Content

Safety information

• Advisory labels
• Service procedures and tool usage

Explanation of numerical code

Explanation of 3-digit numerical code

About this manual

General information

• Introduction
• Engine model identification
• Lubricants and sealants
• Overhaul part replacement

Specifications

• Specifications
• Fastener torque
• Torque specifications
• Fits and limits
• Metric mismatch
• Conversion factors
• Special tools

Engine removal

• General

Engine disassembly

• General
• Centri-max and spin-on filter elements
• Mounting engine in stand
• Alternator
• Fan assembly
• Fuel filter adapter assembly
• Coolant conditioner element
• Thermostat
• Air inlet manifold
• Coolant manifold
• Oil cooler and oil filter housing assembly
• Water pump
• Turbocharger
• Fuel nozzle inlet tube assembly
• Exhaust manifold
• Valve cover and riser
• Rocker arm, valve yoke and push rod
• Nozzle holder
• Cylinder head assembly removal
• Vibration damper and crankshaft hub
• Air compressor
• Injection pump
• Econovance
• Oil pan
• Oil pump
• Timing gear cover
• Auxiliary driveshaft
• Camshaft
• Piston and connecting rod assembly
• Flywheel
• Flywheel housing
• Main bearing cap
• Crankshaft
• Piston cooling spray nozzle
• Cylinder sleeve

Bench procedures

• Cylinder block
• Auxiliary driveshaft
• Connecting rods
• Crankshaft
• Flywheel
• Pistons
• Piston rings
• Connecting rod assembly to piston
• Camshaft
• Cylinder heads
• Inlet and exhaust valves
• Valve rocker arm shaft
• Dynatard engine brake
• Jacobs engine brake
• Engine brake switch and bracket assembly
• Oil cooler assembly
• Water pump
• Oil pump Econovance
• Injection pump drive hub
• Injector nozzles

Engine assembly

• General
• Cylinder block
• Cylinder sleeve
• Piston cooling spray nozzle
• Cylinder block dowel pins
• Crankshaft
• Main bearing cap
• Pistons and connecting rods
• Flywheel housing
• Crankshaft wear ring
• Crankshaft rear oil seal
• Flywheel (E7 engine without pointer on timing cover)
• Camshaft
• Auxiliary driveshaft
• Oil pump
• Timing gear cover
• Timing gear cover seal
• Fuel injection pump installation
• Crankshaft hub
• Vibration damper
• Oil pan
• Cylinder heads
• Nozzle holder assembly
• Valve lifter push rods
• Valve yokes
• Rocker arms
• Valve cover
• Exhaust manifold
• Coolant manifold
• Air compressor
• Econovance
• Fuel injection pump
• Fuel nozzle inlet tube assembly
• Turbocharger
• Thermostat, thermostat housing, thermostat seal and coolant conditioner
• Air inlet manifold
• Fuel filter adapter assembly
• Water pump
• Oil cooler and oil filter head
• Alternator

Setup and adjustments

• Valve yoke and valve lash adjustments (non-jake brake engine and dynatard equipped)
• Valve yoke, valve lash and slave piston adjustments (jacobs brake engine)
• Injection pump fixed-timing procedure
• Locating piston top dead center (TDC)

Engine installation and testing

• Installation
• Final preparation
• Rebuilt engine run-in procedures
• Chassis-mounted charge air cooling

Troubleshooting

• Camshaft timing check
• Camshaft lobe lift check
• Proper fire ring/cylinder sleeve-top combinations

Appendix

• E7 engine serial numbers, jacobs brake application
• E7 lubrication system
• E7 cooling system

Index