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200 ENGINE DISASSEMBLY
Page 4-21
Figure 4-25
—
Oil Pan Bolt L
ocations
1.
Studs
and nuts
at timing
gear cov
er
2.
Studs
and nuts
at flywh
eel hous
ing
3.
Shoul
dered b
olts alon
g pan
rails
5-101.bk Page 21 Friday, March 17, 2006 11:05 AM
78
80
Table of Contents
Main Page
Safety Information
7
Explanation of Numerical Code
11
Explanation of 3-Digit Numerical Code
12
About this Manual
13
Table of Contents
16
200 General Information
25
Introduction
26
Engine Model Identification
27
Engine Information Plate
27
Lubricants and Sealants
29
Overhaul Part Replacement
30
200 Specifications
31
Improved Design
32
Engine General Specifications
32
Engine Features
32
Good Shop Practice - Fasteners
34
Performance Specifications (Oil Pressure and Intake Manifold Temperature)
34
Fastener Torque
35
Fastener Selection and Installation
35
Fastener Sizes and Types
36
Torque Specifications
37
Torque Specifications for Critical Fasteners
37
Torque Specifications for Hose Clamps
40
Torque Specifications for Pipe Plugs
41
Torque Specifications for Non-Critical Fasteners
41
Fits and Limits
44
Metric Mismatch
50
Inch Thread Vs. Metric Thread Fastener Combinations Contributing to Thread Stripping
50
Inch Thread Vs. Metric Thread Fastener Combinations Contributing to Assembly Weakness
51
Incompatible Metric Vs. Metric Fastener Systems
51
Conversion Factors
51
Special Tools
52
Special Tool List
52
V-MAC Tools
54
200 Engine Removal
55
General
56
Vehicle Preparation
56
200 Engine Removal
56
200 Engine Disassembly
59
General
60
[219 Ev] Centri-Max™ and Spin-On Filter Elements
60
Mounting Engine in Stand
61
Special Tools Required
61
[271 Cb] Alternator
63
[215 Hb] Fan Assembly
63
[231 Pb] Fuel Filter Adapter Assembly
64
[215 Ld] Coolant Conditioner Element
65
[215 Nu] Thermostat
66
[214 Hd] Air Inlet Manifold
67
[215 Nk] Coolant Manifold
67
[215 Dw & 219 Ep] Oil Cooler and Oil Filter Housing Assembly
68
[215 Sw] Water Pump
69
[214 Sd] Turbocharger
69
[222 Kd] Fuel Nozzle Inlet Tube Assembly
70
[214 Eg] Exhaust Manifold
71
[213 Jb] Valve Cover and Riser
71
[213 Lp, Nv & Lh] Rocker Arm, Valve Yoke and Push Rod
72
[222 Kg] Nozzle Holder
73
Special Tool Required
73
[213 Ev] Cylinder Head Assembly Removal
74
[212 Rb & Rh] Vibration Damper and Crankshaft Hub
75
[261 Ck] Air Compressor
75
[221 Gp] Injection Pump
77
[221 CD] Econovance
78
V-MAC Equipped Engines
78
[211 Nb] Oil Pan
78
[219 Mu] Oil Pump
80
[211 Rp] Timing Gear Cover
81
[212 CV] Auxiliary Driveshaft
82
[213 Ch] Camshaft
82
[212 Np & Lq] Piston and Connecting Rod Assembly
83
[212 Uc] Flywheel
85
[211 Hd] Flywheel Housing
86
[211 Ja] Main Bearing Cap
86
[212 Hp] Crankshaft
88
[219 Rv] Piston Cooling Spray Nozzle
88
[212 Nc] Cylinder Sleeve
89
Special Tool Required
89
200 Bench Procedures
91
[211 Db] Cylinder Block
92
Cylinder Sleeve Counterbore
92
[212 CV] Auxiliary Driveshaft
95
Description
95
Inspection
95
[212 Lp] Connecting Rods
95
Special Tools Required
97
Inspection
97
Wrist Pin Repair
97
[212 Hp] Crankshaft
99
Description
99
Inspection
100
[212 HA] Crankshaft Dowel Pin Replacement
100
[212 HV] Crankshaft Gear
102
[212 Ub] Flywheel
103
[212 Np] Pistons
103
Description
103
Special Tools Required
104
Disassembly
104
Inspection
105
[212 Nv] Piston Rings
105
Keystone Ring Groove Check
105
Ring Installation
107
[212 Lp & Np] Connecting Rod Assembly to Piston
107
[213 Ch] Camshaft
108
Description
108
Disassembly
108
Inspection
110
Assembly
110
[213 Ev] Cylinder Heads
112
Description
112
Special Tools Required
114
[213 NB] Inlet and Exhaust Valve Removal
115
[213 EX] Cylinder Head Inspection
117
[213 EH] Fire Ring Groove
117
[213 EP] Valve Guides
120
[213 FB] Inlet and Exhaust Valve Seat Inserts
123
[213 MB] Valve Springs
128
[213 GB] Injection Nozzle Holder Insert
128
[213 FH] Valve Yoke Guide Pins
129
[213 FP] Cylinder Head Cup Plugs
131
Cylinder Head Pipe Plugs
132
[213 Nb] Inlet and Exhaust Valves
133
Inspection
133
Valve Identification
133
Inlet and Exhaust Valve Installation
135
[213 Lv] Valve Rocker Arm Shaft
137
Inspection
137
Rocker Arms
137
Valve Rocker Arm Shaft Assembly (Except Jacobs Engine Brake)
137
Valve Rocker Arm Shaft Assembly (with Jacobs Engine Brake)
139
Dynatard Engine Brake Solenoid
141
[266 Kd] Dynatard Engine Brake
141
Dynatard Overload Protection (E7 Engines with Dynatard)
141
Jacobs€ ENGINE BRAKE
143
Engine Brake Switch and Bracket Assembly
143
Description
143
Adjustment (E7 Mechanically Governed Engine with Engine Brake)
143
[215 Dw] Oil Cooler Assembly
144
Description
144
Disassembly
145
Inspection
146
Assembly
146
[215 Sw] Water Pump
147
[219 Mu] Oil Pump
147
Disassembly
147
Inspection
148
Improved "Fast Ratio" Auxiliary Driveshaft
151
Assembly
152
[221 CD] Econovance
152
Econovance Control Valve Assembly
152
Econovance Disassembly
153
Cleaning and Inspection
154
Econovance Assembly
154
[221 Ku] Injection Pump Drive Hub
154
Description
154
Special Tools Required
154
Cleaning
155
Installation of Drive Hub (Mechanically Governed Engines)
155
Installation of Drive Hub (V-MAC Engines)
156
[222 Kg] Injector Nozzles
157
Nozzle Cleaning
157
Engine Assembly
159
General
160
[211 Db] Cylinder Block
160
Special Tools Required
160
Cleaning and Inspection
160
Cup Plug Replacement
161
Pipe Plug Replacement
162
[213 CC] Camshaft Bushings
163
[212 CB] Auxiliary Driveshaft Bushing Replacement
167
[212 Nc] Cylinder Sleeve
169
Description
169
Special Tools Required
169
Installation
169
[219 Rv] Piston Cooling Spray Nozzle
172
Description
172
Special Tools Required
172
Installation
172
Piston Cooling Nozzle Spray Positioning
173
[211 Ha] Cylinder Block Dowel Pins
175
Description
175
Special Tools Required
175
Removal
175
Installation
175
[212 Hp] Crankshaft
177
Installation
177
[212 Hh] Main Bearing Cap
178
Special Tool Required
178
Installation
178
[212 Np & 212 Lp] Pistons and Connecting Rods
181
Description
181
Special Tools Required
181
Installation
182
[211 Hd] Flywheel Housing
184
Description
184
Inspection
184
Dowel Pins
184
Capscrews (Flywheel Housing)
185
Installation
187
Runout
188
[212 Jh] Crankshaft Wear Ring
189
Special Tools Required
189
Removal
189
Installation
189
Wear Ring with Double-Lip Teflon Seal (Automatic Transmission)
190
[212 Jh] Crankshaft Rear Oil Seal
191
Installation
191
Description
193
Installation
194
[213 Ch] Camshaft
195
Description
195
Special Tools Required
195
Inspection
195
Installation (Engine in Stand)
196
Installation (Engine in Chassis)
197
[212 CV] Auxiliary Driveshaft
199
Inspection
199
Installation
199
[219 Mu] Oil Pump
200
Description
200
Installation
201
[211 Rp] Timing Gear Cover
202
[211 Sb] Timing Gear Cover Seal
203
Special Tool Required
203
Installation
203
[221 Gp] Fuel Injection Pump Installation
203
[212 Rh] Crankshaft Hub
203
Inspection
203
[212 Rb] Vibration Damper
204
Description
204
Inspection
204
Installation
204
[211 Nb] Oil Pan
204
Description (Isolating Oil Pan Gasket on E7 Engines)
204
Oil Pan Installation
208
[213 Ev] Cylinder Heads
209
Description
209
Installation
210
[222 Kg] Nozzle Holder Assembly
213
Description
213
Special Tool Required
213
Installation
213
[213 Lh] Valve Lifter Push Rods
215
Inspection
215
Identification
215
Installation
216
[213 Nv] Valve Yokes
216
Description
216
[213 Lp] Rocker Arms
217
Description
217
Installation (Non-Brake and Dynatard Equipped Engines)
217
Installation (Jake Brake-Equipped Engines)
217
Brake Housing Installation
218
[213 Jb] Valve Cover
219
Description
219
Installation
219
[214 Eg] Exhaust Manifold
220
Description
220
Installation
220
[215 Nk] Coolant Manifold
222
Inspection
222
Installation
222
[261 Ck] Air Compressor
223
Installation
223
[221 CD] Econovance
224
Installation
224
[221 Gp] Fuel Injection Pump
224
[222 Kd] Fuel Nozzle Inlet Tube Assembly
228
Installation
228
[214 Sc] Turbocharger
230
Installation (Includes Pre-Lubing Procedures)
230
[215 Nu, Ng & Ld] Thermostat, Thermostat Housing, Thermostat Seal and Coolant Conditioner
231
[214 Hd] Air Inlet Manifold
233
[231 Pb] Fuel Filter Adapter Assembly
233
Installation
233
[215 Sw] Water Pump
234
Installation
234
[215 Dw & 219 Ep] Oil Cooler and Oil Filter Head
235
Assembling a New Oil Filter Adapter
235
Installation
236
[271 Cb] Alternator
238
Installation
238
Fan Belt(S)
238
Setup and Adjustments
241
[213 Nb] Valve Yoke and Valve Lash Adjustments (Non-Jake Brake Engine and Dynatard Equipped)
242
Description
242
Special Tool Required
242
Locating and Marking Flywheel Valve Adjustment Markings
242
Valve Yoke Adjustment
243
Inlet Valve Adjustment
245
Exhaust Valve Adjustment
245
Continuation of Adjustments
246
[213 Nb] Valve Yoke, Valve Lash and Slave Piston Adjustments (Jacobs Brake Engine)
246
Description
246
Housing Identification
247
Special Tools Required
248
Valve Yoke
248
Slave Piston, Inlet Valve and Exhaust Valve Lash Adjustments
249
Inlet Valve Adjustment
249
Exhaust Valve Adjustment
249
Slave Piston Adjustment
250
Continuation of Adjustments
251
[221 Gp] Injection Pump Fixed-Timing Procedures
251
Description
251
Special Tools Required
253
Setting Static Fuel Injection Pump Timing
253
Fuel Injection Pump Driven Gear Installation
255
Checking Pump-To-Engine Timing
258
Fuel Injection Pump Access Cover Installation
258
Fuel Injection Pump Pre-Lubrication
259
Timing Event Marker (TEM) Installation
260
[212 Np] Locating Piston Top Dead Center (Tdc)
261
E7 Series Engines with Front Timing Indicators
261
Special Tool Required
261
Locating Piston TDC
261
200 Engine Installation & Testing
263
Installation
264
Description
264
Removing Engine from Engine Stand
264
Engine Installation into Vehicle
264
Filter Element Installation
265
Final Preparation
266
Lubrication
266
Engine Operational Check
267
Rebuilt Engine Run-In Procedures
267
Description
267
Run-In Check
267
[233 Fa] Chassis-Mounted Charge Air Cooling
268
Description
268
Special Tool Required
268
CMCAC Troubleshooting
268
CMCAC Pressure Test
269
Restriction Pressure Test
270
Core Repair
271
CMCAC Preventive Maintenance
271
Troubleshooting
273
Camshaft Timing Check
282
Camshaft Lobe Lift Check
282
Proper Fire Ring/Cylinder Sleeve-Top Combinations
283
General Information
283
Engines Built Prior to 1993
283
Engines Built from June 1993 to Present (3L Serial Number and Later)
284
Cylinder Head and Cylinder Block Leak Test Procedure
285
200 Appendix
293
E7 Engine Serial Numbers, Jacobs Brake Application
294
E7 Lubrication System
295
E7 Cooling System
296
Index
297
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