FK10102-1 Force REPAIR KIT.

1 Steam clean the engine. Obtain an SOS sample; be sure the oil is hot and well mixed before you take the sample. Disconnect the batteries. 2 Loosen clamps (1), holding hose (3) to breather (2). Remove the hose. Loosen clamp (4) and remove the breather. Remove the valve covers from the valve cover bases. Remove the four bolts holding elbow (5) to the inlet manifold. Remove elbow and inlet pipe (6) as a unit. Remove the valve cover base bolts and the valve cover bases.3 Use 5P5195 Wrench to disconnect fuel line assemblies (7) from the cylinder head. Use 5P0144 Socket to disconnect the fuel line assemblies from the valve bodies. Remove the fuel lines. Install 2F2990 Plugs and 5F2807 Caps on the fuel line connections to keep them free of dirt. 4 Remove nut (8) that holds each body assembly in position. Use 5P6229 Extractor (9) to remove the body assemblies from the adapter assemblies. If the body assembly cannot be removed from the adapter assembly with 5P6229 Extractor, use 1P0074 Puller Assembly and FT1533 Adapter to remove it.5 Remove nozzle assembly (10) from each body (11). Remove seal (12) from each body.6 Use 5P4755 Guide to install the seal on each valve body. Install the nozzle assembly on each valve body. Tighten finger tight only. Put a small amount of clean diesel fuel on each seal.7 Install the body assemblies in the adapter assemblies. Install the nut that holds the body assembly and valve and tighten to a torque of 75 7 N m (55 5 lb.ft.). 8 Remove 2F2990 Caps and 5F2807 Plugs from the fuel line connections. Put fuel lines (13) in position on the engine. Use 5P5195 Wrench and 5P0144 Socket to tighten the fuel line nuts to a torque of 40 7 N m (30 5 lb.ft.).9 No. 1 piston at top center (TC) on the compression stroke is the starting point of all timing procedures. Timing bolt (14) is kept in storage at location (16) and can be installed in either the left side of the engine at location (15) or in the right side of the engine at location (17). There are two threaded holes in the flywheel. These holes are in alignment with the holes with plugs in the left and right front of the wheel housing. The two holes in the flywheel are at a different distance from the center of the flywheel so the timing bolt cannot be put in the wrong hole.10 Remove the bolts and cover from the flywheel housing. Install 9S9082 Turning Tool into the housing until the shoulder of the tool is against the housing. Attach a 1/2" drive ratchet to 9S9082 Turning Tool and turn the flywheel while holding the timing bolt in position in hole location (15) or (17) where the plug was removed. Stop rotation when timing bolt (14) can be installed in the threaded hole of the flywheel.11 Look at the valves of cylinder 1 to see if No. 1 piston is on the compression stroke. If cylinder 1 is on the compression stroke, the valves will be closed. (You should be able to move the rocker arms up and down by hand.) If No. 1 piston is not on the compression stroke, turn the flywheel 360° and install the timing bolt.12 If the flywheel was not turned in the direction of normal engine rotation or was turned past the timing hole, turn the flywheel in the opposite direction of normal engine rotation approximately 30°. This will ensure all play is removed from the timing gears when the engine is at TC. 13 To adjust the valve clearance, turn the adjustment screw in the rocker arm. (Do not change the bridge adjustment for normal valve clearance adjustments.) Put No. 1 piston at TC on the compression stroke. Adjust the valve clearance on the intake valves for cylinders 1, 2 and 4. Then adjust the valve clearance for cylinders 1, 3 and 5. See the line drawing for cylinder and valve location.14 To adjust, loosen the valve adjusting locknut and turn the adjusting screw to allow the proper size feeler gauge to pass between the top of the bridge and the valve rocker arm as shown. After each adjustment, tighten the nut for the valve adjustment screw to 30 4 N m (22 3 lb.ft.) and check the adjustment again.15 Remove the timing bolt and turn the flywheel 360° in the direction of engine rotation. This will put No. 6 piston at TC on the compression stroke. Install the timing bolt in the flywheel.16 Make an adjustment to the valve clearance on the intake valves for cylinders 3, 5 and 6. Make an adjustment to the valve clearance on the exhaust valves for cylinders 2, 4 and 6. Remove the timing bolt from the flywheel when all the adjustments to the valve clearances have been made.17 Install the valve cover base seals in the bases. Install the valve cover bases on the cylinder head. Install the valve cover base bolts. Tighten to a torque of 13.6 2.8 N m (120 24 lb.in.). Put clean oil on the O-ring seal on the inlet pipe and install the inlet pipe into the turbocharger.18 Install the bolts which hold the elbow to the manifold. Install the valve cover seals in the valve covers. Position the valve covers on the valve cover bases. Install the valve cover bolts; tighten to a torque of 13.6 2.8 N m (120 24 lb.in.). Put the breather in position on the valve cover and tighten the clamp. Slide the hose onto the breather and tighten the hose clamps.19 Reconnect the batteries. Start engine. It may be necessary to prime fuel system if engine fails to start.20 Inspect for leaks. Stop the engine and allow the oil to drain. Check to see the oil and coolant are at their correct levels.