 in.)
Thrust Plate Thickness (New) 7.01 mm (0.276 in.)
0.13 mm (0.005 in.)
End Clearance 0.33 mm (0.013 in.)
Camshaft End Play 0.13–0.33 mm (0.005–0.013 in.)
Valve Lever and Shaft Assembly
21.567 mm (0.8491 in.)

Valve Lever Shaft Diameter 21.593 mm (0.8501 in.)
0.048 mm (0.0019 in.)
Valve Lever Clearance on Shaft 0.124 mm (0.0049 in.)
21.64 mm (0.852 in.)
Valve Lever Bushing (I.D.) 21.69 mm (0.854 in.)
Tappets Roller
28.435 mm (1.1195 in.)

Diameter 28.448 mm (1.1200 in.)
74.24 mm (2.923 in.)
Length 75.01 mm (2.953 in.)
0.30 mm (0.012 in.)
Side Clearance (Roller to Tappet Body) 0.66 mm (0.026 in.)
0.064 mm (0.0025 in.)
Tappet Clearance in Crankcase 0.102 mm (0.0040 in.)
Push Rod
273.685 mm (10.7750 in.)*

Length 274.447 mm (10.8050 in.)*
Maximum Run–Out (T.I.R.) 0.51 mm (0.020 in.)
* Length is measured over 0.3125 inch diameter gauge ball in cup end to theoretical end of ball.
EGES 160 – 1
SERVICE MANUAL
Page 3
Valve Lever Shaft Springs
Number of Springs 5
Free Length 103.1 mm (4.06 in.)
Test Length 52.6 mm (2.07 in.)
Test Load 31 Nm (7 lbs.)
O.D. 25.9 mm (1.02 in.)

Camshaft Thrust Plate Bolt 29 Nm (19 lb–ft. or 228 lb–in.)
Camshaft Gear Timing Disk 7 Nm (60 lb–in.)

ZTSE2893C Camshaft Bushing Service Set
ZTSE2241 Valve and Clutch Spring Tester
ZTSE4229 Camshaft Gear Puller
OEM1022 Telescoping Gauge Set
EGES 160 – 1
SERVICE MANUAL
Page 4
ROCKER ARM ASSEMBLY
Refer to the appropriate section of this publication
for the removal procedures for the following items:
Turbocharger oil supply line
Turbocharger oil drain line
Turbocharger
Exhaust manifold
ECM and Mounting Bracket, if equipped
Wiring harness
Valve cover/intake manifold
Cylinder head
REMOVAL
1. Remove valve lever (rocker arm) assembly as
follows: (Refer to Figure 5.2).
a. Loosen all valve lever (rocker arm) adjust-
ing screw nuts to loosen adjusting screw 1/2
turn.
NOTE: Loosening valve lever (rocker arm) ad-
justing screw 1/2 turn will avoid possible valve
train damage during installation.
b. Loosen six (6) valve lever (rocker arm)
bracket bolts (long cylinder head bolts).
c. Lift valve lever (rocker arm) assembly from
the cylinder head.
2. Remove six (6) long bolts and washers from
valve lever (rocker arm) assembly and set
aside.
IMPORTANT
AT THIS STAGE OF DISASSEMBLY, MEASURE
CAMSHAFT LOBE LIFT.
EG–5158
EGES 160 – 1
SERVICE MANUAL
Page 5
ROCKER ARM ASSEMBLY – CONTIN-
UED
MEASURE CAMSHAFT LOBE LIFT
IMPORTANT
CAMSHAFT WEAR CAN BE MEASURED WITH-
OUT COMPLETE ENGINE TEAR DOWN. WITH
THE VALVE LEVER (ROCKER ARM) ASSEMBLY
REMOVED AND THE PUSH RODS IN PLACE,
MEASURE CAMSHAFT LOBE LIFT AS FOL-
LOWS:
1. Mount a magnetic base dial indicator on the cyl-

inder head (Figure 5.3). EG–5160
2. Place dial indicator tip on top of push rod and ro- Figure 5.3 Mounting Magnetic Base Dial Indi-
tate engine until push rod is at its lowest point of cator
travel (base circle). Then “zero” indicator. Re-
fer to Figure 5.3.
3. Rotate the engine and bring the push rod to its
highest point of travel. Record the indicator
reading. Refer to Figure 5.4.
4. Repeat this procedure for all lobes.
IMPORTANT
INTAKE AND EXHAUST VALVE LOBE LIFT
SPECIFICATIONS ARE DIFFERENT. IF WEAR IS
GREATER THAN 0.51 MM (0.020 IN.), REPLACE
THE CAMSHAFT.
NOTE: If a complete engine overhaul is sched-

EG–5161
uled, camshaft lobe wear can be determined by
measuring lobes with a micrometer when the Figure 5.4 Recording Camshaft Lobe Reading
camshaft is removed (Figure 5.5). Refer to
“Camshaft Cleaning and Inspection” in this sec-
tion for details.
EG–5221
Figure 5.5 Measuring Cam Lobes With Mi-

crometer
EGES 160 – 1
SERVICE MANUAL
Page 6
UED
DISASSEMBLY
1. Place valve lever (rocker arm) assembly on a
clean flat surface.
2. Using a snap ring tool, remove valve lever
(rocker arm) retainer ring at end of shaft. (Refer
to Figure 5.6.
3. Slide the rocker arm components off shaft as
shown in Figure 5.7.
EG–5381
CLEANING
1. Immerse all components in a suitable solvent.
2. Remove and dry using filtered compressed air. Figure 5.6. Removing Valve Lever Retaining
Ring
6 2
5 4 3 1
EG–5161
Figure 5.7 Valve Lever Assembly Components

1. Retaining Ring
2. Valve Lever
3. Bracket
4. Spring
5. Bolt
6. Shaft
INSPECTION
1. Visually inspect valve lever (rocker arm) shaft
and rocker arm bushings for scoring or signs of
excessive wear. If visibly damaged, replace
1
shaft and/or valve lever (rocker arm), as re-
quired.
EG–5160
NOTE: Valve levers have an oil spreader groove
on the bushing. The oil spreader groove (0.011
in. – 0.018 in.) {0.028–0.046 mm} depth) is lo-
cated opposite the oil hole and aids in oil disper- Figure 5.8 Valve Lever Oil Spreader Groove
sion over the entire bushing surface. Refer to
Figure 5.8. 1. Oil Spreader Groove
EGES 160 – 1
SERVICE MANUAL
Page 7
UED
2. Measure valve lever bushings using a telescop-
ing gauge (OEM1022) and outside micrometer
as shown in Figure 5.9. Measure bushings at
two (2) locations, 90° apart. Record the read-
ings.
3. Measure the valve lever shaft with a microme-
ter. If more than 0.13 mm (0.005 in.) difference
is found between the valve lever bushing I.D.
and the valve lever shaft O.D., replace the valve
lever and/or shaft, whichever part is worn.
EG–5208
4. If valve levers are within specifications, they
may be reused. Prior to assembly, assure oil Figure 5.9 Measure Valve Lever Bushing
hole in valve levers and bushings is open by
running a wire through the oil hole. Remove any
blockage before assembly. Refer to Figure
5.10.
EG–5380
Figure 5.10 Checking Valve Lever Oil Opening
EGES 160 – 1
SERVICE MANUAL
Page 8
UED
5. Inspect all orifices for blockage. Run a wire
through each to assure they are open. Refer to
Figure 5.11.
6. Inspect valve lever (rocker arm) shaft springs EG–5905
as follows:
Figure 5.11 Checking Valve Lever Compo-
a. Visually inspect for rust, pitting and cracks. nents
b. Measure the spring tension using spring
tester (ZTSE2241). Refer to Figure 5.12
and “SPECIFICATIONS”.
Measure free length (no load applied).
Apply correct test load and measure test
length.
c. Replace rocker arm shaft springs which do
not meet “SPECIFICATIONS”.
ASSEMBLY
1. Lubricate all valve lever bushings with clean en-
gine oil, install a retaining ring at one end of
shaft and assemble components with rocker
arm shaft in the vertical position. Refer to Fig-
ure 5.13.
EG–5202
Figure 5.12 Measuring Valve Lever Spring

Tension
EG–5906
Figure 5.13 Assembly Of Valve Lever Compo-

nents
EGES 160 – 1
SERVICE MANUAL
Page 9
UED
ASSEMBLY – CONTINUED
2. Arrange valve lever (rocker arm) assembly
components as shown in Figure 5.14.
IMPORTANT
THE ROCKER ARM SHAFT IS MARKED WITH
THE WORK “TOP” (FIGURE 5.14). THIS
SHOULD FACE UP AT ALL TIMES.
Figure 5.14 Valve Lever Component Arrangement

1. Retaining Ring
2. Valve Lever
3. Bracket
4. Spring
5. Shaft
6. Cup Plug
EGES 160 – 1
SERVICE MANUAL
Section 5 ROCKER ASSEMBLY, CAMSHAFT ASSEMBLY,
Page 10
UED
NOTE: The brackets must line up over the shaft
bolt grooves. Figure 5.15 shows an end view
position of the valve lever (rocker arm) shaft to
the mounting bracket.
3. When all components of the valve lever (rocker

arm) shaft have been installed in the correct or-
der, attach a retaining ring to secure the compo-
nent to the shaft. Refer to Figure 5.16.
Figure 5.15 Valve Lever Bracket Assembly
NOTE: Cup plugs (at each end of the shaft) are
1. Cylinder Head
replaceable. Refer to Figure 5.14. DO NOT dis-
2. Bracket
turb unless damaged, leaking hard part failure
3. Rocker Arm Shaft Position
or contaminated oil. If replacement is required,
4. Mounting Bolt
pry damaged plug out and press in a new cup
5. Shaft Hole
plug.
EG–5381
Figure 5.16 Valve Lever Shaft Cup Ends
EGES 160 – 1
SERVICE MANUAL
Page 11
UED
INSTALLATION
1. Install the valve lever assembly and adjust the
valve lash as outlined in Section 4, “CYLINDER
HEAD AND VALVES”.
2. Reinstall the valve cover/intake manifold and
crankcase breather tube. Refer to Section 3,
“MANIFOLDS” for further information.
EG–5167
CAMSHAFT GEAR AND CAMSHAFT Figure 5.17 Removing Roller Tappet Guides
REMOVAL
Refer to the appropriate manual sections for re-
moval instructions for fuel, turbocharger, cylin-
der head and front cover items. 2
1. Remove roller tappets and roller tappet guides
1
from their bores. Refer to Figure 5.17.
NOTE: Mark the tappets as to location in the 4
crankcase, so they can be returned to their origi-
nal position.
2. Refer to Figure 5.18, for location of gears and 3

timing marks. Rotate the engine so that timing
marks on lower and upper idler gears, crank-
shaft and camshaft gears are aligned. EG–5313
IMPORTANT
PRIOR TO REMOVING ANY GEAR, MOUNT A Figure 5.18 Gears And Timing Marks
MAGNETIC BASE DIAL INDICATOR ONTO THE
ENGINE AND CHECK FOR GEAR BACKLASH 1. Camshaft Gear
AND END PLAY. REFER TO SECTION 8, “TIM- 2. Upper Idler Gear
ING GEAR TRAIN AND FRONT COVER” FOR IN- 3. Crankshaft Gear
STRUCTION. 4. Lower Idler Gear
EGES 160 – 1
SERVICE MANUAL
Section 5 ROCKER ASSEMBLY, CAMSHAFT ASSEMBLY,
Page 12
CAMSHAFT GEAR AND CAMSHAFT –
CONTINUED
1 2
3. Remove the high pressure pump as outlined in
Section 12, “HIGH PRESSURE LUBE OIL
SYSTEM”.
4. If removing the CAMSHAFT GEAR ONLY use
the following instructions:
3
IMPORTANT
DO NOT PRY ON TIMING DISK PLATE
a. Remove the three (3) screws securing the
timing disk plate to the camshaft gear. Re- EG–5311
move the timing disk plate (Figure 5.19).
Figure 5.19 Removing Timing Disk Plate
b. Install camshaft gear puller ZTSE4229 to
camgear. 1. Camshaft Gear
2. Timing Disk Plate Mounting Bolts
IMPORTANT 3. Timing Disk Plate
DO NOT USE AN IMPACT WRENCH. USE OF AN
IMPACT WRENCH WILL FORCE THE CAM-
SHAFT TO MOVE REARWARD, RESULTING IN
EXCESS CAMSHAFT END PLAY.
c. Turn the camshaft gear puller. When the
camgear has moved out approximately 13
mm (1/2 in.), use a pry bar or ratchet to force
the camshaft gear to its forward most posi-
tion. Finish removing camshaft gear (Fig-
ure 5.20).
EG–5325
Figure 5.20 Moving Camshaft Gear To For-

ward Position
EGES 160 – 1
SERVICE MANUAL
ROCKER ASSEMBLY, CAMSHAFT ASSEMBLY, Section 5
Page 13
CAMSHAFT GEAR AND CAMSHAFT –
CONTINUED
5. IF REMOVING THE CAMSHAFT GEAR AND
CAMSHAFT AS IN ASSEMBLY, remove two
(2) camshaft gear thrust plate bolts. Refer to
Figure 5.21.
NOTE: When the engine is mounted in a turn-
over stand, rotate engine so front of engine is
facing up (engine in vertical position). This
position allows for easy removal of camshaft
assembly.
6. Remove the camshaft from the crankcase by

lifting the assembly straight up. Refer to Figure
5.22. EG–5324
NOTE: This method reduces the risk of damag- Figure 5.21 Removing Camshaft Gear Thrust
ing the camshaft journals and/or bushings. Plate Bolts
EG–5326
Figure 5.22 Removing Camshaft And Gear

From Crankcase
EGES 160 – 1
SERVICE MANUAL
Page 14
CAMSHAFT AND CAMSHAFT GEAR
CLEANING AND INSPECTION
1. Wash the camshaft in a suitable solvent using a
soft bristle brush.
2. Visually inspect camshaft. If any lobes are
scuffed, scored or cracked, replace camshaft.
3. Beyond visual inspection, evaluate camshaft
journal and lobe condition using a micrometer
as follows:
a. Inspect camshaft journal for wear. Using a
micrometer, measure camshaft journal di-
ameter (see SPECIFICATIONS). If journals
are worn beyond limits, replace the cam-
shaft.
b. Check camshaft lobe wear using a microm-
eter as follows: (Figure 5.23)
Measure across (A–D) and across (B–C).
Subtract (B–C) from (A–D). This will give
EG–5221
cam lobe lift (see (SPECIFICATIONS). Re-
place camshaft when cam lobe wear ex- Figure 5.23 Check Camshaft Lobe Wear
ceeds specifications.
4. Visually inspect thrust plate wear, cracks or dis-
tortion. Use a micrometer to measure thrust
plate thickness (see SPECIFICATIONS). Re-
place thrust plate if worn, damaged or if exces-
sive end play is measured, as previously de-
scribed.
5. Visually inspect camshaft drive gear for worn or
damaged teeth. Inspect the timing disk plate.
CAMSHAFT ASSEMBLY
1. Assemble the camshaft, thrust plate, camshaft
gear and timing disk plate as follows:
a. Support the camshaft in an appropriate ar-
bor press.
b. Place the thrust plate on the keyway end of
the camshaft against the bearing journal.
c. Insert the woodruff key into the keyway.
NOTE: Use a thermomelt stick, available at any
welding supply house, to determine tempera-
ture.
d. Press camgear onto camshaft.
EGES 160 – 1
SERVICE MANUAL
ROCKER ASSEMBLY, CAMSHAFT ASSEMBLY, Section 5
Page 15
CAMSHAFT REASSEMBLY – CONTIN-
UED
ASSEMBLY OF CAMGEAR ONTO CAMSHAFT
IMPORTANT
HEATING A CAMSHAFT GEAR BEYOND 177°C
(350° F) WILL CAUSE IT TO TURN BLUE. ANY
CAMSHAFT GEAR WHICH HAS TURNED BLUE
CANNOT BE REUSED.
1. IF ONLY the camgear was removed, perform

the following:
a. Heat the camshaft gear in an oven to
149–177° C (300–350° F).
IMPORTANT
1. BE SURE TO USE WELDING GLOVES. EG–5327
2. CAMSHAFT GEAR SHOULD SLIDE ONTO

CAMSHAFT WITH SLIGHT HAND PRES-
SURE. DO NOT FORCE CAMGEAR.
b. Use welding gloves to install the heated Figure 5.24 Installing Camgear Onto Cam-
camshaft gear. Remove camgear assem- shaft
bly from oven. BE SURE to align the cam-
gear timing marks with the upper idler gear
and install onto camshaft with timing marks
showing. HOLD camshaft gear on cam-
shaft until it tightens as it cools (approxi-
mately 30 seconds, Figure 5.24).
CHECKING CAMSHAFT END PLAY

Attach an indicator dial and check camshaft end
play (Figure 5.25). If there is excessive end play,
the camshaft has probably slipped back. Remove
the camgear and pull the camshaft forward. Repeat
step 1. Refer to “SPECIFICATIONS”.
CAMSHAFT BUSHING INSPECTION

1. Inspect the four (4) camshaft bushings for wear
and proper running clearance as follows:
a. Using a micrometer, measure camshaft
bushing journal diameter at two (2) loca-
EG–5328
tions, 90° apart and record readings.
b. Using a telescoping gauge (OEM1022) and
micrometer, measure the camshaft bushing
I.D. with bushing installed in the crankcase.
Record the readings. Figure 5.25 Check Camshaft End Play
EGES 160 – 1
SERVICE MANUAL
Page 16
CAMSHAFT BUSHING INSPECTION –
CONTINUED
c. Subtract the readings obtained in steps 1a
and b, to determine running clearance.
d. If maximum allowable running clearance is
exceeded (see “SPECIFICATIONS”), re-
place the camshaft bushings using the cam-
shaft bushing remover and installer
(ZTSE2893C).
IMPORTANT
WHEN SERVICING THE CAMSHAFT BUSH-
INGS, THE CRANKSHAFT AND MAIN BEARING
MUST BE REMOVED FROM THE CRANKCASE
TO AVOID DEBRIS CONTAMINATION.
CAMSHAFT BUSHING REMOVAL

1. Use the camshaft bushing service set
(ZTSE2893C) to remove the camshaft bush-
ings. Refer to Figure 5.26.
NOTE: ZTSE2893C includes:

Puller screw
Explanding mandrel
Puller screw extension
Expanding collate
Pulling nut
Back–up nut
Thrust bearing
Figure 5.26 Camshaft Bushing Service Set Components
EGES 160 – 1
SERVICE MANUAL
Page 17
CAMSHAFT BUSHING REMOVAL –
CONTINUED
NOTE: The four camshaft bushings have the
same inside diameter but the outside diameter
and widths of each bushing are different, as is
the crankcase bore into which each bushing
fits. Refer to the chart below.
IMPORTANT
BECAUSE OF THE DIFFERENT SIZE OUTSIDE
DIAMETERS OF THE BUSHINGS, THE ORDER
OF REMOVAL IS LIMITED AS FOLLOWS: RE-
MOVE THE FRONT AND REAR BUSHINGS
FIRST. THEN REMOVE THE TWO INTERMEDI-
ATE BUSHINGS THROUGH THE FRONT OF THE
CRANKCASE.
CAMSHAFT BUSHING CHART
BUSHING BORE DIAMETER IN

BUSHING O.D. BUSHING WIDTH
BUSHING POSITION CRANKCASE
63.665 mm (2.5065 in.) 63.550 mm (2.5020 in.)
Front 25.4 mm (1.00 in.)
63.627 mm (2.5050 in.) 63.512 mm (2.5005 in.)
63.627 mm (2.4865 in.) 63.042 mm (2.4820 in.) 18.0 mm (0.709 in.)
Intermediate/Front
63.157 mm (2.4850 in.) 63.004 mm (2.4805 in.) 17.5 mm (0.689 in.)
62.649 mm (2.4665 in.) 62.534 mm (2.4620 in.) 18.0 mm (0.709 in.)
Intermediate/Rear
62.611 mm (2.4650 in.) 62.611 mm (2.4605 in.) 17.5 mm (0.689 in.)
62.141 mm (2.4465 in.) 62.026 mm (2.4420 in.) 18.7 mm (0.740 in.)
Rear
62.103 mm (2.4450 in.) 61.988 mm (2.4405 in.) 16.7 mm (0.660 in.)
2. Using a camshaft bushing remover and installer

tool (ZTSE2893C), select the proper size ex-
panding collet and back–up nut and assemble
onto the expanding mandrel. With the expand-
ing collet collapsed, install the collet assembly
into the camshaft bushing to be removed and
tighten the back–up nut onto the expanding
mandrel until the collet fits the camshaft hous-
ing. Refer to Figures 5.26 and 5.27.
EGES 160 – 1
SERVICE MANUAL
Page 18
CONTINUED
3. Assemble the puller screw and extension, if
necessary and install onto the expanding man-
drel. Tighten the pulling nut against the thrust
bearing and pulling plate to remove the cam-
shaft bushing (Figure 5.27).
NOTE: Be sure to hold the end of the puller
screw with a wrench to prevent it from turning,
when tightening the pulling nut.
4. Repeat the procedure for each bushing.

NOTE: To remove the rear bushing, install the
puller screw from the rear of the crankcase. All
other bushings are removed by going through Figure 5.27 Camshaft Bushing Location
the front of the crankcase.
CRANKCASE BUSHING BORE INSPECTION

1. Visually inspect each bushing bore in the crank-
case 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.
EG–5244
Figure 5.28 Install New Bushing Onto Collet
CAMSHAFT BUSHING INSTALLATION

1. Identify each bushing by its outside diameter.
Refer to the “CAMSHAFT BUSHING CHART”
which appears earlier in this section.
2. Lubricate new camshaft bushings as well as
crankcase bushing bore with clean engine oil.
3. Install new bushing onto expanding collet and
tighten collet by turning backup nut until bush-
ing is held securely. Refer to Figure 5.28.
4. Mark oil hole location on back up nut of installa-
tion tool to aid in alignment of bushing and
EG–5247
crankcase oil holes. Refer to Figure 5.29.
NOTE: This step must be repeated for each Figure 5.29 Mark Oil Hole Location On Bush-
bushing installed. ing
EGES 160 – 1
SERVICE MANUAL
Page 19
CONTINUED
5. Install rear intermediate bushing through front
of crankcase, then pull it onto place at rear of
crankcase by turning pulling nut on puller
screw. Remove tool and inspect oil hole align-
ment.
IMPORTANT
THE BUSHINGS MUST BE INSTALLED IN THE
PROPER ORDER BECAUSE ON THE DIFFER-
ENT OUTSIDE DIAMETERS OF THE BUSHINGS.
6. Install front intermediate bushing next. Install

through front of crankcase and pull into place
from rear. Refer to Figure 5.30. Figure 5.30 Install Bushing
7. Next install front camshaft bushing by pulling it
into place from rear.
8. The rear camshaft bushing must be pulled into
place from front of crankcase.
IMPORTANT
ALL BUSHING OIL HOLES MUST BE IN ALIGN-
MENT WITH OIL HOLES IN CRANKCASE.
TAPPET INSPECTION
Visually inspect all roller tappets and rollers for pit-
ting, roughness and free rotation of roller. Check di-
mensionally, if specifications are exceeded replace
the tappet.
EG–5375
PUSH ROD CLEANING AND INSPEC- Figure 5.31 Chack Push Rods For Straight-
ness
TION
1. Thoroughly clean each push rod using a suit-
able solvent and dry using filtered compressed
air.
2. Visually inspect each rod for wear at ends. Re-
place as required.
3. Check all push rods for straightness by rolling
on a flat surface, Figure 5.31. Replace any rod
which is bent.
4. Check push rod run–out. If specifications are
exceeded, replace the rod.
EGES 160 – 1
SERVICE MANUAL
Page 20
INSTALLATION
CAMSHAFT ASSEMBLY
1. With the engine in the vertical position, lubricate
the camshaft and the camshaft bushings using
clean engine oil.
IMPORTANT
BE SURE TO AVOID NICKING OR SCRATCHING
CAMSHAFT BUSHINGS WITH CAM LOBES.
2. Gently slide camshaft assembly into crank-

case. Be careful not to damage camshaft bush-
ings.
3. Install two (2) thrust plate mounting bolts and
EG–5323
tighten to the special torque value. Refer to Fig-
ure 5.32.
Figure 5.32 Install Camgear To Thrust Plate
NOTE: Bolts securing timing disk to camgear
SHOULD be replaced every time the timing disk
is removed.
4. Install camgear timing disk plate over two (2)

dowel pins and tighten bolts to the special
5. Install idler gears as described in Section 8,
“TIMING GEAR TRAIN AND FRONT COV-
ER”.
6. Check camshaft gear backlash and camshaft
end play as described in Section 8, “TIMING
GEAR TRAIN AND FRONT COVER”. Specifi-
EG–5312
cations must be met.
Figure 5.33 Install Timing Disk Plate
TAPPETS
If roller tappets are re–usable, lubricate roller tap-
pets and guides with clean engine oil. Install into
their original bores, unless new tappets are used
(Figure 5.34).
NOTE: BE SURE the tappet rollers all turn in the

same direction as when removed.
PUSH RODS
EG–5168
Install push rods with the cup end up. Refer to Sec-
tion 4, “CYLINDER HEAD AND VALVES”. Figure 5.34 Lubricating Roller Tappet Guides
EGES 160 – 1
SERVICE MANUAL
Page 21
for the installation procedures for the following
items:
Turbocharger
Exhaust manifold
Wiring harness
Cylinder head
EGES 160 – 1
SERVICE MANUAL
CONNECTING RODS, PISTONS RINGS AND SLEEVES
SECTION 6 INDEX
Page
EXPLODED VIEW OF CONNECTING RODS, PISTONS, RINGS AND SLEEVES . . . . . . . . . . . . . . . . . . . 1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Piston Rings – Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston Rings – Oil Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PISTON AND ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CYLINDER SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONNECTING ROD, PISTON & RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CYLINDER SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OUT–OF–ROUND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CYLINDER SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
METHOD ONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
METHOD TWO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
METHOD THREE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BEARING FITTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CYLINDER SLEEVE FITTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SURFACE GAUGE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DEPTH MICROMETER METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
METHOD ONE, USE GRADUATED MARKS ON TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
METHOD TWO, USE FEELER GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CONNECTING RODS, PISTONS & RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CYLINDER SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PISTON & CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CONNECTING ROD BEARING INSERTS AND CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
EGES 160 – 1
SERVICE MANUAL
CONNECTING RODS, PISTONS, RINGS AND SLEEVES Section 6
Page 1
EXPLODED VIEW OF CONNECTING RODS, PISTONS, RINGS AND SLEEVES
12
11
Figure 6.1 Exploded View Of Connecting Rods, Pistons, Rings And Sleeves
1. Piston Ring (Top Compression) (6) 7. Piston Pin Bushing (6)
2. Piston Ring Intermediate Compression (6) 8. Connecting Rod Bearing (12)
3. Piston Ring (Oil Regulating) (6) 9. Connecting Rod And Cap (6)
4. Piston Pin Retainer (12) 10. Bolt (12)
5. Piston Pin (6) 11. Sleeve Seals
6. Piston (6) 12. Sleeve (6)
EGES 160 – 1
SERVICE MANUAL
Page 3
Piston Rings – Compression
Number of rings per piston 2
Type (face and finish):
Top Ring Full Keystone (barrel faced) – Plasma Coated
Intermediate Ring :
For engines rated at 230HP and below Rectangular (Negative Twist) – Phosphate Coat
For engines rated at 230HP, HT version and above Full Keystone (taper face) – Chromeless
Ring Gap with New Sleeve:
0.066mm (0.026 in.)
Top Ring 0.040mm (0.014 in.)
1.91mm (0.075 in.)
Intermediate Ring 1.65mm (0.065 in.)
Piston Rings – Oil Control

Number of Rings Per Piston 1Type
One Piece Slotted – Chrome 0.054mm (0.022 in.)
Ring Gap (466E) 0.024mm (0.012 in.)
0.055mm (0.026 in.)
Ring Gap (530E) 0.028mm (0.014 in.)
Piston Pins
46.3mm (1.8251 in.)
Diameter 46.3 mm (1.8249 in.)
88.6mm (3.490 in.)
Length 88.3mm (3.480 in.)
0.027mm (0.0011 in.)
Clearance in Rod 0.011mm (0.0006 in.)
Maximum Permissible Clearance in Rod, before replacing 0.08mm (0.003 in.)
0.015mm (0.00115 in.)
Clearance in Piston 0.028mm (0.00065 in.)
Maximum Permissible Clearance in Piston, before replacing 0.064mm (0.0025 in.)
Cylinder Sleeves
109.258mm (4.3015 in.)
Inside Diameter (New) (466E) 109.233mm (4.3005 in.)
114.5mm (4.5905 in.)
Maximum Permissible Diameter Sleeve Wear, at Top
of Ring Travel before Replacement (Sleeve Taper) 0.10mm (0.004 in.)
8.89mm (0.350 in.)
Counterbore Dimension in Crankcase 8.84mm (0.348 in.)
Maximum Allowable Variation of Counterbore Depth (Between Four Points) 0.025mm (0.001 in.)
Maximum Cylinder Sleeve Counterbore Allowable Depth (Used with shim kit) 10.49mm (0.413in.)
EGES 160 – 1
SERVICE MANUAL
Section 6 CONNECTING RODS, PISTONS RINGS AND SLEEVES
Page 4
Cylinder Sleeves – Continued
8.97mm (0.0353 in.)
Flange Thickness 8.94mm (0.0352 in.)
0.13mm (0.005 in.)
Protrusion above Crankcase 0.05mm (0.002 in.)

Connecting Rod Bolts 156 Nm (115 lb–ft.)

ZTSE2514 Counter Bore Tool
ZTSE2514–4 Counter Bore Cutter Head
ZTSE2515A Cylinder Liner Height Gauge With Holding Adapters
ZTSE2515–1 Cylinder Liner Holding Adapters (Part of Cylinder Liner
Height Gauge Kit)
ZTSE2536 Cylinder Sleeve Puller
ZTSE3020 Piston Groove Wear Measuring Tool
ZTSE4220 Piston Ring Expander
OEM1032 Cylinder Bore Gauge
OEM1022 Telescoping Gauge Set
EGES 160 – 1
SERVICE MANUAL
Page 5
for the removal procedures for the following items:
Turbocharger
Oil filter
Oil cooler
Exhaust manifold
Wiring harness
Rocker arm assembly EG–6901
Cylinder head
Front engine mounting bar Figure 6.2 Removing Connecting Rods
Vibration damper Mounting Bolts
Oil pan pick–up tube
Oil pan
PISTON AND ROD ASSEMBLY

REMOVAL
IMPORTANT
THE CARBON RIDGE MUST BE REMOVED BE-
FORE REMOVING THE PISTON AND ROD AS-
SEMBLY. THIS REDUCES THE CHANCE OF PIS-
TON RING LAND DAMAGE DURING REMOVAL.
1. Using a razor knife, scrape the carbon ridge

from the top of the cylinder sleeve. EG–5909
IMPORTANT
BE SURE TO MARK EACH CONNECTING ROD Figure 6.3 Remove Connecting Rod Main
CAP AND REASSEMBLE TO THE PERSPEC- Bearing Cap
TIVE CONNECTING ROD UPON REMOVAL.
ALSO MARK THE LOCATION OF THE CON-
NECTING ROD WITHIN THE CRANKCASE.
2. Loosen the connecting rod bolts using a socket

and breaker–bar (Figure 6.2).
3. Remove the bolts by hand.
NOTE: The bolts should turn out of the connect-
ing rod freely. If binding exists, check thread
condition carefully.
4. Remove the connecting rod cap and bearing in-
sert. Refer to Figure 6.3).
EGES 160 – 1
SERVICE MANUAL
Section 6 CONNECTING RODS, PISTONS, RINGS AND SLEEVES
Page 6
PISTON AND ROD ASSEMBLY – CON-

TINUED
5. Remove the piston and connecting rod assem-
blies as follows:
a. Rotate the engine in a vertical position, front
end up.
b. Push the piston and rod assembly from the
cylinder bore using a wood or plastic han-
dle. Refer to Figure 6.4.
c. Once the piston rings are free of the cylinder EG–6903
bore, the assembly can be removed from
the top of the crankcase. Refer to Figure Figure 6.4 Pushing Piston And Connecting
6.5. Rod Assembly Thru Crankcase
d. Match connecting rod and piston assem-
blies upon removal so they can be rein-
stalled in their respective cylinder bores.
EG–5335
Figure 6.5 Remove Piston And Connecting

Rod Assembly
EGES 160 – 1
SERVICE MANUAL
Page 7
CYLINDER SLEEVE
IMPORTANT
PRIOR TO INSTALLING THE PULLER, BAR THE
ENGINE OVER SO THE CRANKSHAFT JOUR-
NAL IS LOCATED AT THE BOTTOM (LOW
POINT) OF ITS TRAVEL. THIS PREVENTS POS-
SIBLE DAMAGE TO THE JOURNAL BY THE
PULLER LIFTING JAWS DURING PULLER
INSTALLATION.
1. Use the sleeve puller ZTSE2536 to remove the

cylinder sleeves as follows: (Refer to Figure EG–5341
6.6).
IMPORTANT
WHEN YOU REMOVE THE SLEEVE FROM
PULLER, BE SURE TO MARK SLEEVE WITH ITS Figure 6.6 Removing Sleeve From Crankcase
CYLINDER BORE NUMBER, ALSO MARK
SLEEVE POSITION IN BLOCK FOR PURPOSES
OF INSPECTION AND ASSEMBLY.
a. Position the puller in the sleeve and spread

the lifting jaws so the tangs grip the bottom
of the sleeve.
b. With the lifting bridge firmly on the crank-
case top deck, turn the forcing nut to break
the cylinder sleeve loose from the crank-
case.
c. Lift sleeve and puller from the crankcase.
DISASSEMBLY
1. Use a pic to remove two (2) O–Rings at the low-
er counterbore area of each cylinder sleeve.
2. Discard the O–Rings.
CONNECTING ROD, PISTON & RINGS

DISASSEMBLY EG–5405
1. Using pliers, remove the two (2) piston pin re-
taining rings. Refer to Figure 6.7.
IMPORTANT
MARK COMPONENTS WITH THE PISTON NUM-
BER FROM WHICH THEY WERE REMOVED, SO Figure 6.7 Remove Piston Pin Retaining
THEY MAY BE INSTALLED PROPERLY. Rings
EGES 160 – 1
SERVICE MANUAL
Page 8
CONNECTING ROD, PISTON & RINGS –

CONTINUED
2. Remove the piston pin from its bore, by hand
(Figure 6.8). Then separate the connecting rod
from the piston.
3. Remove the piston skirt from the piston crown
on the two (2) piece piston assemblies found on
the International® 530E (Figure 6.9).
4. Use a piston ring expander tool ZTSE4220 to EG–5230
remove the piston rings. Remove the top ring
first, then the intermediate ring and the oil con-
trol ring. Refer to Figure 6.10. Figure 6.8 Removing Piston Pin
CLEANING 2 3
1. Clean the aluminum pistons using a soap and 1
water solution; soak and then clean piston, us-
ing a non–metallic brush.
NOTE: Never use a caustic solution or a wire
brush for cleaning the aluminum pistons.
2. All piston ring grooves must be cleaned thor-

oughly. Be sure the two (2) cast oil holes
(DT–466E) or oil slots (International® 530E) in 4
EG–5401
the oil ring groove are open.
3. The following disassembled components may
be cleaned using a suitable solvent: Figure 6.9 Two–Piece Piston Assembly
a. Piston rings 1. Piston Pin
b. Piston pins 2. Piston Crown
c. Piston pin retainers 3. Piston Skirt
d. Connecting rods 4. Retaining Ring
4. Clean all rod bolt holes and threads thoroughly.
5. Clean the oil hole at the top of the rod. Make
sure it is not blocked.
CYLINDER SLEEVES
INSPECTION
1. Soak the cylinder sleeves in a soap and water
EG–5242
solution and clean thoroughly using a non–me-
tallic brush.
2. Dry with filtered compressed air. Figure 6.10 Remove Piston Rings
EGES 160 – 1
SERVICE MANUAL
Page 9
PISTONS
INSPECTION
1. Visually inspect the pistons for scuffed or
scored skirts and cracked or worn lands. Re-
place the pistons as required.
2. Check top and intermediate compression ring
groove widths for wear as follows:
IMPORTANT
DT 466E ENGINES RATED AT 230HP, HT VER-
SION AND ALL INTERNATIONAL® 530E EN-
GINES USE FULL KEYSTONE COMPRESSION
RINGS (FIRST AND SECOND GROOVE) AND A
RECTANGULAR OIL CONTROL RING. DT 466E
ENGINES RATED AT 230 HP AND BELOW USE
A FULL KEYSTONE COMPRESSION RING AND
A RECTANGULAR INTERMEDIATE AND OIL
CONTROL RING (SECOND AND THIRD
GROOVE). THE PISTON RING GROOVE CON-
FIGURATION CORRESPONDS TO THE SHAPE
OF THE PISTON RING (FIGURE 6.6). KEY
STONE COMPRESSION RING GROOVES ARE Figure 6.11 Piston Ring Location
MEASURED OVER GAUGE PINS TO DETER-
MINE WEAR. RECTANGULAR RING GROOVES 1. Piston
DO NOT USE GAUGE PINS, BUT SIDE CLEAR- 2. Gauge Pins
ANCE TO DETERMINE PISTON RING GROOVE
WEAR.
a. Install the 2.921 mm (0.1150 in.) gauge pins

from the piston groove wear gauge pin set
(ZTSE3020), into the groove to be mea-
sured. Refer to Figure 6.11).
IMPORTANT
GAUGE PINS MUST BE PARALLEL.
b. Measure the piston diameter over gauge

pins using an outside micrometer (Figure
6.12).
c. If the measurement over the gauge pins is
NOT within specifications, excessive piston
groove wear exists and the piston must be EG–5240
replaced with a new piston. Refer to
“SPECIFICATIONS”. Figure 6.12 Measuring Piston Diameter
EGES 160 – 1
SERVICE MANUAL
Page 10
PISTONS – CONTINUED
3. Check the rectangular oil control ring groove for
side clearance as follows. Refer to Specifica-
tions:
a. Using a new ring, place the outer edge of the
ring in the oil control ring groove.
b. Roll the ring, in its respective groove, entire-
ly around the piston. Make sure the ring is
“free” in the groove.
c. With a feeler gauge check the side clear-
ance of each oil control ring in its respective
groove (Figure 6.13).
EG–5241
d. Excessive side clearance indicates ring
groove wear and requires piston replace-
ment.
4. Check piston to cylinder sleeve running clear- Figure 6.13 Checking Oil Control Ring Clear-
ance, as follows: ance
a. Measure and record the piston skirt diame-

ter. With the piston at room temperature,
place an outside micrometer 27.43 mm
(1.080 in.) below the bottom land of the oil
control ring 90° from the pin bore. Refer to
Figure 6.14.
b. Measure cylinder sleeve inside diameter,
refer to “CYLINDER SLEEVE INSPEC-
TION” later in this section for the procedure.
Record the reading.
c. Subtract the piston skirt diameter from the
cylinder sleeve I.D.. The resulting dimen-
sion is the piston to cylinder sleeve running
clearance.
d. If running clearance is not within “SPECIFI-
CATIONS”, replace the piston.
EGES 160 – 1
SERVICE MANUAL
Page 13
CONNECTING RODS – CONTINUED

7. Measure connecting rod bearing bore taper
(Figure 6.18), by measuring bore I.D. on each
side of bearing bore. Record the readings. The
difference between the two readings is the bore
taper (See “SPECIFICATIONS”). Replace rod
as required.
8. With connecting rod cap removed, visually in-
spect surface finish of connecting rod bearing
bore. The bore must be smooth and free of
scoring, nicks or burrs. Replace as required.
9. CONNECTING ROD BEND AND TWIST:
Often engine component wear patterns can be EG–5237
identified and used to diagnose a problem.

Some common examples of connecting rod Figure 6.18 Measuring Connecting Rod Bear-
wear patterns include: ing Bore Taper
a. A shiny surface on edge of piston pin bush-
ing usually indicates that a connecting rod is
bent or piston pin hole is not in proper rela-
tion to piston skirt and ring grooves.
b. Abnormal connecting rod bearing wear can
be caused by either a bent connecting rod or
a tapered connecting rod bore.
c. Twisted connecting rods will not create an
easily identifiable wear pattern but badly
twisted rods will disturb action of entire pis-
ton, rings and connecting rod assembly and
may be the cause of excessive oil consump-
tion.
If any of these conditions exist, check the connect-
ing rods for bends or twists using a suitable align-
ment fixture. Follow the instructions of the fixture
manufacturer. If bend or twist exceeds “SPECIFI-
CATIONS”, replace the connecting rod.
IMPORTANT
IF THE CONNECTING RODS DO NOT MEET THE
REQUIREMENTS SET FORTH IN “CONNECT-
ING ROD INSPECTION”, PARAGRAPHS 1–9.
REPLACE THE ENTIRE CONNECTING ROD AS-
SEMBLY.
EGES 160 – 1
SERVICE MANUAL
Page 14
PISTON PINS
INSPECTION
1. Visually inspect piston pins for corrosion or
wear. Replace as required.
2. Use a micrometer to measure piston pin O.D. at
two (2) locations. Record the readings. Refer
to Figure 6.19. If piston pin wear exceeds
“SPECIFICATIONS”, replace the pin.
3. Check piston pin clearance in rod as follows:
a. Subtract piston pin O.D. from piston pin
EG–5231
bushing I.D. measurement.
b. If clearance exceeds “SPECIFICATIONS”, Figure 6.19 Measuring Piston Pin O.D.
replace the bushing.
CYLINDER SLEEVES
INSPECTION
1. Visually inspect inside surface of sleeve for
scuffing or scoring and polishing. Replace
sleeve and piston as required. Examine outer
surface of sleeve for cavitation erosion. Re-
place as required. EG–5339
2. Check cylinder sleeves for wear (taper) using Figure 6.20 Measuring Cylinder Sleeve I.D.
any one of the three (3) methods described.
METHOD ONE
“TELESCOPING GAUGE METHOD” (Refer to
Figures 6.20 and 6.21).
Using a telescoping gauge OEM1022, and an out-

side micrometer:
1. Measure sleeve I.D. at top of piston ring travel
(just below carbon ridge area) (Figure 6.20)
and record reading.
2. Measure sleeve I.D. below ring travel area (Fig-
ure 6.21) and record reading.
EG–5340
3. The difference between two readings is cylinder

sleeve taper. If specifications are exceeded, re- Figure 6.21 Measuring Cylinder Sleeve Mea-
place sleeve. surement Gauge
EGES 160 – 1
SERVICE MANUAL
Page 15
CYLINDER SLEEVES – CONTINUED

METHOD TWO
“DIAL BORE GAUGE METHOD” (Refer to Fig-
ures 6.22 and 6.23).
Using a dial bore gauge (OEM1032):

1. Measure at the top of the piston ring travel just
below the carbon ridge area (Figure 6.22) and
record the reading.
2. Measure below ring travel area (Figure 6.23)
and record the reading.
The difference between the two readings is the cyl-
inder sleeve taper. If specifications are exceeded,
replace sleeve.
EG–5337
Figure 6.22 Measuring At The Top Of Cylinder

Sleeve Piston Ring Travel Using Dial Bore
Gauge
EG–5338
Figure 6.23 Measuring Below Cylinder Sleeve

Piston Ring Travel Using Dial Bore Gauge
EGES 160 – 1
SERVICE MANUAL
Page 16
CYLINDER SLEEVES – CONTINUED

METHOD THREE
“FEELER GAUGE METHOD” (Refer to Figures
6.24 and 6.25).
Install a top compression ring squarely at top of ring

travel (Figure 6.24) and measure ring end gap with
a feeler gauge. Record the reading.
Install same piston ring squarely below ring travel

area (Figure 6.25) and measure ring end gap. Re-
cord the readings. EG–5229
NOTE: Use a piston to be sure ring is seated Figure 6.24 Measure Top Compression Ring
squarely into bore. At Top Of Piston Travel
Every 0.07 mm (0.003 in.) increase in ring gap

equals a 0.025 mm (0.001 in.) increase in bore size.
If sleeve is worn beyond specifications, replace

sleeve.
EG–7015
Figure 6.25 Measure Top Compression Ring

Below Piston Travel
EGES 160 – 1
SERVICE MANUAL
Page 17
BEARING FITTING PROCEDURE

1. If bearing–to–crankshaft running clearances
exceed specifications because of wear on the
crankshaft, replace or regrind the crankshaft
and install undersize precision type bearing
shells.
IMPORTANT
DO NOT ATTEMPT TO REDUCE JOURNAL–TO–
BEARING RUNNING CLEARANCES BY RE-
WORKING BEARING CAP, BEARINGS OR
BOTH. REGRIND OR REPLACE THE CRANK-
SHAFT ONLY. REFER TO SECTION 7.
CAUTION
REWORKING THE BEARING CAP WILL DE-
STROY THE ENGINEERED FIT OF THE BEAR-
ING SHELLS IN THEIR BORES.
2. Tighten the connecting rod bolts alternately and

evenly to the special torque value. Figure 6.26 Bearing Fitting Procedure
NOTE: ABOUT BEARING CRUSH AND
SPREAD! Bearing shells must fit tightly in the
bore. When bearing shells are inserted into the
connecting rod and cap, they protrude above
the parting line. This protrusion is required to
achieve “BEARING CRUSH”. Bearing shells
are designed with “SPREAD”. That is, the width
across the open ends are slightly larger than the
diameter of the connecting rod bore into which
they are assembled, as shown in Figure 6.26.
This condition is designed into the bearing shell
causing it to spread outward at the parting line
when “CRUSH” load is applied by tightening the
bolts. Some snap may be lost in normal use but
bearing replacement is not required because of
a nominal loss of snap.
EGES 160 – 1
SERVICE MANUAL
Page 18
BEARING FITTING PROCEDURE –

CONTINUED
When the assembly is drawn up tight, the bearing is
compressed, assuring a positive contact between
the bearing back and the bore as shown in Figure
6.27.
3. Fit connecting rod bearings and measure bear-

ing running clearance as follows:
a. With bearing cap removed, wipe oil from the
face of the bearing insert and exposed por-
tion of the crankshaft journal.
b. Place a piece of “Plastigage®” across the
full width of the bearing about 6 mm (1/4 in.)
off center.
c. Install the cap and tighten bolts evenly and
alternately to special torque value.
NOTE: DO NOT turn the crankshaft during run-
ning clearance check.
Figure 6.27 Checking Bearing Running Clearance
EGES 160 – 1
SERVICE MANUAL
Page 19
BEARING FITTING PROCEDURE –

CONTINUED
d. Remove main bearing cap. The “Plasti-
gage®” material will be found adhering to
either the bearing shell or the crankshaft.
DO NOT REMOVE “PLASTICGAGE®”.
Use “Plasticgage®” scale to measure wid-
est point of flattened plastic material (Fig-
ure 6.28). The number within the graduated
marks on the scale indicates the clearance
in thousandths of an inch or millimeters
(See “SPECIFICATIONS”).
e. Remove the test material and the repeat EG–6904
test for each connecting rod bearing.
NOTE: With the precision bearings used, no Figure 6.28 Placing Plasticgage® For Main
problem should be encountered. If proper Bearing Cap Clearance Check
clearance is NOT achieved, a problem with the
crankshaft may exist which requires regrinding
and the use of undersize bearings. (Refer to
Section 7 for Crankshaft Rework Information.)
Bearing cap torque is very important. Repeat
running clearance check procedure before con-
demning the crankshaft.
4. Check clearance of connecting rod by placing a
feeler gauge between the connecting rod and
the crankshaft journal (Figure 6.29).
EG–7006
5. Check connecting rod side clearance using a
dial indicator as follows:
Figure 6.29 Checking Clearance Between
a. Place the tip of the dial indicator on the con- Connecting Rod And Crankshaft Journal
necting rod cap.
b. Pry the connecting rod towards the rear of
the engine and “zero” the dial indicator.
c. Pry the connecting rod toward the front of
the engine and read the indicator. Refer to
“SPECIFICATIONS” and repeat for all con-
necting rods.
NOTE: The connecting rod side clearance must
be checked to be certain that the specified clear-
ance exists.
Lack of clearance could indicate a damaged rod or
a rod bearing out of position. Excessive clearance
may require replacement of the rods or crankshaft.
Correct as required.
EGES 160 – 1
SERVICE MANUAL
Page 20
CYLINDER SLEEVE FITTING PROCE-

DURE
RECONDITIONING
1. Check the crankcase counterbore depth using
the surface gauge ZTSE2515A or a depth mi-
crometer as follows:
SURFACE GAUGE METHOD

1. “Zero” the dial indicator on the crankcase deck. EG–5344
2. Move the indicator onto the counterbore ledge

and check the depth at four (4) points. Figure 6.30 Measuring Crankcase Counter
Bore Depth Using A Surface Gauge
3. Refer to “SPECIFICATIONS” for counterbore
depth and maximum variation between the
four(4) measurement points.
4. If maximum variation between the four (4)
points exceeds specifications, resurface the
counterbore.
DEPTH MICROMETER METHOD

1. Check the counterbore depth at four (4) points
around the crankcase counterbore.
2. Record the measurements.
EG–5343
3. Refer to “SPECIFICATIONS” and resurface
the counterbore if the maximum variation be- Figure 6.31 Measuring Crankcase Counter
tween measurement points is exceeded. Bore Depth Using A Depth Micrometer
EGES 160 – 1
SERVICE MANUAL
Page 21

DURE – CONTINUED
RECONDITIONING – CONTINUED
DEPTH MICROMETER METHOD – CONTINUED
4. Resurface the counterbore using the counter–
boring tool, ZTSE2514 along with the appropri- 2
ate cutter head as follows: 1
NOTE: The counterbore tool is a low profile tool
which can be used in chassis.
a. PRE–SET TOOL BIT by placing a 0.20 to

0.25 mm (0.008 to 0.010 in.) feeler gauge on
the O.D. of the cutter head ZTSE2514–4.
Push the tool bit out until it touches the feel- 3
er gauge. Lock the tool bit in place using an
Allen wrench as shown in Figure 6.32.
EG–5253
b. INSTALL THE CUTTER HEAD
ZTSE2514–4 onto the driver unit and adapt- Figure 6.32 Preparing Counterbore Cutting
er plate of the counterboring tool. Refer to Head
Figure 6.33. 1. Allen Wrench
2. Locking Plate
3. Tool Bit
6 5
1
2 4 4
3 7 5 7
EG–5252
Figure 6.33 Counterbore Cutting Tool Compo-

nents
1. Cutting Tool
2. Tool Bit
3. Feeler Gauge
4. Washers (2)
5. Mounting Bolts (2)
6. Spacer (2)
7. Locking Plate (7)
EGES 160 – 1
SERVICE MANUAL
Page 22

DURE – CONTINUED
RECONDITIONING – CONTINUED
c. RAISE THE CUTTER HEAD by pulling the
plunger and lifting up on the handle. Mount
the counterboring tool assembly to the
crankcase as shown in Figure 6.34. Tight-
en the cap screw with washers finger–tight
than apply 45 Nm (33 lb–ft.) of torque.
d. LOWER THE CUTTING HEAD by loosen-
ing locking screws on turn knuckles. Pull
plunger up to desired height. Tighten turn
knuckle in opposite direction and lock in
place with locking screws.
e. SET THE DEPTH OF THE CUT using one
of two (2) methods.
EG–5254
METHOD ONE, USE GRADUATED MARKS ON

Figure 6.34 Positioning The Counterbore Cut-
TOOL
ting Tool
Use the following steps:
1. Loosen locking screw.
2. Rotate the adjusting nut in a counterclockwise
direction until the nut contacts the driver unit
housing.
3. Back off the adjusting nut by the amount of cut
desired.
NOTE: Each graduated marking equals 0.025
mm (0.001 in.). If 0.050 mm (0.002 in.) material
is to be removed, you must back off the adjust-
ing nut two (2) marks.
4. Tighten the adjusting nut lock screw.
IMPORTANT
NEVER ATTEMPT TO REMOVE MORE THAN
0.050 MM (0.002 IN.) MATERIAL AT ANY ONE
TIME.
EGES 160 – 1
SERVICE MANUAL
Page 23

DURE – CONTINUED
METHOD TWO USE FEELER GAUGE
Use the following steps (FIGURE 6.35):
1. Loosen locking screw.
2. Insert an appropriate size feeler gauge 0.05
mm (0.002 in.) maximum between upper and
lower turn knuckle. Rotate upper turn knuckle
until feeler gauge is just held in place.
3. Tighten the locking screw and remove the feeler
gauge.
IMPORTANT
TO AVOID DAMAGE TO THE TOOL BIT, NEVER
ROTATE COUNTERCLOCKWISE WHEN TOOL
BIT IS IN CONTACT WITH COUNTERBORE EG–5255
LEDGE.
Figure 6.35 Setting Counterbore Cutting Tool
Using Feeler Gauge
a. CUT THE COUNTERBORE by rotating
handle smoothly in a clockwise direction un-
til unit turns freely and is bottomed out be-
tween adjusting nut and top of driver unit
housing. Refer to Figure 6.36.
4. Remeasure counterbore depth once counter-
bore has been resurfaced and cleaned up. Re-
fer to “CYLINDER SLEEVE FITTING PROCE-
DURE”, step one in this section.
EG–5256
Figure 6.36 Using The Counterbore Cutting

Tool
EGES 160 – 1
SERVICE MANUAL
Page 24

DURE – CONTINUED
METHOD TWO USE FEELER GAUGE – CONTIN-
UED
5. Check cylinder sleeve protrusion as follows:
a. Clean cylinder bore and crankcase counter
bore area.
b. Install the sleeve into its bore without
O–Rings and install the holding adapters
ZTSE2515–1 as shown in Figure 6.37.
EG–5332
Fasten the holding adapters using grade 8
bolts and hardened washers. Tighten the
bolts in two (2) stages as follows:
Figure 6.37
1. 55 Nm (40 lb–ft.)
2. 110 Nm (80 lb–ft.)
c. Using a surface gauge (ZTSE2515A), place
the dial indicator tip on the cylinder sleeve
flange. “Zero” the indicator and move the
block until the indicator tip slides off the
flange to the crankcase deck. Record the
reading. Refer to Figure 6.38.
NOTE: Take readings at three (3) points around
the sleeve and use the average reading to deter-
mine which shim(s), if any is needed to bring the
cylinder sleeve protrusion within the specifica- EG–5333
tion.
6. Adjust the sleeve protrusion as follows: Figure 6.38
a. Remove the holding adapters and cylinder

sleeve.
b. Clean the top deck of the crankcase and the
cylinder sleeve counterbore.
c. Install the shim(s) as required to bring the
protrusion above the crankcase deck within
specifications. Refer to Figure 6.39.
NOTE: Shims are available as a package con-
sisting of the following:
SHIM SIZE SHIM SIZE

0.05 mm 0.002 in.
0.01 mm 0.004 in.
0.25 mm 0.010 in.
0.51 mm 0.020 in.
0.81 mm 0.032 in.
d. Follow cylinder sleeve installation instruc–

tions. Figure 6.39
EGES 160 – 1
SERVICE MANUAL
Page 25
ASSEMBLY
CONNECTING RODS, PISTONS & RINGS

1. FOR TWO PIECE PISTONS ONLY, Assemble the
piston skirt onto the piston crown. Proceed onto
step 2 (Figure 6.40).
NOTE: Refer to TSI 98–12–10 for further assembly
information.
2. Install the rings onto the pistons using a piston
ring expander tool ZTSE4220 as follows: Refer
to (Figure 6.41).
A. Install rings in the following order: Figure 6.40 Assembly of Two - Piece Piston
• Top compression ring
• 2nd compression ring
• Oil control ring
B. Intermediate keystone Rings:
Identification marks must face up.
(Top ring has UP - TOP). Second ring
has UP - 2nd. Stagger the ring gaps
120° apart.
C. Intermediate Rectangular Negative
Twist Ring: identification marks must
face up. The second ring has a
permanently marked “O” on the top side
and an orange paint stripe on it. Stagger
the rings 120° apart.
NOTE: The oil ring does NOT have identification Figure 6.41 Installing Piston Rings
marks. There is no top or bottom, it may be
installed in either direction.
EGES 160 – 1
SERVICE MANUAL
Page 26
CONNECTING RODS, PISTONS & RINGS – CON-
TINUED
3. Assemble the piston and connecting rod as fol-
lows: Refer to Figure 6.42.
a. Lubricate the connecting rod piston pin
bushing with clean engine oil.
b. Install the retaining ring at one end of the
piston pin bore.
c. Insert the connecting rod into the piston
aligning bored holes of the rod and piston
(the short side of the split on the crank end of
the rod is to be toward the side of the piston
marked “CAMSIDE”).
4. Align the pin bores and insert the piston pin.
5. Install the second retaining ring (Figure 6.43).
NOTE: Connecting rod and cap matching num-
bers must be opposite the camside of the pis-
ton.
EG–5404
Figure 6.42 Installing Piston Pin
EG–5405
Figure 6.43 Install Piston Pin Retaining Ring
EGES 160 – 1
SERVICE MANUAL
Page 27
CYLINDER SLEEVES
Installation
1. Lubricate the O–Rings with clean engine oil and
install into cylinder sleeve groove (without
twist). Refer to Figure 6.44.
NOTE: Each cylinder sleeve uses two (2)
O–Rings.
2. If required, assure the proper shim(s) is

installed, in the crankcase counterbore, so cyl-
inder sleeve protrusion is within specifications.
Refer to “CYLINDER SLEEVE FITTING PRO-
CEDURE”, (Figure 6.39).
3. Be sure the O–Rings are properly aligned in the
EG–5346
groove.
4. Apply clean engine oil to the lower crankcase Figure 6.44 Lubricate Cylinder Sleeve and
counterbore, then carefully install cylinder Rings
sleeve. Refer to Figure 6.45. If reusing sleeve,
rotate 90° from its original position and install in
the same bore from which it was removed. Re-
fer to Figure 6.46.
5. After installation, check cylinder sleeve protru-
sion. Refer to “Reconditioning” in this sec-
tion.
6. Check cylinder sleeve bore dimensions and
sleeve taper per specifications. If the sleeve is
not measuring up to specifications, check for
improperly aligned O–Rings.
EG–5345
Figure 6.45 Lubricate Cylinder Sleeve Bore
EG–7219
Figure 6.46 Install Cylinder Sleeve
EGES 160 – 1
SERVICE MANUAL
Page 28
PISTON & CONNECTING ROD
1. Lubricate the piston rings with clean engine oil

and stagger the ring gaps 120° apart.
2. Install the piston ring compressor over the pis-

ton rings (Figure 6.47).
EG–5348
3. Lubricate the cylinder sleeve with clean engine
oil.
Figure 6.47 Install Piston Ring Compression
Tool
NOTE: The piston and rod assemblies can be
installed by turning the crankshaft three (3)
times. Position the Nos.1 and 6 crank pins at
BTDC. Install the Nos.1 and 6 piston assem-
blies. Repeat this procedure for the Nos. 2 and
5 and Nos. 3 and 4 piston and rod assemblies.
4. Insert piston and connecting rod assembly into

sleeve. The numbers on connecting rod must
face away from camshaft while markings on top
of piston faces toward the camshaft side of the
engine.
5. Push piston and connecting rod into the cylin-

der sleeve with a wooden or plastic handle.
6. Guide the connecting rod into place on the Figure 6.48 Guiding Connecting Rod Onto
crankshaft. Refer to Figure 6.48. Crankshaft
EGES 160 – 1
SERVICE MANUAL
Page 29
CONNECTING ROD BEARING INSERTS AND
CAPS
Installation
NOTE: Refer to “BEARING FITTING PROCE-
DURE” located in this section for running and
side clearance procedures.
1. With the bearing inserts lubricated, install the
connecting rod cap so the numbers on the cap
and rod match. Refer to Figure 6.49.
2. Install mounting bolts, by hand into connecting
rods until finger–tight. Tighten mounting bolts
to the special torque value. Refer to Figure EG–5909
6.50.
3. Check connecting rod side clearance (See
“SPECIFICATIONS”).
Figure 6.49 Install Main Bearing Inserts
for the installation procedures for the following
items:
Turbocharger
Oil filter
Oil cooler
Exhaust manifold
Wiring harness
Rocker arm assembly
EG–6902
Cylinder head
Front engine mounting bar
Vibration damper
Oil pan pick–up tube
Oil pan Figure 6.50 Install Main Bearing Caps
EGES 160 – 1
SERVICE MANUAL
VIBRATION DAMPER, CRANKSHAFT, MAIN BEARINGS,
FLYWHEEL AND CRANKCASE
SECTION 7 INDEX
Page
EXPLODED VIEW OF CRANKSHAFT, BEARINGS, FLYWHEEL

AND RELATED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EXPLODED VIEW OF CRANKCASE AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EXPLODED VIEW OF ENGINE MOUNTING, FLYWHEEL HOUSING
AND REAR POWER TAKE–OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLODED VIEW OF OIL PAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FLYWHEEL HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REAR OIL SEAL AND WEAR SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR OIL SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR OIL SEAL AND CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WEAR SLEEVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REAR OIL SEAL AND WEAR SLEEVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REAR OIL SEAL AND CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLING FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CHECKING THE FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHECKING FLYWHEEL HOUSING BORE CONCENTRICITY
AND FACE RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHECKING CRANKSHAFT PILOT CONCENTRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLING THE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REAR PTO HOUSING ASSEMBLY REMOVAL (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REAR PTO HOUSING ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REAR OIL SEAL CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REAR PTO HOUSING ASSEMBLY INSTALLATION (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REAR OIL SEAL CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLING REAR PTO HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FLYWHEEL RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FLYWHEEL RESURFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
RING GEAR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OIL LEVEL GAUGE TUBE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
VIBRATION DAMPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EGES 160 – 1
SERVICE MANUAL
VIBRATION DAMPER, CRANKSHAFT, MAIN BEARINGS,
SECTION 7 INDEX
Page
OIL PICK–UP TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CRANKCASE (RECONDITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
BEARING FITTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
MAIN BEARING AND CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OIL PICKUP TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FRONT MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
EGES 160 – 1
SERVICE MANUAL
VIBRATION DAMPER, CRANKSHAFT, MAIN BEARINGS, Section 7
Page 1
EXPLODED VIEW OF CRANKSHAFT, BEARINGS, FLYWHEEL AND RELATED COM-
PONENTS
Figure 7.1 Exploded View Of Crankshaft, Bearings, Flywheel & Related Components
1. Damper Retaining Plate
2. Woodruff Key
3. Vibration Damper
4. Front Wear Sleeve
5. Seal Washer
6. Oil Pump Drive Spline
7. Crankshaft Gear
8. Roll Pin
9. Crankshaft
10. Crankshaft Bearings (12)
11. Connecting Rod Bearings
12. Thrust Bearing
13. Flywheel Ring Gear
14. Flywheel
15. Rear Oil Seal
16. Crankshaft To Flexplate Adapter
17. Flywheel Adapter
18. Flexplate (Automatic Transmission)
19. Flexplate (Automatic Transmission)
20. Reinforcing Ring
21. Flywheel Mounting Bolt
EGES 160 – 1
SERVICE MANUAL
Section 7 VIBRATION DAMPER, CRANKSHAFT, MAIN BEARINGS,
Page 2
EXPLODED VIEW OF CRANKCASE AND RELATED PARTS
8
6 5
7 5 3
31
4
5 4 1
11 28
3
10 27
9
25 19
24 3
12
29 30
15 12
18
17 26 20
2 13
17
23
22
21 16 14 13
EG–7220
Figure 7.2 Exploded View Of Crankcase And Related Parts

1. Cup Plug, 20.6mm (13/16 in.) 17. Main Front & Intermediate Bearing Caps
2. Oil Jet Cooling Tube 18. Oil Level Gauge Tube Seal
3. Cup Plug, 32mm (1–1/4 in.) 19. Oil Filler Tube
4. Cylinder Head Alignment Dowel 20. Oil Level Gauge
5. Camshaft Bearing Set 21. Oil Inlet Tube Support Bracket (If Applied)
6. Cylinder Sleeve 22. Oil Level Gauge Lower Tube
7. Cylinder Sleeve Seal Rings 23. Oil Filler Tube Clamp
8. Cylinder Sleeve Shim (For Service Only) 24. Crankcase
9. Plug, Pipe Hex Head 1/4 in. NPFT 25. Oil Filler Tube Bracket
10. Plug, Pipe Hex Socket 1/8 in. NPT 26. Oil Filler Tube Clamp
11. Camshaft Seal Ring 27. Rear Oil Seal Carrier
12. Plug, Pipe Sq. Socket 1/2 in. NPTF 28. Rear Oil Seal Carrier Gasket
13. Cup Plug, 15.8mm (5/8 in.) 29. Plug, Pipe Hex Head NPTF
14. Main Rear Bearing Cap (Thrust) 30. Bolt
15. Plug, Pipe Hex Socket 1/8 in. NPT 31. Gasket
16. Main Bearing Cap Mounting Bolt
EGES 160 – 1
SERVICE MANUAL
Page 3
EXPLODED VIEW OF ENGINE MOUNTING, FLYWHEEL HOUSING AND REAR POW-
ER TAKE–OFF
EG 3622
Figure 7.3 Exploded View Of Engine Mounting, Flywheel Housing & Rear PTO
1. Front Engine Mounting Bracket 8. Rear PTO Lube Oil Tube
2. Housing Cover Plate 9. Rear PTO Lube Oil Elbow
3. Hollow Dowel 10. PTO O–Ring (Small)
4. Rear RH Engine Mounting Bracket 11. Rear PTO Nut
5. Flywheel Housing 12. Flywheel Housing Adapter (For AT & MT Trans.)
5A. Flywheel Housing With Rear PTO 13. Trans Fill Tube/Pipe Support Bracket
6. PTO O–Ring (Large) 14. Rear LH Engine Mounting Bracket
7. Tube Connector
EGES 160 – 1
SERVICE MANUAL
Page 4
EXPLODED VIEW OF OIL PAN ASSEMBLY
1
2
3 4
EG–7221
Figure 7.4 Exploded View Of Oil Pan And Related Parts

1. Oil Pan Gasket
2. Oil Pan Assembly
3. Mounting Bar
4. Drain Plug And Seal
EGES 160 – 1
SERVICE MANUAL
Page 5
SPECIFICATIONS
Crankshaft
Type Steel Forging, Induction Hardened,

Grindable
Main Bearing Journal Diameter:
Standard Size 89.8±.0152mm (3.535 ±.0006 in.)
0.254 mm (.010 in.) Undersize 89.5±.0152mm (3.525 ±.0006 in.)
Main Bearing Width (Except Rear Thrust) 33±0.254mm (1.286±.010 in.)
Main Bearing Journal Max. Out–of–Round 0.05mm (0.002 in.)
Main Bearing Thrust Face Runout (TIR Max.) 0.025mm (0.001 in.)
Main Bearing Journal Taper (Max./In.) 0.0711 mm (0.0028 in.)
Main Bearing Journal Fillet Radius 5.72/1.27mm (0.225/0.050 in.)
Rod Journal Fillet Radius 5.72/1.27mm (0.225/0.050 in.)
Rear Oil Seal Journal Runout (Max.) 0.076mm (0.003 in.)
Damper Mounting Area Runout (Max.) 0.013mm (0.0005 in.)
Flywheel Mounting Surface Runout (Max.) 0.05mm (0.002 in.)
Number of Main Bearings 7
Thrust Taken By Rear MainThrust Bearing Journal Length
Thrust Bearing Journal Length
Standard Size to 0.508 mm (.020 in.) Undersize 34.4±0.0254mm (1.3545±.010 in.)
0.762 mm (.030 in.) Undersize 34.4±0.0254mm (1.3545±.010 in.)
Main Bearing to Crankshaft Running Clearance 0.127/0.046mm (0.0050/0.0018 in.)
Connecting Rod Journal Diameter Standard Size 80.0±.0152mm (3.1500±.0006 in.)
0.254 mm (.010 in.) Undersize 79.7±.0152mm (3.1400±.0006 in.)
0.762 mm (.030 in.) Undersize 79.2±.0152mm (3.1200±.0006 in )
Connecting Rod Bearing Width 35.2mm (1.385 in.)
Connecting Rod Journal Max. Out–of–Round 0.0064mm (.00025 in.)
Connecting Rod Journal Taper (Max./In.) 0.0069mm (.00027 in.)
Connecting Rod Bearing to Crankshaft Running Clearance 0.127–0.046mm (.0050–.0018 in.)
Crankshaft Flange O.D. 141mm (5.550 in.)
Crankshaft End Play 0.152–0.305mm (.006–.012 in.)
Crankshaft End Play Max. Wear Limit 0.508mm (.020 in.)
Rod to Crankshaft Side Clearance 0.304±.1143mm (.012±.0045 in.)
Crankshaft Gear Backlash 0.076–0.406mm (.003–.016 in.)
Flywheel Runout (Face Runout):
Flat Flywheel for Clutch Applications:
EGES 160 – 1
SERVICE MANUAL
Page 6
Crankshaft – Continued
Face Runout Measured at 177.8 mm (7.0 in.) Radius 0.18mm (.007 in.)
Pot Flywheel for Clutch Applications:
Face Runout Measured at 165.1 mm (6.5 in.) Radius 0.165mm (0.0065 in.)
Face Runout (Mounting Surface for Clutch Cover Plate):
Measured at 190.5mm (7.5 in.) Radius 0.19mm (0.0075 in.)
Flywheel Concentricity (Radial Runout)
Radial Runout Measured at Clutch Mounting Holes 0.20mm (0.008 in.)
Radial Runout of Clutch Pilot Bore (I.D. of Pot Flywheel) 0.13mm (.005 in.)
Flywheel Resurfacing (For Clutch Applications):
Requires Measurement From Crankshaft Mounting Surface of Flywheel to Clutch Surface of Flywheel
NOTE: DO NOT machine beyond minimum dimension shown.
Flat Flywheel 36.3mm (1.430 in.)
Pot Flywheel 39.4mm (1.550 in.)
Flywheel Housing Bore Concentricity (See NOTE) SAE#1=0.30mm (0.012 in.), SAE#2=
0.28mm (0.011 in.)
Flywheel Housing Face Runout (See NOTE) SAE#1=0.30mm (0.012 in.),
SAE#2=0.28mm (0.011 in.)
NOTE: Must be measured per SAE specification J1033.
Vibration Damper Max. Allowable Member Misalignment 1.5mm (0.060 in.)
Vibration Damper Wobble (Max.) 1.5mm (.060 in.)
Crankcase Deck Flatness 0.076mm (.003 in.)
Crankcase Deck Finish (Micro inches) 125AA
Centerline of Main Bearing Bore to Head Deck 368.3±.0381mm (14.5±.0015 in.)
Crankcase Main Bearing Bore Diameter 97.8±.0127mm (3.8491±.0005 in.)
Crankcase
Tappet Bore Diameter 28.511/28.549mm (1.1225/1.1240 in. )
Valve/Roller Tappet O.D. 28.435/28.448mm (1.1195/1.1200 in.)
Oil Jet Tube Bore Diameter (Spray Hole Dia.) 0.1.22/1.24mm (.048/.049 in.)
Counterbore Dimension in Crankcase 8.86±0.025 /at 132mm (.349±.001/at 0.635 gage
dia.)
Maximum Allowable Variation of Counterbore 0.025mm (0.001)
Depth (Between Four Points)
Maximum Cylinder Sleeve Counterbore Allowable 9.25mm (0.364 in.)
Depth
Protrusion Above Crankcase 0.050 to 0.127mm (0.002 to 0.005 in.)
Main Bearing Type Precision Replaceable
EGES 160 – 1
SERVICE MANUAL
Page 7
Crankcase – Continued
Material Steel–Backed Copper/Lead
Thrust Taken By No. 7 Rear
Cap Attachment 2 Bolts per Cap
Camshaft Bushing Bore Diameter in Crankcase:
Front 63.513/63.550mm (2.5005/2.5020 in.)
Intermediate Front 63.005/63.043mm (2.4805/2.4820 in.)
Intermediate Rear 62.496/62.535mm (2.4605/2.4620 in.)
Rear 61.988/62.026mm (2.4405/2.4420 in.)

Connecting Rod Bolt 155 Nm (115 lb–ft.)
Crankshaft Main Bearing Cap Bolts 176 Nm (130 lb–ft.)
Vibration Damper Pulley Retainer Bolts 136 Nm (100 lb–ft.)
Flywheel Bolts 136 Nm (100 lb–ft.)
Flywheel Housing Mounting Bolts 108 Nm (80 lb–ft.)
Oil Pan Mounting Bolts 23 Nm (17 lb–ft.)
Oil Pick–up Tube Bolts 21 Nm (15 lb–ft. or 180 lb–in.)
Oil Pick–up Tube Bracket Bolt 21 Nm (15 lb–ft. or 180 lb–in.)
Oil Level Gauge Tube Clamp 3 Nm (30 lb–in.)
Front Engine Mounting Bracket Mounting Bolts 385 Nm (284 lb–ft.)
Special Mounting Nut (PTO Application ONLY) 108 Nm (80 lb–ft.)
EGES 160 – 1
SERVICE MANUAL
Page 8

ZTSE2535C Rear Oil Seal/Wear Sleeve Installer
ZTSE4415 PTO Rear Seal Installation Tool
OEM1293 Bevelled Edge Straightedge, 914 mm (36 in.) long
ZTSE4300 Front Seal/Injector Remover
ZTSE4386 Critical Metric Taps
ZTSE3004A Crankshaft – Front Oil Seal Wear Sleeve Installer
OEM4245 Large Gear and Pulley Puller
ZTSE1032 Telescopic Gauge Set
ZTSE4404 Wear Sleeve Removal Tool
ZTSE4375 Flywheel Guide Studs
ZTSE4384 Damper Heater
ZTSE4349 Flex Hone
ZTSE4389 Main Oil Gallery Brush
ZTSE4392 Crankshaft Oil Hole Brush
Refer to the appropriate sections of this publication
and remove the following as required:
Oil, fuel and coolant filters
Auto tensioner
Belt
Road draft tube
Cylinder head
Fuel injectors
Wiring harness
Thermostat
Oil level gauge and tube assembly
Exhaust manifold
Turbocharger
Turbocharger supply and drain lines
Coolant filter header
Fuel filter header and fuel lines
EGES 160 – 1
SERVICE MANUAL
Page 9
FLYWHEEL REMOVAL
NOTE: The rear oil seal can be serviced in chas-
sis. The procedure is performed as part of en-
gine overhaul and separately, when required.
IMPORTANT
IF YOU HAVE A REAR PTO ASSEMBLY, REFER
TO REAR PTO SERVICE PROCEDURES FOUND
IN THE CHASSIS MANUAL.
Remove the following as follows (Figure 7.5):

1. Remove two (2) flywheel mounting bolts lo-
cated at the 3 and 9 o’clock positions. Install
two (2) guide dowel pins ZTSE4375 at these
locations.
2. Remove remaining ten (10) flywheel mounting
bolts.
3. Slide flywheel out of the flywheel housing and
off guide dowel pins.
NOTE: With flywheel removed, guide dowel EG–7222
pins can be removed from crankshaft flange.
Refer to “FLYWHEEL” in this section for further
information on inspection and resurfacing.
IMPORTANT Figure 7.5 Removing The Flywheel
FOR APPLICATIONS USING AUTOMATIC
TRANSMISSIONS, TAKE NOTE OF POSITION
AND ORIENTATION OF FLEXPLATE(S),
SPACERS AND RE–INFORCING RING.
FLYWHEEL HOUSING REMOVAL

NOTE: If required, remove the flywheel housing
as follows (Figure 7.6).
1. Remove eight (8) mounting bolts securing the
flywheel housing to crankcase.
2. Remove flywheel housing from crankcase.
CAUTION
FOR VEHICLES EQUIPPED WITH THE
MT–654CR TRANSMISSION. A TRANSMISSION
ADAPTER RING IS BOLTED TO THE TRANSMIS-
SION SIDE OF THE FLYWHEEL HOUSING. IT IS
NOT NECESSARY TO REMOVE THIS ADAPTER EG–5057
RING FROM THE FLYWHEEL HOUSING. THIS IS
A SPECIAL FLYWHEEL HOUSING WITH THE
ADAPTER RING BOLTED IN PLACE TO MATCH
WITH THE FLYWHEEL HOUSING AS IT WAS MA-
CHINED. Figure 7.6 Removing The Flywheel Housing
EGES 160 – 1
SERVICE MANUAL
Page 10
REAR OIL SEAL AND WEAR SLEEVE
REAR OIL SEAL REMOVAL
Flywheel Housing Installed
NOTE: It is not necessary to remove the fly-
wheel housing or oil seal carrier, if all that is be-
ing replaced is the oil seal and wear sleeve.
Remove rear oil seal as follows:

1. Punch two holes into the rear oil seal at the 3
and 9 o’clock positions. Insert two sheet metal
screws into these holes (Figure 7.7).
2. Using a slide hammer, alternately pry on each EG–5170
screw to remove rear oil seal from the carrier

Figure 7.7 Punching Holes Into Rear Oil Seal
(Figure 7.8). Discard old oil seal.
REAR OIL SEAL AND CARRIER REMOVAL

Flywheel Housing Removed
1. Remove six (6) bolts securing rear oil seal carri-
er to crankcase (Figure 7.9).
2. Remove rear oil seal carrier. Using a hammer,
remove the rear oil seal from the carrier. Dis-
card oil seal.
3. Remove rear oil seal carrier gasket and discard.
EG–5171
Figure 7.8 Removing The Rear Oil Seal
EG–5172
Figure 7.9 Removing Rear Oil Seal Carrier
EGES 160 – 1
SERVICE MANUAL
Page 11
REAR OIL SEAL AND WEAR SLEEVE –
CONTINUED
WEAR SLEEVE REMOVAL
IMPORTANT
BE CAREFUL NOT TO NICK THE CRANKSHAFT
FLANGE DURING THIS PROCEDURE. USE
THIS METHOD ONLY WHEN THE REPAIR IS TO
BE DONE IN–CHASSIS WITH THE FLYWHEEL
HOUSING AND REAR OIL SEAL CARRIER IN
PLACE. EG–5175
Figure 7.10 Installing Wear Sleeve Removal

Tool Collets
1. Install the wear sleeve removal tool ZTSE4404
to the crankshaft flange as follows:
a. Install guide plate against crankshaft and at-

tach three (3) collets around the wear
sleeve, guide and crankshaft flange (Figure
7.10).
b. Place the sleeve around the three (3) collets

(Figure 7.11).
2. Attach a ratchet to the forcing screw and turn to

to remove the wear sleeve (Figure 7.12).
3. Discard the wear sleeve and inspect the crank-

shaft flange for damage. EG–5176
Figure 7.11 Installing Wear Sleeve Removal

Sleeve Around Collets
WEAR SLEEVE REMOVAL
Remove the wear sleeve as follows:
1. With the flywheel, flywheel housing and rear oil

seal carrier removed, use a hammer and tap the
O.D. of the wear sleeve.
NOTE: This causes the wear sleeve to expand

and slide off easily. EG–5177
2. Discard wear sleeve. Figure 7.12 Removing Wear Sleeve
EGES 160 – 1
SERVICE MANUAL
Page 12
CONTINUED
REAR OIL SEAL AND WEAR SLEEVE INSTAL-
LATION
IMPORTANT
INSTALL THE REAR OIL SEAL AND WEAR
SLEEVE AS A UNIT. DO NOT REMOVE THE
SEAL FROM THE WEAR SLEEVE PRIOR TO
INSTALLATION.
Install a new rear oil seal and crankshaft wear

sleeve assembly using installer tool ZTSE2535C as EG–5174
follows:
Figure 7.13 Installing Rear Oil Seal Installer
1. Clean crankshaft flange and seal carrier bore Tool
thoroughly. Remove any debris.
2. Attach rear oil seal/wear sleeve guide to crank-
shaft flange and secure with two (2) mounting
screws (Figure 7.13).
3. Coat inner I.D. of wear sleeve and O.D. of oil
seal with Aviation Permatex #3 (Figure 7.14).
4. Position oil seal and wear sleeve over crank-
shaft.
NOTE: Proper use of installer tool will assure
that seal and wear sleeve are pressed onto the
crankshaft flange to the proper depth.
5. Assemble rear oil seal/wear sleeve installer tool

onto crankshaft. Using a wrench, turn forcing
EG–5178
nut on installer tool until seal and sleeve are
seated in the bore (Figure 7.15). Figure 7.14 Preparing Rear Oil Seal
6. Remove oil seal/wear sleeve installation tool.
EG–5180
Figure 7.15 Installing Rear Oil Seal
EGES 160 – 1
SERVICE MANUAL
Page 13
CONTINUED
REAR OIL SEAL AND CARRIER INSTALLATION
Install rear oil seal carrier as follows:
1. Attach rear oil seal guide ZTSE2535C to crank-
shaft flange and secure by tightening the two (2)
mounting bolts (Figure 7.16).
2. Place a new gasket into rear oil seal carrier.
Install rear oil seal carrier to crankcase and
loosely secure with oil seal carrier mounting
EG–5183
bolts (Figure 7.17).
3. Install the driver guide tool ZTSE2535C over Figure 7.16 Installing Carrier Guide
the crankshaft (Figure 7.18).
EG–6908
Figure 7.17 Installing Gasket Onto Carrier

1. Oil Seal Carrier Gasket
EG–5189
Figure 7.18 Installing Driver Guide Tool
EGES 160 – 1
SERVICE MANUAL
Section 7 VIBRATION DAMPER. CRANKSHAFT, MAIN BEARINGS,
Page 14
CONTINUED
– CONTINUED
Flywheel Housing Removed – Continued
4. Tighten driver nut to center the oil seal carrier to
the crankcase (Figure 7.19). Finger–tighten
the carrier and remove the driver guide tool.
5. Rotate/twist the carrier, if necessary, to align
carrier with crankcase rails. Use straight edge
OEM1293 to verify (Figure 7.20).
6. When the rear oil seal carrier is level, tighten the
mounting bolts to the special torque value (Fig-
ure 7.21).
EG–5190
Figure 7.19 Centering Oil Seal Carrier
EG–5275
Figure 7.20 Aligning Oil Seal Carrier
EG–5186
Figure 7.21 Securing Oil Seal Carrier
EGES 160 – 1
SERVICE MANUAL
Page 15
CONTINUED
– CONTINUED
Flywheel Housing Removed – Continued
IMPORTANT
INSTALL THE REAR OIL SEAL AND WEAR
SLEEVE AS A UNIT. DO NOT REMOVE THE
SEAL FROM THE WEAR SLEEVE PRIOR TO
INSTALLATION.
7. Install a new rear oil seal and crankshaft wear

sleeve assembly using installer tool EG–5174
ZTSE2535C as follows:
Figure 7.22 Attach Guide To Crankshaft
a. Clean crankshaft flange and seal carrier
bore thoroughly. Remove any debris.
b. Attach rear oil seal/wear sleeve guide to
crankshaft flange and secure with two (2)
mounting screws (Figure 7.22).
c. Coat inner I.D. of wear sleeve and O.D. of oil
seal with Aviation Permatex #3 (Figure
7.23).
d. Position oil seal and wear sleeve over
crankshaft.
NOTE: Proper use of installer tool will assure
that seal and wear sleeve are pressed onto the
crankshaft flange to the proper depth.
EG–5178
e. Assemble rear oil seal/wear sleeve installer

Figure 7.23 Preparing Oil Seal/ Wear Sleeve
tool onto crankshaft. Using a wrench, turn
forcing nut on installer tool until seal and
sleeve are seated in the bore (Figure 7.24).
f. Remove oil seal/wear sleeve installation
tool.
EG–5190
Figure 7.24 Installing Oil Seal/ Wear Sleeve
EGES 160 – 1
SERVICE MANUAL
Section 7 VIBRATION DAMPER. CRANKSHAFT, MAIN BEARINGS,
Page 16
INSTALLING FLYWHEEL HOUSING
Install flywheel housing to crankcase as follows:
1. Install new camshaft O–Ring over camshaft

end opening at rear of crankcase (Figure 7.25).
IMPORTANT
BE SURE A NEW CAMSHAFT O–RING IS
INSTALLED BEFORE PRECEDING ANY FUR-
THER WITH THIS PROCEDURE.
2. Install flywheel housing by guiding the housing

and hollow dowels up against the crankcase.
Secure using flywheel housing mounting bolts.
Tighten the eight (8) bolts to the special torque
value. Refer to Figure 7.26.
WARNING
WHEN INSTALLING THE FLYWHEEL HOUSING,
BE SURE THE AUTOMATIC TRANSMISSION
ACCESS COVER, LOCATED ON THE FRONT OF
THE FLYWHEEL HOUSING, DOES NOT GET
CAUGHT BETWEEN THE FLYWHEEL HOUSING
AND THE CRANKCASE.
EG–5169
Figure 7.25 Install Camshaft O–Ring
EG–5053
Figure 7.26 Install Flywheel Housing
EGES 160 – 1
SERVICE MANUAL
Page 17
CHECKING THE FLYWHEEL HOUSING
CHECKING FLYWHEEL HOUSING BORE CON-
CENTRICITY AND FACE RUNOUT
NOTE: Bore concentricity and face runout is
checked to ensure proper engine to transmis-
sion alignment.
CAUTION
FAILURE TO INSURE PROPER BORE CONCEN-
TRICITY AND FACE RUNOUT MAY RESULT IN
REDUCED TRANSMISSION LIFE.
EG–5055
1. Check flywheel housing bore concentricity as
follows. Refer to Figure 7.27: Figure 7.27 Checking Flywheel Bore Concen-
a. Attach a dial indicator to the crankshaft and tricity
place the indicator tip against the flywheel
housing bore.
b. Zero the dial indicator.
c. Rotate the crankshaft slowly and record the
total indicator variation. Refer to SPECIFI-
CATIONS for tolerance.
2. Check flywheel housing face runout as follows.

Refer to Figure 7.28:
a. Attach a dial indicator to crankshaft and
place indicator tip against housing face.
b. Measure at four points, 90° apart for total
face variation.
IMPORTANT EG–5054
KEEP THE CRANKSHAFT END PLAY AT ZERO

IN THE SAME DIRECTION FOR ALL MEA- Figure 7.28 Checking Flywheel Housing Face
SUREMENTS. Runout
c. Refer to SPECIFICATIONS for housing

face runout tolerance.
CHECKING CRANKSHAFT PILOT CONCEN-

TRICITY
Check flywheel crankshaft flywheel pilot concentric-
ity as follows. Refer to Figure 7.29:
1. Attach a dial indicator to flywheel housing and
place tip up against flywheel pilot.
EG–5056
2. Rotate the crankshaft slowly and record the to-
tal indicator variation. Refer to SPECIFI- Figure 7.29 Checking Flywheel Housing Pilot
CATIONS for concentricity tolerance. Concentricity
EGES 160 – 1
SERVICE MANUAL
Page 18
INSTALLING THE FLYWHEEL
Install the flywheel as follows: (Figure 7.30).
1. Install two (2) flywheel guide studs ZTSE4375
into the 3 and 9 o’clock positions of the crank- 1
shaft.
2. Install flywheel over guide studs and secure to
crankshaft with ten (10) flywheel mounting
bolts.
IMPORTANT
TRANSMISSIONS, INSTALL SPACER, FLEX-
PLATE(S) AND REINFORCING RING, THEN
INSTALL THE TEN (10) FLYWHEEL MOUNTING
BOLTS.
EG–5098
3. Remove two (2) guide studs and install remain-
ing two (2) mounting bolts. Tighten all twelve Figure 7.30 Installing Flywheel Guide Studs
(12) flywheel mounting bolts to the special
1. Flywheel Guide Studs
EG–5097
Figure 7.31 Installing Flywheel
EGES 160 – 1
SERVICE MANUAL
Page 19
REAR PTO HOUSING ASSEMBLY RE-
MOVAL (IF EQUIPPED)
FLYWHEEL REMOVAL
Perform the following steps:
CAUTION
BE SURE TO SUPPORT THE BACK END OF THE
ENGINE WHEN SERVICING THE REAR PTO AS-
SEMBLY.
NOTE: The rear oil seal can be serviced in chas-

sis. The procedure is performed as part of the
engine overhaul or separately, when required.
IMPORTANT
THE REAR OIL SEAL IS IN THE REAR PTO
HOUSING ASSEMBLY. THIS REAR SEAL IS DIF-
FERENT THAN THE ENGINE REAR OIL SEAL.
1. Remove two (2) flywheel mounting bolts lo-

cated at the 3 and 9 o’clock positions. Install EG–7223
two (2) guide dowel pins, made locally, at these
locations (Figure 7.32). Figure 7.32 Guide Dowel Pin Locations
2. Remove remaining ten (10) flywheel mounting
bolts.
3. Slide flywheel out of the flywheel housing and
off guide dowel pins.
CAUTION
AFTER THE FLYWHEEL HAS BEEN REMOVED,
DO NOT TO REMOVE THE GUIDE DOWEL PINS
FROM THE CRANKSHAFT FLANGE (FIGURE
7.33).
IMPORTANT
TRANSMISSIONS, TAKE NOTE OF POSITION
AND ORIENTATION OF FLEXPLATE(S),
SPACERS AND REINFORCING RING.
REAR PTO HOUSING ASSEMBLY REMOVAL

1. Install a 5/8 in. –UNC– lifting eye into tapped
hole located on top of the Rear PTO housing. EG–5290
Use an appropriate lifting device to support the
Rear PTO housing. Figure 7.33 Removing Flywheel
EGES 160 – 1
SERVICE MANUAL
Page 20
MOVAL (IF EQUIPPED) – CONTINUED
REAR PTO HOUSING ASSEMBLY REMOVAL –
CONTINUED
2. Loosen nuts securing the lubrication supply
tube connecting crankcase to Rear PTO hous- 1
ing. Remove tube (Figure 7.34).
3. Remove lubrication supply elbow from Rear
PTO housing (1, Figure 7.34).
4. Remove four (4) pipe plugs from the Rear PTO 2
housing (Figure 7.35). Save pipe plugs for
installation.
EG–5289
Figure 7.34 Oil Lubrication Supply Tube Con-

nections
1. Elbow
2. Lubrication Tube Nut
3. Lubrication Tube
EG–5288
Figure 7.35 Removing Pipe Plugs
EGES 160 – 1
SERVICE MANUAL
Page 21
MOVAL (IF EQUIPPED) – CONTINUED
REAR PTO HOUSING ASSEMBLY REMOVAL –
CONTINUED
5. Use a hex key to remove special nut inside Rear
PTO housing found under pipe plug (Figure
7.36).
NOTE: Do not let special nut fall into housing.
6. Remove the three (3) mounting bolts from in-

side the Rear PTO housing after the pipe plugs
have been removed (Figure 7.37). EG–5283
7. Install the four (4) pipe plugs back into the Rear
PTO housing. Figure 7.36 Removing Special Nut And
Mounting Bolts
8. Removing the remaining four (4) mounting bolts
from the Rear PTO housing assembly.
NOTE: Place an oil drain pan underneath Rear
PTO housing assembly. Approximately one (1)
quart of oil remains in the housing sump area.
IMPORTANT
BE SURE TO SUPPORT THE CRANK GEAR
WHEN REMOVING THE PTO HOUSING. IF THE
CRANK GEAR IS NOT SUPPORTED, IT MAY
FALL INTO THE PTO HOUSING.
9. Pull the Rear PTO housing assembly straight

back, away from the crankcase.
10. Remove one (1) hollow dowel pin and four (4)
O–Rings from the housing.
EG–5285
11. Lay Rear PTO housing assembly face down on
the engine mounting surface side. Remove
dowel guide pins. Figure 7.37 Removing PTO Mounting Bolts
NOTE: Some additional oil may drain from the
housing as it is laid flat.
REAR OIL SEAL CARRIER REMOVAL

IMPORTANT
1. THE REAR OIL SEAL IS IN THE REAR PTO
HOUSING ASSEMBLY. REFER TO THE AP-
PROPRIATE CHASSIS SERVICE MANUAL
FOR SERVICE PROCEDURES.
2. THE REAR COVER CAN NOT BE REMOVED
UNTIL THE FOUR (4) BOLTS MOUNTED
THRU THE OIL PAN AND INTO THE BOTTOM
OF THE REAR COVER ARE REMOVED. RE-
FER TO OIL PAN REMOVAL IN THIS SEC-
EG–5277
TION FOR FURTHER INFORMATION.
1. Remove six (6) bolts securing rear carrier to Figure 7.38 Removing Rear Carrier Mounting
crankcase (Figure 7.38). Remove carrier Bolts
EGES 160 – 1
SERVICE MANUAL
Page 22
REAR PTO HOUSING ASSEMBLY
INSTALLATION (IF EQUIPPED)
REAR OIL SEAL CARRIER INSTALLATION
Install rear oil seal cover as follows:
1. Place a new gasket into rear oil seal cover (Fig-
ure 7.39).
2. Install rear oil seal cover. Secure to crankcase 1
by finger–tightening the mounting bolts.
3. Rotate/twist cover to align the oil seal cover with
crankcase oil pan rail. Use straight edge,
OEM1293 to verify (Figure 7.40).
4. When the rear cover is aligned, tighten the
ure 7.41).
EG–6908
Figure 7.39 Rear Oil Seal Carrier Gasket

1. Gasket
EG–6167
Figure 7.40 Aligning Rear Oil Seal Carrier
EG–5276
Figure 7.41 Securing Rear Oil Seal Carrier
EGES 160 – 1
SERVICE MANUAL
Page 23
REAR PTO HOUSING ASSEMBLY
INSTALLATION (IF EQUIPPED) – CON-
TINUED
INSTALLING REAR PTO HOUSING
1. Lay the Rear PTO housing assembly with the
transmission side face down. 2
IMPORTANT 2 3
BE SURE O–RING GROOVES (1 LARGE AND 3
SMALL) ARE CLEAN AND FREE OF ALL OLD
SEALANT MATERIAL.
2. Install one (1) large O–Ring (1, Figure 7.42)

and three (3) small O–Rings (2, Figure 7.42)
into the O–Ring grooves using Aviation Perma- 2
tex #3.
3. Install two (2) hollow dowel pins into Rear PTO 1
housing assembly (3, Figure 7.42).
3
IMPORTANT
BE SURE STUD IS INSTALLED INTO CRANK-
CASE BEFORE INSTALLING REAR PTO HOUS-
ING ASSEMBLY. EG–5291
Figure 7.42 O–Ring And Dowel Pin Locations

4. Inspect threads and replace stud if necessary. 1. Large O–Ring
Install stud into crankcase. (Figure 7.43). 2. Small O–Ring
3. Hollow Dowel Pin Locations
EG–7224
Figure 7.43 PTO Mounting Stud Location
EGES 160 – 1
SERVICE MANUAL
Page 24
REAR PTO HOUSING ASSEMBLY INS-
TALLATION (IF EQUIPPED) – CONTIN-
UED
INSTALLING REAR PTO HOUSING – CONTIN-
UED
5. Install new camshaft O–Ring over camshaft
end opening at rear of crankcase (Figure 7.44).
IMPORTANT
BE SURE A NEW CAMSHAFT O–RING IS
INSTALLED BEFORE PROCEEDING ANY FUR-
THER WITH THIS PROCEDURE. 1
6. Install two (2) guide dowel pins, used during re-

moval procedure, into crankshaft flange at the 3
and 9 o’clock positions (Figure 7.45).
7. If not already done remove the four (4) pipe
EG–7225
plugs from the Rear PTO housing assembly.
Figure 7.44 Installing Camshaft O–Ring
1. Camshaft O–Ring
EG–5279
Figure 7.45 Installing Guide Dowel Pins
EGES 160 – 1
SERVICE MANUAL
Page 25
UED
UED
IMPORTANT
BE SURE INSTALLATION TOOL ZTSE4415 IS
INSTALLED INTO THE PTO HOUSING CRANK-
SHAFT OPENING (2, FIGURE 7.46).
2
8. Lift the Rear PTO housing assembly and align
with the crankcase.
9. Slowly guide the Rear PTO housing assembly
over the two (2) guide pins mounted in the
crankshaft (1, Figure 7.46) and studs mounted
in the crankcase. Install the seven (7) mounting
bolts and tighten to the special torque value 1
(Figure 7.46).
10. Install special nut (Figure 7.47) over the crank-
case stud. EG–7226
11. Hand tighten special nut at the upper hollow

dowel location (Figure 7.48). Figure 7.46 PTO Housing Installed On To
Crankcase
1. Guide Pins
2. Installation Tool
EG–7228
Figure 7.47 Special Mounting Nut
EG–7227
Figure 7.48 Tighten Special Mounting Nut
EGES 160 – 1
SERVICE MANUAL
Page 26
UED
UED
12. Tighten the special nut to the special torque val-
ue (Figure 7.49).
IMPORTANT
DO NOT REMOVE REAR OIL SEAL INSTALLA-
TION TOOL OR GUIDE PINS YET.
13. Install the four (4) pipe plugs and tighten (Fig-
ure 7.50).
14. Remove lifting eye from Rear PTO housing as-
sembly.
EG–7229
Figure 7.49 Tighten Special Mounting Nut To

The Special Torque Value
EG–7230
Figure 7.50 Installing Pipe Plugs
EGES 160 – 1
SERVICE MANUAL
Page 27
UED
UED
15. Install lubrication supply elbow and connect the 1
lubrication supply tube to the crankcase and
Rear PTO housing assembly. Tighten the nuts
securing the tube to the fittings (Figure 7.51).
16. Insert the steel rod of the installation tool 2
(ZTSE4415) through the hole (2, Figure 7.52)
of the tube assembly (1, Figure 7.52).
IMPORTANT
DO NOT PULL THE TUBE ASSEMBLY OUT.
3
17. Pull out on the steel rod until the tube assembly
(1, Figure 7.52) comes out together with the
cover assembly (3, Figure 7.52) of installation
tool ZTSE4415.
18. Push the input gear towards the engine until the EG–5289
input gear reaches the mating surface of the
crankshaft. Figure 7.51 PTO Lubrication Tube
1. Elbow
19. Apply grease to the inner surface of the wear 2. Nut
sleeve/rear oil seal before pressing it onto the 3. Lubrication Tube
input gear.
3
2
1
EG–7231
Figure 7.52 Rear Oil Seal Installation Tool

1. Tube Assembly
2. Steel Rod Location
3. Cover Assembly
EGES 160 – 1
SERVICE MANUAL
Page 28
UED
UED
20. Press the seal into the cover using the oil seal
driver and a hammer (Figure 7.53).
FLYWHEEL INSTALLATION
Install the flywheel as follows: (Figure 7.54)
1. Install flywheel over dowel guide pins and se-

EG–7232
cure to crankshaft with ten (10) flywheel mount-
ing bolts. Figure 7.53 Installing PTO Rear Oil Seal
IMPORTANT
TRANSMISSIONS, INSTALL SPACER, FLEX-
PLATE(S) AND REINFORCING RING, THEN
INSTALL THE TEN (10) FLYWHEEL MOUNTING
BOLTS.
2. Remove two (2) dowel guide pins and install re-

maining two (2) mounting bolts. Tighten all
twelve (12) flywheel mounting bolts to the spe-
cial torque value.
EG–5290
Figure 7.54 Installing The Flywheel
EGES 160 – 1
SERVICE MANUAL
VIBRATION DAMPER. CRANKSHAFT, MAIN BEARINGS, Section 7
Page 29
FLYWHEEL RECONDITIONING
CLEANING
Clean the flywheel with a non–caustic solvent and
dry with compressed air.
INSPECTION
1. Visually inspect the flywheel for cracks, heat
checks and extensive scoring which would
make it unfit for further service. Replace or re-
surface as required.
2. Inspect ring gear for worn, chipped or cracked
teeth. If teeth are damaged, replace ring gear.
FLYWHEEL RESURFACING
Flywheels used with manual transmissions may be
resurfaced to correct minor wear and scoring.
When resurfacing the flywheel, refer to dimension
“A” (Figure 7.55), to determine if the flywheel was
previously refaced or it if has adequate stock for re- Figure 7.55 Flywheel Reconditioning
facing.
NOTE: If the dimensions depicted in Figure 7.55
cannot be maintained, the flywheel must be re-
placed.
CAUTION
FLYWHEEL RESURFACING INFORMATION IS
PROVIDED FOR GUIDANCE ONLY. NAVISTAR
INTERNATIONAL CORPORATION ASSUMES
NO RESPONSIBILITY EITHER FOR THE RE-
SULTS OF ANY WORK PERFORMED IN AC-
CORDANCE WITH THIS INFORMATION OR FOR
THE ABILITY OF SERVICE PERSONNEL TO DE-
TECT HEAT CRACKS. ANY CRACK OR HEAT
CHECK IN THE FLYWHEEL COULD CAUSE IT
TO SEPARATE, CREATING THE POSSIBILITY
OF INJURY TO THE OPERATOR OR BYSTAND-
ERS. CAREFULLY EXAMINE THE FLYWHEEL,
AFTER RESURFACING, FOR ANY CRACKS OR
HEAT CHECKS. IF THERE IS ANY QUESTION,
DO NOT USE THE FLYWHEEL.
IMPORTANT
FLYWHEELS USED WITH AUTOMATIC TRANS-
MISSIONS CANNOT BE RESURFACED. IF DAM-
AGED REPLACE FLYWHEEL.
EGES 160 – 1
SERVICE MANUAL
Page 30
FLYWHEEL RECONDITIONING – CON-
TINUED
RING GEAR REPLACEMENT 1
1. Remove any damaged ring gear from the fly-
wheel as follows:
a. Heat the ring gear with a torch to expand the
gear. 2
b. Once heated, knock the gear off the fly-
wheel. DO NOT HIT THE FLYWHEEL
WHEN REMOVING THE RING GEAR.
2. Install a new ring gear as follows:
EG–5048
a. Heat the new ring gear evenly until the gear
expands enough to slip onto the flywheel.
b. Make sure the ring gear is seated properly Figure 7.56 Removing Oil Pan Mounting Bolts
against the flywheel shoulder.
IMPORTANT 1. Oil Pan
DO NOT HEAT THE RING GEAR TO A TEMPERA- 2. Mounting Bar (2)
TURE HIGHER THAN 278°C (500°F). HEATING
BEYOND THIS TEMPERATURE WILL AD-
VERSELY AFFECT RING GEAR HARDNESS.
OIL PAN
REMOVAL
1. Remove twenty–two (22) oil pan mounting bolts

(Figure 7.56). EG–5051
2. Remove mounting bars.

3. Remove oil pan and gasket from crankcase
(Figure 7.57). Discard gasket. Figure 7.57 Removing Oil Pan
EGES 160 – 1
SERVICE MANUAL
VIBRATION DAMPER. CRANKSHAFT, MAIN BEARINGS, Section 7
Page 31
OIL LEVEL GAUGE TUBE ASSEMBLY
REMOVAL
Perform the following (Figure 7.58):
1. Loosen screw securing oil filler tube clamp to
crankcase.
1
2. Lift oil level gauge, oil filler tube and oil filler tube
clamp from crankcase as an assembly.
3. Discard O–Ring gasket.
4. If necessary, remove oil level gauge tube from
crankcase using a brass drift and hammer.
IMPORTANT 2
REMOVAL OF OIL LEVEL GAUGE TUBE FROM
CRANKCASE REQUIRES REMOVAL OF OIL
PAN. REFER TO OIL PAN REMOVAL IN THIS
SECTION.
CLEANING 3
1. Thoroughly clean both tubes and clear any ob-
structions.
2. Remove all old Loctite® from oil level gauge 5
and crankcase casting area which mates with
the tube.
INSPECTION 4
1. Visually inspect the components for kinks,
bends or restrictions.
2. Replace components as required. EG–7233
INSTALLATION Figure 7.58 Removal/Installation Of Oil Level

Perform the following (Figure 7.58): Gauge And Oil Filler Tube
1. Install the oil level gauge tube into the crank- 1. Oil Filler Tube
case as follows: 2. Tube Clamp
a. Apply Loctite® #609 around entire circum– 3. O–Ring Gasket
ference of tube and casting. 4. Oil Level Gauge
b. Press tube in until the bead is seated in 5. Oil Level Gauge Tube
chamber of the crankcase.
NOTE: The slots in oil level gauge tube need not
be oriented in any special manner.
2. Install new O–Ring gasket onto oil level filler
tube.
3. Insert oil level filler tube into oil level gauge tube
and orient oil filler tube to the rear and as far in-
board as possible.
4. Tighten oil filler tube clamp screw to the special
torque value.
EGES 160 – 1
SERVICE MANUAL
Page 32
VIBRATION DAMPER ASSEMBLY
REMOVAL
1. Prior to pulley damper removal, inspect the
damper for wobble as follows: (Refer to Figure
7.59).
a. Remove paint from the face of the damper
at four (4) points 90° apart.
b. Clamp/attach a dial indicator to the front
cover. Position the indicator point on an un-
painted surface and “zero” the indicator.
c. Pry the crankshaft pulley forward and read
the indicator.
d. Record readings and repeat at each un- EG–5076
painted surface. If wobble exceeds specifi-
cation, replace the damper. Figure 7.59 Inspecting Vibration Damper For
IMPORTANT Wobble
DO NOT PRY THE CRANKSHAFT PULLEY
BACK AND FORTH. PRY ONLY IN ONE DI-
RECTION, TO ELIMINATE THE POSSIBILITY OF
REPLACING A DAMPER FOR EXCESSIVE
WOBBLE WHEN THE CRANKSHAFT END PLAY
WAS REALLY EXCESSIVE FROM ANY READ-
INGS TAKEN.
2. Remove the pulley damper assembly as fol-

lows:
a. Remove three (3) bolts and retainer. Refer
to Figure 7.60.
EG–5068
Figure 7.60 Removing Vibration Damper Re-

tainer
EGES 160 – 1
SERVICE MANUAL
Page 33
VIBRATION DAMPER ASSEMBLY –
CONTINUED
b. Install a universal puller (OEM4245) using
bolts long enough to hold the puller in place.
Turn the forcing screw and remove the
pulley damper assembly. Refer to Figure
7.61.
c. Remove bolts securing the front engine
mounting bracket. Remove bracket (Fig-
ure 7.62).
OIL PICK–UP TUBE EG–5070
REMOVAL Figure 7.61 Removing Vibration Damper

1. With pulley damper removed, remove the oil

pick–up tube as follows: (Refer to Figure 7.63)
(Rear sump tube shown).
a. Remove the two (2) retaining bolts at the
front cover.
EG–5075
Figure 7.62 Removing Front Engine Mounting

Bracket
EG–5297
Figure 7.63 Removing Oil Pick–up Tube
EGES 160 – 1
SERVICE MANUAL
Page 34 FLYWHEEL AND CRANKCASE
OIL PICK–UP TUBE – CONTINUED
b. Support oil pick–up tube and remove retain-
ing bolt at support bracket (Figure 7.64).
c. Remove the pick–up tube and gasket. Dis-
card gasket.
NOTE: Remove piston and connecting rod as-
semblies as described in Section 6.
EG–6895
CRANKSHAFT AND MAIN BEARINGS Figure 7.64 Removing Oil Pick–up Tube Sup-
port Bracket
REMOVAL
1. Rotate the engine stand so the crankshaft is
facing horizontal.
NOTE: Prior to bearing cap removal, check to
see that caps and crankcase are stamped to
identify location. If they are not marked, stamp
in numerical order 1–7, starting with No.1 at the
front of the engine. Stamp the crankcase oil pan
rail and main bearing caps on the camshaft side.
2. Remove the six (6) main bearing caps as fol-

lows:
a. Loosen main bearing cap bolts (Figure
7.66).
Figure 7.65 Main Bearing Cap Locations
EG–6898
Figure 7.66 Removing Main Bearing Cap
EGES 160 – 1
SERVICE MANUAL
Page 35
CRANKSHAFT AND MAIN BEARINGS –
CONTINUED
b. Grasp bolts and rock main bearing cap back
and forth to loosen and remove cap (Figure
7.67).
c. Remove lower bearing shell from main
bearing cap and keep in order with bearing
cap for inspection.
3. Remove No. 7 (rear) thrust bearing as follows
(Figure 7.68):
a. Loosen two (2) rear thrust bearing mounting
bolts.
b. Insert a flat blade screwdriver between
bearing cap and crankcase wall. Twist the
screwdriver and walk bearing cap up. Alter-
nate from side to side of the bearing cap with EG–5354
each twist of the screwdriver.
Figure 7.67 Removing Main Bearing Cap
IMPORTANT
ONLY USE HAND PRESSURE WHEN TWISTING
THE SCREWDRIVER.
c. Remove bearing cap.

4. Remove crankshaft from the crankcase using
an appropriate lifting sling, as shown in Figure
7.69.
IMPORTANT
BE CAREFUL NOT TO DAMAGE THE CRANK-
SHAFT WHEN REMOVED.
EG–5358
Figure 7.68 Removing Rear Thrust Bearing
EG–5359
Figure 7.69 Removing Crankshaft
EGES 160 – 1
SERVICE MANUAL
Page 36 FLYWHEEL AND CRANKCASE
CRANKSHAFT AND MAIN BEARINGS –
CONTINUED
5. Remove upper main bearing shells by pushing
them out of main bearing saddle with your
thumbs as shown in Figure 7.70. Mark the up-
per shells and put with lower shells until a prop-
er inspection can be done.
INSPECTION AND REPAIR

VIBRATION DAMPER
1. Clean the damper using a suitable solvent.
2. Dry with filtered compressed air. EG–5362
3. Visually inspect the vibration damper pulley.
NOTE: Inspect the rubber insert for swelling, Figure 7.70 Removing Upper Main Bearing
separation, or cracking which may indicate pos- Shells
sible failure.
CRANKSHAFT AND MAIN BEARINGS

1. Clean the bearing inserts and caps thoroughly
in solvent and dry with filtered compressed air.
DO NOT SCRAPE GUM OR VARNISH DE-
POSITS FROM BEARING SHELLS.
2. Clean all the internal oil passages of the crank-
shaft using a stiff nylon brush (ZTSE4392).
Loosen all dirt, sludge and deposits which may
have accumulated. Flush the oil passages with
a suitable non–caustic solvent.
3. Blow passages dry with filtered compressed air.
4. Visually inspect the crankshaft journals (main
EG–5223
and rod) for scratches, grooves and scoring.
Use dye penetrant methods to check for cracks.
Figure 7.71 Inspecting Crankshaft
5. Visually inspect all bearing inserts. Replace
bearings that are scored, chipped or worn.
6. Measure the diameter of each journal using a
micrometer. (See “SPECIFICATIONS”). Mea-
sure each journal at two points, at right angles to
each other. Move the micrometer over the en-
tire width of the journal. Refer to Figure 7.71.
NOTE: If journals exceed maximum out–of–
round specification, crankshaft must be re-
ground.
EGES 160 – 1
SERVICE MANUAL
Page 37
INSPECTION AND REPAIR – CONTIN-
UED
CRANKSHAFT AND MAIN BEARINGS – CON-
TINUED
7. The crankshaft can be ground 0.25mm,
0.51mm or 0.76 mm (0.010 in., 0.020 in. or
0.030 in.) undersize as follows:
NOTE: An induction hardened fillet and journal
crankshaft can be reground similar to any preci-
sion crankshaft. However, these shafts require
special treatment when grinding. Before grind-
ing all crankshafts must be checked for hard-
ness.
a. Check crankshaft hardness before regrind-

ing and on every journal which incurred a
bearing failure or shows evidence of over-
heating.
NOTE: Bearing failures can cause overheating
of crankshaft journals and reduction of hard-
ness. When this occurs, the crankshaft
strength may be unacceptably reduced.
b. Check crankshaft journal hardness using a

Rockwell Hardness Tester as follows:
IMPORTANT
THE HARDNESS TEST IS DESTRUCTIVE AND IS
ONLY MADE PRIOR TO GRINDING THE CRANK-
SHAFT. THE GRINDING PROCESS WILL COR-
RECT THE DAMAGE MADE BY THE ROCKWELL
HARDNESS TESTER. DO NOT TEST FOR
HARDNESS UNLESS THE CRANKSHAFT IS TO
BE REGROUND.
Check crankshaft rod and main journals at three

locations: the top, bottom and one other location.
NOTE: The top and bottom is determined with

the crankshaft journal at TDC.
Check as close to the fillet as possible.
If any reading is below 50 RC hardness, REPLACE

the crankshaft. If hardness is acceptable, grind the
crankshaft.
EGES 160 – 1
SERVICE MANUAL
Page 38
UED
TINUED
IMPORTANT
SUPERIOR STRENGTH OF THE FILLET–HARD-
ENED CRANKSHAFT IS DUE TO THE SPECIAL
PROCESS BY WHICH THE BEARING SUR-
FACES AND FILLETS ARE HARDENED. THIS
LOCALIZED HARDENING GREATLY IN-
CREASES THE BENDING STRENGTH OF THE
CRANKSHAFT; IN ORDER TO MAINTAIN THIS
STRENGTH, SPECIAL PRECAUTIONS MUST BE
TAKEN WHEN REGRINDING THE CRANK-
SHAFT. IF SPECIAL PRECAUTIONS ARE NOT
TAKEN, THE CRANKSHAFT CAN BE SEVERELY
WEAKENED. THE METALLURGICAL CHAR-
ACTERISTICS OF THE SHAFT DEMAND EX-
ACTING STANDARDS AND CONTROL WHEN
REGRINDING JOURNALS. HOWEVER, IT CAN
BE REGROUND LOCALLY WHERE EQUIPMENT
AND EXPERIENCE CAN PRODUCE QUALITY
STANDARDS OUTLINED IN THE FOLLOWING
INSTRUCTIONS.
c. Grind the crankshaft as any other precision

crankshaft using the following guidelines:
The crankshafts are reground similar to any preci-

sion crankshaft with the following precautions:
8. A mechanical or an automatic wheel dresser is
mandatory to prevent chatter, burning and poor
surface finish. A hand stone should NEVER be
used to rough or fine dress the face or radii of
the wheel. The radii should blend evenly into
the journal.
9. The selection of the grinding wheel is important
because too hard a wheel will increase the pos-
sibility of burning. An aluminum–oxide wheel
with a grit size of approximately 50 and a maxi-
mum hardness of M will produce satisfactory re-
sults, with other conditions being suitable.
10. The coolant must be such that it minimizes
burning. This requires a fluid with high lubricity
properties. The straight–cutting oils appear to
be the best for grinding crankshafts and are
strongly recommended.
EGES 160 – 1
SERVICE MANUAL
Page 39
UED
TINUED
IMPORTANT
USE EVERY PRECAUTION TO AVOID BURNS
ON THE SHAFT DURING THE GRINDING OP-
ERATION.
11. A grinding wheel speed to 6500 surface feet per

minute with a work spindle speed of approxi-
mately 40 to 45 revolutions per minute is usually
satisfactory.
12. Grind all journals with crankshaft rotating in a
counterclockwise direction (viewed from front
of crankshaft), lap all journals with crankshaft
rotating in clockwise direction. DO NOT RE-
FINISH REAR SEAL FLANGE.
13. Feed rates should be slower than normal to pre-
vent any burning.
14. Maximum allowable taper on crankpins (rod
journals) and main journals 0.38 mm per 25.4
mm (0.015 per 1.0 inch) of length. Crankpins
and journals must be polished to 20 Micro–inch
maximum – to 5 Micro–inch minimum and must
not be over 0.12 mm (0.005 inch) out of round.
NOTE: Do not grind the crankshaft flange.
CAUTION
AS A NORMAL PRECAUTION, IT IS REC-
OMMENDED THAT A CO2 FIRE EXTINGUISHER
BE NEAR THE GRINDING MACHINE, JUST IN
CASE ANY EXCESSIVE HEAT SHOULD IGNITE
THE OIL.
15. Inspection of the crankshaft for dimensional tol-

erances is the same as for conventionally hard-
ened crankshafts, except that extra care must
be taken to be sure the crankshaft is cool before
inspecting. Scrap only those crankshafts which
do not meet the specified tolerances.
EGES 160 – 1
SERVICE MANUAL
Page 40
UED
TINUED
16. In addition to inspecting the dimensional toler-
ances, the crankshaft must also be carefully
checked for surface defects, particularly for
grinding cracks and burns. It is advisable to
spray check the crankshaft (using dye pene-
trant methods) after grinding and lapping to in-
sure that there is no surface cracking.
17. TARASOV ETCH: In order to establish the ac-
ceptability of a regrind procedure, crankshaft
should be etched before lapping to determine
whether the crankshaft was burned during the
regrinding procedure. The best etch to use is
the Tarasov etch, which will show both the re-
hardened and the overtempered areas. The
etching procedure is as follows:
CAUTION
DUE TO THE SHARP ODOR AND FLAMMABIL-
ITY OF THE TARASOV ETCH, THE ETCHING
SHOULD BE DONE IN A WELL–VENTILATED
AREA, AWAY FROM ANY OPEN FLAME.
a. Clean surface with a scouring powder and

water or a good solvent.
b. Wash thoroughly and rinse with alcohol.
c. Apply etchant No. 1 (4 parts nitric acid in 96
parts water) for approximately 16 seconds
with a cotton swab.
d. Rinse with water and dry with filtered com-
pressed air.
e. Apply etchant No. 2 (2 parts hydrochloric
acid in 98 parts acetone) for approximately
15 seconds with a cotton swab.
CAUTION
ACETONE IS HIGHLY FLAMMABLE.
f. Rinse with alcohol and dry thoroughly with

compressed air.
EGES 160 – 1
SERVICE MANUAL
Page 41
UED
TINUED
IMPORTANT
IF THE CRANKSHAFT HAS BEEN BURNED, IT
WILL SHOW UP AS A CHANGE OF COLOR AF-
TER THE ETCH. AREAS HARDENED BY EX-
CESSIVE HEAT APPEAR NEARLY WHITE,
WHILE SOFTENED AREAS TURN DARK GRAY
OR BLACK. AREAS UNAFFECTED BY THE
HEAT OF GRINDING ETCH A LIGHT GRAY.
IMPORTANT
IF ANY BURNS SHOW UP AFTER THE ETCH IS
USED, THE PHYSICAL PROPERTIES OF THE
CRANKSHAFT WILL HAVE BEEN SERIOUSLY
REDUCED, AND THE CRANKSHAFT SHOULD
NOT BE USED.
NOTE: If burning becomes a serious problem,

it can usually be eliminated by reducing the in-
deed rate, using a softer grade of wheel, or in-
creasing the work spindle speed. Sometimes, a
combination of these factors, along with the
recommendations mentioned above, will be
necessary to overcome the problem.
g. After the crankshaft passes the Tarasov

etch test, it may be lapped.
IMPORTANT
THOROUGHLY CLEAN CRANKSHAFT OIL PAS-
SAGES WITH NYLON BRISTLE BRUSH, SOAP
AND WATER TO REMOVE ALL DEBRIS WHICH
MAY HAVE ACCUMULATED DURING REGRIND-
ING PROCEDURE. ANY DEBRIS LEFT IN
CRANKSHAFT OIL PASSAGES CANNOT BE
REMOVED BY OIL FILTERS AND WILL DAMAGE
BEARINGS IMMEDIATELY UPON ENGINE
START–UP. ONCE CLEANED, WRAP CRANK-
SHAFT, TO PROTECT IT FROM CONTAMI-
NATION, UNTIL IT IS INSTALLED.
18. Visually inspect the crankshaft gears for chip-

ping or wear. Replacement as required.
EGES 160 – 1
SERVICE MANUAL
Page 42
UED
CRANKSHAFT GEAR
Removal
Replace the crankshaft gear as follows:
1. Place a chisel between the gear teeth and strike
the chisel with a hammer to split the gear.
2. Remove the oil pump drive spline first to access
the crankshaft gear (Figure 7.72).
3. Be careful not to damage the crankshaft during
gear removal.
Installation
1. With gears removed, heat the crankshaft gear EG–5224
and oil pump drive spline, using ZTSE4384, to
188–202° C (370–395° F). Figure 7.72 Removing Oil Pump Drive Spline
2. Install the crankshaft gear first. Be sure the lo-
cating pin on the crankshaft gear aligns with the
crankshaft properly (Figure 7.73). Press the
gear into place.
3. Install the hot oil pump drive spline onto the
crankshaft until flush with the crankshaft gear
(Figure 7.73).
Figure 7.73 Installing Crankshaft Gear
EGES 160 – 1
SERVICE MANUAL
Page 43
CRANKCASE (RECONDITIONING)
CLEANING
NOTE: The best way to clean the crankcase dur-
ing engine overhaul is in a chemical bath or
“HOT TANK”. This removes all carbonous ma-
terial and mineral deposits which collect in the
cooling passages. If the “HOT TANK” is not
available, use the following cleaning procedure.
1. Clean all old gasket material from the surfaces

of the crankcase using a scraper and a sanding
block.
2. Clean the cylinder sleeve bores using soap, wa-
ter and a nylon brush.
3. Remove main oil gallery cup plug, located at
rear of crankcase by using a hammer and chis-
el, knockout the main oil galley plug (Figure EG–5364
7.74).
4. With the plugs removed from the crankcase,
clean the crankcase as follows:
Figure 7.74 Removing Crankcase Plugs
a. Use a nylon brush (ZTSE4389) with soap
and water to clean the oil galleries.
b. Clean the cross drillings using a nylon brush
with soap and water (Figure 7.75).
c. Blow out all oil galleries and cross drillings
using filtered compressed air.
d. Clean all threaded holes using a tap of ap-
propriate size, use ZTSE4386.
5. Install new main oil gallery cup plug as follows:
a. Clean mating surfaces on plug and crank-
case.
b. Apply Loctite® 262 to the outside edge of
the cup plug.
c. Drive the cup plug in using an arbor approx–
imately 6mm (1/4 in.) smaller in diameter EG–5365
than the plug being installed.
d. Recess the plug 3.2mm (1/8 in.).
6. Install new plugs into rear of crankcase. Figure 7.75 Cleaning Crankcase Galleries
EGES 160 – 1
SERVICE MANUAL
Page 44
CRANKCASE (RECONDITIONING) –
CONTINUED
NOTE: Threaded holes with damaged threads
may be salvaged with the use of a thread insert.
1. Inspect the crankcase deck for flatness using a

straightedge (OEM1293) and feeler gauge.
Use the checking pattern shown in Figure 7.76.
If a 0.076mm (0.003 in.) feeler gauge can pass,
the crankcase must be replaced.
IMPORTANT Figure 7.76 Inspect Crankcase For Flatness
DO NOT RESURFACE THE CRANKCASE. SUR-
FACE DEFECTS BEYOND THOSE LISTED IN
STEP ONE, ABOVE, ARE NOT CORRECTABLE.
REPLACE THE CRANKCASE.
2. Visually inspect the piston oil jet tubes for block-

age as follows (Figure 7.77):
a. Shine a light source under the small orifice
in the tube end which protrudes into the
crankcase from its insertion point in the
bearing saddle.
b. Position your eye to align with the large ori-
fice of the piston cooling jet. If the light
source is visible, the jet tube is clear and re-
quires no further service.
EG–5360
c. If the light source is not visible, the piston
cooling jet tube is blocked. Clean the tube to
remove any blockage. Figure 7.77 Inspecting Piston Oil Jet Tubes
EGES 160 – 1
SERVICE MANUAL
Page 45
CRANKCASE (RECONDITIONING) –
CONTINUED
INSPECTION AND REPAIR – CONTINUED
3. Clean piston oil jet tube blockage as follows:
a. Run an appropriately sized wire or torch tip
cleaner through the tube orifice to remove
blockage.
b. Using filtered compressed air, blow loos-
ened debris out from the jet tube orifice.
c. Reinspect piston cooling jet tube using a
light source as previously described.
NOTE: Do not remove piston cooling jet tubes
unless they are damaged or cannot pass the
visual inspection after cleaning.
CAUTION EG–5361
ALWAYS WEAR SAFETY GLASSES WHEN US-
ING COMPRESSED AIR. Figure 7.78 Cleaning Piston Oil Jet Tube
CRANKSHAFT AND MAIN BEARINGS
Inspection
Check Crankcase Integrity as follows:
1. Rotate engine so the main bearing saddles are
facing upward. Wipe main bearing saddle us-
ing a lint–free cloth. The supports must be free
of oil. DO NOT LUBRICATE THE BACK SIDE
OF THE BEARING INSERTS.
2. Install upper bearing inserts into bearing
saddle. Be sure the locking tangs on the bear-
ings are snapped into the crankcase (Figure
7.79).
3. Apply Prussian Blue® to the crankshaft main
bearing journals. Carefully lower the crankshaft
onto the main bearing inserts in the crankcase.
NOTE: Do not install the main bearing caps and EG–5362
lower bearing inserts at this time.

Figure 7.79 Installing Upper Shell Inserts
4. Rotate the crankshaft 1/2 turn.
5. Carefully remove the crankshaft and inspect
the upper bearing inserts for an even transfer of
bluing from the journals to the bearings.
IMPORTANT
IF VOIDS APPEARED IN THE BLUING TRANS-
FER, THE CRANKCASE INTEGRITY IS QUES-
TIONABLE.
6. When satisfied that crankcase is in good order
and free of distortion and burrs around upper
bearing insert seats, clean all Prussian Blue®
from the bearings and crankshaft journals.
EGES 160 – 1
SERVICE MANUAL
Page 46
INSTALLATION
CRANKSHAFT
1. Lubricate the upper main bearing inserts with
clean engine oil (Figure 7.80).
2. Carefully install the crankshaft into the main
bearing saddle. Use an appropriate lifting sling
to lower the crankshaft (Figure 7.81).
BEARING FITTING PROCEDURE

1. Install a new bearing in the bearing cap, as re-
quired. Be sure the locking tangs on the bearing
inserts are snapped into the bearing cap notch.
2. Check bearing clearance as follows: EG–5363
a. Clean the bearing surface and the exposed

Figure 7.80 Lubricating Upper Main Bearing
half of the crankshaft journal. Be sure these
Insert
surfaces are free of oil.
b. Install the bearing caps and lower inserts
and tighten to the specified torque.
c. Remove one bearing cap with insert one at
a time. Remaining caps are left tight while
checking the fit of the bearing with the cap
removed.
d. Wipe the oil from all contact surfaces of the
exposed journal and bearing insert and cap
removed.
e. Place a piece of Plastigage® across the full
EG–5359
width of the bearing surface on the crank-
shaft journal (or bearing cap insert) approxi-
Figure 7.81 Installing Crankshaft
mately 6 mm (1/4 in.) off center. Install bear-
ing cap and tighten cap bolt to specified
torque.
NOTE: Do not turn crankshaft while making
check with Plastigage®.
NOTE: IN CHASSIS SERVICE ONLY – When
bearing clearance is checked, the crankshaft
will have to be supported and held against the
upper main bearing halves to get a correct Plas-
tigage® reading. Use a jack at counter– weight
next to each main bearing being checked to
support the crankshaft. Failure to support the
crankshaft will result in inaccurate readings.
EGES 160 – 1
SERVICE MANUAL
Page 47
BEARING FITTING PROCEDURE – CONTINUED
f. Remove bearing cap with insert.
g. Do not disturb Plastigage®. Using the
Plastigage® envelope, measure the widest
point of the Plastigage®, Figure 7.82. This
reading indicates the bearing clearance in
thousandths of an inch or millimeters.
h. If the bearing clearance is not within specifi-
cations, the crankshaft must be replaced or
reground and undersize bearings installed
(as described earlier in this section).
EG–5355
MAIN BEARING AND CAP
1. With acceptable bearing clearance, proceed as
follows:
a. Clean Plastigage® from main bearing or Figure 7.82 Placing Plasticgage® On Crank-
crankshaft journal surface. case
b. Coat all bearing surface journals and bolts
with clean engine oil.
c. Place No. 1 through No. 6 main bearing
caps with lower bearing inserts installed.
NOTE: BE SURE the main bearings are installed
with the arrow pointing to the camside and num-
bered from the front of the engine to the rear.
d. Install the main bearing caps and tighten
No.1 through No. 6 main bearing cap bolts
to the special torque value. Refer to Figure
7.83.
e. Install rear thrust bearing as follows:
Insert main bearing cap with rear thrust
bearing into position.
Center rear thrust bearing by moving crank- EG–6897
shaft rearward, then forward.

f. Tighten two (2) rear thrust bearing bolts fin-
ger–tight, then tighten to the special torque
value. Figure 7.83 Installing Main Bearing Cap
EGES 160 – 1
SERVICE MANUAL
Page 48
MAIN BEARING AND CAP – CONTINUED
g. Check crankshaft end play using a dial indi-

cator as follows: Refer to Figure 7.84.
Mount the dial indicator on crankcase with

indicator tip on crankcase flange face.
Lightly pry the crankshaft forward and zero

indicator.
Then pry crankshaft rearward and record

dial indicator reading. Repeat to assure an
accurate reading.
NOTE: If end play exceeds specifications, re-

place thrust bearing and recheck crankshaft
end play. If end play is less than specified, loos-
en main bearing caps, reposition, torque and re-
EG–6900
check end play.
Figure 7.84 Checking Crankshaft End Play

2. Install piston and connecting rod assemblies.
Refer to Section 6.
3. Install front cover. Refer to Section 8.
4. Install oil pump assembly. Refer to Section 9.
EG–5298
Figure 7.85 Installing Oil Pick–up Tube Gasket
OIL PICKUP TUBE
1. Install oil pick–up tube as follows:
a. Install two (2) oil pick up tube mounting bolts

and place new gasket into position (Figure
7.85).
EG–5296
b. Align holes of oil pick–up tube with two (2)

holes in front cover. Secure oil pick–up tube Figure 7.86 Securing Oil Pick–up Tube Mount-
to front cover (Figure 7.86). ing Bolts
EGES 160 – 1
SERVICE MANUAL
Page 49
OIL PICKUP TUBE – CONTINUED
c. Align oil pick–up tube with support bracket
and secure using one (1) bolt. Tighten to
special torque value. Refer to (Figure
7.87).
d. Tighten two (2) front bolts to special torque
value.
IMPORTANT
IF STRESS OCCURS WHEN TIGHTENING THE
MOUNTING BOLT OF THE OIL PICK–UP TUBE
MOUNTING BRACKET AFTER THE FRONT EG–6894
BOLTS ARE TIGHTENED, REPLACE TUBE. IF
NO STRESS OCCURS, TORQUE THE BRACKET Figure 7.87 Installing Oil Pick–up Tube Sup-
BOLT TO THE SPECIAL TORQUE VALUE. port Bracket
OIL PAN
1. Prepare oil pan for installation by using a wire

wheel to clean RTV from the oil pan lip.
IMPORTANT
BE SURE TO CLEAN ALL RTV FROM OIL PAN
LIP CRANKCASE RAILS, FRONT COVER AND
REAR OIL SEAL CARRIER.
Figure 7.88 Applying RTV To Crankcase
2. Apply a 6 mm (1/4 in.) bead of RTV to the loca-
tions shown in Figures 7.88 and 7.89:
a. Where the crankcase and rear half of the
front cover and the crankcase and rear oil
seal carrier contact each other.
b. Also apply a circle of RTV around the
cupped plug crankcase orientation holes lo-
cated on the oil pan rails of the crankcase.
EG–5293
NOTE: DO NOT apply RTV more than 5 minutes
before installing the oil pan. Figure 7.89 Applying RTV To Crankcase Rails
EGES 160 – 1
SERVICE MANUAL
Page 50
OIL PAN – CONTINUED
3. Place the oil pan gasket onto the oil pan so that
the seal bead of the gasket is TOWARD the
crankcase and the edge marked FRONT is fac-
ing the front cover.
4. Install the oil pan onto the crankcase. Place two
(2) oil pan mounting bars on the pan oil rail and
secure with the fourteen (14) long mounting
bolts (Figure 7.90). Use the eight (8) shorter
bolts to secure the oil pan to the front cover and
rear oil seal carrier. Tighten bolts to the special EG–5050
Figure 7.90 Installing Oil Pan Mounting Bars
FRONT MOUNTING BRACKET 1

Install the front mounting bracket to the engine. Se-
cure with four (4) mounting bolts. Tighten to the spe-
cial torque value (Figure 7.92).
2
EG–5049
Figure 7.91 Securing Oil Pan To Crankcase

1. Oil Pan
2. Mounting Bar (2)
EG–5074
Figure 7.92 Installing Front Mounting Bracket
EGES 160 – 1
SERVICE MANUAL
Page 51
VIBRATION DAMPER
IMPORTANT
BE SURE THE FRONT MOUNTING BRACKET IS
MOUNTED TO THE ENGINE BEFORE INSTAL-
LING THE VIBRATION DAMPER.
1. Install the vibration damper as follows:

a. Attach damper heater ZTSE4284 to vibra-
tion damper or place damper directly onto a
hot plate (Figure 7.93 or 7.94). Mark
damper with a thermomelt crayon 198° C
(388° F) and heat. When crayon melts, us-
ing welding gloves, install damper on EG–5371
crankshaft nose. Be sure that keyway on

Figure 7.93 Heating Vibration Damper With
damper aligns with key on crankshaft. DO
Damper Heater
NOT install damper when cold (room tem-
perature) (Figure 7.95).
EG–5372
Figure 7.94 Heating Vibration Damper On Hot

Plate
EG–5071
Figure 7.95 Installing Vibration Damper
EGES 160 – 1
SERVICE MANUAL
Page 52
VIBRATION DAMPER – CONTINUED
b. Apply an RTV bead to to the crankshaft.
Install damper retainer and secure with
mounting bolts (Figure 7.96).
c. Prevent crankshaft from turning and tighten
bolts to the special torque value (Figure
7.97).
MISCELLANEOUS INSTALLATION EG–5069
Refer to the appropriate sections of this publication

for the proper installation procedures of the follow-
ing: Figure 7.96 Applying RTV To Vibration Damp-
er Retainer
Oil, fuel and coolant filters
Auto tensioner
Belt
Road draft tube
Cylinder head
Fuel injectors
Wiring harness
Thermostat
Oil level gauge and tube assembly
Exhaust manifold
Turbocharger
Turbocharger supply and drain lines
Coolant filter header
Fuel filter header and fuel lines lines
EG–5067
IMPORTANT
ADJUST THE VALVE LASH AS SPECIFIED IN
SECTION 4 AND PRIME THE LUBRICATING Figure 7.97 Securing Vibration Damper Re-
SYSTEM AS SPECIFIED IN SECTION 9. tainer
EGES 160 – 1
SERVICE MANUAL
TIMING GEAR TRAIN AND FRONT COVER
SECTION 8 INDEX
Page
EXPLODED VIEW OF CRANKCASE FRONT COVER AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . 1

TIMING GEAR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE GEAR TRAIN TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING ENGINE GEAR TRAIN TIMING WITHOUT REMOVING
FRONT COVER AND/OR ENGINE TEAR DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Method One – Using A Feeler Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Method Two – Using A Dial Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT COVER, FRONT HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GEAR TRAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IDLER GEAR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CAMSHAFT GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CRANKSHAFT GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT COVER, REAR HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Idler Gear Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GEAR TRAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
IDLER GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FRONT COVER, FRONT HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AIR COMPRESSOR/POWER STEERING PUMP (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FAN HUB AND PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ALTERNATOR BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AUTO BELT TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
EGES 160 – 1
SERVICE MANUAL
Section 8
TIMING GEAR TRAIN AND FRONT COVER Page 1
EXPLODED VIEW OF CRANKCASE FRONT COVER AND RELATED PARTS
7 8
6
3
2
1 5
4
11
9
13
12
14 10
EG–3772
Figure 8.1 Exploded View Of Crankcase Front Cover And Related Parts
1. Timing Indicator With Pin
2. Front Crankcase Cover (Front Half)
3. Front Cover Oil Pressure Gasket
4. Relief Valve Assembly 550 kPa (80 psi)
5. Relief Valve O–Ring
6. Front Cover Dowel (Rear Half)
7. Front Crankcase Cover (Rear Half)
8. Front Cover to Crankcase Gasket
9. Water Inlet Elbow Gasket
10. Water Inlet Elbow
11. Front Cover Reservoir Gasket
12. Front Cover Oil Suction Gasket
13. O–Ring, 27.1mm (1.068 in.) O.D.
14. O–Ring, 16mm (0.638 in.) O.D.
EGES 160 – 1
SERVICE MANUAL
Section 8
Page 2 TIMING GEAR TRAIN AND FRONT COVER
TIMING GEAR IDENTIFICATION
4
3
2
5
1 10 9
EG–6168
Figure 8.2 Timing Gear Indicators

1. Rear Half Front Cover
2. Camshaft Gear With Timing Disk Plate
3. Camshaft Gear/Upper Idler Gear Timing Marks
4. High Pressure Pump Gear Location
5. Upper Idler Gear
6. Upper Idler Gear/Lower Idler Gear Timing Marks
7. Air Compressor Gear Location
8. Lower Idler Gear
9. Lower Idler Gear/Crankshaft Timing Marks
10. Crankshaft
EGES 160 – 1
SERVICE MANUAL
Section 8
SPECIFICATIONS
Timing Gears
Crankshaft to Idler Backlash (Maximum) 0.356 mm (.014 in.)
Idler to Camshaft Backlash 0.457 mm (.018 in.)
Idler to Idler Backlash 0.482 mm (.019 in.)
Idler to Air Compressor or Power Steering Pump Backlash 0.508 mm (0.020 in.)
Idler to High Pressure Pump Backlash 0.482 mm (0.019 in.)

Crankcase Front Cover Bolts (Front & Rear Halves) 22 Nm (16 lb–ft.)
Crankcase Front Cover (Rear Half to Crankcase) 26 Nm (19 lb–ft.)
Idler Gear Retaining Bolt (Upper) 332 Nm (245 lb–ft.)
Idler Gear Retaining Nut (Upper) 431 Nm (318 lb–ft.)
Idler Gear Retaining Bolt (Lower) 637 Nm (470 lb–ft.)
Idler Gear Retaining Nut (Lower) 492 Nm (363 lb–ft.)
Camgear Timing Disk Plate 7 Nm (60 lb–in.)
Air Compressor Hose Clamps 4.74 Nm (3.5 lb–ft. 42 lb–in.)
Air Compressor Tail Bracket Mounting Bolts (Crankcase) 115 Nm (85 lb–ft.)
Air Compressor Tail Bracket Mounting Bolt (Compressor) 66 Nm (49 lb–ft.)
Air Compressor Drive Gear Nut 149 Nm (110 lb–ft.)
Air Compressor Mounting Bolts 62 Nm (46 lb–ft.)
Belt Tensioner (Front Cover) 50 Nm (37 lb–ft.)
Belt Tensioner (Freon Compressor) 50 Nm (37 lb–ft.)
Water Pump Pulley 7 Nm (66 lb–in.)
Fan Drive 22 Nm (16 lb–ft. or 192 lb–in.)

ZTSE4383 Lower Idle Gear Socket (3/4 in./20 mm 12 point)
EGES 160 – 1
SERVICE MANUAL
Section 8
ENGINE GEAR TRAIN TIMING
Valve train failures from broken or bent push rods,
valves, rocker arms and worn valve keepers and/or 47mm (1.850 IN.)
rotators in many instances could be caused by im- HORIZONTAL
proper timing of the gear train. Depending on valve DISTANCE
lash setting, if the camshaft gear is improperly timed
by one (1) tooth early, the engine pistons will strike
the intake valve heads or if the timing is set one (1) 1.866 IN.
tooth late, the exhaust valve may contact pistons. RADIAL
DISTANCE
CHECKING ENGINE GEAR TRAIN TIMING SCRIBED MARK EQUAL
WITHOUT REMOVING FRONT COVER AND/OR TO 24.5 ° BTD
ENGINE TEAR DOWN.
NOTE: For testing purposes only! No. 1 intake
valve setting with No. 1 piston @ TDC (compres- DAMPER PULLEY TIMING NOTCH
sion) is 0.74 mm (0.029 in.). EG–7007
Method One – Using A Feeler Gauge Figure 8.3 Checking Engine Gear Train Timing
1. Adjust the No. 1 intake valve with the No. 1 pis-
ton set at TDC (Top Dead Center) compression
stroke to 0.74 mm (0.029 in.).
2. Scribe a straight line or a radial line, in a clock-
wise direction, 47 mm (1.850 in.) in length. Start
from the vibration damper pulley notch, when
facing the engine (Figure 8.3).
3. Turn the engine forward to approximately BDC
(Bottom Dead Center).
4. Place a 0.10 mm (0.004 in.) feeler gauge be-
tween the valve lever and valve stem of the No.
1 intake valve and slowly rotate the engine for-
ward until the feeler gauge becomes tight. This
is now the point at which the No. 1 intake valve
starts to open before top dead center. The
scribed mark should line up with the TDC arrow,
located on the front cover, or be within 0.65 mm
(0.260 in.) on either side of the arrow (equals ±
3.5°).
IMPORTANT
ONE (1) TOOTH “OUT OF TIME” ON THE GEAR
TRAIN EQUALS APPROXIMATELY 11 DEGREE
MOVEMENT (21.431 MM {27/32 IN.} RADIAL DIS-
TANCE) OF VIBRATION DAMPER.
NOTE: If the timing on the No. 1 valve is within

specifications, the other valves barring extreme
camshaft lobe wear or poor adjustment will also
be in time.
EGES 160 – 1
SERVICE MANUAL
Section 8
ENGINE GEAR TRAIN TIMING - 3. Set dial indicator at zero.

CONTINUED
4. Rotate the engine approximately one full
Method One - Using a Feeler Gauge - Continued revolution either direction to a position of 360°
from starting point.
5. Readjust the No. 1 intake valve to its proper
lash, refer to Section 4, "CYLINDER HEAD AND 5. The dial indicator should read 3.81 to 5.08 mm
VALVES". (0.15 to 0.20 in.) for proper gear train timing.
6. If timing is found to be incorrect, removal of the 6. If dial indicator readings are outside the specified
engine’s front cover is required to inspect punch range, the engine’s front cover must be removed
mark and gear tooth position. Figure 8.2depicts and punch mark and gear tooth position adjusted
a properly timed assembly and number of teeth as specified in Figure 8.2.
between marks.
7. Readjust the No. 1 intake valve to its proper lash
as described in Section 4, "Cylinder Head and
Valves".
Method Two - Using A Dial Indicator
1. Adjust the No. 1 intake valve with the No. 1 piston NOTE: ENGINE GEAR TRAIN TIMING
set at TDC (Top Dead Center) compression stroke AND VALVE LASH ADJUSTMENT MUST
to 0.74 mm (0.029 in.). BE PERFORMED. FOLLOWING THESE
PROCEDURES TO ASSURE PROPER VALVE
2. Position the dial indicator fixture magnetic base on
AND PISTON RELATIONSHIP AND PREVENT
the valve cover fence rail with the indicator shaft
PISTONS FROM STRIKING VALVES.
on the No. 1 intake valve rotator.
EGES 160 – 1
SERVICE MANUAL
Section 8
Prior to removing the front cover, the following items
must be removed.
Belt
Front engine mounting bracket
Vibration damper
Oil pump assembly
Water inlet elbow, if required
Oil pan
Water pump and pulley
High pressure pump
Coolant filter header, if required
CMP sensor
Wiring harness
EG–5077
Figure 8.4 Removing Auto Belt Tensioner

FRONT COVER, FRONT HALF
REMOVAL
IMPORTANT
BE SURE OIL HAS BEEN DRAINED FROM THE
ENGINE BEFORE REMOVING THE FRONT COV-
ER.
1. Remove the serpentine belt and auto tensioner

as follows:
a. Install breaker bar into belt tensioner and re-
move tension on belt
b. Remove serpentine belt.
c. Return belt tensioner back to original posi-
tion and remove breaker bar.
d. Loosen mounting bolt and remove belt ten-
sioner. Refer to Figure 8.4.
2. Remove the alternator bracket as follows:
a. Remove the alternator EG–5080
b. Loosen and remove the alternator mounting

bracket bolts. Refer to Figure 8.5.
Figure 8.5 Removing Alternator Mounting
c. Remove the bracket. Bracket
EGES 160 – 1
SERVICE MANUAL
Section 8
FRONT COVER, FRONT HALF – CON-

TINUED
3. Remove the fan drive hub and pulley as follows:
a. Using a special tool, purchased locally, re-
move bolts securing fan pulley to fan drive.
Remove pulley.
b. Remove fan hub drive capscrews and hub.
EG–5081
Figure 8.6 Removing Fan Drive Hub Pulley
EG–5084
Figure 8.7 Removing Fan Drive Hub
EGES 160 – 1
SERVICE MANUAL
Section 8
TINUED
NOTE: Engines may be equipped with or with-
out an air compressor or power steering pump.
4. Remove the air compressor and or power steer-

ing pump (if equipped) as follows:
a. Remove two (2) bolts securing power steer-
ing pump to air compressor (if equipped).
b. Loosen two (2) coolant hose clamps located
at the air compressor and crankcase and re-
move coolant hoses (Figure 8.8).
c. Loosen two (2) nuts securing oil lubrication EG–5064
line to air compressor. Remove oil line (Fig-

ure 8.9). Figure 8.8 Loosen Coolant Hose Clamps
EG–6171
Figure 8.9 Loosen Oil Lubrication Line
EGES 160 – 1
SERVICE MANUAL
Section 8

TINUED
d. Remove two (2) bolts securing air compres-
sor bracket to air compressor. Remove
bracket (Figure 8.10).
e. Remove two (2) bolts securing bracket to
crankcase. Remove bracket (Figure 8.11).
f. Remove two (2) bolts securing air compres-
sor to front cover and remove air compres-
sor.
EG–5062
Figure 8.10 Removing Air Compressor Brack-

et Mounting Bolts
EG–6169
Figure 8.11 Removing Air Compressor To

Crankcase Mounting Bolts
EGES 160 – 1
SERVICE MANUAL
Section 8
TINUED
5. Remove the front cover as follows:
a. Refer to Section 7, “Vibration Damper,
Crankshaft, Main Bearings, Flywheel
and Crankcase” for the removal of the en-
gine front mounting bracket and vibration
damper.
b. Loosen and remove all the front cover
mounting bolts which secure the front cover
(front half) to the rear half of the front cover
and crankcase. Refer to Figure 8.12.
c. Lift the front half of the front cover (with
hardware) from the rear half of the front cov-
er and set aside.
d. Remove gaskets and O–Rings from front EG–5301
cover and discard. Refer to Figure 8.13.

Figure 8.12 Front Cover Mounting Bolts
2
3
1
4
1
EG–6905
Figure 8.13 Front Cover O–Ring And Gasket Locations

1. O–Rings
2. Crankcase Front Cover Reservoir Seal
3. Front Cover Oil Pressure Gasket
4. Front Cover Oil Suction Gasket
SERVICE MANUAL
Section 8

TINUED
IMPORTANT 1
THE OIL PRESSURE RELIEF VALVE (STAMPED
WITH AN “FC”) SHOULD BE TAGGED UPON RE-
MOVAL TO INSURE IDENTIFICATION. DO NOT
MIX OIL PRESSURE RELIEF VALVE WITH OIL
PRESSURE REGULATOR VALVE (FOUND IN
SIDE OF CRANKCASE).
6. Remove oil pressure relief valve from front cov-
EG–5307
er (rear half) and mark to identify its location
(Figure 8.14).
NOTE: Valve may be removed by depressing Figure 8.14 Oil Pressure Relief Valve Location
plunger and trapping a length of copper wire 1. Oil Pressure Relief Valve
when released. Valve may then be removed by
pulling the copper wire.
2
CLEANING
1. Remove all gasket material and RTV from front 1
half of front cover using a scraper or wire brush.
2. Clean all bolt threads prior to assembly. 4
INSPECTION
IMPORTANT
THE FOLLOWING STEPS ARE ESPECIALLY IM- 3
PORTANT IF OIL AND COOLANT CONTAMI-
NATION HAS BEEN FOUND AND NO OTHER EG–5313
CAUSE IS DISCOVERED.
1. Visually inspect the front cover for cracks or po- Figure 8.15 Aligning Timing Marks On Gears
rosity. 1. Camshaft Gear
2. Replace any front cover which fails visual in- 2. Upper Idler Gear
spection. 3. Crankshaft Gear
4. Lower Idler Gear
GEAR TRAIN REMOVAL

INSPECTION
1. Rotate engine so timing marks on lower and up-
per idler gears, crankshaft and camshaft gear
are aligned (Figure 8.15).
NOTE: Once assembled at “marks aligned”
position, engine will require 37 crankshaft revo-
lutions for “marks aligned” position again.
EGES 160 – 1
SERVICE MANUAL
Section 8
GEAR TRAIN REMOVAL – CONTINUED
IMPORTANT
PRIOR TO REMOVING ANY GEAR, MOUNT A
DIAL INDICATOR ONTO THE ENGINE AND
CHECK FOR GEAR BACKLASH.
2. Check upper idler gear lash as follows (Figure

8.16):
a. Mount magnetic base dial indicator on top of
crankcase.
b. Position dial indicator on gear tooth and
“zero” indicator.
c. Place a screwdriver between crankshaft
and lower idler gear.
d. Move upper idler gear back and forth. EG–5309
e. Record reading on dial indicator. If backlash
exceeds specified limits (see “SPECIFI- Figure 8.16 Checking Upper Idler Gear Lash
CATIONS”), replace upper idler gear.
3. Using dial indicator also check upper idler gear
end play.
4. Check lower idler gear lash as follows (Figure
8.17):
a. Mount a magnetic base dial indicator onto
front cover.
b. Position dial indicator on gear tooth and
“zero” indicator.
c. Move lower idler gear back and forth
d. Record reading on dial indicator. If backlash
exceeds specified limits (see “SPECIFI-
CATIONS”), replace lower idler gear.
EG–5308
5. Using dial indicator also check lower idler gear
end play. Figure 8.17 Checking Lower Idler Gear Lash
SERVICE MANUAL
Section 8

6. Check camshaft gear end play as follows (Fig-
ure 8.18):
a. Mount a magnetic base dial indicator to the
top of the crankcase.
b. Position dial indicator onto camshaft tooth
and “zero” dial indicator.
c. Place a screwdriver between the lower and
upper idler gears.
d. Move the camshaft gear back and forth.
e. Record reading on dial indicator. If end play
exceeds specified limits (see “SPECIFI-
CATIONS”), replace camshaft gear.
7. Using dial indicator also check camshaft gear
end play.
EG–5310
Visually inspect all gears for nicks, chips or wear.
Replace as necessary.
Figure 8.18 Checking Camshaft End Play

IDLER GEAR ASSEMBLIES
1. Remove the lower idler gear as follows. Refer
to Figure 8.19:
a. Loosen and remove the idler gear retaining
bolt using idler gear socket ZTSE4383.
b. Remove the idler gear assembly from the
front cover.
IMPORTANT
A NEW UPPER IDLER GEAR BOLT MUST BE
USED WITH EACH INSTALLATION OF THE UP-
PER IDLER GEAR. THERE IS A PREAPPLIED
SEALANT ON THE NEW MOUNTING BOLT.
NOTE: Each idler gear (upper and lower) are

supported on tapered roller bearings and
EG–5318
shafts. The bearing retaining nut should not be
removed as it is required for torquing the nut.
If the bearing is worn or loose, replace the com-
plete gear assembly. Figure 8.19 Removing Lower Idler Gear
EGES 160 – 1
SERVICE MANUAL
Section 8
IDLER GEAR ASSEMBLIES – CONTINUED
2. Remove the upper idler gear as follows. Refer
to Figure 8.20.
3. Remove the idler gear retaining bolt and DIS-
CARD. Remove idler gear.
IMPORTANT
USED WITH EACH INSTALLATION OF THE UP-
PER IDLER GEAR. THERE IS A PREAPPLIED
SEALANT ON THE NEW MOUNTING BOLT.
NOTE: Each idler gear (upper and lower) are
supported on tapered roller bearings and
shafts. The bearing retaining nut should not be
removed as it is required for torquing the nut.
If the bearing is worn or loose, replace the com- EG–5316
plete gear assembly.
CAMSHAFT GEAR REMOVAL Figure 8.20 Removing The Upper Idler Gear
Refer to Section 5, “Rocker Arm Assembly, Cam-
shaft, Tappets and Push Rods” for the removal of
the camgear or camshaft and gear as an assembly
CRANKSHAFT GEAR REMOVAL
Refer to Section 7, “Vibration Damper, Crank-
shaft, Main Bearings, Flywheel and Crankcase”
for the removal of the crankshaft and/or gears.
FRONT COVER, REAR HALF

REMOVAL
1. With the gears removed, remove rear half of
front cover as follows:
a. Remove the nine retaining bolts which se-
cure the front cover to the crankcase. Refer
to Figure 8.21.
b. Lift the front cover (with dowels) off the
crankcase.
c. Discard the O–Ring and clean any sealing
material from the front cover or crankcase. EG–5329
CLEANING
1. Remove sealing material from front cover (rear
half) using a scraper or wire brush. Figure 8.21 Front Cover Rear Half Mounting
2. Clean all bolt threads prior to assembly. Bolts
EGES 160 – 1
SERVICE MANUAL
Section 8
FRONT COVER, REAR HALF – CONTIN-

UED
INSPECTION 3 1
Visually inspect the front cover for cracks or poros-
ity.
NOTE: This is especially important if oil or cool-

ant contamination has been found and no other
cause is discovered.
IDLER GEAR ASSEMBLIES 2

1. Clean all gears and related components, which
EG–7234
are to be reinstalled, as follows:
a. Clean all components in a suitable solvent.
b. Dry with filtered compressed air. Figure 8.22 Rear Half Front Cover Gasket
2. Visually inspect the bearings for looseness. Re- Location
place gear and bearing assembly as required.
1. Gasket
3. Visually inspect the gear teeth for chips or nicks. 2. Front Cover
Replace assembly if required. 3. Crankcase
NOTE: Bearing and Gear are serviced as an as-
sembly. Refer to the proper sections for inspec-
tion of the camshaft, crankshaft, oil pump spline
gears and high pressure pump.
INSTALLATION
1. Install a new crankshaft gear and oil spline gear,
if required. Install the crankshaft, refer to “Sec-
tion 7”.
2. Install front cover (rear half) as follows:
a. Install a new front cover O–Rings and gas-
kets into the grooves in the cover (Figure
8.22).
b. Mount the rear half of the front cover to the
crankcase using nine bolts. Tighten the
bolts to the special torque value (Figure
8.23). EG–5330
3. Refer to “Section 5” for installing the camgear

or camgear and camshaft assembly.
NOTE: Check camshaft end play and be sure Figure 8.23 Installing Rear Half Of Front Cov-
the tappets move freely in their bores. er To Crankcase
EGES 160 – 1
SERVICE MANUAL
Section 8
GEAR TRAIN INSTALLATION
IDLER GEARS 2
1. When an engine has been disassembled and 1
the camshaft, crankshaft or idler gear removed,
the gears must be assembled with the timing 4
marks properly aligned, as shown in Figure
8.24.
NOTE: The single punch marks on the crank-

shaft and lower idler gear and camshaft and up- 3
per idler gear must align, while the two punch
EG–5313
marks on both the idler gears must align.
Figure 8.24 Aligning Of Timing Marks

NOTE: Once assembled at “marks aligned” 1. Camshaft Gear
position, engine will require 37 crankshaft revo- 2. Upper Idler Gear
lutions for “marks aligned” position again. 3. Crankshaft Gear
4. Lower Idler Gear
2. Install the lower idler gear as follows (Figure

8.25):
a. Install the gear with the timing marks facing

out.
b. Align crankshaft and lower idler gear timing

marks.
c. Tighten the retaining bolt to the special

torque value.
IMPORTANT
AFTER INSTALLATION, REMEASURE CRANK- EG–5317
SHAFT TO IDLER GEAR BACKLASH TO CON–
FIRM PROPER ASSEMBLY. Figure 8.25 Installing Lower Idler Gear
EGES 160 – 1
SERVICE MANUAL
Section 8
GEAR TRAIN INSTALLATION – CON-

TINUED
IDLER GEARS – CONTINUED
3. Install the upper idler gear as follows (Figure
8.26):
IMPORTANT
USED AT EACH INSTALLATION OF UPPER
IDLER GEAR.
a. Install the gear with the timing marks facing

out.
b. Align camshaft, upper idler and lower idler EG–5315
gear timing marks.
c. Tighten the retaining bolt to the special Figure 8.26 Installing Upper Idler Gear
torque value.
IMPORTANT
REMEASURE CAMSHAFT TO IDLER GEAR
BACKLASH AFTER INSTALLATION TO CON-
FIRM PROPER ASSEMBLY.
4. Install the high pressure pump into the rear cov-

er. BE SURE to use a new gasket. Secure to
rear cover with mounting bolts.
IMPORTANT
REMEASURE HIGH PRESSURE PUMP TO UP-
PER IDLER GEAR BACKLASH AFTER INSTAL-
LATION TO CONFIRM PROPER ASSEMBLY.
EG–5305
5. Place a new O–Ring onto the oil pressure relief
valve and install the valve into the crankcase Figure 8.27 Installing Oil Pressure Relief
(Figure 8.27). Valve
EGES 160 – 1
SERVICE MANUAL
Section 8
FRONT COVER, FRONT HALF
INSTALLATION
1. Install the front cover as follows: Refer to Fig-
ure 8.28.
a. Apply assembly grease to the three
O–Rings and install into the front cover.
b. Install a new gasket (3 segments) into the
front half of the front cover. Two of the gas- 2
ket segments are molded pieces and the
third is a bulk piece. Once the gasket seg-
ments are in place, apply RTV to the joints. 1
2. Install the front cover on the locating dowel pins
and install the mounting hardware.
3. Tighten the front cover mounting bolts to the
special torque value (Figure 8.29). EG–5373
Figure 8.28 Front Cover O–Rings And Gasket

Locations
1. O–Rings
2. Gasket
EG–5302
Figure 8.29 Installing The Front Cover, Front

Half
EGES 160 – 1
SERVICE MANUAL
Section 8
AIR COMPRESSOR/POWER STEERING

PUMP (IF EQUIPPED)
INSTALLATION
1. Install the air compressor/power steering pump
as follows:
a. Apply a small amount of assembly grease to
the O–Ring and install into groove on front
cover.
b. Mount air compressor to front cover and at-
tach with capscrews (Figure 8.30). Tighten
bolts to the special torque value.
NOTE: DO NOT OVERTORQUE the air compres-
sor mounting bolts. Overtorque will result in
fracturing the front cover.
EG–5066
Figure 8.30 Installing The Air Compressor
EGES 160 – 1
SERVICE MANUAL
Section 8
PUMP (IF EQUIPPED) – CONTINUED
c. Place air compressor bracket against
crankcase, then slide forward to air com-
pressor mounting face. Install two (2) bolts
and finger–tighten to secure bracket to
crankcase (Figure 8.31).
d. Secure air compressor bracket to air com-
pressor using two (2) bolts and two (2)
washers. Tighten to the special torque val-
ue (Figure 8.32).
EG–5063
Figure 8.31 Installing The Air Compressor

Rear Bracket
EG–5062
Figure 8.32 Securing The Rear Bracket To The

Air Compressor
EGES 160 – 1
SERVICE MANUAL
Section 8

IMPORTANT
WHEN INSTALLING THE AIR COMPRESSOR, IT
IS CRITICAL THAT ALL BOLTS ARE TORQUED
IN THE SAME SEQUENCE AS DESCRIBED IN
STEPS B THRU E, SO AS NOT TO CAUSE
WARPAGE TO THE FRONT COVER.
e. Tighten two (2) bolts securing bracket to

crankcase to the special torque value (Fig-
ure 8.33).
f. Install two (2) coolant hoses to air compres-
sor and to crankcase (Figure 8.34).
EG–5061
Figure 8.33 Securing Rear Air Compressor

Bracket To Crankcase
EG–6170
Figure 8.34 Installing Coolant Hoses To The

Air Compressor
EGES 160 – 1
SERVICE MANUAL
Section 8
g. Install lubrication line to air compressor and

tighten nuts in two (2) places (Figure 8.35).
h. Using two (2) bolts, mount steering pump to

air compressor and tighten bolts.
EG–6171
Figure 8.35 Installing Oil Lubrication Hose To

Air Compressor
FAN HUB AND PULLEY
INSTALLATION
1. Install the fan drive hub and pulley as follows:
a. Mount fan drive hub to the front cover. Se-

cure with four (4) mounting bolts (Figure EG–5083
8.36).
Figure 8.36 Installing Fan Drive Hub
b. Mount the fan drive pulley to the fan hub and
tighten to the special torque value. Use a
special holding tool, purchased locally (Fig-
ure 8.37).
ALTERNATOR BRACKET
INSTALLATION
1. Install alternator support bracket to front cover EG–5082
and secure with capscrews coated with Loc-

tite® 262. Figure 8.37 Installing Fan Drive Pulley
EGES 160 – 1
SERVICE MANUAL
Section 8
AUTO BELT TENSIONER

INSTALLATION
1. Install auto tensioner to front cover as follows:
a. Locate recess on front cover and mount ten-
sioner with locating pin at recess (Figure
8.38).
b. Install bolt and secure to front cover. Tight-
en to the special torque value (Figure 8.39).
IMPORTANT
BE SURE THE BOLT IS 80 MM (3–1/8 IN.) IN
LENGTH AND TIGHTEN TO THE SPECIAL
TORQUE VALUE.
EG–5079
Figure 8.38 Installing Auto Belt Tensioner
MISCELLANEOUS
1. Reinstall the following components: Refer to
appropriate section for installation procedures.
Oil pan
Coolant filter header, if required
High pressure pump
Water inlet elbow, if required
Oil pump assembly
Water pump and pulley
Front engine mounting bracket
Vibration damper
CMP sensor
Wiring harness
Belt EG–5078
2. Prime the lubricating system as specified in Figure 8.39 Securing Auto Belt Tensioner To
“Section 9” prior to returning engine to service. Crankcase
EGES 160 – 1
SERVICE MANUAL
Section 9
LUBRICATING OIL PUMP, OIL FILTER AND COOLER Page 1
LUBRICATION SYSTEM SCHEMATIC

Refer to Figure 9.1 for a schematic view of the lu-
brication system.
EG–5889
Figure 9.1 Lubrication System Schematic
EGES 160 – 1
SERVICE MANUAL
Section 9
Page 2 LUBRICATING OIL PUMP, OIL FILTER AND COOLER
EXPLODED VIEW OF LUBRICATING OIL PUMP AND PICK UP TUBE
Figure 9.2 shows an exploded view of the lubricat-
ing oil pump, located at the bottom of the front cover
and the oil pick–up tube.
Figure 9.2 Exploded View Of Lubricating Oil Pump And Pick–up Tube
1. Oil Seal
2. Oil Pump Housing
3. Dowel Pins
4. Rotor Assembly Inner & Outer
5. O–Ring Seal
6. Housing Plate
7. Oil Pump Inlet Pick–Up Tube
8. Gasket
EGES 160 – 1
SERVICE MANUAL
Section 9
EXPLODED VIEW OF OIL COOLER, OIL FILTER AND COOLANT FILTER

Figure 9.3 shows an exploded view of the oil cooler
and coolant filter header and their related parts.
Figure 9.3 Exploded View Of Oil Cooler, Oil Filter And Coolant Filter
1. Connector
2. O–Ring
3. Oil Temperature Control Valve
4. Oil Cooler Water Inlet Tube
5. O–Ring (4)
6. Water Inlet Tube Bracket
7. Gasket
8. Pressure Regulator Valve
9. O–Ring
10. O–Ring
11. Oil Cooler Assembly
12. Coolant Filter
13. Coolant Filter Header
14. Check Valve (2)
15. O–Ring
16. Front Oil Cooler Header
17. Seal
18. Tube
19. Oil Filter
20. Drain Plug (Coolant)
21. Oil Cooler/Filter Header
22. O–Ring
23. Seal
EGES 160 – 1
SERVICE MANUAL
Section 9
SPECIFICATIONS
Oil Pump
Type “GEROTOR”
Drive Crankshaft
0.114 mm (0.0048 in.)
End Clearance Inner and Outer 0.470 mm (0.0020 in.)
0.622 mm (0.0245 in.)
Radial Clearance between Outer Rotor Housing 0.470 mm (0.0185 in.)
Engine Oil Pressure* (Run engine until normal operating temperatures are reached):
At Low Idle Speed (700 rpm) (minimum) 137 kPa (20 psi)
Minimum At High Idle Speed 344 kPa (50 psi)
*Oil Pressure measurement should be made utilizing an oil gallery tap.
Engine Oil Filter

Type “SPIN–ON”
Number 1
Filter Bypass Location In–Filter
Coolant Filter
Number 1
Pressure Regulator Valve Assembly

Location In Crankcase, Behind Filter Header
Setting 331 kPa (48 psi)
27.13 mm (1.068 in.) 0.0005 mm (1.0610 in.)
Valve Assembly Diameter 26.89 mm (1.059 in.) ± 0.0055mm (0.0015 in.)
0.381 mm (0.0015 in.)
Valve Clearance in Bore 0.089 mm (0.0035 in.)
27.00 mm (1.063 in.)
Crankcase Bore I.D. 27.05 mm (1.065 in.)
EGES 160 – 1
SERVICE MANUAL
Section 9

Oil Pickup Tube Mounting Bolts 21 Nm (15 lb–ft. or 180 lb–in.)
Oil Temperature Control Valve 34 Nm (25 lb–ft.)
Oil Cooler Mounting Bolts 26 Nm (19 lb–ft.)

ZTSE3004A Crankshaft Front Oil Wear Sleeve Installer
OEM1293 Bevelled Edge Straightedge, 914 mm (36 in.) Long
EGES 160 – 1
SERVICE MANUAL
Section 9
LUBRICATING OIL PUMP
REMOVAL
1. Remove the vibration damper as described in
“Section 7”.
2. Remove front oil seal as follows:
a. Mount front oil wear seal sleeve removal
tool (ZTSE3004A) into crankshaft nose and
over oil seal.
b. Turn forcing screw to remove seal.
3. Remove the oil pump housing as follows:
a. Loosen and remove the six capscrews (two
short capscrews are located at the two and
three o’clock positions). Refer to Figure EG–5090
9.4.
Figure 9.4 Remove Oil Pump Housing
b. Remove the oil pump housing with O–Ring
seal from the front cover. Refer to Figure
9.5. Discard the O–Ring seal.
c. Remove the outer rotor.
1
4. Using a hammer and chisel, remove the wood-
ruff key from the crankshaft as shown in Figure
9.6.
5. Remove the inner rotor and oil slinger from the
oil pump drive spline. Refer to Figure 9.12.
EG–5092
Figure 9.5 Oil Pump Housing O–Ring

1. O–Ring
EG–5093
Figure 9.6 Removing Woodruff Key
EGES 160 – 1
SERVICE MANUAL
Section 9
LUBRICATING OIL PUMP – CONTIN-

UED
6. Remove the oil pump housing plate. With the

plate removed, remove the sealing O–Ring
from the front cover. Refer to Figure 9.7. Dis-
card the O–Ring seal.
1
2
EG–5096
CLEANING
1. Wash all parts thoroughly in an approved sol- Figure 9.7 Remove Oil Pump Housing Plate
vent. 1. O–Ring
2. Oil Pump Plate
2. Dry with filtered compressed air.
1. Visually inspect the rotors, housing and plate for

nicks, burrs or scoring.
2. Replace any damaged components.
NOTE: The inner and outer rotors are a matched

set and cannot be replaced separately.
3. Inspect for wear by checking the radial clear-

EG–5209
ance between the outer rotor and the pump
housing using a feeler gauge as shown in Fig-
Figure 9.8 Inspect Rotors For Wear
ure 9.8. Refer to “SPECIFICATIONS”. If radial
clearance exceeds the specifications, check
housing to rotor clearance (see step 4).
4. Check housing to rotor clearance as follows:

a. With the O–Ring removed from the oil pump

housing, place a straightedge across the
housing.
b. Insert an appropriate feeler gauge under

the straightedge (OEM1293) at the housing
and outer rotor. (See “SPECIFICATIONS”.)
c. If not within specifications, check the hous- EG–5210

ing and inner rotor for wear. Replace worn
components, as required. Figure 9.9 Checking Housing/Rotor Clearance
EGES 160 – 1
SERVICE MANUAL
Section 9
UED
ASSEMBLY
1. Install a new oil seal into the lubricating oil pump
housing as follows, use ZTSE3004A:
a. Apply gasket eliminator #515 to the O.D. of
the oil seal.
b. Slip oil seal into installing tool.
c. Press the seal into the oil pump housing so
the front of the seal is flush with the front of
the oil pump housing (Figure 9.10).
2. Install a new O–Ring on the front cover, then
install the housing plate (Figure 9.11).
EG–5211
Figure 9.10 Installing Oil Seal Into Lubricating

Oil Pump
1
2
EG–5096
Figure 9.11 Installing New O–Ring And Hous-

ing Plate
1. O–Ring
2. Oil Pump Plate
EGES 160 – 1
SERVICE MANUAL
Section 9

UED
3. Install the inner rotor and oil slinger onto the
crankshaft gear spline (Figure 9.12).
IMPORTANT
OIL SLINGER FITS WITH THE CONCAVE SHAPE
FACING OUT.
4. With the inner rotor installed, tap in the woodruff

key with a hammer (Figure 9.13).
5. Lubricate the outer rotor with clean engine oil
EG–5095
and install rotor into the oil pump housing (Fig-
ure 9.14). Figure 9.12 Installing Inner Rotor And Slinger
6. Install a new O–Ring into the housing groove
and align housing dowel pins with mounting
locations. Install oil pump housing to front cover
(Figure 9.14).
7. Lubricate oil seal prior to installation.
EG–5094
Figure 9.13 Installing Woodruff Key
EG–6172
Figure 9.14 Installing Oil Lubricating Pump

Housing
EGES 160 – 1
SERVICE MANUAL
Section 9
UED
8. Install the six capscrews (two short capscrews
are located at the two and three o’clock posi-
tions) to secure oil pump housing to the front
cover. Tighten the capscrews to the standard
9. Install the vibration damper as specified in
“Section 7”.
EG–5091
Figure 9.15 Securing Oil Pump Housing

Mounting Bolts
EGES 160 – 1
SERVICE MANUAL
Section 9
OIL FILTER AND HEADER

REMOVAL
1. Using a open end wrench, loosen and remove
oil feed supply tube nut located on top of oil filter
header. Remove and discard tube nut O–Ring.
Cap fitting on header (Figure 9.16).
2. With oil and coolant drained from the engine, re-
move the oil filter using an appropriate filter
wrench. Discard the filter (Figure 9.17).
EG–5026
Figure 9.16 Removing Oil Supply Tube
EG–5035
Figure 9.17 Removing Oil Filter
EGES 160 – 1
SERVICE MANUAL
Section 9
OIL FILTER AND HEADER – CONTIN-
UED
NOTE: Remove oil cooler and water coolant
supply tube as an assembly.
3. Remove one (1) bolt and retainer plate securing

water coolant supply tube from crankcase (Fig-
ure 9.18).
4. Remove mounting hardware securing oil cooler
assembly to crankcase (Figure 9.18).
1
3
2
3
EG–5037
Figure 9.18 Removing Oil Cooler Mounting Bolts

1. Retainer Plate and Mounting Bolt
2. Oil Cooler
3. Oil Cooler Mounting Hardware
5. Remove oil cooler and water coolant supply

tube as an assembly from crankcase. Discard
O–Rings, gaskets and seals (Figure 9.19).
EG–5039
Figure 9.19 Removing Oil Cooler
EGES 160 – 1
SERVICE MANUAL
Section 9

UED
LEAKAGE TEST
1
Inspect oil cooler assembly for leaks using an “Air
Pressure” test as follows: Refer to Figure 9.20.
1. Fasten oil cooler leakage test plate to oil cooler 2

headers using new oil cooler gaskets.
2. Install oil filter. 3
3. Install air pressure gauge to oil cooler filter 4
header at turbocharger supply fitting location.
4. Immerse assembly in a container of clean “tap”
water.
5. Apply 690 kPa (100 psi) air pressure while im- 5
mersed.
EG–5214
6. Inspect header castings, O–Ring seals and
1/4NPTF water side opening for moving or
growing bubbles. Replace components as re-
quired.
Figure 9.20 Air Pressure Test Procedure
1. Air Hose
DISASSEMBLY 2. Air Pressure
3. Pressure Test Plate Mounting Bolts
1. With Non–metallic hammer, gently rap front of 4. Pressure Test Plate
oil filter header to loosen O–Rings. Twist head- 5. Oil Filter Gauge/Regulator
ers and separate from cooler bundle.
2. Remove, inspect and install oil temperature
control thermostat located in the oil filter/cooler
header. Install with new O–Ring.
NOTE: Oil pressure regulator valve may be re-
moved by depressing plunger and trapping a
length of copper wire when released. Valve may
then be removed by copper wire.
3. Remove, inspect and install oil pressure regula-

tor valve located in crankcase. Refer to Figure
9.21.
IMPORTANT
IN THE EVENT OF BEARING FAILURE, OIL
COOLER BUNDLE MUST BE REPLACED BE-
EG–5041
CAUSE FAILED BEARING DEBRIS CANNOT BE
REMOVED FROM COOLER BUNDLE.
4. Disassembly oil cooler rear and front header Figure 9.21 Oil Pressure Regulator Valve
from oil cooler bundle. Location
EGES 160 – 1
SERVICE MANUAL
Section 9
UED
CLEANING
1. Immerse oil cooler, front and filter header in a
suitable solvent. Flush and drain cooler to re-
move residue.
2. Dry all components thoroughly with filtered
compressed air.

1. Visually inspect oil cooler for blocked tubes and
corrosion where tubes are assembled to the
bundle. Replace oil cooler tube bundle if re-
quired.
2. Visually inspect header for blocked orifices or
damaged threads at oil filter threaded insert.
3. Remove any debris which may be blocking oil
flow passages.
EG–5219
ASSEMBLY
Perform the following, refer to Figure 9.22. Figure 9.22 Oil Cooler Assembly
IMPORTANT
USE NEW O–RINGS WHEN ASSEMBLING OIL
COOLER. DO NOT NICK, CUT OR DISTORT O–
RINGS DURING ASSEMBLY.
1. Install O–Rings onto oil cooler bundle.
2. Using lubriplate, lubricate oil cooler bundle,
headers and O–Rings on cooler bundle.
3. Carefully press assembly together assuring
that locating clip of oil cooler headers (front and
rear) align in slots of oil cooler bundle and head-
er is not cocked. This procedure can be accom-
plished by using body weight to press assembly
together.
EGES 160 – 1
SERVICE MANUAL
Section 9

UED
INSTALLATION
1. Install water outlet tube in front cover (Figure
9.23). WATER OUTLET
IMPORTANT TUBE
1. INSTALL OIL COOLER ASSEMBLY USING A
NEW SQUARE CUT O–RING AT FRONT
HEADER AND O–RING GASKET AT REAR
FILTER COOLER HEADER.
2. BE SURE TO INSTALL THE OIL PRESSURE
RELIEF VALVE INTO THE CRANKCASE.
2. Install the filter header/oil cooler assembly to

the crankcase. Refer to Figure 9.23 and 9.24.
Secure with appropriate bolts and nuts and EG–5040
tighten to the special torque value.
3. Secure water inlet tube to crankcase. Install the
retainer plate and tighten bolt.
Figure 9.23 Installing Water Outlet Tube
1
3
3
EG–5038
Figure 9.24 Installing Oil Cooler

1. Oil Cooler Retainer Bracket
2. Oil Cooler
3. Mounting Bolts
EGES 160 – 1
SERVICE MANUAL
Section 9
UED
4. Install new oil filter as follows: Refer to Figure
9.25.
a. Lubricate new filter gasket with clean en-
gine oil.
b. Hand tighten filter one (1) full turn after gas-
ket first contacts filter header.
CAUTION
DO NOT OVERTIGHTEN FILTER. DAMAGED
FILTER MAY FRACTURE OR LEAK.
5. Prime lubricating system as described in this

section.
EG–5036
Figure 9.25 Installing Oil Filter
EGES 160 – 1
SERVICE MANUAL
Section 9
PRIME THE LUBRICATING SYSTEM

PREFERRED METHOD
When the engine has been assembled, it is recom-
mended to lubricate the engine with oil before start-
ing. This is done to prevent any damage to internal
parts. The following procedure is the preferred
method to use when priming the lubricating system.
NOTE: Install new lube oil filter.
WARNING
DO NOT ROTATE ANY DIESEL ENGINE WHEN
PRIMING WITH OIL TO PREVENT ENGINE
FROM ACCIDENTALLY STARTING.
1. Pressure prime the lubrication system with oil,

prior to starting as follows:
a. Inject sufficient oil into the engine to fill the
oil filters and charge the entire system.
b. After priming, check the oil level before the
engine is put back into service. Refer to
chart for proper oil capacity.
Crankcase Refill Capacities:

26.4 Liters (28 qts.) with filter change
22.7 Liters (24 qts.) without filter change
NOTE: Engines equipped with a by–pass filter-

ing system require additional oil.
IMPORTANT
BE SURE THE ENGINE IS WELL OILED DURING
ASSEMBLY IN ORDER TO USE THIS PROCE-
DURE. IF THE ENGINE IS NOT WELL OILED DO
NOT USE THIS PROCEDURE, REFER TO
”PRIME THE LUBRICATING SYSTEM (PRE-
FERRED METHOD)” IN THIS SECTION FOR
FURTHER INFORMATION.
Use the following instructions prior to starting the

engine. This is done to prevent any damage to inter-
nal parts.
1. Using the cranking motor, spin but DO NOT

start the engine, until oil pressure is read on the
oil pressure gauge.
2. When oil pressure is read, the engine may be
started.
EGES 160 – 1
SERVICE MANUAL
Section 9
ENGINE RUN–IN PROCEDURE
IMPORTANT
AFTER INSTALLING NEW PISTONS AND/OR
NEW RINGS, THE ENGINE MUST BE “RUN–IN”
AS FOLLOWS:
1. Operate engine at low idle (no load) for 5 min-

utes.
a. Check for leaks in the water, lube oil, fuel
and air induction systems.
2. Operate engine at 3/4 rated speed (RPM) and
1/2 to 3/4 throttle for 10 minutes.
3. Operate engine at rated speed and full throttle
for 30 minutes. Recheck for lube oil, fuel, water
and air leaks.
4. Run–In Checks:
Start the engine and operate at low RPM for a few
minutes before loading engine.
Operate the engine, observing the turbocharger for

any of the following:
1. Unusual noise.
2. Lubrication leaks.
3. Insecure fastening to the engine.
4. Excessive vibration.
5. Excessive exhaust smoke.
6. Air leaks in the air cleaner–to–turbocharger or
turbocharger–to–intake manifold ducting.
Investigate and correct any of these conditions im-
mediately to avoid possible turbocharger or engine
failure.
Retighten capscrews, hold–down nuts, air connec-

tions to and from the turbocharger after the initial
warm–up.
EGES 160 – 1
SERVICE MANUAL
WATER PUMP AND THERMOSTAT
SECTION 10 INDEX
Page
EXPLODED VIEW OF FAN DRIVE, THERMOSTAT AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COOLANT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WATER INLET ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EGES 160 – 1
SERVICE MANUAL
Section 10
WATER PUMP AND THERMOSTAT Page 1
EXPLODED VIEW OF FAN DRIVE, THERMOSTAT AND WATER PUMP

Figure 10.1 shows an exploded view of fan drive, thermostat and water pump.
Figure 10.1 Exploded View Of Fan Drive, Thermostat And Water Pump
1. Thermostat Assembly 9. Fan Drive Belt

2. O–Ring 10. Auto Tensioner
3. Fan Mounting Support Bracket (Use With 11. Water Pump Pulley
465 mm (18.3 in.) Fan Center 12. Water Pump Assembly
4. Fan Mounting Bracket W/Hub 13. Thermostat Bypass Housing (For Retarder
5. Fan Pulley Equipped Auto Transmission)
6. Freon Drive Pulley 14. Coolant Passage Insert (Auto Trans.)
7. Fan Spacer 15. O–Ring
8. Special Flange Bolt 16. Water Pump O–Ring
EGES 160 – 1
SERVICE MANUAL
Section 10
Page 2 WATER PUMP AND THERMOSTAT
SPECIFICATIONS
Coolant Filter
Number 1
Thermostat
Type Poppet Valve, Pellet Operated
Operating Temperature Range:
Start to Open Temperature 82° – 85° C (180° – 185° F)
Full Open Temperature 94° C (202° F)

Water Pump Pulley (6 mm) 7 Nm (66 lb–in.)
Water Pump Mounting (6 mm) 7 Nm (66 lb–in.)
Coolant Filter Header Mounting Bolts 26 Nm (19 lb–ft.)

No special tools required for this section.
EGES 160 – 1
SERVICE MANUAL
Section 10
WATER PUMP
REMOVAL
1. Place oil strap around water pulley and secure
when removing pulley mounting bolts.
2. Remove the four (4) water pump pulley bolts.
3. Remove the pulley from the water pump hub.
4. Remove the seven (7) bolts which secure the
water pump to the front cover. Refer to Figure
10.3.
NOTE: The bolt at the twelve (12) O’clock posi-
tion goes through front cover and is held with a
nut (Figure 10.3).
5. Remove the water pump from the front cover.

Discard the O–Ring.
EG–5085
Figure 10.2 Removing Water Pump Pulley
EG–5088
Figure 10.3 Removing Water Pump
EGES 160 – 1
SERVICE MANUAL
Section 10
WATER PUMP – CONTINUED
INSPECTION
The water pump should be visually inspected for
damaged impeller, cracks and other faulty condi-
tions. If any defects are noted, replace the water
pump as an assembly.
INSTALLATION
Install the water pump and pulley as follows:
1. Apply a small amount of assembly grease to
water pump and install a new O–Ring onto wa-
ter pump assembly (Figure 10.4).
EG–5089
2. Install water pump to front cover. Mount one
bolt and nut at the twelve o’clock position and Figure 10.4 Water Pump O–Ring
the remaining bolts in the mounting holes.
Tighten mounting bolts to the special torque val-
ue (Figure 10.5).
IMPORTANT
BE SURE WATER PUMP ROTATES FREELY AF-
TER INSTALLATION.
EG–5088
Figure 10.5 Installing Water Pump
EGES 160 – 1
SERVICE MANUAL
Section 10
WATER PUMP – CONTINUED

3. Slide water pump pulley over water pump hub.
Place oil filter strap over pulley and secure.
Fasten pulley to hub using four (4) mounting
bolts. Tighten mounting bolts to the special
EG–5086
Figure 10.6 Install Water Pump Pulley
EGES 160 – 1
SERVICE MANUAL
Section 10
THERMOSTAT
REMOVAL
1. Loosen the worm clamp at the water outlet hose
and remove from the thermostat.
2. Remove the two flanged head bolts which se-
cure thermostat to cylinder head (Figure 10.7).
3. Remove the thermostat from cylinder head.
Remove and discard O–Ring (Figure 10.8).
INSPECTION
1. Inspect thermostat for cracks and pitting.
IMPORTANT
WHEN SERVICING THERMOSTAT, IT IS ESSEN-
TIAL THAT THERMOSTAT OPENS FULLY AT
SPECIFIED TEMPERATURE TO AVOID AN EG–5140
OVERHEATING CONDITION WHICH MAY
CAUSE ENGINE DAMAGE.
Figure 10.7 Remove Thermostat Mounting
ONLY GENUINE INTERNATIONAL® THERMO– Bolts
STATS ASSURE PROPER COOLANT FLOW
AND POSITIVE SEALING CHARACTERISTICS
REQUIRED TO PROVIDE PROPER ENGINE
COOLING.
2. Check thermostat operation as follows, (Figure

10.9):
CAUTION
EXERCISE CAUTION AND GOOD JUDGMENT
TO AVOID INJURY WHEN DEALING WITH HOT
WATER AND OBJECTS DURING THERMOSTAT
OPERATION CHECK. USE HEAT RESISTANT
GLOVES AND WEAR APPROPRIATE EYE
PROTECTION.
a. Manually open thermostat enough to insert

a nylon ribbon under valve seat. Suspend
thermostat in container so thermostat does
not touch bottom of container.
b. Heat container filled with water to “START–
TO–OPEN” temperature of thermostat
82.2° 0/2.8°C (180° 0/+5° F). Observe ther-
mometer and record temperature as soon EG–5141
as thermostat drops from nylon ribbon.
THIS IS THE “START–TO–OPEN” TEM-
PERATURE. Figure 10.8 Remove Thermostat
EGES 160 – 1
SERVICE MANUAL
Section 10
THERMOSTAT – CONTINUED
Figure 10.9 Testing Thermostat
c. Continue to heat water to “FULL–OPEN”

temperature of thermostat 202° F (94.4° C).
Observe thermometer and movement of
thermostat. Observe thermostat movement
when “FULL–OPEN” temperature is
achieved. Minimum travel at “FULL–
OPEN” temperature is 9.0 mm (.410 inch-
es). Refer to Figure 10.10.
CAUTION
BE SURE TO WEAR PROTECTIVE CLOTHING
WHEN RETRIEVING THERMOSTAT FROM
BOILING HOT WATER CONTAINER.
d. Remove thermostat from water, inspect

seat area for pitting and foreign deposits.
e. Replace thermostat if it does not operate as
described or meet visual inspection criteria.
Figure 10.10 Thermostat Open/Closed Posi-

tion
1. Thermostat
2. Maximum Travel 19.23mm(0.757 in.)
3. Closed Dimension 29.64mm (1.167 in.)
4. Minimum Travel 10.41mm (0.410 in)
EGES 160 – 1
SERVICE MANUAL
Section 10
THERMOSTAT – CONTINUED
3. Visually inspect thermostat for the following
conditions, which may cause improper closure:
a. Debris or loose fit at seat.
b. Rough or uneven wear at seal seat location.
c. Uneven seat.
INSTALLATION
1. Install a new O–Ring onto the thermostat as-
sembly (Figure 10.11).
2. Install thermostat assembly into opening on top
of cylinder head and secure with flanged head
bolts. Tighten bolts to standard torque.
COOLANT FILTER
REMOVAL
EG–5141
CAUTION
WHEN REMOVING PRESSURE TYPE CAP
FROM DEAERATION TANK, PERFORM THE OP-
ERATION IN FOUR STEPS: (ALLOW ENGINE TO
COOL) Figure 10.11 Installing The Thermostat
1. WRAP A THICK, HEAVY CLOTH AROUND
CAP.
2. LOOSEN CAP SLOWLY.
3. PAUSE A MOMENT TO ALLOW PRESSURE
AND/OR STEAM TO ESCAPE. (THIS WILL
AVOID POSSIBLE SCALDING BY HOT WA-
TER OR STEAM.)
4. CONTINUE TO TURN CAP AND REMOVE.
1. Relieve cooling system pressure by removing

radiator cap prior to removing coolant filter.
2. Loosen and remove coolant filter using filter
wrench/strap. The filter is located on the rear
right hand side of the front cover (Figure
10.12). EG–5033
NOTE: Coolant filter header is equipped with

two check valves to stop flow of coolant when
filter is removed. Figure 10.12 Removing Coolant Filter
EGES 160 – 1
SERVICE MANUAL
Section 10
COOLANT FILTER – CONTINUED

3. Loosen and remove three (3) coolant filter
header mounting bolts (Figure 10.13). Re-
move coolant filter header, check valves, seal
and O–Ring. Discard O–Ring and seal (Figure
10.14).
INSTALLATION
1. Install a new O–Ring and seal into the rear of
the coolant filter header (Figure 10.14).
2. If removed, place check valves into header and
install coolant filter header onto mounting pad
of front cover and secure with mounting bolts. EG–5034
Tighten to the special torque value (Figure
10.13). Figure 10.13 Remove Coolant Filter Header
3. Lubricate coolant filter gasket with clean engine

oil and install a new coolant filter. Tighten cool-
ant filter until gasket makes contact with the
coolant filter header, then tighten one (1) addi-
1
tional full turn (Figure 10.15). 2
EG–5377
Figure 10.14 Coolant Filter Header O–Rings

1. Seal
2. Check Valve
3. O–Ring
EG–5033
Figure 10.15 Installing Coolant Filter
EGES 160 – 1
SERVICE MANUAL
Section 10
WATER INLET ELBOW
REMOVAL
1. Remove three (3) mounting bolts that attach
water inlet elbow to crankcase cover (Figure
10.16).
2. Remove water inlet elbow and gasket. Discard
gasket.
INSTALLATION
1. Install water inlet elbow with new gasket to
crankcase. Secure water inlet elbow using
three (3) flanged bolts and tighten to the special
EG–5299
Figure 10.16 Remove Water Inlet Elbow
EG–5300
Figure 10.17 Install Water Inlet Elbow
EGES 160 – 1
SERVICE MANUAL
ENGINE ELECTRICAL
SECTION 11 INDEX
Page
ENGINE SENSOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ENGINES EQUIPPED WITH CHASSIS MOUNTED ECM AND IDM UNITS . . . . . . . . . . . . . . . . . . . . . 1
ENGINES EQUIPPED WITH ENGINE MOUNTED, FRONT ECM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINES EQUIPPED WITH ENGINE MOUNTED, REAR ECM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE MOUNTED ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing The ECM And Mounting Bracket As A Single Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing The Mounting Bracket And ECM As Separate Units . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAIN ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ENGINES EQUIPPED WITH CHASSIS MOUNTED ECM AND IDM UNITS . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINES EQUIPPED WITH ENGINE MOUNTED ECM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
VERIFYING CMP SENSOR CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CMP Sensor Clearance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE SENSORS AND CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Camshaft Position Sensor (CMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Coolant Temperature Sensor (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Oil Temperature Sensor (EOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Oil Pressure Sensor (EOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Injection Control Pressure Sensor (ICP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Injection Pressure Regulator Valve (IPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Manifold Absolute Pressure Sensor (MAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
EGES 160 – 1
SERVICE MANUAL
Section 11
ENGINE ELECTRICAL Page 1
ENGINE SENSOR LOCATION

ENGINES EQUIPPED WITH CHASSIS MOUNTED ECM AND IDM UNITS
Figure 11.1 shows the electrical sensor locations for engines equipped with a separate Electronic Control
Module (ECM) and an Injector Driver Module (IDM).
TOP VIEW
Figure 11.1 Sensor Locations For Engines Equipped With Chassis Mounted ECM And IDM Units
1. Engine Wiring Harness 11. Under Valve Cover Harness O–Ring
2. Injection Control Pressure Sensor 12. Wiring Harness to Fuel Injector Connector
3. Engine Oil Temperature Sensor 13. Wiring Harness Channel
4. Flange Nut 14. Fuel Injector Shoulder Bolt
5. Wiring Harness Clamp 15. ICP Connector Seal
6. Special Flange Bolt 16. Reducer Bushing
7. 31 Pin Wiring Harness Support 17. Engine Coolant Temperature Sensor
8. IPR Connector 18. CMP Sensor
9. Special Flange Bolt 19. CMP Sensor Seal
10. Under Valve Cover Wiring Harness
EGES 160 – 1
SERVICE MANUAL
Section 11
Page 2 ENGINE ELECTRICAL
ENGINE SENSOR LOCATIONS – CONTINUED
ENGINES EQUIPPED WITH ENGINE MOUNTED, FRONT ECM UNIT
11 1
10
2
9
EG–6931
Figure 11.2 Sensor Locations For Engines Equipped With Front Engine Mounted ECM Unit
1. Manifold Absolute Pressure Sensor (MAP) 7. Engine Oil Pressure Sensor (EOP)
2. Injection Control Pressure Sensor (ICP) 8. Injection Pressure Regulator Valve (IPR)
3. Valve Cover Wiring Harness Connector 9. Engine Oil Temperature Sensor (EOT)
4. Camshaft Position Sensor (CMP) 10. Electronic Control Module (ECM)
5. Engine Coolant Temperature Sensor (ECT) 11. ECM Connector
6. Main Wiring Harness
EGES 160 – 1
SERVICE MANUAL
Section 11
ENGINE SENSOR LOCATIONS – CONTINUED

ENGINES EQUIPPED WITH ENGINE MOUNTED, REAR ECM UNIT
12 1 2 3
11 10 9 8 7 6 5
EG–6930
Figure 11.3 Sensor Locations For Engines Equipped With Rear Engine Mounted ECM Unit
1. Manifold Absolute Pressure Sensor (MAP) 7. ECM Connector

2. Valve Cover Wiring Harness Connector 8. Wiring Harness
3. Injection Control Pressure Sensor (ICP) 9. Engine Oil Pressure Sensor (EOP)
4. Electronic Control Module (ECM) 10. Injection Pressure Regulator Valve (IPR)
5. ECM Mounting Bolt 11. Engine Oil Temperature Sensor (EOT)
6. ECM Connector Mounting Bolt 12. Engine Coolant Temperature Sensor (ECT)
EGES 160 – 1
SERVICE MANUAL
Section 11
SPECIFICATIONS
Camshaft Position Sensor
Location Front Cover
Operating Actuator Speed 15 to 2000 rpm
Operating Temperature –40° C to +130° C (–40° F to 54° F)
CMP Sensor Clearance Air Gap:
Crankshaft rotated in a clockwise direction 29.90 ± 0.356 mm (1.177 ± 0.014 in.)
Crankshaft rotated in a counterclockwise direction 29.67 ± 0.356 mm (1.168 ± .014 in.)

Injection Control Pressure Sensor (ICP) (See Note) 26 Nm (19 lb–ft)
Front And Rear Engine Mounted ECM:
Electronic Control Module (ECM) Connector Retaining Screw 3.9 Nm (35 in.–lb.)
ECM Mounting Bolts 15 Nm (20 lb–ft.)
ECM Mounting Bracket Mounting Bolts 15 Nm (20 lb–ft.)
ECM Mounting Bracket Mounting Nuts 15 Nm (20 lb–ft.)
NOTE: Apply Loctite® #277 to threads prior to assembly.

No special tools required for this section.
EGES 160 – 1
SERVICE MANUAL
Section 11
ENGINE MOUNTED ECM

NOTE: Refer to the following for electrical 4
system diagnostics and troubleshooting
procedures. 3
2
For Engines Equipped With The Chassis
Mounted ECM Unit
1
EGES 145 Diagnostic Manual
EGED 150 Hard Start/No Start Diagnostic Form 1
EGED 155 Electronic Diagnostic Form
2 3
EG–7236
For Engines Equipped With The Engine
Mounted ECM Unit
Figure 11.4 Remove ECM Connector Covers
EGES 175 Diagnostic Manual
1. Connector Shield Screw
EGED 180 Mechanical Diagnostic Form 2. Connector Shield
EGED 185 Electrical Diagnostic Form 3. Connector Cover
4. ECM Unit
1
NOTE: Removal procedures for the front 2
mounted or rear mounted Electronic Control
Module (ECM) are identical, except where
noted.
REMOVAL
1. Disconnect batteries. EG–6822
2. Remove screws (1, Figure 11.4) and connector Figure 11.5 Loosen Wiring Harness Bolt
cover shields (2, Figure 11.4) from the ECM
connector covers (3, Figure 11.4). 1. ECM
2. Engine Wiring Harness Connector
3. Remove ECM connector covers (3, Figure
11.4) from the wiring harness connectors.
4. Loosen the chassis wiring harness connector 1 2
mounting bolt and remove wiring harness from
the ECM.
5. Loosen engine wiring harness connector
mounting bolt (Figure 11.5) and disconnect
engine wiring harness from the ECM, (Figure
11.6).
6. Remove the foam insert from each wiring
harness.
7. Remove the ECM wiring harness connector EG–6823
gaskets from the ECM unit.
NOTE: If the ECM DOES NOT have to be Figure 11.6 Remove Engine Wiring Harness
removed from the mounting bracket, proceed to 1. ECM
step 9. 2. Engine Wiring Harness Connector
EGES 160 – 1
SERVICE MANUAL
Section 11
ENGINE MOUNTED ECM – CONTINUED
REMOVAL – CONTINUED 1
8. If it is necessary to remove the ECM from the
mounting bracket, remove the four (4) ECM
mounting bolts and lift the ECM from the
bracket (Figure 11.7 or 11.8).
2
9. Remove the bottom mounting bolts of the ECM
mounting bracket (Figure 11.9).
EG–6825
Figure 11.7 Front ECM Unit

1. Front Mounted ECM
2. ECM Mounting Bolts
EG–6932
Figure 11.8 Rear ECM Unit

1. Rear Mounted ECM
EG–6834
Figure 11.9 Bottom ECM Bracket Bolts
EGES 160 – 1
SERVICE MANUAL
Section 11

REMOVAL – CONTINUED 2 3 1
10. Remove the three (3) top mounting nuts (3,
Figure 11.10) of the ECM mounting bracket
and lift bracket (1, Figure 11.10) away from
engine.
11. If required, remove bushings and pins (2,
Figure 11.10) from mounting bracket. Proceed
to “Inspection” for further information.
EG–6832
INSPECTION
Inspect ECM mounting bushings and pins for Figure 11.10 ECM Bushings, Pins And Nuts
cracks, cuts, worn spots, etc.. Replace as required 1. ECM Mounting Bracket
(Figure 11.11). 2. Bushings and Pin Location
3. ECM Mounting Bracket Nuts
Inspect the engine wiring harness connectors,
connector covers, foam inserts and cover shields
for cracks, cuts or worn areas. Replace as required 1
(Figure 11.12). 2
EG–6381
Figure 11.11 ECM Bushings And Pin

1. Bushings
2. Pin
2 3
1 5
6
EG–7237
Figure 11.12 Connector Cover Parts

1. Foam Insert
2. Wiring Connector Cover
3. Connector Cover Shield
4. Screw
6. ECM Gasket
EGES 160 – 1
SERVICE MANUAL
Section 11
INSTALLATION
NOTE: Installation procedures of the front 1 2
mounted or rear mounted ECM are identical, 3
except where noted.
Installing The ECM And Mounting Bracket As A

Single Unit
1. Install the ECM and mounting bracket to the
engine. Tighten the three (3) top mounting nuts
to the special torque value (Figure 11.13).
2. Install the two (2) bottom bolts for the mounting
bracket and tighten to the special torque value EG–6829
(Figure 11.14).
Figure 11.13 ECM Bushings, Pins And Nuts
3. Install the two ECM gaskets into the ECM
1. ECM
connector receptacles.
2. ECM Mounting Bracket
4. Open the foam insert at the slit and place 3. ECM Mounting Bracket Nuts
around the chassis and engine wiring
harnesses, near the connectors.
5. Connect the engine wiring harness (2, Figure
11.15) to the ECM (1, Figure 11.15) and tighten
the connector retaining screw to the special
torque value.
6. Connect the second wiring harness to the ECM
and tighten the connector retaining screw to the
EG–6827
Figure 11.14 Bottom ECM Bracket Bolts
1
2
EG–6822
Figure 11.15 Install Engine Wiring Harness

1. ECM
EGES 160 – 1
SERVICE MANUAL
Section 11

4
3
Installing The ECM And Mounting Bracket As A 2
Single Unit – Continued
1
7. Install the ECM connector covers (3, Figure
11.16) over the wiring harness connectors. 1
IMPORTANT 2 3
EG–7236
BE SURE THE FOAM INSERTS FIT INTO THE
END CHANNEL OF THE CONNECTOR COVERS
Figure 11.16 Install ECM Connector Covers
BEFORE SECURING TO THE COVERS TO THE
CONNECTORS. 1. Connector Shield Screw
2. Connector Shield
3. Connector Cover
4. ECM Unit
8. Place the connector shields (2, Figure 11.16) 2 3 1

onto the connector covers (3, Figure 11.16)
and secure with the connector cover shield
screw (1, Figure 11.16).
9. Connect the batteries.
EG–6832
Installing The Mounting Bracket And ECM As
Separate Units
Figure 11.17 ECM Bushings, Pins And Nuts
NOTE: Installation of the front or rear mounted 1. ECM Mounting Bracket

ECM to the engine are identical, except where 2. Bushings and Pin Location
3. ECM Mounting Bracket Nuts
noted.
1. Install the four (4) pins and eight (8) mounting

bushings into the mounting bracket (2, Figure
11.17).
2. Install the mounting bracket to the engine.

Tighten the top three (3) mounting bolts to the
special torque value (Figure 11.17).
3. Install the two (2) bottom bolts for the mounting EG–6827
bracket and tighten to the special torque value
(Figure 11.18). Figure 11.18 Bottom ECM Bracket Bolts
EGES 160 – 1
SERVICE MANUAL
Section 11
INSTALLATION – CONTINUED 2 1
Separate Units – Continued
4. Install the front mounted ECM onto the
mounting bracket and tighten the four (4)
mounting bolts to the special torque value
(Figure 11.19).
5. Install the rear mounted ECM onto the
mounting bracket and tighten the four (4)
mounting bolts to the special torque value
(Figure 11.20). EG–6824
6. Install the two ECM gaskets into the ECM

Figure 11.19 Front ECM Unit
connector receptacles.
7. Open the foam insert at the slit and place 2. Front Mounted ECM
8. Connect the engine wiring harness to the ECM
(Figure 11.21) 1
EG–6932
Figure 11.20 Rear ECM Unit

1. Rear Mounted ECM
1 2
EG–6823
Figure 11.21 Install ECM Connector

1. ECM
EGES 160 – 1
SERVICE MANUAL
Section 11

Separate Units – Continued
9. Tighten the connector retaining screw to the
10. Install and connect the second wiring harness
to the ECM. Tighten the connector retaining
screw to the special torque value.
11.16) over the wiring harness connectors.
EG–6821
IMPORTANT
BE SURE THE FOAM INSERTS FIT INTO THE Figure 11.22 Securing ECM Connector
END CHANNEL OF THE CONNECTOR COVERS
CONNECTORS. 4
12. Place the connector shields (2, Figure 11.23) 3
onto the connector covers (3, Figure 11.23) 2
and secure with the connector cover shield
1
1
2 3
EG–7236
Figure 11.23 Install ECM Connector Covers

2. Connector Shield
3. Connector Cover
4. ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 11
MAIN ENGINE WIRING HARNESS
ENGINES EQUIPPED WITH CHASSIS
MOUNTED ECM AND IDM UNITS
1 2
IMPORTANT
SEE DIAGNOSTIC MANUAL EGES 145 FOR
DETAILS ON ENGINE ELECTRICAL SYSTEM
TROUBLE SHOOTING.
3
Removal
EG–5059
1. Disconnect batteries.
Figure 11.24 Disconnect Wiring Harness
2. Pull out the wiring harness connector from the
under valve cover fuel injector wiring harness 1. Main Wiring Harness
connector (3, Figure 11.24). 2. 31–Pin Connector
3. Valve Cover/Intake Manifold Disconnect Point
3. Push against the connector to loosen it from the
valve cover.
4. Disconnect main engine harness 31–pin

connector (1, Figure 11.24).
5. Remove two (2) bolts securing main engine

harness 31–pin connector to valve cover/intake
manifold (2, Figure 11.24).
IMPORTANT
OVERSTRESSING CONNECTOR LOCK TABS
CAN RESULT IN BREAKAGE OF TABS.
SPREAD TABS ONLY FAR ENOUGH TO
RELEASE CONNECTOR.
6. Unlatch and separate Camshaft Position

Sensor (CMP) connector from CMP sensor. If EG–5072
necessary, remove CMP mounting bolt and pull
CMP sensor from front cover (Figure 11.25). Figure 11.25 Removing CMP Sensor
EGES 160 – 1
SERVICE MANUAL
Section 11
MAIN ENGINE WIRING HARNESS –

CONTINUED
MOUNTED ECM AND IDM UNITS – CONTINUED
7. Unlatch and separate Engine Oil Temperature
(EOT) sensor connector from sensor. If
necessary, unscrew sensor from front cover
(Figure 11.26).
NOTE: When the EOT sensor is removed from
the front cover, oil will leak out the port.
8. Unlatch and separate Engine Coolant

Temperature (ECT) connector from sensor. If
necessary, unscrew the sensor from the
cylinder head (Figure 11.27).
EG–5024
Figure 11.26 Remove EOT Sensor
EG–7235
Figure 11.27 ECT Sensor Location
EGES 160 – 1
SERVICE MANUAL
Section 11
CONTINUED
Remove the Injection Control Pressure (ICP)
Sensor as follows:

9. Unlatch and separate ICP connector from
sensor. If necessary, remove ICP sensor,
together with O–Ring, from the three–way
fitting of the supply manifold (Figure 11.28).
installation.
EG–5117
OR
Figure 11.28 Removing ICP Sensor From Old
Engines Equipped With New Three–Way Fitting Three–Way Fitting
9. Unlatch and separate ICP connector from
sensor. If necessary, remove ICP sensor,
together with O–Ring, from the three–way
installation.
EG–6843
Figure 11.29 Removing Sensor From New

Three–Way Fitting
EGES 160 – 1
SERVICE MANUAL
Section 11

CONTINUED
10. Unlatch and separate Injection Pressure
Regulator (IPR) connector from solenoid
(Figure 11.30).
NOTE: Refer to Section 12, “HIGH PRESSURE
LUBE OIL SYSTEM” for the proper procedure on
the removal and installation of the IPR valve.
11. Remove harness securing clamps from valve
EG–5101
cover/intake manifold and front cover.
12. Carefully lift entire main wiring harness free Figure 11.30 Disconnecting Injection Pressure
from engine. Regulator Valve
CAUTION
SHOULD ANY RESISTANCE BE ENCOUN–
TERED, DO NOT TUG ON HARNESS TO FREE IT.
INVESTIGATE SOURCE OF RESISTANCE AND
FREE CONNECTOR OR CLIP, THEN REMOVE
HARNESS FROM ENGINE.
Inspection
Use the following steps when inspecting the wiring
harness:
1. Be sure to clean any and all Loctite®, if present
from the threads of the sensors.
2. Check all connector pins on sensors. If bent or
corroded, replace sensor.
3. Carefully inspect wiring harness for worn
conduit, frayed insulation or heat damage on
wires. Refer to the following repair section
should repair be necessary.
4. Inspect each connector for the following
conditions. Replace as required.
a. Corroded connectors – green or gray–white
deposits on metal terminals.
b. Female connector sleeves spread open.
c. Terminals incorrectly latched into connector
body or “pushed back” relative to other
terminals in the same connector.
EGES 160 – 1
SERVICE MANUAL
Section 11
CONTINUED 4
ENGINES EQUIPPED WITH ENGINE MOUNTED
ECM UNIT 3
2
IMPORTANT
SEE DIAGNOSTIC MANUAL EGES 175 FOR
DETAILS ON ENGINE ELECTRICAL SYSTEM 1
TROUBLE SHOOTING.
1
Removal
NOTE: Removing the main wiring harness from 2 3
EG–7236
the front mounted or rear mounted ECM is
identical, except where noted. Figure 11.31 Remove ECM Connector Covers
1. Disconnect batteries.
2. Connector Shield
2. Remove screws (1, Figure 11.31) and 3. Connector Cover
connector cover shields (2, Figure 11.31) from 4. ECM Unit
the ECM connector covers (3, Figure 11.31).
3. Remove ECM connector covers (3, Figure
1
11.31) from the wiring harness connectors. 2
4. Loosen the chassis wiring harness connector
mounting bolt and remove wiring harness from
the ECM.
5. Loosen engine wiring harness connector
mounting bolt (Figure 11.32) and disconnect
engine wiring harness from the ECM, (Figure
11.33).
6. Remove the foam insert from each wiring
harness. EG–6822
Figure 11.32 Loosen Wiring Harness Bolt

1. ECM
1 2
EG–6823
Figure 11.33 Remove Engine Wiring Harness

1. ECM
EGES 160 – 1
SERVICE MANUAL
Section 11

CONTINUED
3
ECM UNIT – CONTINUED
Removal – Continued 2
7. Pull out the wiring harness connector from the
under valve cover fuel injector wiring harness
connector (Figure 11.34).
8. Unlatch and separate the Injection Control
Pressure (ICP) sensor connector from the main
wiring harness (Figure 11.35). If necessary, 1
EG–6818
unscrew the sensor from the supply manifold.
Figure 11.34 Disconnecting Main Wiring
9. Unlatch and separate the Injection Pressure
Harness
Regulating valve (IPR) connector from the
sensor (Figure 11.36). 1. ECM
2. Valve Cover/Intake Manifold Connector
NOTE: Refer to Section 12, “High Pressure 3. Valve Cover/Intake Manifold Connector Tabs
Lube Oil System” for the proper procedure on
the removal and installation of the IPR valve.
EG–6813
Figure 11.35 Remove ICP Sensor Connector
EG–6814
Figure 11.36 Remove IPR Valve Connector
EGES 160 – 1
SERVICE MANUAL
Section 11
CONTINUED
10. Unlatch and separate the Engine Oil Pressure
(EOP) sensor connector from the main wiring
harness (Figure 11.37).
11. Unlatch and separate the Manifold Absolute
Pressure (MAP) sensor connector, located on
top of the valve cover, from the main wiring
harness.
EG–6820
12. Unlatch and separate Engine Oil Temperature
sensor (EOT) sensor connector from the main Figure 11.37 Remove EOP Sensor Connector
wiring harness (Figure 11.38).
NOTE: When the EOT sensor is removed from

the front cover, oil will leak out the port.
13. Unlatch and separate the Engine Coolant

Temperature (ECT) sensor connector from the
main wiring harness (Figure 11.39).
EG–6811
Figure 11.38 Remove EOT Sensor Connector
EG–7235
Figure 11.39 Remove ECT Sensor Connector
EGES 160 – 1
SERVICE MANUAL
Section 11

CONTINUED
14. Unlatch and separate Camshaft Position
Sensor (CMP) sensor from from the main wiring
harness. If necessary, remove CMP mounting
bolt and pull CMP sensor from front cover
(Figure 11.40).
15. Remove any wiring harness clamps securing
the wiring harness to the engine.
16. Carefully lift entire main wiring harness free
from the engine.
CAUTION
SHOULD ANY RESISTANCE BE
ENCOUNTERED , DO NOT TUG ON THE WIRING
HARNESS TO FREE IT. INVESTIGATE SOURCE EG–5072
OF RESISTANCE AND FREE CONNECTOR OR
CLIP, THEN REMOVE WIRING HARNESS FROM
ENGINE.
Figure 11.40 Removing CMP Sensor
Inspection
Use the following steps when inspecting the wiring
harness:
2 3
1. Be sure to clean any and all Loctite®, if present
from the threads of the sensors.
2. Check all connector pins on sensors. If bent or
corroded, replace sensor. 4
3. Carefully inspect wiring harness for worn
conduit, frayed insulation or heat damage on 1 5
wires. Refer to the following repair section
should repair be necessary. 6
4. Inspect each connector for the following
EG–7237
conditions. Replace as required.
a. Corroded connectors – green or gray–white
deposits on metal terminals.
b. Female connector sleeves spread open. Figure 11.41 Connector Cover Parts
c. Terminals incorrectly latched into connector
body or “pushed back” relative to other 1. Foam Insert
terminals in the same connector. 2. Wiring Connector Cover
5. Inspect the engine wiring harness connectors, 3. Connector Cover Shield
connector covers, foam inserts and cover 4. Screw
shields for cracks, cuts or worn areas. Replace 5. Wiring Harness Connector
as required (Figure 11.41). 6. ECM Gasket
EGES 160 – 1
SERVICE MANUAL
Section 11
CONTINUED
ASSEMBLY
IMPORTANT
ASSEMBLY PROCEDURES, FOR ENGINES
EQUIPPED WITH SEPARATELY MOUNTED ECM
AND IDM UNITS OR ENGINES EQUIPPED WITH
THE ENGINE MOUNTED ECM UNIT, ARE THE
SAME EXCEPT WHERE NOTED.
NOTE: Refer to Section 12, “HIGH PRESSURE

LUBE OIL SYSTEM” for the proper installation
procedure for the IPR valve.
1. If removed, install the EOP, ECT, MAP and EOT

EG–5073
sensors into their proper locations and tighten.
NOTE: Refer to steps 2 and 3 for installation
procedures for the CMP and ICP sensors.
Figure 11.42 Installing CMP Sensor
2. Install CMP sensor, if removed, into front cover
as follows (Figure 11.42):
a. If it is necessary to check the clearance of
the CMP sensor, refer to “Verifying CMP
Sensor Clearance” in this section.
b. Place new O–Ring onto CMP sensor and
lubricate with clean engine oil. Insert into
front cover.
c. Secure CMP sensor to front cover with
mounting bolt. Tighten bolt.
3. Install the ICP sensor as follows:


installation.
a. Apply Loctite #277 to the threads of the ICP

sensor.
EG–5117
b. Install Injection Control Pressure (ICP)
sensor, together with O–Ring, to the
three–way fitting of the supply manifold
(Figure 11.43). Tighten to the special Figure 11.43 Installing The ICP Sensor Into
torque value. The Old Three–Way Fitting
EGES 160 – 1
SERVICE MANUAL
Section 11

CONTINUED
a. Apply Loctite #277 to the threads of the ICP

sensor.
b. Install Injection Control Pressure (ICP) sen-

sor, together with O–Ring, to the three–way
Tighten to the special torque value.

EG–6843
a. Apply Loctite #277 to the threads of the ICP Figure 11.44 Installing The ICP Sensor Into
sensor. The New Three–Way Fitting
b. Install Injection Control Pressure (ICP) sen-
sor, together with O–Ring, to the supply
manifold (Figure 11.45). Tighten to the spe-
cial torque value.
IMPORTANT
BE CERTAIN THAT EACH CONNECTOR HAS ITS
RIBBED SEAL IN PLACE BEFORE INSTALLING
ONTO SENSOR. IN SOME CASES, UPON DIS-
ASSEMBLY, A RIBBED SEAL MAY PULL OFF OF EG–6877
ITS CONNECTOR AND REMAIN IN THE MATING
SOCKET OF A SENSOR OR ACTUATOR. A
Figure 11.45 Installing The ICP Sensor Into
CONNECTOR ASSEMBLED WITHOUT THE AP-
The Supply Manifold
PROPRIATE RIBBED SEAL CAN BECOME CON-
TAMINATED WITH MOISTURE AND CORRODE
TERMINALS RESULTING IN A POOR ELEC-
TRICAL CONNECTION. 1 2
4. Install wiring harness onto the engine and care-

fully align connectors with sensors. Push each
connector into its mating socket until locking
tabs are fully latched.
5. Install the two ECM gaskets into the ECM con-

nector receptacles.
6. Open the foam insert at the slit and place EG–6823

Figure 11.46 Install ECM Connector
7. Connect the engine wiring harness to the ECM 1. ECM
(Figure 11.46) 2. Wiring Harness Connector
EGES 160 – 1
SERVICE MANUAL
Section 11
CONTINUED
8. Tighten the connector retaining screw to the
9. Install and connect the second wiring harness
to the ECM. Tighten the connector retaining
screw to the special torque value.
11.48) over the wiring harness connectors.
IMPORTANT
EG–6821
BE SURE THE FOAM INSERTS FIT INTO THE
END CHANNEL OF THE CONNECTOR COVERS Figure 11.47 Securing ECM Connector
CONNECTORS.
4
11. Place the connector shields (2, Figure 11.48)
onto the connector covers (3, Figure 11.48)
and secure with the connector cover shield 3
2
12. Reinstall wiring harness routing clips.
1
1
2 3
EG–7236
Figure 11.48 Installing ECM Connector Covers

2. Connector Shield
3. Connector Cover
4. ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 11
VERIFYING CMP SENSOR CLEARANCE
1. Remove CMP sensor mounting bolt from en-

gine front cover and pull CMP sensor out.
Clean sensor mounting surface (Figure 11.49).
2. Manually rotate the crankshaft at least two (2)

complete revolutions in a clockwise direction
when viewing the engine from the front. This in-
sures the CMP sensor air gap is at its maximum
with the camshaft gear in contact with its rear
thrust face.
IMPORTANT
BE SURE, WHEN MAKING THE FOLLOWING
MEASUREMENT, TO MEASURE UP TO THE
TOOTH ON THE TRIGGER WHEEL. DO NOT EG–5073
MEASURE INTO THE WINDOW BETWEEN THE
TEETH.
Figure 11.49 Remove CMP Sensor
3. Using a depth micrometer or a precision caliper,

carefully measure the distance to the nearest
one thousandth of an inch from the CMP sensor
mounting surface to the camshaft gear trigger
wheel tooth (Figure 11.50). Record this mea-
surement in the appropriate box on worksheet.
4. Manually rotate crankshaft 180° in a clockwise

direction, when viewed from the front of the en-
gine, and repeat step 3. Continue this process
two (2) more times so that the distance from the
cover to the trigger wheel is measured at four EG–5894
(4) locations. Variations in these measure-

ments determine run out of the trigger wheel. Figure 11.50 Measuring CMP Sensor Clear-
Variation should not exceed 0.005 inches. ance
5. Using a depth micrometer or precision caliper

carefully measure CMP sensor from the tip to its
mounting flange (Figure 11.51). Record this di-
mension in the appropriate box on work sheet.
6. Perform the math as directed on the work sheet

then select appropriate combination of shims
from shim kit, if required. Refer to the DT 466E
and 530E Parts Manual for the proper kit part
number.
NOTE: Use the proper combination of shims to EG–5896

achieve a measurement as close to 0.30 inch as
possible. Figure 11.51 Measuring Depth Micrometer
EGES 160 – 1
SERVICE MANUAL
Section 11
VERIFYING CMP SENSOR CLEARANCE – CONTINUED
7. Install the CMP sensors with the shims re-
quired. Insure that the shims are centered on
the CMP sensor flange. Use a small amount of
grease to hold then if necessary. Reconnect
sensor wiring harness and test engine.
NOTE: Use the following work sheet to com-
plete the CMP sensor air gap analysis, as de-
scribed in steps 1 thru 7. Enter the measure-
ments in the boxes on the work sheet.
CMP SENSOR CLEARANCE WORKSHEET
STEP OPERATION MEASUREMENT

1. Rotate crankshaft clockwise at least two revolutions.
2. Measure distance from CMP sensor mounting surface
to trigger wheel tooth.
3. Rotate crankshaft clockwise, 1/2 turn, repeat step 2.
6. Add measurements from steps 2 thru 5. =
7. Obtain average dimension by dividing by 4: =
8. Measure CMP sensor length from tip to surface of

mounting flange.
9. Subtract step 8 from step 7.
10. Desired air gap: 0.030 inch
11. Subtract step 10 from step 9.
(This is the required thickness.)
12. Select shims as required from shim kit (two 0.005 in.
and two 0.010 in. shims provided). Use one or more
shims from kit to get as close as possible to thickness
determined in step 12. Measure thickness of shim(s).
Enter shim pack thickness here:
13. Place shims over the CMP sensor tip. Insure shims
are centered on CMP sensor flange. Install CMP sen-
sor/shim assembly in front cover. Tighten clamp bolt to
15 lb–ft. (20 Nm) and reconnect wiring harness.
EGES 160 – 1
SERVICE MANUAL
Section 11
ENGINE SENSORS AND CONNECTORS
Camshaft Position Sensor (CMP)
A Hall effect sensor stacked in front of a magnet with

a signal conditioning integrated circuit. It responds
to a rotating actuator positioned on the camshaft
gear. The camshaft actuator has twenty–four (24)
stamped windows. This produces a rectangular
wave pulse for each tooth as the actuator rotates
past the sensor. The pulses are used to indicate en-
gine speed and camshaft position for control of fuel
quantity, injection timing and overspeed shutdown.
It is located on the engine front cover, RH side
above the water pump pulley (Figure 11.52). EG–5436
Figure 11.52 Camshaft Position Sensor

Engine Coolant Temperature Sensor (ECT)
A thermistor type sensor which senses changes in

engine coolant temperature. Located on the front
RH side of the cylinder head, below the thermostat
(Figure 11.53).
Engine Oil Temperature Sensor (EOT)

EG–6377
A thermistor type sensor which senses engine oil Figure 11.53 Engine Coolant Temperature/
temperature. Located on back LH side of the front Engine Oil Temperature Sensor
cover above the high pressure pump housing. This
sensor is used to provide engine temperature signal
to the ECM which uses the information for fuel rate
and timing adjustments (Figure 11.53).
Engine Oil Pressure Sensor (EOP)
A ceramic diaphragm sensor used to indicate low

EG–6379
engine oil pressure via a signal from the ECM. Lo-
cated on the LH side of the crankcase, below the
fuel filter (Figure 11.54). Figure 11.54 Engine Oil Pressure Sensor
EGES 160 – 1
SERVICE MANUAL
Section 11
ENGINE SENSORS AND CONNECTORS
– CONTINUED
Injection Control Pressure Sensor (ICP)
A ceramic diaphragm sensor used to measure in-
jection control/rail pressure. Located on the LH side
of the engine. The sensor is either mounted in the
three–way fitting, for engines equipped with the
chassis mounted ECM or in the middle of the supply
manifold, for engines equipped with the engine
mounted ECM. This sensor provides injection con-
trol pressure feedback to the ECM for closed loop
control of injector oil pressure (Figure 11.55).
Injection Pressure Regulator Valve (IPR)

The valve achieves injection control pressure regu-
lation. Located on LH side of high pressure pump. EG–5439
The IPR is a pulse width modulated valve which
controls injector oil pressure via a signal from the Figure 11.55 Injection Control Pressure Sen-
ECM (Figure 11.56). Refer to engine diagnostic sor
manual for further information.
Manifold Absolute Pressure Sensor (MAP)

A ceramic diaphragm sensor which indicates man-
ifold boost pressure or vacuum via a signal from the
ECM. Located on on top of the valve cover/intake
manifold (Figure 11.57).
EG–5445
Figure 11.56 Injection Pressure Regulator

Valve
EG–6378
Figure 11.57 Manifold Sensor
EGES 160 – 1
SERVICE MANUAL
HIGH PRESSURE LUBE OIL SYSTEM
SECTION 12 INDEX
Page
HIGH PRESSURE LUBE OIL SYSTEM FLOW AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Injection Oil Pressure Control Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
High Pressure Pump Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING AND INSTALLING SUPPLY MANIFOLD END PLUG 3
SUPPLY MANIFOLD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISCONNECT LOCATIONS AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVING THE LUBE OIL SUPPLY HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engines Equipped With Old Three–Way Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVING THE ICP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engines Equipped With The Old Three–Way Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSPECTION FOR WARPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HIGH PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVING THE INJECTION PRESSURE REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SUPPLY MANIFOLD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONNECTION LOCATIONS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLING THE ICP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engines Equipped With The Old Three–Way Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLING THE LUBE OIL SUPPLY HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EGES 160 – 1
SERVICE MANUAL
Section 12
HIGH PRESSURE LUBE OIL SYSTEM Page 1
HIGH PRESSURE LUBE OIL SYSTEM FLOW AND COMPONENTS

Refer to Figure 12.1 or 12.2 for a view of the lube oil system and its main components.
EG–5890
Figure 12.1 Front Mounted ICP Sensor
INJECTOR
HIGH PRESSURE MANIFOLD
HIGH PRESSURE PUMP

HOSE
INJECTION PRESSURE
RESERVOIR REGULATOR VALVE EG–3771
Figure 12.2 Mid Mounted ICP Sensor
EGES 160 – 1
SERVICE MANUAL
Section 12
Page 2 HIGH PRESSURE LUBE OIL SYSTEM
SPECIFICATIONS
Injection Oil Pressure Control Regulator
Operating Temperature Range –40° to125° C (–40° to 257° F)
Maximum Flow Rate 17.5 L/min. (4.62 GPM)
Maximum Operating Pressure 20.7 MPa (3000 psi)
High Pressure Pump Drive Gear

Gear Backlash 0.140 – 0.256 mm (0.0055 – 0.0101 in.)
End Play 0.45 – 1.22 mm (0.018 – 0.048 in.)

High Pressure Oil Pump Gear Bolt 129 Nm (95 lb–ft.)
High Pressure Oil Pump Mounting Bolts 27 Nm (20 lb–ft.)
Injection Control Pressure Sensor (ICP) (See Note) 26 Nm (19 lb–ft.)
Injection Control Pressure Valve 47 Nm (35 lb–ft.)
Injection Control Pressure Valve Tinnermann Nut 6 Nm (5.5 lb–in.)
Supply Manifold Elbow Fitting (On Engines Equipped 26 Nm (19 lb–ft.)
With Engine Mounted ECM Unit)
Supply Manifold Mounting Bolts 27 Nm (20 lb–ft.)
Fuel Return Valve Assembly 35 Nm (26 lb–ft.)
Fuel Return Valve Banjo Fitting 35 Nm (26 lb–ft.)
Banjo Fuel Line Connections 35 Nm (26 lb–ft.)
NOTE: Apply Loctite® #277 to sensor before installing.

ZTSE4295 High Pressure Oil System Cap Set
ZTSE2499 Hand Operated Vacuum Pump
OEM1293 Bevelled Edge Straightedge, 914mm (36 in.) long
ZTSE4320 Cleaning Brush Set (Consists of 4 Brushes)
EGES 160 – 1
SERVICE MANUAL
Section 12
REMOVING AND INSTALLING SUPPLY

MANIFOLD END PLUG
IMPORTANT
THE SUPPLY MANIFOLD OIL RAIL MUST BE
DRAINED PRIOR TO REMOVING THE FUEL IN-
JECTORS TO PREVENT LEAKAGE INTO THE
CYLINDER BORE.
NOTE: BE SURE to clean any and all Loctite®

from the end plug.
1. Drain the supply manifold from the end plug of EG–5130

the supply manifold (Figure 12.3).
Figure 12.3 Removing Supply Manifold End
NOTE: Be sure to clean any old Loctite® found Plug
on the threads of the plug prior to installation.
2. Install a new O–Ring and back–up ring onto the

end plug.
3. Apply Loctite® #277 to the threads of the end 1
plug and install into the supply manifold (Figure 2
12.4). Tighten plug to the special torque value
(Figure 12.5).
EG–5132
Figure 12.4 End Plug, O–Ring And Back–Up

Ring Locations
1. End Plug
2. Back–up Ring
3. O–Ring
EG–5131
Figure 12.5 Install Supply Manifold End Plug
EGES 160 – 1
SERVICE MANUAL
Section 12
SUPPLY MANIFOLD REMOVAL
DISCONNECT LOCATIONS AND REMOVAL
Disconnect the fuel supply line from the fuel filter
header to the supply manifold:
1. Figure 12.6 shows the fuel supply line on en-

gines equipped with the front mounted primer
pump and old three–way fitting.
a. Loosen and remove the hollow screws and
copper sealing gaskets at the fuel filter EG–5113
header and supply pump.

b. Cap the fuel filter header and supply pump Figure 12.6 Removing Fuel Line On Engines
openings. Equipped With Old Three–Way Fitting
gines equipped with the new three–way fitting
and top mounted primer pump.
a. Loosen fitting and remove fuel filter header
to supply pump line.
b. Cap the fuel filter header and supply pump
openings.
gines equipped with the top mounted primer
pump and the engine mounted ECM unit.
EG–6864
Figure 12.7 Removing Fuel Line On Engines
b. Cap the fuel filter header and supply pump Equipped With New Three–Way Fitting
openings.
EG–6885
Figure 12.8 Removing Fuel Line On Engines

Equipped With Engine Mounted ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 12

TINUED
DISCONNECT LOCATIONS AND REMOVAL –
CONTINUED
REMOVING THE LUBE OIL SUPPLY HOSE
Engines Equipped With Old Three–Way Fitting 2
4. Loosen the nuts (2, Figure 12.9) and discon-
nect high pressure oil supply hose (3, Figure
12.9) from the three–way fitting and the high
pressure pump (1, Figure 12.9). 1
3
OR
12.10) from the three–way fitting and the high
pressure pump (3, Figure 12.10).
OR
2
EG–7005
Figure 12.9 Removing Oil Supply Hose On

Engines Equipped With The Old Three–Way
Fitting
3. Oil Supply Line
1
2
EG–6873
Figure 12.10 Removing Oil Supply Hose On

Engines Equipped With The New Three–Way
Fitting
2. Oil Supply Line
EGES 160 – 1
SERVICE MANUAL
Section 12
TINUED
CONTINUED
3 1
Unit 2
12.11) from the supply manifold and the high
pressure pump (3, Figure 12.11).
5. Cap high pressure pump fittings and supply 1 EG–6883
manifold fittings using high pressure oil cap set
ZTSE4295.
Figure 12.11 Removing Oil Supply Hose From
REMOVING THE ICP SENSOR Engines Equipped With Engine Mounted ECM
Use one of the following procedures when removing Unit
the Injection Control Pressure Sensor. 1. Oil Supply Line Mounting Nuts
2. Oil Supply Line
Engines Equipped With Old Three–Way Fitting 3. High Oil Pressure Pump
6. Disconnect wiring harness, if not already done,
and remove ICP sensor, together with O–Ring,
from the three–way fitting of the supply manifold
(Figure 12.12).
installation.
EG–5117
Figure 12.12 Removing ICP Sensor From Old

Three–Way Fitting
EGES 160 – 1
SERVICE MANUAL
Section 12

TINUED
CONTINUED
6. Disconnect the wiring harness, if not already
done, and remove ICP sensor, together with
O–Ring, from the three–way fitting of the supply
installation.

Unit
6. Disconnect the wiring harness, if not already
done and remove ICP sensor, together with EG–6843
O–Ring, from the supply manifold (Figure

12.14). Figure 12.13 Removing ICP Sensor From New
Three–Way Fitting
installation.
7. Remove the banjo fitting at the fuel return valve,

located at the rear of the supply manifold (Fig-
ure 12.15).
EG–6877
Figure 12.14 Removing ICP Sensor From Sup-

ply Manifold
EG–5122
Figure 12.15 Remove Banjo Fitting From Fuel

Return Valve
EGES 160 – 1
SERVICE MANUAL
Section 12
TINUED
CONTINUED
8. Remove the fuel return valve from the supply
9. If not already done, remove the supply manifold
end plug. Refer to “Removing and Installing
Supply Manifold End Plug”, in this section.
IMPORTANT
WHEN THE SUPPLY MANIFOLD IS REMOVED,
DO NOT PLACE MANIFOLD FACE DOWN ON
ANY SURFACE. THE MANIFOLD FACE COULD
EG–5128
BE SCRATCHED, THUS PREVENTING A GOOD
MATING SURFACE SEAL. ALWAYS PLACE
SUPPLY MANIFOLD FACE UP. Figure 12.16 Remove Fuel Return Valve
10. Remove twelve (12) mounting bolts securing

the supply manifold to the cylinder head. Re-
move supply manifold and gasket.
a. Figure 12.17 shows the supply manifold on
an engine equipped with the old three–way
fitting.
EG–5133
Figure 12.17 Removing Supply Manifold On Engines Equipped With Old Three–Way Fitting
EGES 160 – 1
SERVICE MANUAL
Section 12

TINUED
CONTINUED
b. Figure 12.18 shows the supply manifold on
an engine equipped with the new three–way
fitting.
EG–6876
Figure 12.18 Removing Supply Manifold On Engines Equipped With New Three–Way Fitting
c. Figure 12.19 shows the supply manifold on
an engines equipped with the engine
mounted ECM unit.
EG–6879
Figure 12.19 Removing Supply Manifold On Engines Equipped With Engine Mounted ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 12
CLEANING
1. Insert a stiff nylon brush, ZTSE4320, into the oil
and fuel galleries of the supply manifold for
cleaning.
2. Use compressed air to clean out debris from the
oil galley.
Figure 12.20 Checking Supply Manifold Gas-

INSPECTION FOR WARPAGE ket For Warpage
Using a straightedge, OEM1293, and feeler gauge,

check the supply manifold gasket surface for warp-
age utilizing the checking pattern shown in Figure
12.20. Inspect for cracks.
HIGH PRESSURE PUMP

REMOVING THE INJECTION PRESSURE REGU-
EG–5101
LATOR VALVE
NOTE: IT IS NOT NECESSARY to remove the in- Figure 12.21 Engines Equipped With ICP Sen-
jection pressure relief valve from the high pressor Mounted In The Three–Way Fitting
sure pump, prior to removal of the pump. How-
ever, the solenoid, sleeve and tinnermann nut
can be removed for easy access to the high
pressure pump mounting bolts.
EG–5101
Remove the Injection Pressure Regulator (IPR)

valve as follows:
1. For engines with Serial Number 988150 and
below. Disconnect the wiring harness from the
IPR valve (Figure 12.21).
EG–6814
1. For engines with Serial Number 988151 and
up. Disconnect the wiring harness from the IPR Figure 12.22 Engines Equipped With ICP Sen-
valve (Figure 12.22). sor Mounted In The Supply Manifold
EGES 160 – 1
SERVICE MANUAL
Section 12
HIGH PRESSURE PUMP – CONTINUED

REMOVING THE INJECTION PRESSURE REGU-
LATOR VALVE – CONTINUED
2. Remove tinnermann nut securing solenoid to
IPR valve. Remove sleeve and solenoid (Fig- 2
ures 12.23 and 12.24).
3. Unscrew the IPR valve from the high pressure
pump using a 28 mm (1–1/8 in.) deep wall sock-
et (Figure 12.25)
1
EG–5102
Figure 12.23 Remove Tinnermann Nut

1. Pump
2. Tinnermann Nut
2 3
1
EG–5103
Figure 12.24 Remove IPR Sleeve & Solenoid

1. IPR Valve
2. Solenoid
3. Sleeve
1
EG–5104
Figure 12.25 Remove IPR Valve

1. Pump
2. IPR Valve
EGES 160 – 1
SERVICE MANUAL
Section 12
REMOVAL
Use the following steps to remove the high pressure
lube oil pump.
CAUTION
BEFORE PERFORMING THIS PROCEDURE, BE
SURE THE HIGH PRESSURE PUMP RES-
ERVOIR HAS BEEN DRAINED OF OIL. DRAIN
THE RESERVOIR BY REMOVING THE ENGINE
OIL TEMPERATURE SENSOR (FIGURE 12.26) EG–6810
FROM THE REAR HALF OF THE FRONT COVER.
EXTRACT OIL BY INSERTING THE TUBE FROM Figure 12.26 Removing Engine Oil Tempera-
THE HAND OPERATED VACUUM PUMP TOOL ture Sensor From High Pressure Oil Reservoir
ZTSE2499 INTO THE COVER (FIGURE 12.27).
IMPORTANT
IF THE IPR VALVE HAS NOT BEEN REMOVED,
BE SURE THE IPR VALVE SOLENOID HAS BEEN
DISCONNECTED FROM THE MAIN WIRING
HARNESS (FIGURE 12.21 OR 12.22).
NOTE: BE SURE the lube oil supply hose has

been disconnected, refer to “Supply Manifold
Removal” in this section, for the proper removal
procedures.
1. Remove two (2) capscrews securing high pres- EG–6893
sure lube pump to front cover. Remove pump

Figure 12.27 Removing Oil From High Pres-
and gasket from front cover
sure Oil Reservoir
a Figure 12.28 shows the high pressure
pump on engines with serial number
988150 and below.
EG–5121
Figure 12.28 Remove High Pressure Oil Pump

On Engines S/N 988150 & Below
EGES 160 – 1
SERVICE MANUAL
Section 12

b Figure 12.29 shows the high pressure
pump on engines with serial number
988151 and up.
INSTALLATION
Use the following steps to install the high pressure
lube oil pump.
1. On Engines With S/N 988150 & Below: Place

new gasket onto high pressure pump and place
the pigh pressure pump into its location.
EG–6874
1. On Engines With S/N 988151 & Up: Install a
new face seal into the groove of the front cover Figure 12.29 Remove High Pressure Oil Pump
and place the pigh pressure pump into its loca- On Engines S/N 988151 & Up
tion.
2. Install two (2) capscrews and secure the high
pressure pump to the front cover. Tighten the
ures 12.29).
3. If removed, install IPR valve into the high pres-
sure pump. Tighten valve to the special torque
value (Figure 12.30).
4. Install the IPR valve sleeve and solenoid to the
IPR valve (Figure 12.31).
EG–5105
Figure 12.30 Install IPR Valve
2 3
1
EG–5103
Figure 12.31 Install IPR Sleeve & Solenoid

1. IPR Valve
2. Solenoid
3. Sleeve
EGES 160 – 1
SERVICE MANUAL
Section 12
5. Install and tighten tinnermann nut to the special
SUPPLY MANIFOLD INSTALLATION

CONNECTION LOCATIONS AND INSTALLA-
TION
Install and connect the supply manifold to the en-
gine per the following steps: 2
CAUTION
NEVER PLACE THE SUPPLY MANIFOLD FACE
DOWN ON A TABLE OR WORKBENCH. THE
FLAT SURFACE FINISH OF THE MANIFOLD
MAY SCRATCH, PROHIBITING A SEAL BE-
TWEEN THE MANIFOLD AND THE CRANK-
CASE.
1
NOTE: Install the supply manifold gasket with

EG–5102
the tab stamped “FRONT”, located on the lower
left hand side of the gasket, facing the manifold
assembly.
1. Place a new supply manifold gasket onto sup-
ply manifold (the gasket should have the tab lo- Figure 12.32 Installing Tinnermann Nut
cated in the lower front corner for correct place-
ment) (Figure 12.33). 1. High Pressure Pump
2. Tinnermann Nut
2
1
EG–5135
Figure 12.33 Installing Supply Manifold and Gasket To Cylinder Head

1. Supply Manifold
2. Supply Manifold Gasket
EGES 160 – 1
SERVICE MANUAL
Section 12
SUPPLY MANIFOLD INSTALLATION –

CONTINUED
TION – CONTINUED
2. Install supply manifold to cylinder head and se-
cure using twelve bolts. Tighten bolts to the
Figure 12.34 shows an engine with the old style
three–way fitting.
IMPORTANT
WHEN TIGHTENING SUPPLY MANIFOLD
BOLTS, BE SURE TO TIGHTEN FROM THE CEN-
TER OUTWARD.
EG–5134
Figure 12.34 Installing Supply Manifold On Engines Equipped With Old Three–Way Fitting
Figure 12.35 shows an engine with the new
style three–way fitting.
EG–6875
Figure 12.35 Installing Supply Manifold On Engines Equipped With New Three–Way Fitting
EGES 160 – 1
SERVICE MANUAL
Section 12
CONTINUED
TION – CONTINUED
Figure 12.36 shows an engine with the engine
mounted ECM unit.
EG–6878
Figure 12.36 Installing Supply Manifold On Engines Equipped With Engine Mounted ECM Unit
3. Install the supply manifold end plug. Refer to

“Removing and Installing Supply Manifold
End Plug”, in this section.
4. Install the fuel return valve into the rear of the
supply manifold (Figure 12.37).
EG–5129
Figure 12.37 Install Fuel Return Valve
EGES 160 – 1
SERVICE MANUAL
Section 12

CONTINUED
TION – CONTINUED
5. Tighten fuel return valve to special torque value
(Figure 12.38).
6. Install banjo fitting to fuel return valve. Tighten
to the special torque value (Figure 12.39).
7. Install the fuel supply line and connect it from
the fuel filter header to the front of the supply
manifold. Tighten fitting to the special torque
value.
a. Figure 12.40 shows the fuel supply line on
engines equipped with the front mounted EG–5126
primer pump.
Figure 12.38 Tighten Fuel Return Valve
EG–5123
Figure 12.39 Tighten Fuel Return Banjo Fit-

ting
EG–5124
Figure 12.40 Install Fuel Supply Line On En-

gines Equipped With Front Mounted Primer
Pump
1. Transfer Pump To Supply Manifold
2. Transfer Pump To Fuel Filter Return
3. Fuel Filter Header
EGES 160 – 1
SERVICE MANUAL
Section 12
CONTINUED
TION – CONTINUED
b. Figure 12.41 shows the fuel supply line on
engines equipped with top mounted primer
pump.
c. Figure 12.42 shows the fuel supply line on
engines equipped with the top mounted
primer pump and the engine mounted ECM
unit. EG–6863
INSTALLING THE ICP SENSOR

Use one of the following procedures when installing gines Equipped With Top Mounted Primer
the ICP Sensor. Pump
Engines Equipped With The Old Three–Way Fit-

ting
8. Apply Loctite® #277 to the threads of the ICP
sensor.
9. Install the ICP sensor with a new O–Ring into
the supply manifold elbow, located at the front
of the supply manifold. Tighten to the special
EG–6888

Unit
EG–5117
Figure 12.43 Install ICP Sensor Into Old

Three–Way Fitting
EGES 160 – 1
SERVICE MANUAL
Section 12

CONTINUED
TION – CONTINUED
sensor.
the supply manifold elbow, located at the front
of the supply manifold. Tighten to the special EG–6843
Figure 12.44 Install ICP Sensor Into New
Three–Way Fitting
Unit
sensor.
center of the supply manifold elbow, located at
the front of the supply manifold. Tighten to the
INSTALLING THE LUBE OIL SUPPLY HOSE EG–6877
Use one of the following steps to connect the high Figure 12.45 Install ICP Sensor Into Supply
pressure pump lube oil supply hose to the pump and Manifold
supply manifold.

10. Install the hose to the high pressure pump and
supply manifold. Tighten the nuts securing the
hose to the special torque value (Figure 12.46).
1
3
2
EG–7005
Figure 12.46 Install Oil Supply Line On En-

gines Equipped With Old Three–Way Fitting
3. Oil Supply Line
EGES 160 – 1
SERVICE MANUAL
Section 12
CONTINUED
TION – CONTINUED
10. Install the hose to the high pressure pump and 1
supply manifold. Tighten the nuts securing the 2
Unit 1
10. Install the hose to the high pressure pump and
supply manifold. Tighten the nuts securing the
3
EG–6873

gines Equipped With New Three–Way Fitting
2. Oil Supply Line
3 1
1 EG–6883

Unit
2. Oil Supply Line
EGES 160 – 1
SERVICE MANUAL
FUEL SYSTEM
SECTION 13 INDEX
Page

WITH A FRONT MOUNTED PRIMER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WITH A TOP MOUNTED PRIMER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WITH ENGINE MOUNTED ECM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRIMING FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
EGES 160 – 1
SERVICE MANUAL
Section 13
FUEL SYSTEM Page 1
COMPONENT LOCATION FOR ENGINES EQUIPPED WITH A FRONT MOUNTED

PRIMER PUMP
Figure 13.1 shows the component location for engines equipped with three–way fitting.
9 1
10
11 12 3
5
6
4
EG–7008
Figure 13.1 Fuel System Component Locations For Engines Equipped With A Front Mounted
Hand Primer Pump
1. Supply Manifold
3. Fuel Filter Strainer
4. Fuel Filter
5. Fuel Filter Header to Supply Pump Line
7. Supply Pump
8. High Pressure Pump to Supply Manifold Hose
9. Injection Control Pressure (ICP) Sensor
10. Fuel Filter Header to Supply Manifold Line
11. Supply Pump to Fuel Filter Line
12. Hand Primer Pump
EGES 160 – 1
SERVICE MANUAL
Section 13
Page 2 FUEL SYSTEM
COMPONENT LOCATION FOR ENGINES EQUIPPED WITH A TOP MOUNTED PRIM-
ER PUMP
Figure 13.2 shows the component location for engines equipped with the engine mounted ECM unit.
11
1
12
2
3
10
6
8
9
7
EG–6836
Figure 13.2 Fuel System Component Locations For Engines Equipped With A Top Mounted Hand
Primer Pump
1. Supply Manifold
3. Hand Primer Pump
5. Fuel Filter
8. Supply Pump
EGES 160 – 1
SERVICE MANUAL
Section 13
FUEL SYSTEM Page 3
COMPONENT LOCATION FOR ENGINES EQUIPPED WITH ENGINE MOUNTED ECM

UNIT
Figure 13.3 shows the component location for engines equipped with the engine mounted ECM unit.
1
3
5
12 2
4
10
8
11 9
EG–6835
Figure 13.3 Fuel System Component Locations For Engines Equipped With The Engine Mounted
ECM Unit
1. Supply Manifold
5. Hand Primer Pump
7. Fuel Filter
10. Supply Pump
EGES 160 – 1
SERVICE MANUAL
Section 13
Page 4 FUEL SYSTEM
SPECIFICATIONS
Fuel Return Valve
Valve to unseat at 414 kPa (60 psi)
Fuel Filter
Type Spin–On and Fuel Strainer

Fuel Filter Header Mounting Bolt 18 Nm (13 lb–ft.)
Injector Hold Down Bolt 13 Nm (120 lb–in.)
Shoulder Injector Bolt 13 Nm (120 lb–in.)

ZTSE4294 Fuel System Cap Set
EGES 160 – 1
SERVICE MANUAL
Section 13
FUEL SYSTEM Page 5
FUEL SYSTEM
REMOVAL
1. Using an appropriate filter wrench/strap, loosen
and remove the fuel filter from the fuel filter
header and discard.
a. Figure 13.4 shows the engines equipped
with the front mounted hand primer pump.
b. Figure 13.5 shows the engines equipped
with the top mounted hand primer pump.
EG–5107
Figure 13.4 Remove Fuel Filter On Engines

Equipped With Front Mounted Hand Primer
Pump
EG–6892
Figure 13.5 Remove Oil Filter On Engines

Equipped With Top Mounted Hand Primer
Pump
EGES 160 – 1
SERVICE MANUAL
Section 13
Page 6 FUEL SYSTEM
2. Remove the fuel filter strainer as follows (Fig-
ure 13.6):
3
a. Remove plastic strainer cover from filter
strainer assembly using a 29 mm or 1–1/8
inch socket.
b. Clean or replace strainer after inspection
2
and reinstall strainer and cover to fuel filter
header assembly. Refer to “Installation” in
this section. 1
IMPORTANT
INSTALL STRAINER WITH OPEN END TOWARD
FILTER HEADER. EG–5109
Figure 13.6 Remove Fuel Strainer Assembly

3. On Engines Equipped With Front Mounted
Hand Primer Pump: Remove the supply pump 1. Strainer Cover
inlet fuel line as follows (Figure 13.7): 2. O–Ring
3. Strainer
copper sealing gaskets at the fuel filter
b. Cap the fuel filter header and supply pump 2
1
openings using ZTSE4294.
3. On Engines Equipped With A Top Mounted
Hand Primer Pump: Remove the supply pump
inlet fuel line as follows (Figure 13.8):
3
openings using ZTSE4294. EG–5112
Figure 13.7 Remove Fuel Supply Line, Front

Mounted Primer Pump
1. Transfer Pump
2. Fuel Filter Header Inlet Fuel Line
3. Fuel Filter Header To Transfer Pump Line
EG–6862
Figure 13.8 Remove Fuel Supply Line, Top

Mounted Primer Pump
EGES 160 – 1
SERVICE MANUAL
Section 13
FUEL SYSTEM Page 7

Hand Primer Pump: Remove the final fuel fil-
ter inlet fuel line as follows (Figure 13.9):
copper sealing gaskets at fuel filter header
and supply pump.
EG–5114
Figure 13.9 Remove Final Fuel Filter, Front
4. On Engines Equipped With A Top Mounted Mounted Hand Primer Pump
Hand Primer Pump: Remove the final fuel fil-
ter inlet fuel line as follows (Figure 13.10):
a. Loosen fitting and remove the final fuel filter
inlet fuel line.
4. On Engines Equipped With An Engine
Mounted ECM Unit: Remove the final fuel filter
inlet fuel line as follows (Figure 13.11):
a. Loosen fitting and remove the final fuel filter
inlet fuel line.
EG–6866
openings using ZTSE4294. Figure 13.10 Remove Final Fuel Filter, Top
Mounted Hand Primer Pump
EG–6887
Figure 13.11 Remove Final Fuel Filter, On En-

gines Equipped With An Engine Mounted ECM
Unit
EGES 160 – 1
SERVICE MANUAL
Section 13
Page 8 FUEL SYSTEM
Hand Primer Pump: Disconnect the fuel sup-
ply line from the fuel filter header to the supply
copper sealing gaskets at the fuel filter
EG–5113
Figure 13.12 Remove Fuel Supply Line, Front
5. On Engines Equipped With A Top Mounted Mounted Hand Primer Pump
Hand Primer Pump: Disconnect the fuel sup-
5. On Engines Equipped With An Engine
Mounted ECM Unit: Disconnect the fuel sup-
EG–6864
to supply pump line. Figure 13.13 Remove Fuel Supply Line, Top
b. Cap the fuel filter header and supply pump Mounted Hand Primer Pump
EG–6885
Figure 13.14 Remove Fuel Supply Line, On

Engines Equipped With An Engine Mounted
ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 13
FUEL SYSTEM Page 9

6. Remove the two (2) mounting bolts which se-
cure the fuel filter header to the crankcase.
a. Figure 13.15 shows the fuel filter header on
engines equipped with the front mounted
hand primer pump.
b. Figure 13.16 shows the fuel filter header on
engines equipped with a top mounted hand
primer pump. EG–5115
c. Figure 13.17 shows the fuel filter header on

Figure 13.15 Remove Front Mounted Hand
engines equipped with the engine mounted
Primer Pump
ECM unit.
EG–6869
Figure 13.16 Remove Top Mounted Hand

Primer Pump
EG–6882
Figure 13.17 Remove Top Mounted Hand

Primer Pump On Engines Equipped With En-
gine Mounted ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 13
Page 10 FUEL SYSTEM
7. Loosen three (3) bolts securing the supply
pump to the high pressure pump. Remove sup-
ply pump.
a. Figure 13.18 shows the supply pump on en-
gines equipped with the front mounted hand 3
primer pump.
b. Figure 13.19 shows the supply pump on en-
gines equipped with the top mounted hand 2
primer pump. 1
8. If it is necessary to remove the supply manifold,
refer to Section 12, “High Pressure Lube Oil EG–5118
System” for removal, inspection and assembly Figure 13.18 Remove Supply Pump On En-
procedures. gines Equipped With A Front Mounted Hand
Primer Pump
1. Supply Pump
2. Supply Pump Mounting Bolts (3)
3
2
1
EG–6870
Figure 13.19 Remove Supply Pump On En-

gines Equipped With An Engine Mounted ECM
Unit
1. Supply Pump Mounting Bolts (3)
2. Supply Pump
3. High Pressure Pump Oil Supply Line
EGES 160 – 1
SERVICE MANUAL
Section 13
FUEL SYSTEM Page 11

Inspect the supply pump tappet. Observe for
straightness, burrs or cracks.
Figure 13.20 shows the engine equipped with the

front mounted hand primer pump.
Figure 13.21 shows the engine equipped with a top

mounted hand primer pump.
EG–5120
Figure 13.20 Inspect Supply Pump Tappet On

Engines Equipped With A Front Mounted
Hand Primer Pump
EG–6872
Figure 13.21 Inspect Supply Pump Tappet On

Engines Equipped With A Top Mounted Hand
Primer Pump
EGES 160 – 1
SERVICE MANUAL
Section 13
Page 12 FUEL SYSTEM
INSTALLATION
1. If it was necessary to remove the supply man- 1
ifold, refer to Section 12, “High Pressure
Lube Oil System” installation procedures. 2
2. Install supply pump to high pressure pump
housing. Secure with three (3) bolts. Tighten to
the standard torque value.
Figure 13.22 shows the engine equipped with
the front mounted hand primer pump.
Figure 13.23 shows the engine equipped with a
top mounted hand primer pump.
EG–5119
Figure 13.22 Install Supply Pump On Engines

Equipped With A Front Mounted Hand Primer
Pump
1. Supply Pump Mounting Bolts
2. Supply Pump
EG–6871
Figure 13.23 Install Supply Pump On Engines

Equipped With A Top Mounted Hand Primer
Pump
1. Supply Pump
2. Supply Pump Mounting Bolts
EGES 160 – 1
SERVICE MANUAL
Section 13
FUEL SYSTEM Page 13

3. Mount the fuel filter header as follows: Figure
13.24 shows the engine equipped with the front
mounted hand primer pump. Figure 13.25
shows the engine equipped with a top mounted
hand primer pump. Figure 13.25 shows an en-
gine equipped with the engine mounted ECM
unit.
a. Insert the header at the crankcase mount- EG–5115
ing pad. Fasten the header using the two
mounting bolts and washers. Figure 13.24 Install Front Mounted Hand Prim-
b. Tighten the mounting bolts to the standard er Pump
torque value.
c. Remove nylon cap above fuel strainer and
observe check ball. If check ball is not in this
location, priming pump will not work.
EG–6868
Figure 13.25 Install Top Mounted Hand Primer

Pump
EGES 160 – 1
SERVICE MANUAL
Section 13
Page 14 FUEL SYSTEM
IMPORTANT 1
WHEN INSTALLING HOLLOW SCREW END FIT-
TING FUEL LINES, BE SURE TO USE NEW COP-
PER GASKETS. 3
4. Install the supply pump return to the fuel filter 2

header return line as follows: Figure 13.26
shows the engine equipped with the front
mounted hand primer pump. Figure 13.27
shows the engine equipped with a top mounted
hand primer pump. Figure 13.28 shows an en- EG–5124
gine equipped with the engine mounted ECM

unit. Figure 13.26 Install Fuel Supply Pump Return
Line To Fuel Filter Header On Engines With A
a. Remove protective caps from supply pump
Front Mounted Hand Primer Pump
and fuel filter header inlet ports.
1. Supply Pump To Supply Manifold Fuel Line
b. HOLLOW SCREW FUEL LINE. Secure 2. Supply Pump To Fuel Filter Return Fuel Line
with hollow screws and new copper sealing 3. Fuel Filter Header
gaskets. Tighten to the special torque val-
ue.
b. THREADED FITTING FUEL LINE. Posi-
tion the line to the supply pump and fuel filter
header. Tighten end fittings.
EG–6867
Figure 13.27 Install Fuel Supply Pump Return

Line To Fuel Filter Header On Engines With A
Top Mounted Hand Primer Pump
EG–6886
Figure 13.28 Install Fuel Supply Pump Return

Line To Fuel Filter Header On Engines With An
Engine Mounted ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 13
FUEL SYSTEM Page 15

IMPORTANT 1
WHEN INSTALLING HOLLOW SCREW END FIT-
PER GASKETS. 3
5. Install fuel filter header to supply manifold fuel 2

line as follows: Figure 13.29 shows the engine
equipped with the front mounted hand primer
pump. Figure 13.30 shows the engine
equipped with a top mounted hand primer
pump. Figure 13.31 shows an engine EG–5124
equipped with the engine mounted ECM unit.

Figure 13.29 Install Fuel Filter Header To Sup-
ply Manifold Fuel Line On Engines With A
and fuel filter header inlet ports.
Front Mounted Hand Primer Pump
b. HOLLOW SCREW FUEL LINE. Secure 1. Supply Pump To Supply Manifold Fuel Line
with hollow screws and new copper sealing 2. Supply Pump To Fuel Filter Return Fuel Line
gaskets. Tighten to the special torque val- 3. Fuel Filter Header
ue.
EG–6865

ply Manifold Fuel Line On Engines With A Top
Mounted Hand Primer Pump
EG–6884

ply Manifold Fuel Line On Engines Equipped
With An Engine Mounted ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 13
Page 16 FUEL SYSTEM
IMPORTANT
WHEN INSTALLING HOLLOW SCREW END FIT- 2
PER GASKETS.
6. Install fuel filter header to supply pump line as

follows: Figure 13.32 shows the engine
equipped with the front mounted hand primer
pump. Figure 13.33 shows the engine
equipped with a top mounted hand primer 1
pump. Figure 13.34 shows an engine
equipped with the engine mounted ECM unit. EG–5125

and fuel filter header inlet ports. Figure 13.32 Install Fuel Filter Line To Supply
Pump On Engines With Front Mounted Hand
b. HOLLOW SCREW FUEL LINE. Secure Primer Pump
with hollow screws and new copper sealing
1. Fuel Filter Return Line To Supply Pump
gaskets. Tighten to the special torque val-
ue.
EG–6863
Figure 13.33 Install Fuel Filter Line To Supply

Pump On Engines With Top Mounted Hand
Primer Pump
EG–6888
Figure 13.34 Install Fuel Filter Line To Supply

Pump On Engines Equipped With An Engine
Mounted ECM Unit
EGES 160 – 1
SERVICE MANUAL
Section 13
FUEL SYSTEM Page 17

7. Install a new strainer as follows (Figure 13.35).
3
a. Lubricate the threads of the strainer cover
and install a new O–Ring.
b. Install strainer in cover and hand–tighten
into fuel filter header.
2
IMPORTANT
INSTALL STRAINER WITH OPEN END TOWARD
FILTER HEADER. 1
8. Install a new fuel filter as follows (Figure 13.36).

NOTE: Engines equipped with a top mounted
EG–5109
hand primer pump shown. Engines equipped
with a front mounted hand primer pump use the
same procedure. Figure 13.35 Install Fuel Filter Strainer
1. Strainer Cover
a. Lubricate the filter gasket with clean diesel 2. O–Ring
fuel. 3. Strainer
b. Tighten until the gasket touches the filter
header.
c. Tighten by hand an additional 1/2 turn.
IMPORTANT
DO NOT CRANK ENGINE FOR MORE THAN 15
SECOND INTERVALS.
EG–6891
Figure 13.36 Install Fuel Filter
EGES 160 – 1
SERVICE MANUAL
Section 13
Page 18 FUEL SYSTEM
PRIMING FUEL INJECTION SYSTEM
After replacing fuel supply lines, prime the fuel sys-
tem using this procedure:
1. Loosen the bleed screws at the fuel filter header
(Figure 13.37).
2. Operate priming pump until pump action pro-
vides solid fuel at the bleed screw. Close the
screw.
IMPORTANT
DO NOT CRANK ENGINE FOR MORE THAN 15
SECOND INTERVALS.
3. Crank engine for fifteen seconds.

NOTE: Do not add fuel to the new filter.
EG–6812
4. Start engine and operate until engine runs

smoothly. Figure 13.37 Loosen Fuel Filter Bleeder Screw
EGES 160 – 1
SERVICE MANUAL
APPENDIX
INDEX
Page
GENERAL ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DT 466E DIESEL ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
THE INTERNATIONAL® 530E DIESEL ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DT 466E AND THE INTERNATIONAL® 530E DIESEL ENGINE RATINGS . . . . . . . . . . . . . . . . . . . . . 3
POWER RATINGS AND SPEED SETTINGS, DT 466E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER RATINGS AND SPEED SETTINGS, INTERNATIONAL® 530E . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPONENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve Lever And Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tappets Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Push Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston Rings – Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston Rings – Oil Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Regulator Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Injection Control Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
High Pressure Pump Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuel Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TORQUE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GENERAL TORQUE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tension Values for Standard Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fastener Thread Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL NUT AND BOLT TORQUE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL SERVICE TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 1
GENERAL ENGINE SPECIFICATIONS

DT 466E DIESEL ENGINE SPECIFICATIONS
Engine Specifications
Number of Cylinders 6
Bore 109.2 mm (4.301 in.)
Stroke 135.9 mm (5.350 in.)
Displacement 7.6 Liter (466 cu. in.)
Brake Horsepower (See Note) See Engine Power Ratings Chart
Torque (lb–ft.) See Engine Power Ratings Chart
Horsepower (A.M.A.) See Engine Power Ratings Chart
Compression Ratio 16.2:1
Firing Order 1–5–3–6–2–4
Valve Tappet Clearance (hot or cold): Intake Exhaust
0.635 mm (0.025 in.) 0.635 mm (0.025 in.)
Engine Lube Oil Pressure:
Engine Lube Oil Pressure with SAE 15W–40 oil:
Low Idle (Minimum 700 rpm) 137 kPa (20 psi)
High Idle 344 kPa (50 psi)
Crankcase Capacity:
Rear Sump (without filter) 22.7 Liters (24 quarts)
Rear Sump (with filter) 26.4 Liter (28 quarts)
NOTE: SAE J1995 Horsepower. No deration required up to 3048 meters (10,000 ft.).
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 2
GENERAL ENGINE SPECIFICATIONS – CONTINUED

THE INTERNATIONAL® 530E DIESEL ENGINE SPECIFICATIONS
Engine Specifications
Number of Cylinders 6
Bore 114.3 mm (4.590 in.)
Stroke 135.9 mm (5.350 in.)
Displacement 8.7 Liter (530 cu. in.)
Brake Horsepower (See Note) See Engine Power Ratings Chart
Torque (lb–ft.) See Engine Power Ratings Chart
Horsepower (A.M.A.) See Engine Power Ratings Chart
Compression Ratio 16.2:1
Firing Order 1–5–3–6–2–4
Valve Tappet Clearance (hot or cold): Intake Exhaust
0.025 in. (0.635 mm ) 0.025 in. (0.635 mm)
Engine Lube Oil Pressure:
Engine Lube Oil Pressure with SAE 15W–40 oil:
Low Idle (Minimum 700 rpm) 137 kPa (20 psi)
High Idle 344 kPa (50 psi)
Crankcase Capacity:
Rear Sump (without filter) 22.7 Liters (24 quarts)
Rear Sump (with filter) 26.4 Liters (28 quarts)
NOTE: SAE J1995 Horsepower. No deration required up to 3048 meters (10,000 ft.).
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 3

DT 466E AND THE INTERNATIONAL® 530E DIESEL ENGINE RATINGS
MEETS EMISSION
BHP* PEAK TORQUE ENGINE
STANDARDS FOR
175 HP @ 2300 rpm 430 lb–ft. @ 1500 rpm 466E 50 State
195 HP @ 2300 rpm 520 lb–ft. @ 1450 rpm 466E HT 50 State
250 HP @ 2300 rpm 800 lb–ft. @ 1300 rpm International® 530E 50 State
1997 Model Year
*Horsepower based on J1995 Standards 152.4 meters (500 ft.) altitude and 29.5° C (85° F) ambient. No dera-
tion required up to 3,048 meters (10,000 ft.).
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 4

POWER RATINGS AND SPEED SETTINGS, DT 466E
DT 466E, 1995 Model Year

RPM MODE A175 @ 175 A190 @ 190 A210 @ 210 A230 @ 230
Brake Horsepower @ rpm 2300 2300 2300 2300

High Idle rpm (no load) 2350–2450 2350–2450 2350–2450 2359–2450
Low Idle rpm 700 700 700 700
A195HT @ 195 A210HT @ 210 230HT 250HT

Low idle rpm 700 700 700 700
DT 466E, 1996 Model Year and Up

RPM MODE A175 @ 175 A190 @ 190 A210 @ 210 A230 @ 230

Low Idle rpm 700 700 700 700
A195HT @ 195 A210HT @ 210 230HT 250HT

Low idle rpm 700 700 700 700
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 5

POWER RATINGS AND SPEED SETTINGS, INTERNATIONAL® 530E
International® 530E, 1995 Model Year

RPM MODE A250 @ 250 A275 @ 275 A275 @ 275 A300 @ 300 A300 @ 300
Brake Horsepower @ rpm 2200 2000 2200 2000 2200

High Idle rpm (no load) 2200 2000 2200 2000 2200
Low Idle rpm 700 700 700 700 700
International® 530E, 1996 Model Year

RPM MODE A250@ AL275@ A275@ AF275@ A300@ AF300@ AL300@
250 275 275 275 300 300 300
Brake
Horsepower 2000 2000 2000 2000 2000 2000 2000
@ rpm
High Idle
2250 – 2250 – 2050 – 2250 – 2050 – 2250 – 2250 –
rpm (no
2350 2350 2150 2350 2150 2350 2350
load)
Low Idle
700 700 700 700 700 700 700
rpm
International®, 1997 Model Year

RPM MODE A250 @ 250 A275 @ 275 AF275 @ 275 AL275 @ 275

Low Idle rpm 700 700 700 700
A300 @ 300 AF300 @ 300 AL300 @ 300 AF320 @ 300

Low idle rpm 700 700 700 700
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 6
COMPONENT SPECIFICATIONS
Turbocharger
Turbine Shaft Axial End Play 0.02–0.10 mm (0.001–0.004 in.)

Turbine Shaft Radial Shaft Movement (Play) 0.08–0.15 mm (0.003–0.006 in.)
Wastegate Actuator Movement 0.369 mm at 196 kPa (.015 in. at 28.5 psi)
Intake Manifold
Exhaust Manifold

Maximum Allowable Removal of Material 0.635 mm (0.025 in.)
Flange Thickness (Minimum) 18.41 mm (0.725 in.)
Exhaust Valves
9.423 mm (0.3710 in.)

Stem Diameter 9.441 mm (0.3717 in.)
Stem to Guide Clearance (Max. Allowable Before Replacement) 0.15 mm (0.006 in.)
Face to Stem Run–Out (T.I.R. Max.) 0.038 mm (0.0015 in.)
Valve Face Angle 45° – 00’ – 45° – 15’
Valve Face Margin (Min.) 0.64 mm (0.045 in.)
Valve Lash 0.64 mm (0.025 in.)
Intake Valves
9.444 mm (0.3718 in.)

Stem Diameter 9.461 mm (0.3725 in.)
Stem to Guide Clearance (Max. Allowable Before Replacement) 0.15 mm (0.006 in.)
Face to Stem Run–Out (T.I.R. Max.) 0.038 mm (0.0015 in.)
Valve Face Angle 30° – 00’ – 30° – 15’
Valve Face Margin (Min.) 2.24 mm (0.088 in.)
Valve Lash 0.64 mm (0.025 in.)
Cylinder Head
Valve Guide Type Replaceable

Valve Guide Length (overall) 66.294 ±.508 mm (2.610 ± .020 in.)
15.844 mm (0.6238 in.)
Valve Guide Bore Dia. in Cylinder Head for Valve Guide Insert 15.880 mm (0.6252 in.)
15.898 mm (0.6259 in.)
Service Valve Guide O.D. 15.918 mm (0.6267 in.)
Service Valve Guide I.D. 9.500 mm (0.3740 in.)
(After Assembly) 9.525 mm (0.3750 in.)
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 8
COMPONENT SPECIFICATIONS – CONTINUED

Valve Springs – Continued
Exhaust:
Identification Color Strip White
Valve Spring Free Length 62.18 mm (2.448 in.)
Test Length (Valve Closed) 50.29 mm (1.980 in.)
Test Length (Valve Open) 38.86 mm (1.530 in.)
Camshaft
Cam Lobe Lift (Total):
Intake 8.070 mm (0.3177 in.)
Exhaust 7.369 mm (0.2901 in.)
Maximum Permissible Cam Lobe Wear 0.51 mm (0.020 in.)
0.05 mm (0.002 in.)
Camshaft Running Clearance 0.18 mm (0.007 in.)
Maximum Permissible Camshaft Running Clearance 0.20 mm (0.008 in.)
58.026 mm (2.2845 in.)
Bushing I.D. (Installed in Crankcase) 58.115 mm (2.2880 in.)
57.948 mm (2.2814 in.)
Bushing Journal Diameter 57.976 mm (2.2825 in.)
Service Bushings Furnished to Size Yes
6.96 mm (0.274 in.)
Thrust Plate Thickness (New) 7.01 mm (0.276 in.)
0.13 mm (0.005 in.)
End Clearance 0.33 mm (0.013 in.)
Camshaft End Play 0.13–0.33 mm (0.005–0.013 in.)
Valve Lever And Shaft Assembly

21.567 mm (0.8491 in.)
Valve Lever Shaft Diameter 21.593 mm (0.8501 in.)
0.048 mm (0.0019 in.)
Valve Lever Clearance on Shaft 0.124 mm (0.0049 in.)
21.64 mm (0.852 in.)
Valve Lever Bushing (I.D.) 21.69 mm (0.854 in.)
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 10

Pistons
0.018mm (0.0045 in.)
Running Clearance between Piston and Cylinder Sleeve (466E) 0.064mm (0.0025 in.)
(Measured 90° from pin bore and 109.1mm (4.298 in.)
Skirt Diameter 83mm (3.271 in.) below bottom ring land) (466E) 109.1mm (4.297 in.)
0.016mm (0.005 in.)
Running Clearance between Piston and Cylinder Sleeve (530E) 0.07mm (0.003 in.)
(Measured 90° from pin bore and 116.4mm (4.5865 in.)
Skirt Diameter 60mm (2.358 in.) below bottom ring land) (530E) 116.4mm (4.5855 in.)
Number of Rings per Piston 3
Piston Ring Groove Widths:
Top Compression Ring – Measure over 2.921 mm (0.1150 in.) gauge pins 466E 110mm (4.3118 in.)
Top Compression Ring – Measure over 2.921 mm (0.1150 in.) gauge pins 530E 114mm (4.5015 in.)
Intermediate Compression Ring:
Measured over 2.921 mm (0.1150 in.) gauge pins (466E) 110mm (4.3168 in.)
Measured over 2.921 mm (0.1150 in.) gauge pins (530E) 118mm (4.6050 in.)
Rectangular Negative Twist (466E, for engines rated with 230 HP and below) 109mm (4.2844 in.)
Full Keystone (466E, for engines rated with 230 HP, HT version and above) 109mm (4.2844 in.)
Full Keystone (530E) 116mm (4.5712 in.)
Side Clearance: 0.088mm (.0040 in.)
Oil Control Ring 0.0040mm (.0020 in.)
Piston Rings – Compression

Number of rings per piston 2
Type (face and finish):
Top Ring Full Keystone (barrel faced) – Plasma Coated
Intermediate Ring :
For engines rated at 230HP and below Rectangular (Negative Twist) – Phosphate Coat
For engines rated at 230HP, HT version and above Full Keystone (taper face) – Chromeless
Ring Gap with New Sleeve:
0.066mm (0.026 in.)
Top Ring 0.040mm (0.014 in.)
1.91mm (0.075 in.)
Intermediate Ring 1.65mm (0.065 in.)
Piston Rings – Oil Control

Number of Rings Per Piston 1Type
One Piece Slotted – Chrome 0.054mm (0.022 in.)
Ring Gap (466E) 0.024mm (0.012 in.)
0.055mm (0.026 in.)
Ring Gap (530E) 0.028mm (0.014 in.)
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 11

Piston Pins
46.3 mm (1.8251 in.)
Diameter 46.3 mm (1.8249 in.)
88.6mm (3.490 in.)
Length 88.3mm (3.480 in.)
0.027mm (0.0011 in.)
Clearance in Rod 0.011mm (0.0006 in.)
Maximum Permissible Clearance in Rod, before replacing 0.08mm (0.003 in.)
0.015mm (0.00115 in.)
Clearance in Piston 0.028mm (0.00065 in.)
Maximum Permissible Clearance in Piston, before replacing 0.064mm (0.0025 in.)
Cylinder Sleeves
109.258mm (4.3015 in.)
114.5mm (4.5905 in.)
Maximum Permissible Diameter Sleeve Wear, at Top
of Ring Travel before Replacement (Sleeve Taper) 0.10mm (0.004 in.)
8.89mm (0.350 in.)
Counterbore Dimension in Crankcase 8.84mm (0.348 in.)
Maximum Allowable Variation of Counterbore Depth (Between Four Points) 0.025mm (0.001 in.)
Maximum Cylinder Sleeve Counterbore Allowable Depth (Used with shim kit) 10.49mm (0.413in.)
8.97mm (0.0353 in.)
Flange Thickness 8.94mm (0.0352 in.)
0.13mm (0.005 in.)
Protrusion above Crankcase 0.05mm (0.002 in.)
Crankshaft
Type Steel Forging, Induction Hardened,

Grindable
Main Bearing Journal Diameter:
Standard Size 89.8±.0152mm (3.535 ±.0006 in.)
Main Bearing Width (Except Rear Thrust) 33±0.254mm (1.286±.010 in.)
Main Bearing Journal Max. Out–of–Round 0.05mm (0.002 in.)
Main Bearing Thrust Face Runout (TIR Max.) 0.025mm (0.001 in.)
Main Bearing Journal Taper (Max./In.) 0.0711 mm (0.0028 in.)
Main Bearing Journal Fillet Radius 5.72/1.27mm (0.225/0.050 in.)
Rod Journal Fillet Radius 5.72/1.27mm (0.225/0.050 in.)
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 12

Rear Oil Seal Journal Runout (Max.) 0.076mm (0.003 in.)
Damper Mounting Area Runout (Max.) 0.013mm (0.0005 in.)
Flywheel Mounting Surface Runout (Max.) 0.05mm (0.002 in.)
Number of Main Bearings 7
Thrust Taken By Rear Main Thrust Bearing Journal Length
Thrust Bearing Journal Length:
Standard Size to 0.508 mm (.020 in.) Undersize 34.4±0.0254mm (1.3545±.010 in.)
0.762 mm (.030 in.) Undersize 34.4±0.0254mm (1.3545±.010 in.)
Main Bearing to Crankshaft Clearance 0.127/0.046mm (0.0050/0.0018 in.)
Connecting Rod Journal Diameter Standard Size 80.0±.0152mm (3.1500±.0006 in.)
0.762 mm (.030 in.) Undersize 79.2±.0152mm (3.1200±.0006 in )
Connecting Rod Bearing Width 35.2mm (1.385 in.)
Connecting Rod Journal Max. Out–of–Round 0.0064mm (.00025 in.)
Connecting Rod Journal Taper (Max./In.) 0.0069mm (.00027 in.)
Connecting Rod Bearing to Crankshaft Running Clearance 0.127–0.046mm (.0050–.0018 in.)
Crankshaft Flange O.D. 141mm (5.550 in.)
Crankshaft End Play 0.152–0.305mm (.006–.012 in.)
Crankshaft End Play Max. Wear Limit 0.508mm (.020 in.)
Rod to Crankshaft Side Clearance 0.304±.1143mm (.012±.0045 in.)
Crankshaft Gear Backlash 0.076–0.406mm (.003–.016 in.)
Flywheel Runout (Face Runout):
Face Runout Measured at 177.8 mm (7.0 in.) Radius 0.18mm (.007 in.)
Face Runout Measured at 165.1 mm (6.5 in.) Radius 0.165mm (0.0065 in.)
Face Runout (Mounting Surface for Clutch Cover Plate):
Measured at 190.5mm (7.5 in.) Radius 0.19mm (0.0075 in.)
Flywheel Concentricity (Radial Runout)
Radial Runout Measured at Clutch Mounting Holes 0.20mm (0.008 in.)
Radial Runout of Clutch Pilot Bore (I.D. of Pot Flywheel) 0.13mm (.005 in.)
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 13

Flywheel Resurfacing (For Clutch Applications):
Requires Measurement From Crankshaft Mounting Surface of Flywheel to Clutch Surface of Flywheel
NOTE: DO NOT machine beyond minimum dimension shown.
Flat Flywheel 36.3mm (1.430 in.)
Pot Flywheel 39.4mm (1.550 in.)
Flywheel Housing Bore Concentricity (See NOTE) SAE#1=0.30mm (0.012 in.), SAE#2=
0.28mm (0.011 in.)
Flywheel Housing Face Runout* SAE#1=0.30mm (0.012 in.),
SAE#2=0.28mm (0.011 in.)
NOTE: Must be measured per SAE specification J1033.
Vibration Damper Max. Allowable Member Misalignment 1.5mm (0.060 in.)
Vibration Damper Wobble (Max.) 1.5mm (.060 in.)
Crankcase Deck Flatness 0.076mm (.003 in.)
Crankcase Deck Finish (Micro inches) 125AA
Centerline of Main Bearing Bore to Head Deck 368.3±.0381mm (14.5±.0015 in.)
Crankcase Main Bearing Bore Diameter 97.8±.0127mm (3.8491±.0005 in.)
Crankcase
Tappet Bore Diameter 28.511/28.549mm (1.1225/1.1240 in. )
Valve/Roller Tappet O.D. 28.435/28.448mm (1.1195/1.1200 in.)
Oil Jet Tube Bore Diameter (Spray Hole Dia.) 0.1.22/1.24mm (.048/.049 in.)
Counterbore Dimension in Crankcase 8.86±0.025 /at 132mm (.349±.001/at 5.1885 gage
dia.)
Maximum Allowable Variation of Counterbore 0.025mm (0.001)
Depth (Between Four Points)
Maximum Cylinder Sleeve Counterbore Allowable 9.25mm (0.364 in.)
Depth
Protrusion Above Crankcase 0.050 to 0.127mm (0.002 to 0.005 in.)
Main Bearing Type Precision Replaceable
Material Steel–Backed Copper/Lead
Thrust Taken By No. 7 Rear
Cap Attachment 2 Bolts per Cap
Camshaft Bushing Bore Diameter in Crankcase:
Front 63.513/63.550mm (2.5005/2.5020 in.)
Intermediate Front 63.005/63.043mm (2.4805/2.4820 in.)
Intermediate Rear 62.496/62.535mm (2.4605/2.4620 in.)
Rear 61.988/62.026mm (2.4405/2.4420 in.)
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 14

Timing Gears
Crankshaft to Idler Backlash (Maximum) 0.356 mm (.014 in.)
Idler to Camshaft Backlash 0.457 mm (.018 in.)
Idler to Idler Backlash 0.482 mm (.019 in.)
Idler to Air Compressor or Power Steering Pump Backlash 0.508 mm (0.020 in.)
Idler to High Pressure Pump Backlash 0.482 mm (0.019 in.)
Oil Pump
Type “GEROTOR”
Drive Crankshaft
0.114 mm (0.0048 in.)
End Clearance Inner and Outer 0.470 mm (0.0020 in.)
0.622 mm (0.0245 in.)
Radial Clearance between Outer Rotor Housing 0.470 mm (0.0185 in.)
Engine Oil Pressure* (Run engine until normal operating temperatures are reached):
*Oil Pressure measurement should be made utilizing an oil gallery tap.
At Low Idle Speed (700 rpm) (minimum) 137 kPa (20 psi)
Minimum At High Idle Speed 344 kPa (50 psi)
Engine Oil Filter

Number 1
Filter Bypass Location In–Filter
Pressure Regulator Valve Assembly

Location In Crankcase, Behind Filter Header
Setting 331 kPa (48 psi)
27.13 mm (1.068 in.) 0.0005 mm (1.0610 in.)
Valve Assembly Diameter 26.89 mm (1.059 in.) ± 0.0055mm (0.0015 in.)
0.381 mm (0.0015 in.)
Valve Clearance in Bore 0.089 mm (0.0035 in.)
27.00 mm (1.063 in.)
Crankcase Bore I.D. 27.05 mm (1.065 in.)
Coolant Filter
Number 1
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 15

Thermostat
Type Poppet Valve, Pellet Operated
Operating Temperature Range:
Start to Open Temperature 82° – 85° C (180° – 185° F)
Full Open Temperature 94° C (202° F)
Camshaft Position Sensor

Location Front Cover
Operating Actuator Speed 15 to 2000 rpm
Operating Temperature –40° C to +130° C (–40° F to 54° F)
CMP Sensor Clearance:
Crankshaft rotated in a clockwise direction 29.90 ± 0.356 mm (1.177 ± 0.014 in.)
Crankshaft rotated in a counterclockwise direction 29.67 ± 0.356 mm (1.168 ± .014 in.)
Injection Control Pressure Regulator Valve

Operating Temperature Range –40° to125° C (–40° to 257° F)
Maximum Flow Rate 17.5 L/min (4.62 GPM)
Maximum Operating Pressure 20.7 MPa (3000 psi)
High Pressure Pump Drive Gear

Gear Backlash 0.140 – 0.256 mm (0.0055 – 0.0101 in.)
End Play 0.45 – 1.22 mm (0.018 – 0.48 in.)
Fuel Pressure Regulating Valve

Valve to unseat at 414 kPa (60 psi)
Fuel Filter
Type Spin–On and Fuel Strainer
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 16
TORQUE DATA
GENERAL TORQUE GUIDELINES
Many conditions affect torque and the results of
torque applications. The major purpose in tighten-
ing a fastener to a specified torque is to obtain ten-
sion in the fastener (i.e., bolt, nut, etc.), which in turn
develops a clamping load which exceeds any pos-
sible loading imposed on parts due to engine rpm or
vibration.
Tension Values for Standard Fasteners

The “Standards Nut and Bolt Torque Chart” pro-
vides tightening torque for general purpose applica-
tions using original equipment standard hardware
as listed in the Parts Catalog for the application in-
volved. DO NOT SUBSTITUTE. Original equip-
ment standard hardware is defined as Type 8,
coarse thread bolts and nuts and thru hardened flat
washers (Rockwell “C” 38–45), all phosphate
coated and assembled without supplemental lu-
brication (as received condition).
NOTE: Phosphate coating is a dry lubricant.
Fastener Thread Condition

Threads that are dry, excessively rough, battered or
filled with dirt require considerable effort just to ro-
tate. then when the clamping load is developed or
the bolt tension is applied, the torque reading
mounts rapidly (due to thread friction) to the speci-
fied torque value. However, the desired bolt tension
and maximum clamping effect is not achieved. this
condition can lead to failure of the fastener to main-
tain component integrity. The proper bolt tension
and clamping effect can never be attained if the fas-
tener is dry. The fastener threads must have a film
of clean lubricant (engine oil) to be considered lubri-
cated.
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 17
TORQUE DATA – CONTINUED

STANDARD NUT AND BOLT TORQUE CHART
HEX FLANGE HEAD
Thread Diameter Torque lb–ft. Torque Nm Wrench Size (mm)
M6x1 8 11 8
M8x1.25 18 24 10
M10x1.5 36 49 13
M12x1.75 61 83 15
M16x2 154 208 21
HEX HEAD
Thread Diameter Torque lb–ft. Torque Nm Wrench Size (mm)
M6x1 6 8 10
M8x1.25 15 20 13
M10x1.5 30 40 16
M12x1.75 51 69 18
M16x2 128 173 24
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 18
SPECIAL NUT AND BOLT TORQUE DATA
Air Compressor Drive Gear Nut 149 Nm (110 lb–ft.)

Air Compressor Hose Clamp 4.74 Nm (3.5 lb–ft. 42 lb–in.)
Air Compressor Mounting Bolts 62 Nm (46 lb–ft.)
Air Compressor Tail Bracket Mounting Bolts (Crankcase) 115 Nm (85 lb–ft.)
Air Compressor Tail Bracket Mounting Bolt (Compressor) 66 Nm (49 lb–ft.)
Back Plate–to–Center Housing Capscrews 21–24 Nm (185–215 lb–in.)
Camshaft Gear Timing Disk 7 Nm (60 lb–in.)
Center Housing–to–Compressor Housing Capscrews 21–24 Nm (185–215 lb–in.)
Center Housing–to–Turbine Housing Capscrews 13.5 Nm (115 lb–in.)
Coolant Filter Header Mounting Bolts 26 Nm (19 lb–ft.)
Compressor Wheel (Non–Wastegate Turbocharger) (See 13.5–15.2 Nm (115–135 lb–in.)
NOTE)
Compressor Wheel (Wastegate Turbocharger) (See NOTE) 10–12.5 Nm (90–111 lb–in.)
Connecting Rod Bolts 156 Nm (115 lb–ft.)
Crankcase Front Cover Bolts (Front & Rear Halves) 22 Nm (16 lb–ft.)
Crankcase Front Cover Bolts (Rear Half to Crankcase) 26 Nm (19 lb–ft.)
Crankshaft Main Bearing Cap Bolts 176 Nm (130 lb–ft.)
Cylinder Head Bolts See Notes & Figure A.1
Exhaust Manifold Bolts 81 Nm (60 lb–ft.)
Flywheel Bolts 136 Nm (100 lb–ft.)
Flywheel Housing Mounting Bolts 108 Nm (80 lb–ft.)
Front and Rear Engine Mounted ECM:
Electronic Control Module (ECM) Connector Retaining Screw 3.9 Nm (35 in.–lb.)
ECM Mounting Bolts 15 Nm (20 lb–ft.)
ECM Mounting Bracket Mounting Bolts 15 Nm (20 lb–ft.)
ECM Mounting Bracket Mounting Nuts 15 Nm (20 lb–ft.)
Front Engine Mounting Bracket Mounting Bolts 385 Nm (284 lb–ft.)
Fuel Filter Header Mounting Bolt 18 Nm (13 lb–ft.)
Fuel Injector Hold Down Clamp Mounting Bolt 13 Nm (120 lb–in.)
Fuel Injector Hold Down Clamp Shoulder Bolt 13 Nm (120 lb–in.)
Fuel Return Valve Banjo Fitting 35 Nm (26 lb–ft.)
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 19

SPECIAL NUT AND BOLT TORQUE DATA – CONTINUED
High Pressure Oil Pump Gear Bolt 129 Nm (95 lb–ft.)
High Pressure Oil Pump Mounting Bolts 27 Nm (20 lb–ft.)
Idler Gear Retaining Bolt (Lower) 637 Nm (470 lb–ft.)
Idler Gear Retaining Bolt (Upper) 332 Nm (245 lb–ft.)
Idler Gear Retaining Nut (Lower) 492 Nm (363 lb–ft.)
Idler Gear Retaining Nut (Upper) 431 Nm (318 lb–ft.)
Injector Hold Down Bolt 13 Nm (110 lb–in.)
Injection Control Pressure Valve 47 Nm (35 lb–ft.)
Injection Control Pressure Sensor (ICP) (See Note) 26 Nm (19 lb–ft.)
NOTE: Apply Loctite #277 to threads prior to assembly.
Injection Control Pressure Valve Tinnermann Nut 6 Nm (5.5 lb–in.)
Oil Cooler Mounting Bolts 26 Nm (19 lb–ft.)
Oil Pick–up Tube Bolts 21 Nm (15 lb–ft. or 180 lb–in.)
Oil Pick–up Tube Bracket Bolt 21 Nm (15 lb–ft. or 180 lb–in.)
Oil Temperature Control Valve 34 Nm (25 lb–ft.)
Shoulder Injector Bolt 13 Nm (110 lb–in.)
Special Mounting Nut (PTO Application ONLY) 108 Nm (80 lb–ft.)
Supply Manifold Elbow Fitting (On Engines Equipped With 26 Nm (19 lb–ft.)
Engine Mounted ECM Unit)
Supply Manifold Fuel Return Nut 27 Nm (20 lb–ft.)
Supply Manifold Mounting Bolt 27 Nm (20 lb–ft.)
Supply Manifold Three–way Fitting Nut 35 Nm (26 lb–ft.)
Turbocharger Mounting Nuts 66 Nm (49 lb–ft.)
Valve Adjusting Screw Nut 27 Nm (20 lb–ft.)
Valve Cover/Intake Manifold Bolts 18 Nm (13 lb–ft. or 156 lb–in.)
Vibration Damper Pulley Retainer Bolts 136 Nm (100 lb–ft.)
Water Pump Pulley (6 mm) 7 Nm (66 lb–in.)
Water Pump Mounting (6 mm) 7 Nm (66 lb–in.)
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 20

SPECIAL NUT AND BOLT TORQUE DATA – CONTINUED
NOTE: Tighten cylinder head bolts following the assembly steps listed (Figure A.1).
1. Lubricate bolt threads, bolt head seating areas and washers with clean engine oil.
2. Tighten bolts in three (3) stages:
EG–6152
Figure A.1 Cylinder Head Bolts Special Torque Sequence
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 22
SPECIAL TOOLS – CONTINUED

SPECIAL SERVICE TOOL LIST – CONTINUED
MANUAL SECTION TOOL DESCRIPTION TOOL ORDER NO.
SIX Counter Bore Tool ZTSE2514
Counter Bore Cutter Head ZTSE2514–4
Cylinder Liner Height Gauge With Holding Adapters ZTSE2515A
Cylinder Liner Holding Adapters ZTSE2515–1
Cylinder Sleeve Puller ZTSE2536
Piston Groove Wear Measuring Tool ZTSE3020
Piston Ring Expander OEM4220
Cylinder Bore Gauge OEM1032
Telescoping Gauge Set OEM1022
SEVEN Rear Oil Seal/Wear Sleeve Installer ZTSE2535C
PTO Rear Seal Installation Tool ZTSE4415
Bevelled Edge Straightedge OEM1293
Front Seal/Injector Remover ZTSE4300
Critical Metric Taps ZTSE4386
Crankshaft – Front Oil Seal/Wear Sleeve Installer ZTSE3004A
Telescopic Gauge Set ZTSE1032
Large Gear and Pulley Puller OEM4245
Wear Sleeve Removal Tool ZTSE4404
Flywheel Guide Studs ZTSE4375
Damper Heater ZTSE4384
Flex Hone ZTSE4349
Main Oil Gallery Brush ZTSE4389
Crankshaft Oil Hole Brush ZTSE4392
EIGHT Lower Idler Gear Socket (3/4 in./20 mm 12 point) ZTSE4383
NINE Crankshaft Front Oil Seal/Wear Sleeve Installer ZTSE3004A
TEN No Special Tools Required
ELEVEN No Special Tools Required
TWELVE High Pressure Oil System Cap Set ZTSE4295
Hand Operated Vacuum Pump ZTSE2499
Cleaning Brush Set (Consists of 4 brushes) ZTSE4320
THIRTEEN Fuel System Cap Set ZTSE4294
EGES 160 – 1
SERVICE MANUAL
Appendix
Page 23
CONVERSION TABLE
Figure A.2 contains a English to Metric dimension conversion table.
EG–7240
Figure A.2 English/Metric Conversion Table
EGES 160 – 1

EGES1602

Uploaded by

Copyright:

Available Formats

EGES1602

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

EGES1602

Uploaded by

Copyright:

Available Formats

SERVICE MANUAL

DT 466E AND THE INTERNATIONAL 530E

DT-466E and THE INTERNATIONAL 530E

© 2003 International Truck and Engine Corporation

SECTION 1 – MOUNTING ENGINE ON STAND

SECTION 4 – CYLINDER HEAD AND VALVES

SECTION 5 – ROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS

SECTION 6 – CONNECTING RODS, PISTONS, RINGS AND SLEEVES

SECTION 7 – VIBRATION DAMPER, CRANKSHAFT, MAIN BEARINGS, FLYWHEEL

SECTION 8 – TIMING GEAR TRAIN AND FRONT COVER

SECTION 9 – LUBRICATING OIL PUMP, OIL FILTER AND COOLER

SECTION 10 – WATER PUMP AND THERMOSTAT

SECTION 11 – ENGINE ELECTRICAL

SECTION 12 – HIGH PRESSURE LUBE OIL SYSTEM

SECTION 13 – FUEL SYSTEM

MAIN INDEX – Continued

SECTION 1 – MOUNTING ENGINE ON STAND

MAIN INDEX – Continued

SECTION 4 – CYLINDER HEAD AND VALVES

MAIN INDEX – Continued

MAIN INDEX – Continued

SECTION 6 – CONNECTING RODS, PISTONS, RINGS AND SLEEVES

MAIN INDEX – Continued

SECTION 6 – CONNECTING RODS, PISTONS, RINGS AND SLEEVES – Continued

SECTION 7 – VIBRATION DAMPER, CRANKSHAFT, MAIN BEARINGS,

MAIN INDEX – Continued

MAIN INDEX – Continued

SECTION 8 – TIMING GEAR TRAIN AND FRONT COVER

MAIN INDEX – Continued

SECTION 10 – WATER PUMP AND THERMOSTAT

MAIN INDEX – Continued

MAIN INDEX – Continued

SECTION 13 – FUEL SYSTEM

MAIN INDEX – Continued

Foreword Technical Service Literature

Technical Service Literature is revised periodically

Service Diagnosis repeat failure occurs. This can be prevented if specific

Form No. EGES 160–1

Be sure to reinstall safety devices, guards or shields

After servicing, be sure all tools, parts, or servicing

Be sure to wear safe work clothing. It should be well

Do not wear rings, wrist watches or loose fitting

Do not use defective portable power tools. Check

Be careful when using compressed air. Never apply

Use approved air blow guns, do not exceed recom-

When refueling, keep the hose and nozzle or the

Do not over fill the fuel tank – overflow creates a fire

Do not smoke when refueling and never refuel when

Electric storage batteries give off highly flammable

Do not under any circumstances allow an electric

Keep a “charged” fire extinguisher within reach

Also, be sure you have the correct type of extin-

The permanent engine serial number is stamped on

The Engine Emission Label identifies engine model

Other nameplates, are located, on the turbocharger

Figure i.1 Engine Serial Number and Emission Label Locations

1. Engine Emission Label 2. Engine Serial Number Stamp

530 = Engine Identifying Code

TURBOCHARGER IDENTIFICATION (NON WASTEGATE VERSION)

Figure i.2 Non Wastegate Turbocharger Component Locations