Labot t Guide 2000 Usa

TABLE OF CONTENTS

Section Page

FOREWORD ............................................................................................... 3

SAFETY ...................................................................................................... 3

DEFINITION OF A WARRANTY ................................................................ 3

ELEMENTS OF TIME MANUAL ................................................................ 3

DESCRIPTION OF OPERATIONS ............................................................. 4

DIAGNOSIS OF TESTS ............................................................................. 5

REAPPRAISAL REQUESTS ..................................................................... 5

REVIEW PROCEDURE .............................................................................. 5

SERVICE LEVELS ..................................................................................... 6

SERIES 2000 LABOR OPERATION INDEX (ALPHABETICAL) ............... 7

SERIES 2000 OPERATION NUMBERS ..................................................... 10

SERIES 2000 LABOR TIME GUIDE

(Rev. 3/04) All information subject to change without notice.2 12SE2000 0403 Copyright © 2004 DETROIT DIESEL CORPORATION


FOREWORD

The labor times in this Manual represent the time required to perform a repair, replacement,and/or adjustment operation on DDCÆ/MTUÆ Series 2000Æ Engines not affected by collisiondamage. The labor times are representative of an average technician in a typical distributorship ordealership using normally available tools, service equipment, and all essential Special ServiceTools to diagnose and perform the repair. The use of genuine DDC/MTU parts and repairprocedures prescribed in the DDC/MTU Series 2000 Service Manual is the basis for this Manual.

SAFETY

Detroit DieselÆ Corporation (DDC) assumes that all required approved Safety Lock-out tags,locks, and other appropriate safety devices will be utilized by the technician prior to the start ofany repairs of a Series 2000 engine. Also, this manual assumes use of all appropriate protectivesafety equipment and clothing.

DEFINITION OF A WARRANTY

A warranty repair restores to operating condition, by repair or replacement, only the defective ordamaged parts necessary to remove and replace the defective parts, according to the terms of theappropriate warranty statement. Other parts removed in the repair process will be reinstalledas-is, unless the user authorizes the additional expense. The intent of a warranty repair is torepair or replace the warranted parts and restore the rest of the component to its operatingcondition prior to the warrantable failure, not to restore the product to like new condition

Procedure for Development of Labor Time Manual

The time to complete a repair, replacement, and/or adjustment operation, as provided in thisManual, is developed by Detroit Diesel Corporation personnel under conditions comparable toa typical distributorship or dealership. Development of most guides are generally based onthe following:

Product: Production Series 2000 engine.

Tools: Use of normally available tools, service equipment, and all essential Special ServiceTools indicated in the Series 2000 Service Manual. Special Service Tools required to perform anoperation will be called out under Notes section of that operation.

Technicians: The manual assumes use of competent engine technicians (not specialists in anyparticular operating system), who have attended company training programs and are accustomedto following Service Manual procedures.

ELEMENTS OF TIME MANUAL

Each operation includes time to perform all elements of a complete repair operation in the Series2000 Service Manual. Elements that comprise the time manual include the following:

All information subject to change without notice. (Rev. 3/04)12SE2000 0403 Copyright © 2004 DETROIT DIESEL CORPORATION 3


Repair Time: The actual time to perform the repair is obtained by timing a technician in theactual performance of the repair. It includes tasks such as removal, disassembly, cleaning,inspection, reassembly, installation, and/or adjustment of the affected component or assembly.The cleaning time in each operating is limited to that directly associated with the installation orreplacement of components, such as mating surfaces and/or internal parts involved in the repair.It does not include cleaning other areas of the engine which may have been contaminated bythe failure of the component being replaced.

This time also includes time to perform other associated elements, such as open/close vehiclehood, raise/lower engine on hoist, procure special tools, and/or mount on overhaul stand.

Personal Allowance: An allowance is added to the above repair time to provide for the personalneed of the technician during a repair operation.

Contingency Allowance: An additional allowance is provided, based on the total of the abovetimes, to allow for variation in engine age and condition, seized components, and broken orseized bolts, studs, etc. Normal diagnosis requiring only limited time and no special equipmentis also covered by this allowance.

A dash (-) in the Service Level column for a labor operation indicates that no time study data isavailable and actual time used during repair to perform this operation should be used.

DESCRIPTION OF OPERATIONS

The following topics support types of operations.

Types of Operations

Basic Operation: An operation which is complete in itself and includes all of the steps neededto perform the operations as described in the Series 2000 Service Manual. The time for thisoperation includes Repair Time, Personal Allowance, and Contingency Allowance.

Combination Operation: An operation which describes additional work which may beperformed in combination with a basic operation, usually when a major assembly or componenthas been removed from the engine. The time for a combination operation is in addition to the timespecified for the basic operation, or for any applicable basic operation.

Overlapping Operations: Overlapping labor is the duplicate labor time allowance that mayoccur if more than one basic operation is claimed for performing a repair, and the same repairsteps are included in each of the basic operations. Such overlapping labor is not reimbursable.

To avoid claiming basic operations with overlapping time allowances, use an applicablecombination operation for any added repair steps that are required, in addition to the basicoperation being performed. If you experience an unusual repair situation, where an applicablecombination operation is not available, then you should claim the actual time required to performthe added repair steps and provide an explanation of the situation in the ì Narrativeî section of theApplication for Adjustment (AFA).

General Operation: Is only to be used when there is no operation listed, and must be completelyexplained in the "Narrative" section of the AFA.



DIAGNOSIS OF TESTS

Normal Diagnosis: This is the diagnosis time required to determine the cause of a routine serviceproblem. Normal diagnosis includes defining those symptoms which are readily apparent tothe senses. Normal diagnosis also includes the use of common testers by technicians, such asammeters, compression testers, and integrated computer analysis.

Abnormal Diagnosis: This is the diagnosis time required to determine the cause of an exceptionalservice problem that normal diagnosis fails to identify. Abnormal diagnosis time is reimbursableonly when reasonable and fully explained on the Adjustment for Application (AFA).

Road or Dynamometer Test: A supplemental allowance for performance of a post-repair testmay be included on the AFA, if such a test is deemed to be required to verify correction of aproblem.

REAPPRAISAL REQUESTS

Applicable labor times are subject to periodic review. However, a change in operation times isnever made arbitrarily. Each change is a response to at least one of the following events orconditions:

Component design changeDesign change in other components that affect accessibility of the component beingrepairedChange in the procedure or method of repairChange in the tools or equipment used in the repair processFinal review and verification of times or review of reappraisal requests from distributorsand dealers

REVIEW PROCEDURE

The following actions are needed to assure accurate appraisal.

Service Outlet Action

The following actions are required by the distributor or dealer:

1. Verify that the technician has followed the procedures outlined in the applicable ServiceManual and used all specified special tools and equipment.

2. Complete a Suggested Labor Time Manual Operation Change form (18SE10), availablethrough normal literature distribution channels.

3. Use one form for each time operation in question (or a combination of operationsrepresenting one repair job).



4. Provide video, with time and date displayed on screen, of total operation in question.Submit form and video to:

Detroit Diesel Corporation13400 Outer Drive, WestDetroit, Michigan 48239-4001Attn: Warranty Manager

5. Identify the technician involved to facilitate review of the process.

6. Provide any additional comments, including time requirements for individual steps, whichmay help in identifying the problem area.

DDC Action

When the video and reappraisal request is received, DDC will take the following actions:

1. Review the labor time operation in question. Recommendations and assistance will beoffered in accordance with the results of this review.

2. DDC may conduct review at the service outlet, if necessary. Comparative reviewsat additional service outlets may also be conducted, if they are required to providevalid results.

3. Provide results of the review to the service outlet, and to the appointing distributor, ifsuch service outlet is a dealer.

SERVICE LEVELS

The Series 2000 engines are used by the following Original Equipment Manufacturers (OEMs).When preparing your Adjustment for Application (AFA), identify the appropriate model, andnote the proper service level. Make sure the proper service level is used while consulting theLabor Time Manual. Listed in Table 1are the service levels.

OEM Model DescriptionServiceLevel

Engine Removed All All ENG REM

Construction & Industrial All All Construction & Industrial C & I

Generator All All Generator GEN

Marine All All Marine MAR

If your OEM is not listed, record that on your AFA.

Table 1 Service Levels



SERIES 2000 LABOR OPERATION INDEX (ALPHABETICAL)

Listed in Table 2 is the labor operation index (alphabetical).

DESCRIPTION OPERATION NOS.

Air Compressor - R & RAir Compressor Hose - R & RAir Compressor Drive - R & R

12.40-00-03-05

Air Filter and Housing - R & RAir Filter Element - R & R (Each)Air Inlet Manifold - R & R (Complete)Air Shutdown Mechanism - R & RCharge Air Cooler Coolant Piping - R & R (Each Section)Charge Air Piping to Turbocharger - R & RCharge Air Cooler Assembly - R & RCharge Air Cooler Cover - R & RCharge Air Cooler Base - R & R

03.10-00-01-02-03-05-06-07-08-09

Alternator/Generator - R & R 07.10-00

Belt Set - R & R 01.37-00

Camshaft - R & RCam Followers - R & R (All)

01.70-00-06

Crankshaft (Engine Removed) - R & RCrankshaft Front Drive Hub - R & RCrankshaft Rear Drive Hub - R & R

01.30-00-01-02

Crankshaft Oil Seal (Front) - R & R 01.32-00

Crankshaft Oil Seal (Rear) - R & R 01.33-00

Crankshaft Pulley - R & R 01.38-00

Crankshaft Thrust Washers - R & R 01.31-00

Cylinder Block- R & RCylinder Block - R & R (From Short Block)Engine Stand - R & RSteam Clean and Paint EngineCylinder Block - Pressure Test (Engine Removed)

01.10-00-01-02-05-11

Cylinder Head - R & R (One)Cylinder Head - R & R (All)Valve Springs (Head Removed) - R & R (One Head)Valve Seal - R & R (One Head)Cylinder Head - Pressure Test (One)

01.20-00-01-03-04-06

Cylinder Kit - R & R (One)Cylinder Kit - R & R (Each Additional)Piston Cooling Jet - R & R (One)

01.60-00-01-02

Electronic Control Module (MDEC/DDEC) - R & RReprogram ECM or MDEC (Per Module)

02.19-00-01

Electronic Unit Pump - R & R (One)Electronic Unit Pump - R & R (Each Additional)

02.11-00-01




Engine Assembly - R & R (without OEM Module) from ChassisEngine Assembly - R & R (with OEM Module) from ChassisEngine Assembly - R & R from OEM ModuleCoolant or Lube Oil - Drain & Refill

00.00-01-23-24-25

Engine Dynamometer Test 13.20-00

Engine Lifter Bracket - R & R 01.22-00

Engine Mount (Front Trunnion) - R & R 11.10-00

Engine Performance TestEngine Performance Test (Load Box Method)Test Run (Check for Leaks)

13.22-00-05-10

Engine Tune-UpValve Lash (Intake Exhaust) - Adjustment

14.00-00-01

Exhaust Manifold - R & R (Each)Exhaust Manifold - R & R (All)

06.10-00-01

Flywheel - R & R 01.40-00

Flywheel Housing - R & RGear Case (Complete) - R & R

01.50-00-01

Fuel Manifold (Rail) - R & RFuel Delivery Rail/Pressure Regulator - R & R

02.40-00-01

Fuel Filter Elements (Primary) - R & R (Set of 2) 02.30-01

Fuel Filter Assembly (Secondary) - R & R 02.33-00

Fuel Lines (Nozzle Holder) - R & R (One)Fuel Lines (Nozzle Holder) - R & R (Each Additional)Fuel Return Line Assembly - R & R

02.50-00-08-10

Fuel Pump and/or Coupling - R & R 02.20-00

Fuel System - Prime (Complete System) 02.70-00

Gear Case Cover - R & RIdler Gears - R & R (Both)

01.34-00-03

Hydraulic Pump (Power Steering) - R & R 12.50-00

Injector Nozzle Assembly - R & R (Each)Each Additional Injector Nozzle AssemblyHigh Pressure Fuel Tube - R & R (Each)Fuel System - Pressure TestCompression Test (Each Cylinder)Injector Harness (EUP) - R & R

02.10-00-01-02-03-04-05

Main Bearings - R & R (All)Main Bearing - R & R (Each Set)Rod Bearings - R & R (All)Rod Bearing - R & R (Each Set)

01.35-00-01-02-03

Oil Cooler Elements - R & ROil Cooler Housing - R & ROil Cooler Housing Cover - R & R

04.41-00-01-05




Oil Filter Elements - R & ROil Filter Housing - R & R

04.20-00-01

Oil Pan & Gasket - R & RDipstick Tube & Adapter - R & R

04.70-00-01

Oil Pump - R & ROil Pressure Relief Valve - R & ROil Pick Up Tube and Bracket - R & ROil Transfer Tube - R & R

04.10-00-01-05-06

Radiator Assembly - R & RFan - R & RFan Hub Assembly - R & RBelt Tensioner and Bracket - R & RCooling System - Pressure CheckFan Hub Mounting Bracket - R & R

05.30-00-01-02-04-05-08

Repair Validation 13.21-00

Rocker Cover - R & R (Each)Breather - R & RBreather Tube - R & R

01.85-00-01-02

Starter Motor and Drive Assembly - R & RStarter Solenoid (Starter Removed) - R & R

07.30-00-01

Synchronous Reference Sensor or Timing Reference Sensor - R & RDDEC Sensor Harness - R & RTemperature or Pressure Sensor - R & R (Each)

02.18-00-01-05

Thermostat - R & RThermostat Housing Seal (Engine) - R & R (Each)Thermostat Housing - R & RWater/Oil Distribution Manifold - R & R

05.20-00-01-02-04

Turbocharger - R & R (One)Turbocharger Wastegate - R & R (One)Turbocharger - R & R (Each Additional)

03.50-00-02-08

Turbocharger Oil Drain - R & R (One)Turbocharger Oil Drain - R & R (All)

03.52-00-01

Turbocharger Oil Supply Line - R & R (One)Turbocharger Oil Supply Line - R & R (All)

03.51-00-02

Valve Mechanism - R & R (One Cylinder) 01.80-00

Valve Springs and/or Seals (Head Installed) - R & RPush Rod - R & R (Each)

01.83-00-02

Vibration Damper - R & R (All) 01.36-00

Water Pump (Fresh Water or Engine Coolant) - R & RCooling System - FlushCooling System - Reverse Flush (When Needed)

05.10-00-02-03

Water Pump (Raw Water or Separate Circuit) - R & R 05.60-00

Table 2 Series 2000 Labor Operation Index



SERIES 2000 OPERATION NUMBERS

Listed in Table 3 are the engine assembly operation numbers.

SERVICE LEVELSOPER.NOS.

ENGINE ASSEMBLYNO.OF

CYLENGREM

C&I GEN MAR

00.00-01 Engine Assembly - R & R (without OEM Module) from ChassisINCLUDED:

Disconnect all battery power, both positive and ground

from vehicle.

R & R all hydraulic hose connections, electrical harness

connections, exhaust connections and air intake piping.

R & R all radiator grills, deck plates, ladders and any

other OEM equipment necessary to remove the engine

assembly from the truck.

Run engine and make all final inspections and checks.

Coolant and lube oil draining, filling, and disposal (as

needed).NOT INCLUDED:

13.22-00 Engine Performance Test

R & R radiator, fan, and guard.NOTES:

Requires special lifting equipment to perform this

operation.

081216

---

20.030.040.0

20.030.040.0

30.040.050.0

00.00-23 Engine Assembly - R & R (with OEM Module) from ChassisINCLUDED:

Refer to Group 00.00-01 for details.NOTES:


operation.

081216

---

---

---

---

00.00-24 Engine Assembly - R & R from OEM ModuleINCLUDED:

Refer to Group 00.00-01 for details.

R & R any other OEM equipment necessary to remove

the engine assembly from module.

R & R engine mounts from module.NOT INCLUDED:

R & R radiator, fan, and guard.NOTES:


operation.

081216

---

---

---

---




ENGINE ASSEMBLYNO.OF

CYLENGREM

C&I GEN MAR

00.00-25 Coolant or Lube Oil - Drain & RefillINCLUDED:

Disposal of removed coolant and lube oil.NOT INCLUDED:

R & R of any filters.

081216

---

0.50.50.5

0.50.50.5

1.01.01.0

00.09-00 General OperationNOTES:

Use this operation for work performed in this group

which is not covered by an operation number.

081216

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Table 3 Engine Assembly Operation Numbers

Listed in Table 4 are the basic engine operation numbers.


BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.10-00 Cylinder Block- R & RINCLUDED:

Drain fuel from fuel rail.

Disassemble, clean and measure ring grooves, replace

piston rings.

Clean, as required, cylinder head, cylinder block top

surface, and rocker cover.

Mount engine on overhaul stand.

Remove all subassemblies.

Completely disassemble engine.

Clean reusable parts and subassemblies.

Measure journals of crankshaft and camshaft.

Measure cylinder block and cylinder liners for correct

liner-to-block fit and liner height.

01.10-02 Engine Stand - R & R

01.20-01 Cylinder Head - R & R (All)

01.30-00 Crankshaft (Engine Removed) - R & R

01.30-01 Crankshaft Front Drive Hub - R & R

01.30-02 Crankshaft Rear Drive Hub - R & R

01.31-00 Crankshaft Thrust Washers - R & R

01.32-00 Crankshaft Oil Seal (Front) - R & R

081216

30.035.040.0

---

---

---




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.10-00 Cylinder Block- R & R (Continued)

01.33-00 Crankshaft Oil Seal (Rear) - R & R

01.34-00 Gear Case Cover - R & R

01.34-02 Gear Case Cover (Lower Front) - R & R

01.35-00 Main Bearings - R & R (All)

01.35-02 Rod Bearings - R & R (All)

01.36-00 Vibration Damper - R & R

01.38-00 Crankshaft Pulley - R & R

01.40-00 Flywheel - R & R

01.50-00 Flywheel Housing - R & R

01.60-01 Cylinder Kit - R & R (Each Additional)

01.60-02 Piston Cooling Jet - R & R (First One)

01.70-00 Camshaft - R & R

01.70-06 Cam Followers - R & R

01.80-00 Valve Mechanism - R & R

01.85-00 Rocker Cover - R & R (Each)

02.10-00 Injector Nozzle Assembly - R & R

02.10-02 High Pressure Fuel Tubes - R & R

02.11-00 Electronic Unit Pump - R & R (One)

02.18-01 DDEC Sensor Harness - R & R

02.18-05 Temperature or Pressure Sensor - R & R

02.20-00 Fuel Pump and/or Coupling - R & R

02.40-00 Fuel Manifold (Rail) - R & R

02.50-00 Fuel Lines (Nozzle Holder) - R & R (One)

02.50-10 Fuel Return Line Assembly - R & R

03.10-02 Air Inlet Manifold - R & R

03.50-08 Turbocharger - R & R (Each)

03.51-02 Turbocharger Oil Supply Line - R & R (All)

03.52-01 Turbocharger Oil Drain - R & R (All)

03.70-07 Charge Air Cooler Assembly - R & R

04.10-00 Oil Pump - R & R

04.10-05 Oil Pick Up Tube and Bracket - R & R

04.10-06 Oil Transfer Tube - R & R

04.20-01 Oil Filter Housing - R & R

04.41-00 Oil Cooler Elements - R & R

04.70-00 Oil Pan & Gasket - R & R

05.10-00 Water Pump (Fresh Water or Engine Coolant)

- R & R

05.20-04 Water/Oil Distribution Manifold - R & R

06.10-00 Exhaust Manifold - R & R (Each)

14.00-00 Engine Tune-Up




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.10-00 Cylinder Block- R & R (Continued)NOT INCLUDED:

01.22-00 Engine Lifter Bracket - R & R

01.37-00 Belt Set - R & R

02.19-00 Electronic Control Module - R & R

02.33-00 Fuel Filter Assembly (Secondary) - R & R

02.70-00 Fuel System - Prime

03.10-00 Air Filter and Housing - R & R

04.20-00 Oil Filter Elements - R & R

04.40-02 Oil Cooler Elements - R & R (All)

04.70-01 Dipstick Tube & Adapter - R & R

05.20-00 Thermostat (Fresh Water or Engine) - R & R

05.30-02 Fan Hub Assembly - R & R

05.30-08 Fan Hub Mounting Bracket - R & R

05.60-00 Water Pump (Raw Water or Separate Circuit)

- R & R

07.10-00 Alternator/Generator - R & R

07.30-00 Starter Motor and Drive Assembly R & R (One)

11.10-00 Engine Mount (Front Trunnion) - R & R

13.20-00 Engine Dynamometer Test

Coolant or lube oil draining, filling, or disposal.NOTES: (Requires)


operation.

J 35791 Liner Remover

J 41570 Injector Nozzle Puller Adapter

J 41595 Flywheel Guide Studs

J 42255 Cylinder Liner Installer & Hold Down

J 42256 Piston Ring Compressor

J 42258 Cam Follower Installer/Remover

J 42259 Rear Crank Seal Installer 8V

J 42261 Front Seal Installer

J 42262 Engine Stand Adapter Plate (8V Only)

J 42264 Camshaft Pilot, 17 in. Long

J 43001 Front/Rear Crank Hub Installer/Remover

J 43011 Piston Ring Pliers

J 43028 Crankshaft Position Timing Tool

J 43048 Main Bearing Guide Studs

J 43394 Gearcase Alignment Tool

34.30025S MHUB ITH Hub Expansion Set

J 43395 Engine Barring Tools




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.10-01 Cylinder Block - R & R (From Short Block)INCLUDED:

01.30-00 Crankshaft (Engine Removed) - R & R

01.60-01 Cylinder Kit - R & R (Each Additional)

01.70-00 Camshaft - R & RNOTES:

Engine removed time does not apply to marine.

081216

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---

---

---

01.10-02 Engine Stand - R & RINCLUDED:

All labor required to install and remove either a Short

Block or Cylinder Block from engine work stand.NOTES:


operation.

With engine lifter brackets installed.

081216

1.01.01.0

1.01.01.0

1.01.01.0

1.01.01.0

01.10-05 Steam Clean and Paint Engine 081216

1.01.01.0

1.51.51.5

1.51.51.5

1.51.51.5

01.10-11 Cylinder Block - Pressure Test (Engine Removed) 081216

---

---

---

---




081216

---

---

---

---

01.20-00 Cylinder Head - R & R (One)INCLUDED:


01.83-02 Pushrods - R & R



14.00-01 Valve Lash (Intake Exhaust) - AdjustmentNOT INCLUDED:

Removal of OEM Equipment

00.00-25 Coolant or Lube Oil - Drain & Refill



06.10-00 Exhaust Manifold - R & R (Each)NOTES: (Requires)


081216

2.12.12.1

5.15.15.1

5.15.15.1

5.95.95.9




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.20-01 Cylinder Head - R & R (All)INCLUDED:



01.85-00 Rocker Cover - R & R





03.50-00 Turbocharger - R & R


14.00-01 Valve Lash (Intake Exhaust) - AdjustmentNOT INCLUDED:



03.70-05 Charge Air Cooler Coolant Piping - R & R




081216

10.614.018.0

16.021.027.0

16.021.027.0

27.035.045.0

01.20-03 Valve Springs (Head Removed) - R & R (One Head) 081216

0.30.30.3

---

---

---

01.20-04 Valve Seal (Head Removed) - R & R (One Head)INCLUDED:

01.20-03 Valve Springs (Head Removed) - R & R (One

Head)

081216

0.30.30.3

---

---

---

01.20-06 Cylinder Head - Pressure Test (One)NOT INCLUDED:

01.20-00 Cylinder Head - R & RNOTES: (Requires)

J 42267 Cylinder Head Pressure Test Kit

081216

0.30.30.3

0.30.30.3

0.30.30.3

0.30.30.3

01.22-00 Engine Lifter Bracket - R & R 081216

0.40.40.4

0.50.50.5

0.50.50.5

0.50.50.5




081216

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---

---

---




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.30-00 Crankshaft (Engine Removed) - R & RINCLUDED:








01.34-02 Gear Case Cover (Lower Front) - R & R

01.35-00 Main Bearings - R & R (All)


01.37-00 Belt Set - R & R





01.70-00 Camshaft - R & R







02.18-00 Synchronous Reference Sensor or Timing

Reference Sensor - R & R

02.18-05 Temperature or Pressure Sensor - R & R







03.10-06 Charge Air Piping to Turbocharger - R & R

03.10-07 Charge Air Cooler Assembly - R & R


03.51-00 Turbocharger Oil Supply Line - R & R (One)

03.52-00 Turbocharger Oil Drain - R & R (One)


081216

28.035.037.1

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---

---




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.30-00 Crankshaft (Engine Removed) - R & R (Continued)

04.10-00 Oil Pump - R & R





04.41-00 Oil Cooler Elements - R & R



05.20-04 Water/Oil Distribution Manifold - R & R


07.30-00 Starter Motor and Drive Assembly - R & R

(One)

Engine removed time does not apply to marine.NOT INCLUDED:

01.10-05 Steam Clean and Paint Engine

01.34-03 Idler Gears - R & R

05.20-00 Thermostats (Fresh Water or Engine) - R & R



- R & R





operation.






J 42256 Piston Ring Compressor

J 42258 Cam Follower Installer/Remover









BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.30-01 Crankshaft Front Drive Hub - R & RNOT INCLUDED:


01.37-00 Belt Set - R & R


Belt guards - R & RNOTES: (Requires)




081216

1.51.51.5

3.13.13.1

3.13.13.1

3.13.13.1

01.30-02 Crankshaft Rear Drive Hub - R & RINCLUDED:


01.40-00 Flywheel - R & RNOTES: (Requires)




081216

1.91.91.9

3.03.03.0

2.02.02.0

8.012.512.5

01.31-00 Crankshaft Thrust Washers - R & RINCLUDED:

Main Bearing Cap (See 01.35-01 Main Bearing - R & R)

Inspect thrust washers. Check crankshaft endplay.NOT INCLUDED:

04.10-00 Oil Pump - R & R




081216

0.50.50.5

0.90.90.9

0.80.80.8

1.01.01.0

01.32-00 Crankshaft Oil Seal (Front) - R & RINCLUDED:



01.37-00 Belt Set - R & R

01.38-00 Crankshaft Pulley - R & RNOT INCLUDED:





081216

2.92.92.9

6.56.56.5

6.56.56.5

8.58.58.5




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.33-00 Crankshaft Oil Seal (Rear) - R & RINCLUDED:


01.30-02 Crankshaft Rear Drive Hub - R & RNOTES: (Requires)



081216

2.32.32.3

5.05.05.0

3.53.53.5

11.011.011.0

01.34-00 Gear Case Cover - R & RINCLUDED:




01.37-00 Belt Set - R & R



05.10-00 Water Pump (Fresh Water or Engine Coolant)

- R & R

05.20-04 Water/Oil Distribution Manifold - R & RNOT INCLUDED:



05.20-00 Thermostats (Fresh Water or Engine) - R & R



- R & R





operation.


J 42257 Front Wear Sleeve Installer




081216

5.05.05.0

9.99.99.9

9.99.99.9

16.018.018.0

01.34-03 Idler Gears - R & R (Both)NOT INCLUDED:


081216

0.20.20.2

0.20.20.2

0.20.20.2

0.20.20.2




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.35-00 Main Bearings - R & R (All)INCLUDED:


04.10-05 Oil Pick-Up and Bracket - R & R

04.70-00 Oil Pan & Gasket - R & RNOT INCLUDED:

04.10-00 Oil Pump - R & R

Coolant and Lube Oil - Drain & Refill.NOTES: (Requires)

J 43048 Engine Bearing Guide Studs


081216

2.32.43.5

8.010.012.0

8.010.012.0

12.020.025.0

01.35-01 Main Bearing - R & R (Each Set)NOT INCLUDED:

04.10-00 Oil Pump - R & R






081216

0.30.30.3

1.51.51.5

1.51.51.5

2.52.52.5

01.35-02 Rod Bearings - R & R (All)INCLUDED:

04.70-00 Oil Pan & Gasket - R & RNOT INCLUDED:



081216

2.13.14.1

5.66.87.9

5.66.87.9

7.615.816.2

01.35-03 Rod Bearing - R & R (Each Set)NOT INCLUDED:




081216

0.10.10.1

0.30.30.3

0.30.30.3

0.70.70.7

01.36-00 Vibration Damper - R & R (All)INCLUDED:

01.37-00 Belt Set - R & R


081216

0.80.80.8

5.06.08.0

5.06.08.0

8.012.012.0

01.37-00 Belt Set - R & RINCLUDED:

Adjust required brackets. Check belt tension.


J 23586ñB Belt Tension Gage

081216

0.30.30.3

0.50.50.5

0.60.60.6

1.01.01.0




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.38-00 Crankshaft Pulley - R & RNOT INCLUDED:

01.37-00 Belt Set - R & R

Belt guards - R & R

081216

0.30.30.3

0.70.70.7

0.70.70.7

0.70.70.7




081216

---

---

---

---

01.40-00 Flywheel - R & RINCLUDED:

Flywheel Mounted TRS Pulse Wheel, Centrifugal Mass,

and Ring Gear - R & RNOT INCLUDED:

02.18-00 Synchronous Reference Sensor or Timing

Reference Sensor - R & R

Transmission - R & RNOTES: (Requires)


operation.


081216

0.40.40.4

2.02.02.0

1.51.51.5

3.03.03.0




081216

---

---

---

---

01.50-00 Flywheel Housing - R & RINCLUDED:





07.30-00 Starter Motor and Drive Assembly - R & R

(One)NOT INCLUDED:

01.34-03 Idler Gear - R & R

03.70-05 Charge Air Cooler Piping - R & R

11.10-01 Engine Mount (Rear) - R & RNOTES: (Requires)


operation.





081216

4.04.65.2

9.39.39.8

7.37.37.8

15.516.016.5




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.50-01 Gear Case (Complete) - R & RINCLUDED:


05.20-02 Thermostat Housing - R & R

05.30-08 Fan Mounting Bracket - R & R


11.10-00 Engine Mount (Front Trunnion) - R & RNOT INCLUDED:



- R & R

Coolant or lube oil draining, filling, or disposal.

Removal of OEM equipment.NOTES: (Requires)

J 42257 Front Wear Sleeve Installer





081216

6.36.36.3

14.014.014.0

14.014.014.0

20.522.522.5




081216

---

---

---

---




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.60-00 Cylinder Kit - R & R (One)INCLUDED:

01.20-00 Cylinder Head - R & R

01.35-03 Rod Bearings - R & R (Each Set)



01.83-02 Pushrod - R & R




04.10-00 Oil Pump - R & R (If needed)



14.00-01 Valve Lash (Intake / Exhaust) - Adjustment

Disassemble kit, clean and measure ring grooves, replace

piston rings, clean-up block bores, measure liner height

and liner bores, and check piston ring end gap.NOT INCLUDED:




operation.

J 35791 Liner Remover



J 43011 Piston Ring Pliers


081216

8.48.48.4

11.512.513.5

11.512.513.5

13.015.018.0

01.60-01 Cylinder Kit - R & R (Each Additional)INCLUDED:

04.10-00 Oil Pump - R & R (If needed)

081216

0.90.90.9

1.91.91.9

1.91.91.9

4.04.04.0

01.60-02 Piston Cooling Jet - R & R (One)DOES NOT INCLUDE:


081216

0.20.20.2

0.20.20.2

0.20.20.2

0.20.20.2




081216

---

---

---

---




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.70-00 Camshaft - R & RNOT INCLUDED:




02.11-00 Electronic Unit Pump - R & R (One)NOTES: (Requires)

J 42264 Camshaft Pilot 17 in. Long


081216

0.50.50.5

2.52.52.5

2.52.52.5

4.04.04.0

01.70-06 Cam Followers - R & R (All) 081216

0.30.40.5

---

0.60.80.8

0.60.80.9




081216

---

---

---

---

01.80-00 Valve Mechanism - R & R (One Cylinder)INCLUDED:

This operation includes valve bridge and valve

mechanism - R & R.



14.00-01 Valve Lash (Intake Exhaust) - AdjustmentNOTES: (Requires)


081216

0.80.80.8

2.22.42.9

2.22.42.9

2.72.93.4

01.83-00 Valve Springs and/or Seals (Head Installed) - R & R (AllCylinders)INCLUDED:



14.00-01 Valve Lash (Intake Exhaust) - AdjustmentNOTES: (Requires)


081216

1.62.43.2

4.87.29.6

4.87.29.6

4.87.29.6

01.83-02 Push Rod - R & R (Each)NOT INCLUDED:

01.83-00 Valve Springs and/or Seals (Head Installed) -

R & R (One Cylinder)


081216

0.10.10.1

0.10.10.1

0.10.10.1

0.10.10.1

01.85-00 Rocker Cover - R & R (Each) 081216

0.20.20.2

0.20.20.2

0.20.20.2

0.20.20.2




BASIC ENGINENO.OF

CYLENGREM

C&I GEN MAR

01.85-01 Breather - R & R 081216

0.30.30.3

0.30.30.3

0.30.30.3

0.30.30.3

01.85-02 Breather Tube - R & R 081216

0.20.20.2

0.20.20.2

0.20.20.2

0.20.20.2




081216

---

---

---

---

Table 4 Basic Engine Operation Numbers



Listed in Table 5 are the fuel system operation numbers.


FUEL SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

02.10-00 Injector Nozzle Assembly - R & R (Each)INCLUDED:


02.10-02 High Pressure Fuel Tube - R & R

Check for leaks.NOTES: (Requires)


081216

0.40.40.4

0.60.60.6

0.50.50.5

0.80.80.8

02.10-01 Each Additional Injector Nozzle Assembly 081216

0.40.40.4

0.40.40.4

0.40.40.4

0.60.60.6

02.10-02 High Pressure Fuel Tube - R & R (Each)NOT INCLUDED:


Coolant draining, filling, or disposal.NOTES: (Requires)


J 45648 Fuel Line Wrench Adapter

081216

0.10.10.1

0.10.10.1

0.10.10.1

0.10.10.1

02.10-03 Fuel System - Pressure Test 081216

1.01.01.0

1.01.01.0

0.90.90.9

1.01.01.0

02.10-04 Compression Test (Each Cylinder)NOT INCLUDED:


081216

0.50.50.5

0.70.70.7

0.60.60.6

0.70.70.7

02.10-05 Injector Harness (EUP) - R & RINCLUDED:


081216

0.71.01.3

2.12.12.1

2.02.02.0

3.53.53.5

02.11-00 Electronic Unit Pump - R & R (One)INCLUDED:

02.10-02 High Pressure Fuel Tube - R & R

03.10-02 Air Inlet Manifold - R & RNOT INCLUDED:


02.70-00 Fuel System - PrimeNOTES: (Requires)


081216

0.81.11.3

2.02.02.0

1.91.91.9

3.03.03.0




FUEL SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

02.11-01 Electronic Unit Pump - R & R (Each Additional)INCLUDED:

02.10-02 High Pressure Fuel Tube - R & RNOT INCLUDED:

03.30-02 Air Inlet Manifold - R & RNOTES: (Requires)


081216

0.20.20.2

0.50.50.5

0.40.40.4

0.50.50.5

02.18-00 Synchronous Reference Sensor or Timing Reference Sensor -R & R

081216

0.10.10.1

0.10.10.1

0.10.10.1

0.10.10.1

02.18-01 DDEC Sensor Harness - R & RNOT INCLUDED:


081216

0.10.10.1

0.50.50.5

0.50.50.5

0.50.50.5

02.18-05 Temperature or Pressure Sensor - R & R (Each) 081216

0.10.10.1

0.10.10.1

0.10.10.1

0.10.10.1

02.19-00 Electronic Control Modules (MDEC/DDEC) - R & RNOT INCLUDED:


081216

0.30.30.3

0.50.50.5

0.50.50.5

1.51.51.5

02.19-01 Reprogram ECM or MDEC (Per Module) 081216

0.50.50.5

0.50.50.5

0.50.50.5

0.50.50.5

02.20-00 Fuel Pump and/or Coupling - R & RINCLUDED:


Check for leaks.NOT INCLUDED:


081216

0.30.30.3

1.21.21.2

1.11.11.1

2.02.02.0




081216

---

---

---

---

02.30-01 Fuel Filter Elements (Primary) - R & R (Set of 2)NOT INCLUDED:


081216

0.40.40.4

0.40.40.4

0.40.40.4

0.50.50.5

02.33-00 Fuel Filter Assembly (Secondary) - R & RINCLUDED:

02.50-00 Fuel Lines (Nozzle Holder) - R & R (One)NOT INCLUDED:


081216

0.20.20.2

0.20.20.2

0.20.20.2

0.30.30.3




FUEL SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

02.40-00 Fuel Manifold (Rail) - R & RINCLUDED:



081216

-0.40.4

-3.33.3

-3.23.2

-4.04.0

02.40-01 Fuel Delivery Rail/Pressure Regulator - R & RINCLUDED:

02.10-02 High Pressure Fuel Tube - R & R (One Bank)



Drain fuel from fuel rail.

Disconnect fuel lines.NOT INCLUDED:



02.70-00 Fuel System - PrimeNOTES:

8V time applies to fuel regulator only.

081216

1.72.02.6

2.03.53.5

2.03.23.2

3.06.56.5

02.50-00 Fuel Lines (Nozzle Holder) - R & R (One)NOT INCLUDED:


081216

0.20.20.2

0.30.30.3

0.30.30.3

0.30.30.3

02.50-08 Fuel Lines (Nozzle Holder) - R & R (Each Additional) 081216

0.20.20.2

0.30.30.3

0.30.30.3

0.30.30.3

02.50-10 Fuel Return Line Assembly - R & R (All) 081216

0.30.30.4

0.60.70.8

0.60.70.8

0.80.91.0

02.70-00 Fuel System - Prime (Complete System) 081216

0.50.50.5

0.50.50.5

0.50.50.5

1.01.01.0

02.99-00 General Operation)NOTES:



081216

---

---

---

---

Table 5 Fuel System Operation Numbers



Listed in Table 6 are the air system operation numbers.


AIR SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

03.10-00 Air Filter and Housing - R & RINCLUDED:

R & R piping and connections. Clean, inspect, and

reassemble.

081216

0.10.10.1

0.40.40.4

0.30.30.3

1.01.01.0

03.10-01 Air Filter Element - R & R (Each) 081216

0.10.10.1

0.10.10.1

0.10.10.1

0.20.20.2

03.10-02 Air Inlet Manifold - R & R (Complete)NOT INCLUDED:


02.19-00 Electronic Control Module - R & R (One)


081216

0.50.81.0

1.91.91.9

1.61.61.6

3.03.03.0

03.10-03 Air Shutdown Mechanism - R & RNOT INCLUDED:


Charge Air Cooler Cover Only - R & RNOTES:

Use this operation for air-inlet-manifold mounted air

shutdown assembly.

081216

0.10.10.1

0.20.20.2

0.20.20.2

0.20.20.2

03.10-05 Charge Air Cooler Coolant Piping - R & R (Each Section)NOT INCLUDED:


081216

0.20.30.4

0.50.60.8

0.50.60.8

0.81.01.2

03.10-06 Charge Air Piping to Turbocharger - R & RNOT INCLUDED:


081216

0.10.10.1

0.50.50.5

0.50.50.5

0.60.70.8

03.10-07 Charge Air Cooler Assembly - R & RINCLUDED:

R & R piping and connections, clean, and visually inspect.NOT INCLUDED:


081216

0.90.90.9

5.05.05.0

5.05.05.0

10.010.010.0

03.10-08 Charge Air Cooler Cover - R & RINCLUDED:

R & R piping and connections.

081216

0.30.30.3

1.51.51.5

1.51.51.5

1.51.51.5




AIR SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

03.10-09 Charge Air Cooler Base - R & RINCLUDED:

03.10-07 Charge Air Cooler Assembly - R & RNOT INCLUDED:

03.10-06 Charge Air Piping to Turbocharger - R & R

03.10-08 Charge Air Cooler Cover - R & R



081216

1.61.61.6

6.06.06.0

6.06.06.0

11.011.011.0

03.50-00 Turbocharger - R & R (One)INCLUDED:


03.52-00 Turbocharger Oil Drain - R & R (One)NOT INCLUDED:

03.10-00 Air Cleaner and Adapter - R & R

081216

1.01.01.0

2.02.02.0

1.51.51.5

4.04.04.0

03.50-02 Turbocharger Wastegate - R & R (One) 081216

0.50.50.5

0.50.50.5

0.50.50.5

0.50.50.5

03.50-08 Turbocharger - R & R (Each Additional)INCLUDED:


03.52-00 Turbocharger Oil Drain - R & R (One)NOT INCLUDED:

03.10-00 Air Cleaner and Adapter - R & R

081216

0.60.60.6

1.51.51.5

1.01.01.0

2.52.52.5

03.51-00 Turbocharger Oil Supply Line - R & R (One) 081216

0.10.10.1

0.20.20.2

0.20.20.2

0.20.20.2

03.51-02 Turbocharger Oil Supply Line - R & R (All) 081216

0.30.30.3

0.30.30.3

0.30.30.3

0.30.30.3

03.52-00 Turbocharger Oil Drain - R & R (One) 081216

0.10.10.1

0.20.20.2

0.20.20.2

0.30.30.3

03.52-01 Turbocharger Oil Drain - R & R (All) 081216

0.20.20.2

0.40.40.4

0.40.40.4

0.50.50.5




081216

---

---

---

---

Table 6 Air System Operation Numbers



Listed in Table 7 are the lubricating system operation numbers.


LUBRICATING SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

04.10-00 Oil Pump - R & RINCLUDED:

04.10-01 Oil Pressure Relief Valve - R & R (Eight

Cylinder Engines Only)


04.10-06 Oil Transfer Tube - R & RNOT INCLUDED:

04.10-02 Oil Pressure Relief Valve - R & R (12 and 16

Cylinder Engines)


081216

1.01.01.0

1.81.81.8

1.61.61.6

2.02.02.0

04.10-01 Oil Pressure Relief Valve - R & RNOT INCLUDED:


081216

0.10.10.1

0.20.20.2

0.20.20.2

0.20.20.2

04.10-05 Oil Pick Up Tube and Bracket - R & RNOT INCLUDED:



081216

0.20.20.2

0.40.40.4

0.40.40.4

0.50.50.5

04.10-06 Oil Transfer Tube - R & RNOT INCLUDED:


081216

0.20.20.2

0.40.40.4

0.40.40.4

0.50.50.5

04.20-00 Oil Filter Elements - R & RNOT INCLUDED:


081216

0.20.20.2

0.20.20.2

0.20.20.2

0.20.20.2

04.20-01 Oil Filter Housing - R & RNOT INCLUDED:



081216

0.20.20.2

1.01.01.0

0.90.90.9

1.31.31.3

04.41-00 Oil Cooler Elements - R & RNOT INCLUDED:


081216

0.50.50.5

0.60.60.6

0.60.60.6

1.01.01.0

04.41-01 Oil Cooler Housing - R & RNOT INCLUDED:



04.41-05 Oil Cooler Housing Cover - R & R


081216

0.60.60.6

0.80.80.8

0.70.70.7

1.21.21.2

04.41-05 Oil Cooler Housing Cover - R & RNOT INCLUDED:


081216

0.40.40.4

0.50.50.5

0.50.50.5

0.60.60.6




LUBRICATING SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

04.70-00 Oil Pan & Gasket - R & RINCLUDED:

04.70-01 Dipstick Tube & Adapter - R & RNOT INCLUDED:

Lube Oil - Drain & RefillNOTES:


operation.

081216

1.31.92.5

2.52.53.0

2.02.03.0

2.53.03.5

04.70-01 Dipstick Tube & Adapter - R & R 081216

0.30.30.3

0.40.40.4

0.40.40.4

0.50.50.5




081216

---

---

---

---

Table 7 Lubricating System Operation Numbers



Listed in Table 8 are the cooling system operation numbers.


COOLING SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

05.10-00 Water Pump (Fresh Water or Engine Coolant) - R & RNOT INCLUDED:


081216

0.40.40.4

2.22.22.2

2.02.02.0

2.52.52.5

05.10-02 Cooling System - Flush 081216

---

1.21.21.2

1.01.01.0

1.51.51.5

05.10-03 Cooling System - Reverse Flush(When Needed)

081216

---

1.91.91.9

1.91.91.9

1.91.91.9

05.20-00 Thermostat - R & RINCLUDED:



Coolant or lube oil draining, filling, or disposal.NOTES:

Engine removed time does not apply to the marine engine

configuration.

081216

0.80.80.8

1.61.61.6

1.51.51.5

2.02.02.0

05.20-01 Thermostat Housing Seal (Engine) - R & R (Each) 081216

0.40.40.4

1.01.01.0

1.01.01.0

2.02.02.0

05.20-02 Thermostat Housing - R & RINCLUDED:



Coolant or lube oil draining, filling, or disposal.NOTES:

Engine removed time does not apply to the marine engine

configuration.

081216

0.60.60.6

0.80.80.8

0.70.70.7

1.01.01.0

05.20-04 Water/Oil Distribution Manifold - R & RNOT INCLUDED:


05.20-00 Thermostat - R & R

05.20-01 Thermostat Housing Seal - R & R

05.20-02 Thermostat Housing - R & R



081216

0.60.60.6

3.03.03.0

2.52.52.5

8.08.08.0




COOLING SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

05.30-00 Radiator Assembly - R & R 081216

---

3.53.53.5

3.03.03.0

---

05.30-01 Fan - R & R 081216

---

1.51.51.5

1.31.31.3

---

05.30-02 Fan Hub Assembly - R & RNOT INCLUDED:

01.37-00 Belt Set - R & R

05.30-01 Fan - R & R

081216

0.20.20.2

1.91.91.9

1.51.51.5

---

05.30-04 Belt Tensioner and Bracket - R & RNOT INCLUDED:

01.37-00 Belt Set - R & RNOTES: (Requires)

Belt Tension Gage

081216

0.10.10.1

1.51.51.5

1.41.41.4

---

05.30-05 Cooling System - Pressure Check 081216

0.50.50.5

0.50.50.5

0.50.50.5

0.50.50.5

05.30-08 Fan Hub Mounting Bracket - R & RNOT INCLUDED:


05.30-04 Belt Tensioner and Bracket - R & R

081216

0.40.40.4

0.50.50.5

0.50.50.5

---

05.60-00 Water Pump (Raw Water or Separate Circuit) - R & RINCLUDED:


081216

0.30.30.3

2.52.52.5

2.52.52.5

3.03.03.0

05.99-00 General OperationUse this operation for work performed in this group which is notcovered by an operation number.

081216

---

---

---

---

Table 8 Cooling System Operation Numbers



Listed in Table 9 are the exhaust system operation numbers.


EXHAUST SYSTEMNO.OF

CYLENGREM

C&I GEN MAR

06.10-00 Exhaust Manifold - R & R (Each)INCLUDED:

Drain water from manifold.NOT INCLUDED:


081216

0.20.30.4

1.41.61.8

1.41.61.8

2.62.93.2

06.10-01 Exhaust Manifold - R & R (All)INCLUDED:

Refer to Group 06.10-00 for details.

081216

0.40.60.8

2.83.23.6

2.83.23.6

5.25.86.4


081216

---

---

---

---

Table 9 Exhaust System Operation Numbers

Listed in Table 10 are the electrical instruments operation numbers.


ELECTRICAL INSTRUMENTSNO.OF

CYLENGREM

C&I GEN MAR

07.10-00 Alternator/Generator - R & RNOT INCLUDED:

01.37-00 Belt Set - R & R

081216

0.10.10.1

1.51.51.5

1.51.51.5

2.02.02.0

07.30-00 Starter Motor and Drive Assembly - R & R 081216

0.40.40.4

1.81.81.8

1.81.81.8

2.02.02.0

07.30-01 Starter Solenoid (Starter Removed) - R & R 081216

0.20.20.2

---

---

---


081216

---

---

---

---

Table 10 Electrical Instruments Operation Numbers



Listed in Table 11 are the engine mounting operation numbers.


ENGINE MOUNTINGNO.OF

CYLENGREM

C&I GEN MAR

11.10-00 Engine Mount (Front Trunnion) - R & RNOT INCLUDED:


01.37-00 Belt Set - R & R

081216

0.20.20.2

1.41.41.4

1.31.31.3

1.51.51.5


081216

---

---

---

---

Table 11 Engine Mounting Operation Numbers

Listed in Table 12 are the miscellaneous operation numbers.


MISCELLANEOUSNO.OF

CYLENGREM

C&I GEN MAR

12.40-00 Air Compressor - R & RNOT INCLUDED:


081216

0.50.50.5

0.70.70.7

0.60.60.6

2.02.02.0

12.40-03 Air Compressor Hose - R & R 081216

0.20.20.2

0.20.20.2

0.20.20.2

0.30.30.3

12.40-05 Air Compressor Drive - R & R 081216

0.30.30.3

0.60.60.6

0.50.50.5

1.01.01.0

12.50-00 Hydraulic Pump (Power Steering) - R & R 081216

0.50.50.5

1.01.01.0

1.01.01.0

1.51.51.5


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Table 12 Miscellaneous Operation Numbers



Listed in Table 13 are the engine performance test operation numbers.


ENGINE PERFORMANCE TESTNO.OF

CYLENGREM

C&I GEN MAR

13.20-00 Engine Dynamometer TestINCLUDED:

Set-up and warm engine. Perform basic engine run-in.

Complete dyno test report, and remove engine from dyno.

081216

3.03.54.0

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13.21-00 Repair ValidationNOTES:

Use this operation for repairs that do not affect

driveability, such as: Sensors, water pump, front

cover, ECM/MDEC, air compressor, starter, alternator,

tensioner, accessory drive, belts, manifolds, flywheel

housing, fuel lines, gaskets, seals, etc...

081216

0.20.20.2

0.20.20.2

0.20.20.2

0.20.20.2

13.22-00 Engine Performance TestNOTES:

Use this operation to check engine performance by

equiptment operation test under load when necessary to

test the engine without using a chassis dynamometer.

081216

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1.01.01.0

1.01.01.0

2.02.02.0

13.22-05 Engine Performance Test (Load Box Method) 081216

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0.50.50.5

0.50.50.5

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13.22-10 Test Run (Check for Leaks) 081216

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0.30.30.3

0.30.30.3

0.30.30.3




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Table 13 Engine Performance Test Operation Numbers



Listed in Table 14 are the engine tune-up operation numbers.


ENGINE TUNE-UPNO.OF

CYLENGREM

C&I GEN MAR

14.00-00 Engine Tune-UpINCLUDED:


14.00-01 Valve Lash (Intake Exhaust) - Adjustment

081216

0.91.11.6

1.92.12.6

1.92.12.6

2.42.63.1

14.00-01 Valve Lash (Intake / Exhaust) - Adjustment 081216

0.70.91.4

1.71.92.4

1.71.92.4

2.22.42.9




081216

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Table 14 Engine Tune-Up Operation Numbers


Labot t Guide 2000 Usa

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