REPAIR INSTRUCTIONS

11.Remove the air inlet tube by slightly rotating the turbocharger compressor to allow release of the tube, connecting hoses and spring clamps. 101

13.Remove the turbocharger assembly and recover the steel plate gasket between the turbocharger and the exhaust manifold. 103

Fuel Nozzle Inlet Tube Assembly

12.While

Removal

1.Loosen six tube sleeve nuts at the injection pump. Be careful to avoid twisting lines while loosening nuts.

2.Loosen the rear inlet tube bracket by removing the two exhaust manifold bolts.

Exhaust manifold attaching bolt lengths vary depending on bolt location. The bolts retaining fuel inlet tube bracket are both 6.50 inches (165 mm).

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Repair Instructions

3.Loosen tube sleeve nuts and tube clamping bracket screws at the cylinder heads.

104

5.Loosen the clamp and remove the exhaust manifold coolant inlet hose. Then remove the exhaust manifold coolant inlet and vent fittings. Removal of these fittings is necessary to allow access for the front fuel inlet lines to pass by the end of the exhaust manifold.

106

1. Front 1, 2 and 3 Fuel Nozzle Inlet Tube Bracket to Block Capscrew

2. Rear 4, 5 and 6 Fuel Nozzle Inlet Tube Brackets to Manifold Bolts

105

3. Tube Sleeve Nuts at Cylinder Heads

4.Remove rear 4, 5 and 6 tube assemblies with clamp bracket.

1. Vent Line Fitting

3. Exhaust Manifold Coolant Inlet Hose

6.Loosen the clamp and remove the remaining end of the exhaust manifold coolant inlet hose at the water pump tube.

107

7.Separate the fuel nozzle inlet tube clamp bracket for the lines 1, 2 and 3 by removing the clamp bolts. Remove the lower fuel nozzle inlet tube clamp bracket by removing the injection pump nut. Remove the front 1, 2 and 3 fuel inlet tube sleeve nuts at the injection pump, if not previously done.

108

1. Fuel Nozzle Inlet Tube Lower Clamp Bracket Bolts

2. Fuel Nozzle Inlet Tube Lower Clamp Bracket

9.If necessary, separate fuel inlet tubes (4) from bracket assembly. Remove nuts (6) from capscrews (1) and remove clamp plate (2), insulators (3) and bracket (5).

110

3. Lower Clamp Bracket to Injection Pump Nut

4. Front 1, 2 and 3 Fuel Nozzle Inlet Tubes

8.With the fuel nozzle inlet tube top clamp bracket attached, remove fuel inlet tubes 1, 2 and 3 as an assembly.

109

Repair Instructions

10.Cap all lines and top of delivery valves of injection pump to prevent contaminants from entering the system. 111

Injection Pump Throttle Return to Idle Mechanism

1.Remove the injection pump throttle return to idle back-up spring using hand pressure. Then remove the throttle return spring and throttle return back-up cable from the throttle return pivot lever bracket. 112

2.Remove the capscrews retaining the throttle return back-up spring bracket and remove the bracket. Then remove the capscrews retaining the throttle return back-up pivot lever bracket to the cylinder block and remove the bracket. 113

Engine Oil Fill Tube Removal

1.Remove the two capscrews securing the oil fill tube to the cylinder block and remove the tube. 114

2.Scrape any remaining gasket material from the tube and block.