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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Disassembly of the Jacobs engine brakes on a Cummins M11 series engine

    ① If the engine is equipped with Jacobs engine brakes, the connector should be pressed into the front housing, as shown in Figure 2-74, to leave space for housing removal.

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  ② Remove the mounting bolts and brakes from the engine, as shown in Figure 2-75.

 

 

 

 Figure 2-74 shows the connector being pressed into the front housing. Figure 2-75 shows the removal of the mounting bolts and brake.

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

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(1) Disassembly of the rocker arm housing components: Remove the crankcase breather clamp, rocker arm housing cover bolts, vibration damping washers, and spacers. Remove the rocker arm housing cover and gasket, as shown in Figure 2-71. 

 (2) Disassembly of the rocker arm housing housing partition: 

 ① If the engine is equipped with a Jacobs engine brake, disconnect the two electrical connectors from the inside and outside of the partition.

 

Figure 2-70 Remove a section of the actuator wiring harness inside. Figure 2-71 Remove the rocker arm chamber cover, gasket, and breather tube clamp. 1—Clamp

 

 

Disconnect the oil supply hose connector and remove the oil supply hose, as shown in Figure 2-72. ② Remove the 16 bolts and the partition, as shown in Figure 2-73. 

 

 

 

 

 

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 Figure 2-72 Remove the two electrical connectors and disconnect the oil supply pipe. 

Figure 2-73 Remove the rocker arm housing partition.

 

       

How to disassemble the Cummins M11 series engine sensor wiring harness and internal actuator wiring harness

Disassembly of Sensor Harness and Internal Actuator Harness 

① Remove the sensor harness and actuator harness connector, and mark them (see Figure 2-64). 

② Remove the harness bracket from the cylinder block, remove the oil temperature sensor and oil pressure sensor, and remove the engine position sensor from the rear of the gear housing (see Figure 2-65). 

 ③ Use a Torx screwdriver (T25) to loosen the actuator harness fixing screws at the rear of the rocker arm housing, and disconnect the two parts of the actuator harness (see Figure 2-66).

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④ Remove the actuator wire grounding terminal from the engine and the connector from the rocker arm housing, as shown in Figure 2-67. Remove the wire connector from the injector, as shown in Figure 2-68. Label the connector for easy installation. Remove the five bolts and clamps securing the wiring harness, as shown in Figure 2-69.

 

Figure 2-64 Remove and label the sensor harness 1—Connector 2—Engine position sensor 3—Oil temperature sensor 4—Oil pressure sensor

 

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Figure 2-65 Removal of three sensors: 1 - Oil temperature sensor 2 - Oil pressure sensor 3 - Engine position sensor

 

 

 

 

 

Figure 2-66 shows the process of loosening the screws with a screwdriver and disconnecting the two parts of the actuator harness. 

 

 

 

 

 

 

 

Figure 2-67 Disconnect the actuator harness grounding terminal and remove the plug 1—Harness Grounding Terminal

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 Figure 2-68 Remove the injector connector and mark it. Figure 2-69 Remove the wiring harness fixing bolts and clamps.

How to disassemble the hydraulic pump of a Cummins M11 series engine

 1) Disassembly of the hydraulic pump 

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① Remove the two bolts, the hydraulic pump and the gasket, as shown in Figure 2-61.

 

Figure 2-59 Remove coolant inlet/outlet pipes, bolts, and air compressor. 1—Inlet pipe; 2—Outlet pipe; 3—Nut; 4—Bolt

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Figure 2-60 Removing the inlet and outlet pipes, connectors, and positioning screws 1—Inlet pipe 2—Connector 3—Positioning screw

 

 

  Figure 2-61 Removing the hydraulic pump and gasket

 

Figure 2-62 Remove the mounting bolts of the hydraulic pump drive unit 

 ③ Remove the hydraulic pump drive adapter, O-ring, and drive gear, as shown in Figure 2-63.

  Figure 2-63 Remove the adapter, O-ring, and drive gear. 

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