Series 40E – Section 3.6 High Pressure Lube Oil System

Section 3.6
High Pressure Lube Oil System

The supply manifold information is also covered in Section 1.4.‪

Section 3.6.1
Supply Manifold End Plug Removal

Follow these steps to remove and install the supply manifold end plug. ‪

Note: The supply manifold oil rail must be drained prior to removing the fuel injectors, to prevent leakage into the cylinder bore.

1. Drain the supply manifold from the end plug of the supply manifold. See Figure "Removing Supply Manifold End Plug" .
   

   Figure 1. Removing Supply Manifold End Plug

2. Install a new O-ring and backup ring onto the end plug. See Figure "End Plug, O-ring and Backup Ring Locations" .
   

   1. O-ring‪	3. End Plug‪
   2. Backup Ring‪	‪

   Figure 2. End Plug, O-ring and Backup Ring Locations

   Note: Clean off any old Loctite from the end plug prior to installation.

3. Apply Loctite® #277 to the threads of the end plug, and install into the supply manifold. Torque plug to specifications. See Figure "Installing Supply Manifold End Plug" .

Figure 3. Installing Supply Manifold End Plug

Section 3.6.2
Supply Manifold Removal

Disconnect the fuel supply line from the fuel filter header to the supply manifold as follows:‪

1. For engines equipped with the top-mounted primer pump and the engine-mounted ECM unit, follow these steps.
   1. Loosen fitting and remove the fuel filter header to supply pump line.
   2. Cap the fuel filter header and supply pump openings.
2. If equipped with an engine mounted ECM unit, Loosen the nuts and disconnect the high pressure oil supply hose from the supply manifold and the high pressure pump. See Figure "Removing Oil Supply Hose" .
   

   1. Oil Supply Line Mounting Nuts‪	3. Oil Supply Line‪
   2. High Oil Pressure Pump‪	‪

   Figure 4. Removing Oil Supply Hose

3. Cap the high pressure pump fittings and supply manifold fittings.
4. Remove the ICP sensor by first disconnecting the wiring harness, if not already disconnected. See Figure "Disconnecting Main Wiring Harness" . Remove the ICP sensor and O-ring from the supply manifold. See Figure "Removing ICP Sensor" .
   

   Figure 5. Disconnecting Main Wiring Harness

   

   Figure 6. Removing ICP Sensor

5. Remove the banjo fitting at the fuel return valve, located at the rear of the supply manifold. See Figure "Removing Banjo Fitting " .
   

   Figure 7. Removing Banjo Fitting

6. Remove the fuel return valve from the supply manifold. See Figure "Removing Fuel Return Valve " .
   

   Figure 8. Removing Fuel Return Valve

   NOTICE: ‪

   When the supply manifold is removed, do not place it face down on any surface. The manifold face could be scratched, thus preventing a good mating surface seal. Always place supply manifold face up.‪

7. If not already removed, remove the supply manifold end plug. Refer to "3.6.1 Supply Manifold End Plug Removal" .
8. Remove twelve mounting bolts securing the supply manifold to the cylinder head. Remove the supply manifold and gasket. See Figure "Removing Supply Manifold" .
   

   Figure 9. Removing Supply Manifold

Section 3.6.2.1
Cleaning

Perform the following steps to clean the supply manifold:‪

1. Insert a stiff nylon brush into the oil and fuel galleries of the supply manifold for cleaning.

   To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.‪

2. Use compressed air to clean out debris from the oil gallery.

Section 3.6.2.2
Inspection

Perform the following steps to check for warpage:‪

Using a straight edge and feeler gage, check the supply manifold gasket surface for warpage, utilizing the checking pattern shown. See Figure "Warpage Check" . ‪

Figure 10. Warpage Check

Section 3.6.3
High Pressure Pump Removal

It is not necessary to remove the injection pressure relief valve from the high pressure pump prior to removal of the pump. However, the solenoid, sleeve and tinnermann nut can be removed for easy access to the high pressure pump mounting bolts.‪

1. For engines with Serial No. 988151 and up, disconnect the wiring harness from the IPR valve.
2. Remove the tinnermann nut securing the solenoid to the IPR valve. Remove sleeve and solenoid.
3. Unscrew the IPR valve from the high pressure pump, using a 28 mm (1–1/8 in.) deep wall socket.

Note: Before performing the next procedures, ensure the high pressure pump reservoir has been drained of oil. Drain the reservoir by removing the engine oil temperature sensor from the rear half of the front cover. Extract oil by inserting the tube from the hand operated vacuum pump tool,J 39257 , into the cover.

Note: If the IPR valve has not been removed, ensure the IPR valve solenoid has been disconnected from the main wiring harness.

Note: Ensure the lube oil supply hose has been disconnected. Refer to "3.6.2 Supply Manifold Removal" .

Remove two capscrews securing the high pressure lube pump to the front cover. Remove the pump and gasket from the front cover. See Figure "High Pressure Oil Pump Removal" . ‪

1. Capscrews‪

2. High Pressure Oil Pump‪

Figure 11. High Pressure Oil Pump Removal

Section 3.6.4
High Pressure Pump Installation

Follow these steps to install the high pressure lube oil pump.‪

1. Install a new face seal into the groove of the front cover and place the high pressure pump into its location.
2. Install two capscrews and secure the high pressure pump to the front cover. Torque the mounting bolts to specifications. Refer to . See Figure "High Pressure Oil Pump Installation" .
   

   1. Capscrews‪

   2. High Pressure Oil Pump‪

   Figure 12. High Pressure Oil Pump Installation

3. If removed, install the IPR valve into the high pressure pump. Torque the valve to specifications. Refer to . See Figure "IPR Valve Installation" .
   

   Figure 13. IPR Valve Installation

4. Install the IPR valve sleeve and solenoid to the IPR valve.

Section 3.6.5
Supply Manifold Installation

Follow this procedure to install the supply manifold.‪

Note: Install the supply manifold gasket with the tab stamped FRONT, located on the lower left hand side of the gasket, facing the manifold assembly.

1. Place a new supply manifold gasket onto the supply manifold. The gasket should have the tab located in the lower front corner for correct placement. See Figure "Supply Manifold and Gasket Installation to the Cylinder Head" .
   

   1. Supply Manifold‪

   2. Supply Manifold Gasket‪

   Figure 14. Supply Manifold and Gasket Installation to the Cylinder Head

2. Install the supply manifold on the engine. See Figure "Supply Manifold Installation to the Engine" .
   

   Figure 15. Supply Manifold Installation to the Engine

3. Install the supply manifold end plug. Refer to .
4. Install the fuel return valve into the rear of the supply manifold. See Figure "Fuel Return Valve Installation" .
   

   Figure 16. Fuel Return Valve Installation

5. Torque fuel return to specifications. Refer to . See Figure "Tighten Fuel Return Valve" .
   

   Figure 17. Tighten Fuel Return Valve

6. Install the banjo fitting to the fuel return valve. Torque to specifications. Refer to . See Figure "Tighten Fuel Return Banjo Fitting" .
   

   Figure 18. Tighten Fuel Return Banjo Fitting

7. Install the fuel supply line and connect it from the fuel filter header to the front of the supply manifold. Torque the fitting to specifications. Refer to . See Figure "Install Fuel Supply Line" .
8. 

   1. Fuel Supply Line‪

   Figure 19. Install Fuel Supply Line

9. Apply Loctite #277 to the threads of the ICP sensor.
10. Install the ICP sensor with a new O-ring into the center of the supply manifold elbow, located at the front of the supply manifold. Torque to specifications. Refer to . See Figure "Installation of ICP Sensor" .
    

    Figure 20. Installation of ICP Sensor

11. Install the lube oil supply hose to the high pressure pump and supply manifold. Torque the nuts securing the hose to specifications. Refer to . See Figure "Installation of Oil Supply Line" .
    

    1. Oil Supply Line Mounting Nuts‪	3. Oil Supply Line‪
    2. High Pressure Oil Pump‪	‪

    Figure 21. Installation of Oil Supply Line