Archive for the ‘Engine’ Category
Series 40E Supply Manifold
Drain the supply manifold oil rail before removing the fuel injectors to prevent leakage into the cylinder bore.
|
| The supply manifold oil rail must be drained prior to removing the fuel injectors to prevent leakage into the cylinder bore. |
Drain Supply Manifold
Drain the supply manifold as follows:
- Remove the supply manifold end plug from the supply manifold.
- Install a new O-ring and backup ring onto the end plug and install into the supply manifold. Torque plug.
Removal of Supply Manifold
Disconnect the supply manifold as follows:
- Loosen the nuts and disconnect the high pressure oil supply hose from the Injection Control Pressure (ICP) Sensor elbow and the high pressure pump.
- Disconnect the fuel supply line from the fuel filter header to the supply manifold.
- If it is necessary to remove the supply manifold, disconnect the fuel return line and remove the 12 mounting bolts securing the supply manifold to the cylinder head.
- Remove the supply manifold and gasket. Discard the gasket.
Sensor Removal
Disconnect the sensor as follows:
- Remove ICP sensor and O-ring from the front elbow of the supply manifold.
- Discard O-ring and replace.
Series 40E Valve Cover Intake Manifold
Use the following procedure to remove the valve cover/intake manifold.
- Disconnect the main wiring harness connector from the valve cover/intake manifold.
- Remove 13 valve cover/intake manifold capscrews.
- Lift the valve cover/intake manifold; bend back the tabs located in the wiring channel harness.
- Disconnect the six fuel injector solenoids from the wiring harness by spreading the tabs and pushing down. Or, release the retaining tabs of the wiring harness connector and push the connector body toward the inside of the valve cover/intake manifold. Remove the valve cover/intake manifold, leaving the wiring harness connected to the fuel injectors.
5. Remove valve cover/intake manifold and gasket from cylinder head. See Figure 31073 and see Figure 31074 .
Road Draft Tube
Use the following procedure to remove the road draft tube.
- Remove two bolts securing the road draft tube to the crankcase.
- Pull road draft tube out from the valve cover/intake manifold and away from the crankcase.
Series 40E CYLINDER HEAD
Prior to the removal of the cylinder head, refer to the appropriate sections of the service manual and remove the following items.
- Turbocharger,
- Turbocharger oil supply tube,
- Turbocharger oil drain tube,
- Road draft tube,
- Exhaust manifold,
- ECM and mounting bracket, if equipped,
- Main wiring harness,
- Valve cover/Intake manifold,
- Fuel supply line to supply manifold from filter header,
| 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 w/Valves | 21. Valve Guide |
| 7. Oil and Fuel Supply Manifold Gasket | 22. Intake Valve Seat Insert |
| 8. High Pressure Oil/Fuel Supply Manifold | 23. Intake Valve |
| 9. Manifold End & Oil Supply Plug O-ring | 24. Exhaust Valve Spring |
| 10. Plug Backup Ring | 25. Exhaust Valve Insert |
| 11. Supply Manifold End Plug | 26. Exhaust Valve |
| 12. Flange Bolt 40 mm (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 Mount ICP) | 29. Pipe Plug 1/8 in. NPT |
| 15. Cup Plug 1-1/4 in. (32 mm) | 30. Supply Manifold Plug (Mid Mount ICP) |
Exploded View Cylinder Head and Related Parts
Repair or Replacement of Cylinder Head
To determine if repair is possible or replacement is necessary, perform the following procedure
