4.  Tighten the nut on Tooling (A) until electronic unit

injector sleeve (1) is pulled free from the cylinder

head.

g01043165

Illustration 17

g01393881

Illustration 16

5.  Remove O-ring seals (2) and O-ring seal (3) from

electronic unit injector sleeve (1).

i02754766

Electronic Unit Injector Sleeve

- Install

Installation Procedure

Table 5

Required Tools

Tool

Part Number

GE50021

GE50023

GE50024

GE50022

CV60893

Part Description

Injector Sleeve Tool

Tapered Brush

Qty

1

g01393891

Illustration 18

A

1

2.  Install new O-ring seals (2) and (3) to electronic

unit injector sleeve (1).

B

C

Small Bore Brush

End Brush

1

1

3.  Install electronic unit injector sleeve (1) to Tooling

(A).

Retaining Compound

1

4.  Apply a small continuous bead of Tooling (C) to

NOTICE

surface (X) of electronic unit injector sleeve (1).

Keep all parts clean from contaminants.

5.  Lubricate O-ring seals (2) with clean engine oil.

Contaminants may cause  rapid wear and  shortened

component life.

6.  Position electronic unit injector sleeve (1) and

Tooling (A) in the cylinder head. Use care not to

damage O-ring seals (2) and (3).

1.  Use Tooling (B) to clean the bore in the cylinder

head for the electronic unit injector sleeve.

7.  Use Tooling (A) and a soft faced hammer to install

electronic unit injector sleeve (1) to the cylinder

head.

NOTICE

Ensure that the electronic unit injector sleeve and the

cylinder head bore are completely free of oil, dirt, and

sealant debris.

Note: Ensure that the electronic unit injector sleeve

is properly seated in the cylinder head.

This document has been printed from SPI². Not for Resale

KENR6906

13

Disassembly and  Assembly Section

8.  Install the electronic unit injectors.  Refer to

Disassembly and Assembly, “Electronic  Unit

Injector - Install”.

Installation Procedure

9.  Fill the cooling system with coolant.  Refer to

Operation and Maintenance, “Cooling System

Coolant - Change”.

i02754770

Air Cleaner -  Remove and

Install

g01380888

Removal Procedure

Illustration 20

Typical example

NOTICE

Keep all parts clean from contaminants.

1.  If necessary, position mounting bracket (4) on the

cylinder head and install the bolts  that secure

the mounting bracket. Tighten theM12 bolts to a

torque of 100 N·m (74 lb ft). Tighten the 3/8" bolts

to a torque of 47 N·m (35 lb ft).

Contaminants may cause  rapid wear and  shortened

component life.

2.  Position air cleaner (3) on mounting bracket (4).

Ensure the correct orientation of the air cleaner.

3.   Install fasteners (1). Tighten the fasteners to a

torque of 55 N·m (41 lb ft).

4.  Connect hose (2) and tighten the hose clamp

securely.

i02754771

Turbocharger - Remove

g01380888

Illustration 19

Typical example

Removal Procedure

1.  Loosen the hose clamp and disconnect hose (2).

Start By:

2.  Remove fasteners (1) and remove air cleaner (3)

from mounting bracket (4). Note the orientation

of the air cleaner.

a.  Remove the exhaust elbow. Refer to Disassembly

and Assembly, “Exhaust Elbow - Remove and

Install”.

3.  If necessary, remove the  bolts that secure

mounting bracket (4) and remove the mounting

bracket.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

This document has been printed from SPI². Not for Resale

14

KENR6906

Disassembly and  Assembly Section

c.  Remove tube assembly (2) and joint (3) from

turbocharger (4).

NOTICE

Keep all parts clean from contaminants.

3.  Follow Steps 3 through 3.c in order to remove the

tube assembly for the oil drain to the turbocharger.

Contaminants may cause  rapid wear and  shortened

component life.

a.  Remove bolts (6) and (7).

b. Remove tube assembly  (8).

c.  Remove joints (5) and (9).

1.  Disconnect the air hoses from the turbocharger

inlet and from the turbocharger outlet.

4.  Attach a suitable lifting device to turbocharger (4).

The weight of the turbocharger is approximately

32 kg (71 lb).

g01382805

Illustration 22

Typical example

5.  Remove nuts (10). Use the lifting device to remove

turbocharger (4) from the exhaust manifold.

6.  Remove gasket (11).

i02754772

Turbocharger - Install

g01380889

Illustration 21

Installation Procedure

Typical example

Table 6

2.  Follow Steps 2.a through 2.c in order to remove the

Required Tools

Part

tube assembly for the oil feed to the turbocharger.

a.  Disconnect tube assembly (2) from the engine

oil filter base.

Tool

Number

Part Description

Qty

A

CV60889

Anti-Seize Compound

1

b. Remove  bolts (1).

This document has been printed from SPI². Not for Resale

KENR6906

15

Disassembly and  Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

1.  Ensure that all mating surfaces are clean and free

from damage.

g01382805

Illustration 23

Typical example

2.  Position a new gasket  (11) on the exhaust

manifold.

3.  Attach a suitable lifting device to turbocharger

(4). The weight of turbocharger is approximately

32 kg (71 lb). Use the lifting device to install the

turbocharger to the exhaust manifold.

g01413397

Illustration 24

4.  Apply Tooling (A) to the threads of the exhaust

Typical example

manifold studs.

6.  Follow Steps 6.a through 6.c in order to install the

tube assembly for the oil drain to the turbocharger.

5.  Install nuts (10). Tighten the nuts to a torque of

55 N·m (41 lb ft).

a.  Place a new joint (9) and tube assembly (8) in

position and install bolts (7) finger tight.

If a new turbocharger is  installed, loosen the

V-band clamps and rotate the bearing housing and

the compressor housing to the correct positions.

b. Position a new joint (5) between turbocharger

(4) and tube assembly (8).  Install bolts (6)

finger tight.

c.  Tighten bolts (6) and (7) to a torque of 28 N·m

(21 lb ft).

7.  Lubricate the bearings of turbocharger (4) with

clean engine oil through oil inlet port (X). Rotate

the shaft of the turbocharger in order to distribute

the lubricant.

This document has been printed from SPI². Not for Resale