M11 Series – Service Manual – 003-013   Rocker Lever Housing

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Disconnect the battery.
  Refer to Procedure 013-009 (Battery Cables and Connections) in Section 13.
• Remove the air piping from the intake manifold.
• Remove the rocker lever cover.
  Refer to Procedure 003-011 (Rocker Lever Cover) in Section 3.
• Remove the engine brakes, if applicable, from the engine.
  Refer to Procedure 020-001 (Clutch Switch) in Section 20.
• Remove all valve push tubes and injector push rods from the engine.
  Refer to Procedure 004-014 (Push Rods or Tubes) in Section 4.
• Remove the crossheads to prevent them from falling into the lower area of the engine.
• Disconnect the internal actuator harness. Refer to Procedure 019-063 (Internal Actuator Wiring Harness, in the CELECT™ Plus Troubleshooting and Repair Manual, Bulletin 3666130 (CELECT™ and CELECT™ Plus).
• Disconnect the oil supply line and remove the STC oil manifold.
  Refer to Procedure 006-036 (STC Oil Control Valve (Electrical)) in Section 6 (STC
  only).
• Remove the rocker lever assemblies.
  Refer to Procedure 003-009 (Rocker Lever Assembly) in Section 3.
• Remove the injectors.
  Refer to Procedure 006-026 (Injector) in Section 6

Remove the rocker housing mounting capscrews.

Remove the rocker housing and the intake manifold as a complete unit.

NOTE: If troubleshooting high blowby, the rocker housing gasket
must be inspected before it is removed from the cylinder head.

WARNING  When using a steam cleaner, wear protective clothing, and safety glasses or a face shield. Hot steam can cause serious personal injury.

Use steam to clean the rocker lever housing. Dry with compressed air.

Clean the cylinder head gasket surface.

Inspect the rocker housing gasket for cuts or damage on the portion of the gasket that seals around the intake ports. Damage to the gasket can cause high blowby.

Inspect the housing for cracks or other damage.

If the housing is cracked, it
must be replaced.

Use a new gasket and install the rocker lever housing.

CAUTION  Check the grade of the capscrew on the capscrew head before torquing the capscrew. Capscrews will fail if tightened beyond recommended torque.

CAUTION  The rocker housing on L10 and M11 engines is aluminum. Excessive torque on the fasteners can damage the housing.

Torque Procedure:

1. Snug all bolts.
2. Tighten all bolts (grade 8.8) to 47 N•m [35 ft lb] in specified sequence.
3. Tighten all bolts (grade 10.9) to 61 N•m [45 ft lb] in specified sequence.

NOTE: The grade of the bolt depends on the engine family.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the injectors.
  Refer to Procedure 006-026 (Injectors) in Section 6.
• Install the rocker lever assemblies.
  Refer to Procedure 003-009 (Rocker Lever Assembly) in Section 3.
• Install the crossheads in the same positions they were removed from, and rotate the rocker levers down.
• Install the push rods and push tubes.
  Refer to Procedure 004-014 (Push Rods or Tubes) in Section 4.
• Adjust the valves and injectors.
  Refer to Procedure 003-004 (Overhead Set) in Section 3.
• Install the engine brakes, if applicable.
  Refer to Procedure 020-001 (Clutch Switch) in Section 20.
• Install the rocker lever cover.
  Refer to Procedure 003-011 (Rocker Lever Cover) in Section 3.
• Install the air piping to the intake manifold. Refer to the manufacturer’s specifications for the correct torque value.
• Connect the battery.
  Refer to Procedure 013-009 (Battery Cables and Connections) in Section 13.
• Operate the engine and check for leaks.