N14 Base Engine Troubleshooting and Repair Manual – 003-013   Rocker Lever Housing

Drain the cooling system. Refer to Procedure

008-018-005.

Remove the rocker lever covers. Refer to Procedure

003-011-002.

Remove the engine brake. Refer to Procedure

020-001-002.

Release the fan drive belt tension.

Remove the engine lifting brackets if the rocker lever housings are being replaced. Refer to Procedure

016-001-002.

Remove the fan bracket brace between the fan bracket and the lifting bracket.

Loosen the valve and injector adjusting screw lock nuts on each rocker lever.

Turn the adjusting screws

counterclockwise
until the rocker levers are loose.

CAUTION  Do not attempt to remove or install the rocker lever shaft assemblies without resetting the lash.

Remove the rocker lever assemblies. Refer to Procedure

003-009-002.

NOTE: To prevent increased wear, mark each rocker lever housing as it is removed so it can be installed back in its original location.

Remove the crossheads. Make sure to mark them appropriately so they can be installed in the same location and orientation during the installation procedure.

NOTE: Excessive crosshead wear can result if the crossheads are

not
installed in their original locations. The larger hole on the underside of the crosshead

must
be oriented toward the exhaust side of the engine.

Disconnect the injector solenoid leads from the pass through connector in the rocker lever housing.

Remove the injector hold down clamp capscrew.

Remove the injector hold down clamp.

Remove the water manifold tube clamps. Use jumper tube removal tool, Part No. 3823819, to push or pry the adjacent water tubes into the rocker lever housing cavity.

For example, the tube between housing No. 1 and No. 2

must
be pushed into housing No. 2. The tube between housing No. 2 and No. 3

must
be pushed into housing No. 3.

Remove the coolant thermostat housing from the front rocker lever housing. Refer to Procedure

008-014-002.

Remove the rocker lever housing mounting capscrews.

NOTE: To prevent increased wear, mark each rocker lever housing as it is removed so it can be installed back in its original location.

Remove the rocker lever housings.

Remove the gaskets.

NOTE: On CELECT™ engines while handling the rocker lever housings, protect the wiring harness pass through connectors. Do

not
subject the pass through connectors to impact forces and do

not
rest the housing on the face with the pass through connectors.

Remove the o-ring, o-ring plug, and water tube from the water manifold with jumper tube removal tool, Part No. 3823819.

Inspect the o-rings, o-ring plugs, and water tubes. Replace if necessary.

NOTE: Do

not
remove the rocker shaft dowel pins, dowel rings, or brass cup plug for cleaning.

Steam clean the rocker lever housings.

Dry with compressed air.

NOTE: Make sure the oil supply hole is free of dirt or other deposits.

Visually inspect the housings for cracks or damage, and replace if necessary.

Visually inspect the capscrew holes for damaged threads. If threads are damaged, refer to the Alternative Repair Manual, Bulletin No.

3379035, for thread repair instructions.

Visually inspect the rocker lever shaft dowel rings (1) and the dowel pins (2). Replace if necessary.

Use cam box dowel extractor, Part No. 3823821, to remove the dowel pins and dowel rings.

Install two o-rings (1) on each of the two water tubes (2). Install one o-ring (1) on each of the two water plugs (3).

Install the o-rings on the water tubes and plugs.

Apply soap to the o-rings on the tubes and plugs.

Install the water tubes (A) in the front of the No. 2 and No. 3 rocker lever housings. Install the plugs (B) in the front to the No. 1 rocker lever housing and in the rear of the No. 3 rocker lever housing.

Install new rocker lever housing gaskets onto the cylinder heads.

Install the rocker lever housings.

Tighten the rocker lever housing capscrews in the sequence shown (1 thru 6).

Tighten the rocker lever housing capscrews in the sequence shown (7 and 8).

Use jumper tube removal tool, Part No. 3823819, to slide the two water tubes into the adjacent water manifold.

Install the two water tube retainer clamps.

Install and tighten the retainer clamp capscrews.

Install the injectors.

Install the wiring harness pass through. Tighten the 5/16-inch pass through mounting capscrew.

WARNING  The injector must be fully seated before installing the hold down clamp. The hold down clamp can not pull the injector into the bore. Engine damage can occur if the injector is not fully seated.

Install the hold down clamp capscrew.

Take care to route the injector solenoid leads to avoid contact with the valve and injector push tubes.

Connect the injector solenoid wiring to the rocker lever housing pass through.

Install the valve crossheads.

CAUTION  If the adjusting screws protrude beyond the maximum listed below, the push rods can be damaged when the housing capscrews are tightened. Do not attempt to install the rocker lever shaft assemblies again without resetting the lash.

Loosen the rocker lever adjusting screws so there is a maximum of 32 mm [1.250 inch] from the top surface of the lever and the ball end of the adjusting screw.

Install the rocker lever assemblies. Refer to Procedure

003-009-026.

Adjust the valves and injectors. Refer to Procedure

003-004-029.

Install the coolant thermostat housing. Refer to Procedure

008-014-026.

Connect the wiring harness.

Install and adjust the engine brakes. Refer to Procedures

020-001-026 and

020-001-029, respectively.

Install the rocker lever covers. Refer to Procedure

003-011-026.

Install the engine lifting brackets. Refer to Procedure

016-001-026.

Install the fan bracket brace between the fan bracket and the lifting bracket.

Tighten the fan drive belt. Refer to Procedure

008-002-026.

Fill the cooling system. Refer to Procedure

008-018-028.

Operate the engine until it reaches a temperature of 82°C [180°F], and check for leaks.