How to disassemble the crankshaft pulley, shock absorbers, and crankshaft assembly of the Cummins M11 series engine.

 (1) Disassembly of the crankshaft pulley and damper: When disassembling, first remove one mounting bolt and install one guide pin, then remove the remaining bolts, pulley, and damper, as shown in Figure 2-110. Do not use hammers or screwdrivers when disassembling the viscous damper to avoid damaging it.

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  (2) Disassembly of the idler assembly: ① Remove the crankshaft front oil seal, as shown in Figure 2-111.

 

 

 

 Figure 2-110 Disassembly of crankshaft pulley and shock absorber

 

 

 Figure 2-111 Removal of the front crankshaft oil seal 1—Pressure ring 2—Seal 3—Oil seal 4—Gasket

 

 

Figure 2-112 Removal of the engine front bracket

 

② Remove the front engine mount, see Figure 2-112. 

 ③ Remove the gear chamber cover and rectangular seal, see Figure 2-113. 

 ④ The engine has three idler assemblies, see Figure 2-114. These three idler assemblies are the water pump and oil pump idler, the camshaft idler, and the hydraulic pump idler. Remove the camshaft idler and water pump idler in the order shown in Figure 2-115. If using an SAE "B" type hydraulic pump drive, mark the position of the idler shaft when removing it. During reassembly, each shaft should be reinstalled in its original position. 6. Remove the hydraulic pump drive in the order shown in Figure 2-116.

 

 Moving idler gear assembly. If using an SAE "A" type drive unit, a rectangular seal ring 4 is not required on the rear surface of the gear positioning plate.

 

 

 Figure 2-113 Disassembly of the gear chamber cover and rectangular seal ring 

 

Figure 2-113 Disassembly of the gear chamber cover and rectangular seal ring

 

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 Figure 2-114 shows three idler assemblies mounted on the engine: 1—Water pump and oil pump idler 2—Camshaft idler 3—Hydraulic pump idler

 

 

 

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 Figure 2-115 Disassembly of Camshaft Idler and Water Pump Idler 4—Gear Positioning Plate 5—Front Thrust Bearing 6—Idler Gear 7—Rear Thrust Bearing 8—Idler Gear Shaft 9—Wear-resistant Plate

 

 

 

 

 

 

 

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

How to disassemble the Cummins M11 series engine. Repto flywheel housing disassembly.

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① Remove the REPTO oil supply pipe from the flywheel housing and oil sump pipe joint, see Figure 2-98.

 Figure 2-97 Remove 12 bolts, guide pins, and flywheel housing.

 

 

 Figure 2-98 Remove the REPTO oil supply hose

 

 ② Remove the crankshaft drive gear and the two guide pins from the crankshaft, as shown in Figure 2-99. ③ Remove the idler shaft fixing bolts and use an idler shaft puller to remove the idler shaft, as shown in Figure 2-100.

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 Figure 2-99 Removing the crankshaft drive gear and guide pin

 

 

 

Figure 2-100 Remove the idler gear shaft using a puller

④ Fabricate the idler gear and idler gear bearing removal sleeve according to the following dimensions, see Figure 2-101. The sleeve dimensions should be: outer diameter D 38.1 mm (1.50 in), material PVC, aluminum, or similar; length L 25.4 mm (1.00 in), opening W 6.3 mm (0.25 in). When removing the idler gear and idler gear bearing, insert the sleeve through the idler gear shaft hole into the idler gear hole to secure the idler gear and idler gear bearing together. Remove the idler gear to facilitate the removal of other flywheel housing bolts, see Figure 2-102. 6. Before removing the flywheel housing bolts, use a punch to drive the expansion plug directly into the flywheel housing, see Figure 2-103. Remove the expansion plug from the inside of the flywheel housing. Never unscrew the expansion plug to remove it from the housing, as this will damage the expansion plug.

 

 

 

 

 

 Figure 2-101 Fabricating the disassembly sleeve according to dimensions

 

The expansion plug can cause oil leakage. Once removed, the expansion plug cannot be reused; a new expansion plug must be used. Remove the two bolts inside the housing and install the two guide pins to support the flywheel housing during disassembly, see Figure 2-104. Use a socket wrench to remove the bolts. 8. Remove the remaining bolts and gently tap the housing with a rubber mallet to loosen it, allowing the flywheel housing and guide pins to be removed, see Figure 2-105.

 

 

 

 

 

 

 

 

Figure 2-102 Using a sleeve to secure the bearing for removal of the idler gear

 

 

 

 

 Figure 2-103 Inserting the expansion plug into the flywheel housing

 

 

 

 

 

 

 Figure 2-104 Remove the two bolts and install the two guide pins.

 

 

 

 

 

 

 

 

Figure 2-105 Removing the flywheel housing and guide pin

 

       

 

 

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.