How to disassemble the main bearing cap, bearing shell, and thrust bearing of the Cummins M11 series engine

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(1) Removal of the main bearing cap, lower bearing shell, and thrust bearing 

① Rotate the engine on the test bench so that the oil pan mounting flange faces upwards. The markings on the main bearing cap must match the numbers on the cylinder block oil pan flange, see Figure 2-134. During installation, the numbers on the main bearing cap and oil pan flange should match, and the locating tongue of the main bearing cap must be aligned with the locating tongue. 

 ②Use the ST-1178 main bearing cap puller to remove the main bearing cap, see Figure 2-135. The No. 4 main bearing cap is connected to the cylinder block by a locating pin, and the No. 4 main bearing shell is fitted with a thrust bearing. During disassembly, it is strictly forbidden to shake the main bearing cap; only the puller can be used to pull the main bearing cap vertically upwards.

 

 

 

 Figure 2-133 Marking the tongue plane for positioning the bearing shell on the connecting rod.

 

 

 

③ Remove the lower bearing shell from the main bearing cover and mark the journal number at the time of disassembly on the surface of the locating tongue, as shown in Figure 2-136. ④ Remove the lower thrust bearing from the No. 4 main bearing cover and mark it with the letters "L" and "front" or "rear", as shown in Figure 2-137.

 

 

 

 Figure 2-134 shows markings on the main bearing cap and oil pan flanges.

 

 

 

 

 Figure 2-135 Remove the main bearing cover using a puller

 

 

 

 

Figure 2-136 Marking on the surface of the bearing locating tongue

 

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Figure 2-137 Marking on the lower thrust bearing: “L” for front and “front” or “rear”.

 

 

 (2) 

① Crankshaft and Upper Bearing Removal Place nylon slings over connecting rod journals 3 and 4, and use a crane to remove the crankshaft, as shown in Figure 2-139. 

② Remove the upper bearing and mark the journal number at the time of removal on the surface of the bearing locating tongue, as shown in Figure 2-140.

 

 

 Figure 2-138 Mark "U" and "front" or "rear" on the upper thrust bearing.

 

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How to disassemble the Cummins M11 series engine: oil pump, camshaft, and gear housing.

  (1) Removal of the oil pump When removing the oil pump, it is strictly forbidden to pry the gear pump flange to avoid damaging the oil pump. Remove the three mounting bolts and two spacers, screw the two M8-1.25 bolts into the puller, and remove the oil pump from the engine, as shown in Figure 2-117.

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(2) Camshaft Removal Rotate the camshaft until the camshaft gear hole aligns with the thrust bracket bolt hole. Remove the two thrust bracket bolts, then remove the three bolts, rear cover plate, and gasket (see Figure 2-118). ② Install the camshaft installation guide tool (part number 3376388). Insert the expander (part number 3376923) through the opening in the rear cover plate into the camshaft. Rotate the bolt inside the expander clockwise to open the expansion plug (see Figure 2-119).

 

 Figure 2-117 Remove the bolts and use a puller to remove the oil pump.

 ③ Place the mandrel bushing onto the expander, and install the positioning guide extension rod on the expander, as shown in Figure 2-120. 

 ④ Slowly rotate the camshaft by hand to pull it out of the cylinder block, as shown in Figure 2-121. Support the removed camshaft with your other hand and remove the camshaft guide tool. 

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 (3) Removal of the gear housing: Remove all bolts from the gear housing and the gear housing itself, as shown in Figure 2-122, and remove the rear rectangular seal ring.

 

 Figure 2-118 Remove the camshaft thrust bracket bolts, rear cover plate, and gasket.

 

 Figure 2-119 Installing the expander into the camshaft 1 - Expander

 

 

 Figure 2-120 Insert the mandrel bushing onto the expander and install the extension rod. 2-Mandrel bushing 3-Extension rod  

 

Figure 2-121 The rotating camshaft pulls it out of the cylinder block. 

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How to disassemble the Cummins M11 series engine, including the pistons and connecting rods.

 Rotate the crankshaft to expose the carbon deposits above the piston inside the cylinder liner. Remove the carbon deposits using a fine-fiber abrasive pad (such as Scotch-Brite 7448, part number 3823258 or equivalent) and solvent, as shown in Figure 2-125.

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 Figure 2-122 Removing the gear chamber housing

 ② Use a crankshaft turning tool to rotate the crankshaft and fix the connecting rod at the bottom dead center (BDC) position so that the connecting rod bolts can be removed and loosened, as shown in Figure 2-126.

 

 

 Figure 2-123 Install the crankshaft turning tool onto the flywheel end of the crankshaft.

 

 

 Figure 2-124 Remove the cooling nozzle

 

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 Figure 2-125 Removing carbon buildup from the upper inner surface of the piston

 

 

 Figure 2-126. Rotate the crankshaft to fix the connecting rod at the bottom dead center position, then loosen the connecting rod bolts.

 ③ Use a hammer to tap the connecting rod bolt head to loosen the connecting rod cap from the annular locating pin. Remove the connecting rod bolt and connecting rod cap, see Figure 2-127. ④ Mark the cylinder number and the letter "L" on the surface of the lower bearing locating tongue, see Figure 2-128. However, it is strictly forbidden to make marks on the mating surface between the bearing and the crankshaft, to avoid damaging the crankshaft if the bearing continues to be used.

 

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Figure 2-127 Gently tap the connecting rod bolt head to loosen the connecting rod cap, then remove the connecting rod cap and bolt.

 

 Figure 2-128 Marking on the lower bearing locating tongue.

 

 Install the connecting rod guide pin (part number 3376038) in the connecting rod bolt hole. Use a wooden dowel and a hammer to push the connecting rod away from the crankshaft, as shown in Figure 2-129. Continue pushing the connecting rod until the piston rings protrude from the cylinder block.

 

6. Remove the piston and connecting rod assembly and mark it, as shown in Figure 2-130. If the removed piston and connecting rod assembly is still usable, it must be reassembled with the original cylinder number. 

7Place the piston and connecting rod assembly on a special test bench to prevent damage, as shown in Figure 2-131. 

 8. Mark the connecting rod and its mating connecting rod cap with special markings, as shown in Figure 2-132. During assembly, the markings on the connecting rod and connecting rod cap must match and be on the same side of the engine. 

 9. Remove the upper connecting rod bearing and mark the cylinder number and the letter "u" on the flat surface of the locating tongue, as shown in Figure 2-133.

 

 

 Figure 2-129. Install the guide pin in the connecting rod bolt hole, and use a hammer to push the connecting rod away from the crankshaft.

 

Figure 2-130 Remove the piston connecting rod assembly and mark it.

 

 Figure 2-131 Placing the piston and connecting rod assembly on a special test bench.

 

 Figure 2-132 Special markings are made on each pair of connecting rods and connecting rod caps.

         

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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