The supply manifold information is also covered in Section 1.4.
Supply Manifold End Plug Removal
Follow these steps to remove and install the supply manifold end plug.
Note:
The supply manifold oil rail must be drained prior to removing the fuel injectors, to prevent leakage into the cylinder bore.
Drain the supply manifold from the end plug of the supply manifold. See Figure
31584
.
Removing Supply Manifold End Plug
Install a new O-ring and backup ring onto the end plug. See Figure
31586
.
1. O-ring
3. End Plug
2. Backup Ring
End Plug, O-ring and Backup Ring Locations
Note:
Clean off any old Loctite from the end plug prior to installation.
Apply Loctite #277 to the threads of the end plug, and install into the supply manifold. Torque plug to specifications. See Figure
31585
.
Installing Supply Manifold End Plug
Supply Manifold Removal
Disconnect the fuel supply line from the fuel filter header to the supply manifold as follows:
For engines equipped with the top-mounted primer pump and the engine-mounted ECM unit, follow these steps.
Loosen fitting and remove the fuel filter header to supply pump line.
Cap the fuel filter header and supply pump openings.
If equipped with an engine mounted ECM unit, Loosen the nuts and disconnect the high pressure oil supply hose from the supply manifold and the high pressure pump. See Figure
31583
.
1. Oil Supply Line Mounting Nuts
3. Oil Supply Line
2. High Oil Pressure Pump
Removing Oil Supply Hose
Cap the high pressure pump fittings and supply manifold fittings.
Remove the ICP sensor by first disconnecting the wiring harness, if not already disconnected. See Figure
31268
. Remove the ICP sensor and O-ring from the supply manifold. See Figure
31290
.
Disconnecting Main Wiring Harness
Removing ICP Sensor
Remove the banjo fitting at the fuel return valve, located at the rear of the supply manifold. See Figure
33487
.
Removing Banjo Fitting
Remove the fuel return valve from the supply manifold. See Figure
33488
.
Removing Fuel Return Valve
NOTICE:
When the supply manifold is removed, do not place it face down on any surface. The manifold face could be scratched, thus preventing a good mating surface seal. Always place supply manifold face up.
If not already removed, remove the supply manifold end plug. Refer to section
.
Remove twelve mounting bolts securing the supply manifold to the cylinder head. Remove the supply manifold and gasket. See Figure
33493
.
Removing Supply Manifold
Cleaning
Perform the following steps to clean the supply manifold:
Insert a stiff nylon brush into the oil and fuel galleries of the supply manifold for cleaning.
To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.
Use compressed air to clean out debris from the oil gallery.
Inspection
Perform the following steps to check for warpage:
Using a straight edge and feeler gage, check the supply manifold gasket surface for warpage, utilizing the checking pattern shown. See Figure
31917
.
Warpage Check
High Pressure Pump Removal
It is not necessary to remove the injection pressure relief valve from the high pressure pump prior to removal of the pump. However, the solenoid, sleeve and tinnermann nut can be removed for easy access to the high pressure pump mounting bolts.
For engines with Serial No. 988151 and up, disconnect the wiring harness from the IPR valve.
Remove the tinnermann nut securing the solenoid to the IPR valve. Remove sleeve and solenoid.
Unscrew the IPR valve from the high pressure pump, using a 28 mm (11/8 in.) deep wall socket.
Note:
Before performing the next procedures, ensure the high pressure pump reservoir has been drained of oil. Drain the reservoir by removing the engine oil temperature sensor from the rear half of the front cover. Extract oil by inserting the tube from the hand operated vacuum pump tool,J 39257
, into the cover.
Note:
If the IPR valve has not been removed, ensure the IPR valve solenoid has been disconnected from the main wiring harness.
Note:
Ensure the lube oil supply hose has been disconnected. Refer to
.
Remove two capscrews securing the high pressure lube pump to the front cover. Remove the pump and gasket from the front cover. See Figure
33485
.
1. Capscrews
2. High Pressure Oil Pump
High Pressure Oil Pump Removal
High Pressure Pump Installation
Follow these steps to install the high pressure lube oil pump.
Install a new face seal into the groove of the front cover and place the high pressure pump into its location.
Install two capscrews and secure the high pressure pump to the front cover. Torque the mounting bolts to specifications. Refer to section
. See Figure
33485
.
1. Capscrews
2. High Pressure Oil Pump
High Pressure Oil Pump Installation
If removed, install the IPR valve into the high pressure pump. Torque the valve to specifications. Refer to section
. See Figure
33491
.
IPR Valve Installation
Install the IPR valve sleeve and solenoid to the IPR valve.
Supply Manifold Installation
Follow this procedure to install the supply manifold.
Note:
Install the supply manifold gasket with the tab stamped FRONT, located on the lower left hand side of the gasket, facing the manifold assembly.
Place a new supply manifold gasket onto the supply manifold. The gasket should have the tab located in the lower front corner for correct placement. See Figure
33492
.
1. Supply Manifold
2. Supply Manifold Gasket
Supply Manifold and Gasket Installation to the Cylinder Head
Install the fuel supply line and connect it from the fuel filter header to the front of the supply manifold. Torque the fitting to specifications. Refer to section
. See Figure
33494
.
1. Fuel Supply Line
Install Fuel Supply Line
Apply Loctite #277 to the threads of the ICP sensor.
Install the ICP sensor with a new O-ring into the center of the supply manifold elbow, located at the front of the supply manifold. Torque to specifications. Refer to section
. See Figure
31290
.
Installation of ICP Sensor
Install the lube oil supply hose to the high pressure pump and supply manifold. Torque the nuts securing the hose to specifications. Refer to section
. See Figure
31583
.