WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the rocker lever covers. Refer to Procedure 003-011 in Section 3.
• Remove the engine brake. Refer to Procedure 020-024 in Section 20.
• Release the fan drive belt tension.
• Remove the engine lifting brackets if the rocker lever housings are being replaced. Refer to Procedure 016-001 in Section 16.
• 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 in Section 3.

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 Number 3823819, to push or pry the adjacent water tubes into the rocker lever housing cavity.

For example, the tube between housing Number 1 and Number 2 must be pushed into housing Number 2. The tube between housing Number 2 and Number 3 must be pushed into housing Number 3.

Disconnect the wiring harness.

Remove the coolant thermostat housing from the front rocker lever housing. Refer to Procedure 008-014 in Section 8.

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 and 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 Number 3823819.

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

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

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

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.

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

Inspect the capscrew holes for damaged threads. If threads are damaged, repair the threads. Reference the Alternative Repair Manual, Bulletin 3379035.

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

Use cam box dowel extractor, Part Number 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 Number 2 and Number 3 rocker lever housings. Install the plugs (B) in the front to the Number 1 rocker lever housing and in the rear of the Number 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 sequence as illustrated (1 thru 6).

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

Use jumper tube removal tool, Part Number 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 32.0 mm [1.25 in] 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 in Section 3.

Adjust the valves and injectors. Refer to Procedure 003-004 in Section 3.

Install the coolant thermostat housing. Refer to Procedure 008-014 in Section 8.

Connect the wiring harness.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Install the fan bracket brace between the fan bracket and the lifting bracket.
• Install the engine lifting brackets. Refer to Procedure 016-001 in Section 16.
• Tighten the fan drive belt. Refer to Procedure 008-002 in Section 8.
• Install and adjust the engine brakes. Refer to Procedure 020-024 in Section 20.
• Install the rocker lever covers. Refer to Procedure 003-011 in Section 3.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine until it reaches a temperature of 82°C [180°F], and check for leaks.