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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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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How to disassemble the starter and air compressor of a Cummins M11 series engine

 (1) Removal of the starter motor: Use a wrench to remove the three bolts and the starter motor, see Figure 2-57. 

(2) Removal of the air compressor: ① Remove the bolts, loosen the hose clamps, and disconnect the air supply pipe, see Figure 2-58.

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Figure 2-53 Disconnecting the Atmospheric Pressure Sensor and Connecting Wires 1—Atmospheric Pressure Sensor

Figure 2-54 Removing the actuator harness and sensor harness from the ECM 1, 2 - Position on the ECM bracket

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 Figure 2-55 Remove ECM mounting bolts,                             Figure 2-56 Remove ECM cooling plate         washers, and ECM.                                                                    and mounting bracket.

   Figure 2-57 shows the removal of three bolts and the starter motor. 

 

 Figure 2-57 Remove the three bolts and the starter motor.

Figure 2-58 Removing the air supply pipe from the air compressor: 1 - Bolt; 2 - Clamp

 

② Remove the coolant inlet/outlet pipes from the air compressor, remove the mounting bolts, and remove the air compressor, as shown in Figure 2-59. 

 ③ Remove the coolant inlet pipe and connector, and remove the coolant outlet pipe positioning screw and outlet pipe, as shown in Figure 2-60.

 

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

 

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How to disassemble the fuel system and ECM cooling plate of a Cummins M11 series engine

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  (1) Install the engine on the test bench 

① Using an engine overhaul test bench (part number 3375194) and a connecting plate (part number 3376432), install the connecting plate onto the test bench using five bolts with part number 5/8-11x2in. Tighten to a torque of 180 N·m, see Figure 2-43. 

 ② Install two guide pins (part number 3376488) at bolt holes 1 and 2 on the water channel cover. Use a lifting device to install the engine onto the connecting plate on the test bench, see Figure 2-44.

 

 Figure 2-43 shows the connection plate being installed onto the overhaul stand using 5 bolts.

 

 

 

 

Figure 2-44 shows the engine being mounted onto the connecting plate. 1, 2—bolt holes.

③ Secure the connecting plate to the cylinder block using 8 bolts (part number 3376434), tightening to a torque of 47 N·m, see Figure 2-45. ④ Remove the lifting lugs from the engine cylinder block, see Figure 2-46.

  

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 Figure 2-45 shows the connecting plate being secured to the cylinder block with bolts. 

 

  3—Connecting plate 4, 5, 6—Bolt holes 7, 8—Hole Remove the fan hub bracket, see Figure 2-47.

(2) Fuel system component disassembly ①Remove the fuel supply hose and fuel filter housing, see Figure 2-48. 

 

Figure 2-47 Remove the fan hub bracket

 

Figure 2-48 Removing the fuel hose and filter housing 1, 2—Hose connectors

 

② Remove the fuel supply pipe and return pipe from the cylinder head, and remove the fuel gear pump cooling pipe, as shown in Figure 2-49. 

 

 ③ Remove the actuator wiring harness from the fuel pump fuel cut-off valve and label the wires for easy identification, as shown in Figure 2-50.

 

 

 

 

 Figure 2-49 Removal of fuel supply pipe, return pipe, and gear pump cooling pipe 1 - Supply pipe 2 - Return pipe 3 - Cooling pipe

 

 

Figure 2-50 Remove the fuel shut-off valve actuator harness and label it.

 

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④ Remove the four mounting bolts connected to the fuel pump, the fuel pump, the gasket, and the star coupling, as shown in Figure 2-51. 

5 Remove the access cover and gasket on the fuel pump side, as shown in Figure 2-52. 

 

Figure 2-51 shows the removal of the fuel pump, gasket, and coupling.

 

 

 

Figure 2-52 shows the removal of the access cover and gasket on the fuel pump side.

 

(3) Removal of ECM and ECM Cooling Plate 

① If an atmospheric pressure sensor is installed on the engine, remove the atmospheric pressure sensor and connecting wires from the front bracket of the ECM, see Figure 2-53. 

 

② Remove the wiring harness clamps from positions 1 and 2 on the ECM bracket, loosen the AMP connector mounting bolts on the sensor wiring harness, and remove the actuator wiring harness and sensor wiring harness from the ECM, see Figure 2-54. 

 

 ③ Remove the ECM mounting bolts, star washers, and the ECM, see Figure 2-55. 

 

 ④ Remove the four fixing bolts, the ECM cooling plate, and the mounting bracket, see Figure 2-56.

 

 

How to Disassemble the Cummins M11 series engine water pump and accessories

 (1) Disassembly of the water pump 

 ① Remove the two inlet pipe connector bolts and the three water pump mounting bolts. Rotate the water pump outwards to remove the inlet pipe connector, see Figure 2-36. 

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 ② Rotate the top of the water pump outwards to tilt the rear of the pump downwards, and remove the water pump from the thermostat housing bracket, see Figure 2-37.

 (2) Disassembly of water pump accessories

 ① Disconnect the wiring harness from the coolant temperature sensor, loosen the air compressor return pipe connector, remove the four bolts and the thermostat housing bracket, see Figure 2-38. 

② Remove the four bolts, the coolant heater housing, and the gasket, see Figure 2-39. 

③ Remove the three bolts, remove the coolant filter seat and the two O-rings, see Figure 2-40. 

④ Remove the water channel cover mounting bolts, sealing gasket, and guide pin, see Figure 2-41. 

⑤ Remove the inspection hole cover and oil dipstick tube bracket, see Figure 2-36. Remove the connector bolts and mounting bolts, and remove the water inlet pipe connector.

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Figure 2-37 shows the water pump being removed from the thermostat housing. 

 

 

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Figure 2-38 Removing the thermostat housing bracket 

 

 

Figure 2-39 Removal of coolant heater housing and gasket

 

Figure 2-40 Remove the coolant filter housing and two O-rings. 

 

 

 

Figure 2-41 Removing the drain cover 1, 2—Bolts 

 

 

Figure 2-42 Remove the access cover and oil dipstick bracket. Bolts 1 and 2