How to disassemble the Cummins M11 series engine flywheel and flywheel housing

 (1) Flywheel Removal ① Install two M10-1.50X40 bolts at positions 1 and 2 as shown in Figure 2-91. After removing the bolts, install two guide pins. For engines equipped with a rear engine power take-off unit (REPTO), the crankshaft gear should be supported by two guide pins before removing the crankshaft rear oil seal.

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Figure 2-90 Remove the front oil collection tank suction pipe

 

② The specifications of the clutch pressure plate bolt holes may be 3/8-16, 7/16-14, or 1/2-13. Before installing the T-handles, the specifications of the pressure plate mounting bolts should be determined to avoid damaging the flywheel. Install the two T-handles onto the flywheel and remove the 7 bolts on the flywheel, as shown in Figure 2-92. 

 ③ Use nylon straps and a crane to remove the flywheel, as shown in Figure 2-93. Before lifting the flywheel, alternately tighten bolts 1 and 2 to loosen it. 

 ④ Remove the two bolts and the guide pin, as shown in Figure 2-94.

 

 

Figure 2-91 shows the installation of bolts 1 and 2, and the removal of bolt 3. (1, 2, 3—bolts)

 

 

 Figure 2-92 Installing the T-handle, removing 7 bolts 4 and 5 – T-handle

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Figure 2-93 Removing the flywheel using a crane - Bolts 1 and 2

 

 Figure 2-94 Remove bolts and guide pins

 

5 Remove the 12 bolts, pressure ring, and crankshaft rear oil seal, as shown in Figure 2-95.

  (2) Disassembly of the flywheel housing ① Remove the bolts and the two engine rear brackets, see Figure 2-96.

 

Figure 2-95 Removing the crankshaft rear oil seal 1—Pressure ring 2—Dust seal 3—Oil seal 4—Sealing gasket

 

 Figure 2-96 Remove the flywheel housing bolts and rear bracket 1, 2 bolts

 ② Remove the 12 bolts and flywheel housing, see Figure 2-97.

      

How to disassemble the oil pan and oil lines of the Cummins M11 series engine.

 ① Rotate the engine on the engine overhaul bench so that its side faces upward. Remove the two parts at positions 1 and 2 in Figure 2-88.

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① Remove the bolts and install the guide pin, then remove the remaining 32 oil pan bolts. 

 ② Remove the oil supply pipe from the rear-mounted oil pan (see Figure 2-89), and discard the two O-rings. 

③ If the engine has a front-mounted oil pan suction pipe, remove it from the cylinder block (see Figure 2-90), and discard the O-rings.

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Figure 2-86 Removing the cam follower using tools

 

 Figure 2-87 shows the lifting cam follower assembly; remove it from the engine.

 

 Figure 2-88 Removal of the oil pan 1, 2—bolts

 

 Figure 2-89 Remove the oil supply pipe from the rear-mounted oil pan.

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This document describes the disassembly of the injectors and rocker arm housing of the Cummins M11 series engine.

 

① Remove the injector fixing screws and clamps, and use an injector puller (part number 3823579) to remove the injectors from the engine. Mark the cylinder number on each injector, see Figure 2-80. ② Remove the rocker arm housing and other parts, see Figure 2-81. (6) Cylinder Head Removal 

 ① Remove 7 bolts from the cylinder head, and remove the three bolts inside the intake port, see Figure 2-82. 

 ② Remove the remaining 32 bolts from both ends to the middle, see Figure 2-83. The order shown in the figure is the tightening order when installing the bolts; the order is reversed during disassembly. 

 ③ Install the cylinder head lift bracket (part number 3822479) in the middle of the cylinder head, see Figure 2-84. Bolt 1 is M14-2.00x35, bolt 2 is M10-1.50x15, and the tightening torque is 47 N·m.

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Figure 2-80: Remove the fuel injectors using a puller and mark their cylinder numbers. 

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 Figure 2-81 Removing parts such as the rocker arm chamber housing

 

Figure 2-82 Remove cylinder head bolts

 

 Figure 2-83 Remove the remaining 32 bolts from both ends to the middle.

 

④ Use a crane to lift the cylinder head and lower it down, as shown in Figure 2-85, and remove the cylinder head gasket. 

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 Figure 2-84 Installing the cylinder head lift bracket in the middle of the cylinder head using bolts 1 and 2.

 

 

 

 Figure 2-85 shows the cylinder head being lifted and lowered using a crane.

Remove the nut and washer from the cam follower bracket. Insert the cam follower removal tool (part number 3824519) under the follower and around the bracket, continuing to insert the tool forward until the adjusting screw at the top of the tool can be screwed into the injector cam follower recess by hand, as shown in Figure 2-86. Lift the cam follower assembly and remove it from the engine, as shown in Figure 2-87.

 

How to Install the Thermostat from a Cummins M11 series engine

 Installation
1.Install the thermostat.
…
2.Install the gasket.|
3.lInstall the water outlet pipe.
·Connect outlet pipe and tighten bolts to the
specified torque.
Tightening torque: 19 N-m(1.9 kg-m/14Ib-ft)
4.Install the radiator upper hose at the radiator side.
5.Installthe turbocharger coolant hose.

 6.Close the engine cover.(Non-tilt cab model

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7.Connedt the battery cable negative terminal

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How to remove the Thermostat from a Cummins M11 series engine

                              

 Legend
1.Water outlet pipe

2.Gasket

3.Thermostat

 Removal
1.Drain the engine coolant.
Prepare a container for discharge and use it for
filling when installing the thermostat.The amount
of coolant to be discharged should be enough to
avoid coolant from spilling from the housing on the
cylinder head side.

 2.Open the engine cover.(Non-tilt cab model only)

 3.Remove the turbocharger coolant hose.

 4.Remove the radiator upper hose at the radiator
side.
5.Remove the water outlet pipe.
6.Remove the thermostat.

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 Inspection
·Place the thermostat in water,and raise the water
temperature while thoroughly stirring it.
Measure the temperatures when the valve starts
opening and whenit is fully opened.

 

    

How to disassemble the injector and rocker arm housing of a Cummins M11 series engine

① Remove the injector fixing screws and clamps, and use an injector puller (part number 3823579) to remove the injectors from the engine. Mark the cylinder number on each injector, as shown in Figure 2-80.

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 Figure 2-80 shows the fuel injectors being removed using a puller and their cylinder numbers being marked.

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 ② Remove the rocker arm chamber housing and other parts, see Figure 2-81.

 

 

 

How to disassemble the pushrod, rocker arm assembly, and T-plate of a Cummins M11 series engine

 ①Loosen the adjusting screw, remove the valve pushrod and injector pushrod, and mark their positions as shown in Figure 2-76. (The process of disassembling...)

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When disassembling, if the pushrod is in a spring-compressed state, use a wrench to rotate the crankshaft to release the spring tension. 

 ② Install a 1/4-inch wide and 18-inch long positioning bracket on top of the front bracket of the four rocker arm assemblies. Secure the positioning bracket to the bracket with four bolts (M10-1.5x25), as shown in Figure 2-77. Secure one end of the bracket to the engine brake mounting hole with two bolts on the end bracket. Secure the other end of the bracket to the engine brake mounting hole with two bolts on the middle bracket.

 

Figure 2-76 Remove the valve pushrods and injectors, and mark their positions.

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Figure 2-77 shows the positioning bracket being fixed to the support using bolts.

③ Loosen the eight rocker arm shaft bolts that connect the rocker arm assembly. Grasp the positioning bracket and lift the front rocker arm assembly from the engine to complete the disassembly of the rocker arm assembly, as shown in Figure 2-78. ④ Remove the T-plates and mark their locations, as shown in Figure 2-79.

 

Figure 2-78 Lifting the front rocker arm assembly from the engine

 

 

Figure 2-79 Remove the T-shaped pressure plate and mark its position.

 

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