Labot T Guide 2000 Usa

TABLE OF CONTENTS
Section FOREWORD ............................................................................................... SAFETY ...................................................................................................... DEFINITION OF A WARRANTY ................................................................ ELEMENTS OF TIME MANUAL ................................................................ DESCRIPTION OF OPERATIONS ............................................................. DIAGNOSIS OF TESTS ............................................................................. REAPPRAISAL REQUESTS ..................................................................... REVIEW PROCEDURE .............................................................................. SERVICE LEVELS ..................................................................................... SERIES 2000 LABOR OPERATION INDEX (ALPHABETICAL) ............... SERIES 2000 OPERATION NUMBERS ..................................................... Page 3 3 3 3 4 5 5 5 6 7 10
SERIES 2000 LABOR TIME GUIDE
(Rev. 3/04)
All information subject to change without notice.
12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION
FOREWORD
The labor times in this Manual represent the time required to perform a repair, replacement, and/or adjustment operation on DDC/MTU Series 2000 Engines not affected by collision damage. The labor times are representative of an average technician in a typical distributorship or dealership using normally available tools, service equipment, and all essential Special Service Tools to diagnose and perform the repair. The use of genuine DDC/MTU parts and repair procedures prescribed in the DDC/MTU Series 2000 Service Manual is the basis for this Manual.
SAFETY
Detroit Diesel Corporation (DDC) assumes that all required approved Safety Lock-out tags, locks, and other appropriate safety devices will be utilized by the technician prior to the start of any repairs of a Series 2000 engine. Also, this manual assumes use of all appropriate protective safety equipment and clothing.
DEFINITION OF A WARRANTY
A warranty repair restores to operating condition, by repair or replacement, only the defective or damaged parts necessary to remove and replace the defective parts, according to the terms of the appropriate warranty statement. Other parts removed in the repair process will be reinstalled as-is, unless the user authorizes the additional expense. The intent of a warranty repair is to repair or replace the warranted parts and restore the rest of the component to its operating condition prior to the warrantable failure, not to restore the product to like new condition
Procedure for Development of Labor Time Manual

The time to complete a repair, replacement, and/or adjustment operation, as provided in this Manual, is developed by Detroit Diesel Corporation personnel under conditions comparable to a typical distributorship or dealership. Development of most guides are generally based on the following: Product: Production Series 2000 engine. Tools: Use of normally available tools, service equipment, and all essential Special Service Tools indicated in the Series 2000 Service Manual. Special Service Tools required to perform an operation will be called out under Notes section of that operation. Technicians: The manual assumes use of competent engine technicians (not specialists in any particular operating system), who have attended company training programs and are accustomed to following Service Manual procedures.
ELEMENTS OF TIME MANUAL

Each operation includes time to perform all elements of a complete repair operation in the Series 2000 Service Manual. Elements that comprise the time manual include the following:
(Rev. 3/04)
Repair Time: The actual time to perform the repair is obtained by timing a technician in the actual performance of the repair. It includes tasks such as removal, disassembly, cleaning, inspection, reassembly, installation, and/or adjustment of the affected component or assembly. The cleaning time in each operating is limited to that directly associated with the installation or replacement of components, such as mating surfaces and/or internal parts involved in the repair. It does not include cleaning other areas of the engine which may have been contaminated by the failure of the component being replaced. This time also includes time to perform other associated elements, such as open/close vehicle hood, raise/lower engine on hoist, procure special tools, and/or mount on overhaul stand. Personal Allowance: An allowance is added to the above repair time to provide for the personal need of the technician during a repair operation. Contingency Allowance: An additional allowance is provided, based on the total of the above times, to allow for variation in engine age and condition, seized components, and broken or seized bolts, studs, etc. Normal diagnosis requiring only limited time and no special equipment is also covered by this allowance. A dash (-) in the Service Level column for a labor operation indicates that no time study data is available and actual time used during repair to perform this operation should be used.
DESCRIPTION OF OPERATIONS
The following topics support types of operations.
Types of Operations
Basic Operation: An operation which is complete in itself and includes all of the steps needed to perform the operations as described in the Series 2000 Service Manual. The time for this operation includes Repair Time, Personal Allowance, and Contingency Allowance. Combination Operation: An operation which describes additional work which may be performed in combination with a basic operation, usually when a major assembly or component has been removed from the engine. The time for a combination operation is in addition to the time specified for the basic operation, or for any applicable basic operation. Overlapping Operations: Overlapping labor is the duplicate labor time allowance that may occur if more than one basic operation is claimed for performing a repair, and the same repair steps are included in each of the basic operations. Such overlapping labor is not reimbursable. To avoid claiming basic operations with overlapping time allowances, use an applicable combination operation for any added repair steps that are required, in addition to the basic operation being performed. If you experience an unusual repair situation, where an applicable combination operation is not available, then you should claim the actual time required to perform the added repair steps and provide an explanation of the situation in the Narrative section of the Application for Adjustment (AFA). General Operation: Is only to be used when there is no operation listed, and must be completely explained in the "Narrative" section of the AFA.
(Rev. 3/04)
DIAGNOSIS OF TESTS
Normal Diagnosis: This is the diagnosis time required to determine the cause of a routine service problem. Normal diagnosis includes defining those symptoms which are readily apparent to the senses. Normal diagnosis also includes the use of common testers by technicians, such as ammeters, compression testers, and integrated computer analysis. Abnormal Diagnosis: This is the diagnosis time required to determine the cause of an exceptional service problem that normal diagnosis fails to identify. Abnormal diagnosis time is reimbursable only when reasonable and fully explained on the Adjustment for Application (AFA). Road or Dynamometer Test: A supplemental allowance for performance of a post-repair test may be included on the AFA, if such a test is deemed to be required to verify correction of a problem.
REAPPRAISAL REQUESTS
Applicable labor times are subject to periodic review. However, a change in operation times is never made arbitrarily. Each change is a response to at least one of the following events or conditions: Component design change Design change in other components that affect accessibility of the component being repaired Change in the procedure or method of repair Change in the tools or equipment used in the repair process Final review and verification of times or review of reappraisal requests from distributors and dealers
REVIEW PROCEDURE
The following actions are needed to assure accurate appraisal.
Service Outlet Action

The following actions are required by the distributor or dealer: 1. Verify that the technician has followed the procedures outlined in the applicable Service Manual and used all specified special tools and equipment. 2. Complete a Suggested Labor Time Manual Operation Change form (18SE10), available through normal literature distribution channels. 3. Use one form for each time operation in question (or a combination of operations representing one repair job).
(Rev. 3/04)
4. Provide video, with time and date displayed on screen, of total operation in question. Submit form and video to: Detroit Diesel Corporation 13400 Outer Drive, West Detroit, Michigan 48239-4001 Attn: Warranty Manager 5. Identify the technician involved to facilitate review of the process. 6. Provide any additional comments, including time requirements for individual steps, which may help in identifying the problem area.
DDC Action
When the video and reappraisal request is received, DDC will take the following actions: 1. Review the labor time operation in question. Recommendations and assistance will be offered in accordance with the results of this review. 2. DDC may conduct review at the service outlet, if necessary. Comparative reviews at additional service outlets may also be conducted, if they are required to provide valid results. 3. Provide results of the review to the service outlet, and to the appointing distributor, if such service outlet is a dealer.
SERVICE LEVELS
The Series 2000 engines are used by the following Original Equipment Manufacturers (OEMs). When preparing your Adjustment for Application (AFA), identify the appropriate model, and note the proper service level. Make sure the proper service level is used while consulting the Labor Time Manual. Listed in Table 1are the service levels.
OEM
Engine Removed Construction & Industrial Generator Marine
If your OEM is not listed, record that on your AFA.
Model
All All All All
Description
All All Construction & Industrial All Generator All Marine
Service Level
ENG REM C & I GEN MAR
Table 1
Service Levels
(Rev. 3/04)
SERIES 2000 LABOR OPERATION INDEX (ALPHABETICAL)

Listed in Table 2 is the labor operation index (alphabetical).
DESCRIPTION
Air Compressor - R & R Air Compressor Hose - R & R Air Compressor Drive - R & R Air Filter and Housing - R & R Air Filter Element - R & R (Each) Air Inlet Manifold - R & R (Complete) Air Shutdown Mechanism - R & R Charge Air Cooler Coolant Piping - R & R (Each Section) Charge Air Piping to Turbocharger - R & R Charge Air Cooler Assembly - R & R Charge Air Cooler Cover - R & R Charge Air Cooler Base - R & R Alternator/Generator - R & R Belt Set - R & R Camshaft - R & R Cam Followers - R & R (All) Crankshaft (Engine Removed) - R & R Crankshaft Front Drive Hub - R & R Crankshaft Rear Drive Hub - R & R Crankshaft Oil Seal (Front) - R & R Crankshaft Oil Seal (Rear) - R & R Crankshaft Pulley - R & R Crankshaft Thrust Washers - R & R Cylinder Block- R & R Cylinder Block - R & R (From Short Block) Engine Stand - R & R Steam Clean and Paint Engine Cylinder Block - Pressure Test (Engine Removed) Cylinder Head - R & R (One) Cylinder Head - R & R (All) Valve Springs (Head Removed) - R & R (One Head) Valve Seal - R & R (One Head) Cylinder Head - Pressure Test (One) Cylinder Kit - R & R (One) Cylinder Kit - R & R (Each Additional) Piston Cooling Jet - R & R (One) Electronic Control Module (MDEC/DDEC) - R & R Reprogram ECM or MDEC (Per Module) Electronic Unit Pump - R & R (One) Electronic Unit Pump - R & R (Each Additional)
OPERATION NOS.
12.40-00 -03 -05 03.10-00 -01 -02 -03 -05 -06 -07 -08 -09 07.10-00 01.37-00 01.70-00 -06 01.30-00 -01 -02 01.32-00 01.33-00 01.38-00 01.31-00 01.10-00 -01 -02 -05 -11 01.20-00 -01 -03 -04 -06 01.60-00 -01 -02 02.19-00 -01 02.11-00 -01
(Rev. 3/04)
DESCRIPTION
Engine Assembly - R & R (without OEM Module) from Chassis Engine Assembly - R & R (with OEM Module) from Chassis Engine Assembly - R & R from OEM Module Coolant or Lube Oil - Drain & Refill Engine Dynamometer Test Engine Lifter Bracket - R & R Engine Mount (Front Trunnion) - R & R Engine Performance Test Engine Performance Test (Load Box Method) Test Run (Check for Leaks) Engine Tune-Up Valve Lash (Intake Exhaust) - Adjustment Exhaust Manifold - R & R (Each) Exhaust Manifold - R & R (All) Flywheel - R & R Flywheel Housing - R & R Gear Case (Complete) - R & R Fuel Manifold (Rail) - R & R Fuel Delivery Rail/Pressure Regulator - R & R Fuel Filter Elements (Primary) - R & R (Set of 2) Fuel Filter Assembly (Secondary) - R & R Fuel Lines (Nozzle Holder) - R & R (One) Fuel Lines (Nozzle Holder) - R & R (Each Additional) Fuel Return Line Assembly - R & R Fuel Pump and/or Coupling - R & R Fuel System - Prime (Complete System) Gear Case Cover - R & R Idler Gears - R & R (Both) Hydraulic Pump (Power Steering) - R & R Injector Nozzle Assembly - R & R (Each) Each Additional Injector Nozzle Assembly High Pressure Fuel Tube - R & R (Each) Fuel System - Pressure Test Compression Test (Each Cylinder) Injector Harness (EUP) - R & R Main Bearings - R & R (All) Main Bearing - R & R (Each Set) Rod Bearings - R & R (All) Rod Bearing - R & R (Each Set) Oil Cooler Elements - R & R Oil Cooler Housing - R & R Oil Cooler Housing Cover - R & R
OPERATION NOS.
00.00-01 -23 -24 -25 13.20-00 01.22-00 11.10-00 13.22-00 -05 -10 14.00-00 -01 06.10-00 -01 01.40-00 01.50-00 -01 02.40-00 -01 02.30-01 02.33-00 02.50-00 -08 -10 02.20-00 02.70-00 01.34-00 -03 12.50-00 02.10-00 -01 -02 -03 -04 -05 01.35-00 -01 -02 -03 04.41-00 -01 -05
(Rev. 3/04)
DESCRIPTION
Oil Filter Elements - R & R Oil Filter Housing - R & R Oil Pan & Gasket - R & R Dipstick Tube & Adapter - R & R Oil Pump - R & R Oil Pressure Relief Valve - R & R Oil Pick Up Tube and Bracket - R & R Oil Transfer Tube - R & R Radiator Assembly - R & R Fan - R & R Fan Hub Assembly - R & R Belt Tensioner and Bracket - R & R Cooling System - Pressure Check Fan Hub Mounting Bracket - R & R Repair Validation Rocker Cover - R & R (Each) Breather - R & R Breather Tube - R & R Starter Motor and Drive Assembly - R & R Starter Solenoid (Starter Removed) - R & R Synchronous Reference Sensor or Timing Reference Sensor - R & R DDEC Sensor Harness - R & R Temperature or Pressure Sensor - R & R (Each) Thermostat - R & R Thermostat Housing Seal (Engine) - R & R (Each) Thermostat Housing - R & R Water/Oil Distribution Manifold - R & R Turbocharger - R & R (One) Turbocharger Wastegate - R & R (One) Turbocharger - R & R (Each Additional) Turbocharger Oil Drain - R & R (One) Turbocharger Oil Drain - R & R (All) Turbocharger Oil Supply Line - R & R (One) Turbocharger Oil Supply Line - R & R (All) Valve Mechanism - R & R (One Cylinder) Valve Springs and/or Seals (Head Installed) - R & R Push Rod - R & R (Each) Vibration Damper - R & R (All) Water Pump (Fresh Water or Engine Coolant) - R & R Cooling System - Flush Cooling System - Reverse Flush (When Needed) Water Pump (Raw Water or Separate Circuit) - R & R
OPERATION NOS.
04.20-00 -01 04.70-00 -01 04.10-00 -01 -05 -06 05.30-00 -01 -02 -04 -05 -08 13.21-00 01.85-00 -01 -02 07.30-00 -01 02.18-00 -01 -05 05.20-00 -01 -02 -04 03.50-00 -02 -08 03.52-00 -01 03.51-00 -02 01.80-00 01.83-00 -02 01.36-00 05.10-00 -02 -03 05.60-00
Table 2
Series 2000 Labor Operation Index
(Rev. 3/04)
SERIES 2000 OPERATION NUMBERS

Listed in Table 3 are the engine assembly operation numbers.
NO. OF CYL
08 12 16
SERVICE LEVELS ENG REM

-
OPER. NOS.
ENGINE ASSEMBLY
C&I
20.0 30.0 40.0
GEN
20.0 30.0 40.0
MAR
30.0 40.0 50.0
00.00-01 Engine Assembly - R & R (without OEM Module) from Chassis INCLUDED:
Disconnect all battery power, both positive and ground from vehicle. R & R all hydraulic hose connections, electrical harness connections, exhaust connections and air intake piping. R & R all radiator grills, deck plates, ladders and any other OEM equipment necessary to remove the engine assembly from the truck. Run engine and make all final inspections and checks. Coolant and lube oil draining, filling, and disposal (as needed).
NOT INCLUDED:
13.22-00 Engine Performance Test R & R radiator, fan, and guard.

NOTES:
Requires special lifting equipment to perform this operation.

00.00-23 Engine Assembly - R & R (with OEM Module) from Chassis INCLUDED: 08 12 16 -
Refer to Group 00.00-01 for details.

NOTES:

00.00-24 Engine Assembly - R & R from OEM Module INCLUDED: 08 12 16 -
Refer to Group 00.00-01 for details. R & R any other OEM equipment necessary to remove the engine assembly from module. R & R engine mounts from module.
NOT INCLUDED:
R & R radiator, fan, and guard.

NOTES:
(Rev. 3/04)
10
OPER. NOS.
ENGINE ASSEMBLY
NO. OF CYL
08 12 16

-
C&I
0.5 0.5 0.5
GEN
0.5 0.5 0.5
MAR
1.0 1.0 1.0
00.00-25 Coolant or Lube Oil - Drain & Refill INCLUDED:
Disposal of removed coolant and lube oil.

NOT INCLUDED:
R & R of any filters.

00.09-00 General Operation NOTES: 08 12 16 -
Use this operation for work performed in this group which is not covered by an operation number.
Table 3
Engine Assembly Operation Numbers
Listed in Table 4 are the basic engine operation numbers.

NO. OF CYL
08 12 16

30.0 35.0 40.0
OPER. NOS.
01.10-00 Cylinder Block- R & R INCLUDED:
BASIC ENGINE
C&I
-
GEN
-
MAR
-
Drain fuel from fuel rail. Disassemble, clean and measure ring grooves, replace piston rings. Clean, as required, cylinder head, cylinder block top surface, and rocker cover. Mount engine on overhaul stand. Remove all subassemblies. Completely disassemble engine. Clean reusable parts and subassemblies. Measure journals of crankshaft and camshaft. Measure cylinder block and cylinder liners for correct liner-to-block fit and liner height. 01.10-02 Engine Stand - R & R 01.20-01 Cylinder Head - R & R (All) 01.30-00 Crankshaft (Engine Removed) - R & R 01.30-01 Crankshaft Front Drive Hub - R & R 01.30-02 Crankshaft Rear Drive Hub - R & R 01.31-00 Crankshaft Thrust Washers - R & R 01.32-00 Crankshaft Oil Seal (Front) - R & R
(Rev. 3/04)
11
OPER. NOS.
BASIC ENGINE
NO. OF CYL
SERVICE LEVELS ENG REM C&I GEN MAR
01.10-00 Cylinder Block- R & R (Continued)
01.33-00 Crankshaft Oil Seal (Rear) - R & R 01.34-00 Gear Case Cover - R & R 01.34-02 Gear Case Cover (Lower Front) - R & R 01.35-00 Main Bearings - R & R (All) 01.35-02 Rod Bearings - R & R (All) 01.36-00 Vibration Damper - R & R 01.38-00 Crankshaft Pulley - R & R 01.40-00 Flywheel - R & R 01.50-00 Flywheel Housing - R & R 01.60-01 Cylinder Kit - R & R (Each Additional) 01.60-02 Piston Cooling Jet - R & R (First One) 01.70-00 Camshaft - R & R 01.70-06 Cam Followers - R & R 01.80-00 Valve Mechanism - R & R 01.85-00 Rocker Cover - R & R (Each) 02.10-00 Injector Nozzle Assembly - R & R 02.10-02 High Pressure Fuel Tubes - R & R 02.11-00 Electronic Unit Pump - R & R (One) 02.18-01 DDEC Sensor Harness - R & R 02.18-05 Temperature or Pressure Sensor - R & R 02.20-00 Fuel Pump and/or Coupling - R & R 02.40-00 Fuel Manifold (Rail) - R & R 02.50-00 Fuel Lines (Nozzle Holder) - R & R (One) 02.50-10 Fuel Return Line Assembly - R & R 03.10-02 Air Inlet Manifold - R & R 03.50-08 Turbocharger - R & R (Each) 03.51-02 Turbocharger Oil Supply Line - R & R (All) 03.52-01 Turbocharger Oil Drain - R & R (All) 03.70-07 Charge Air Cooler Assembly - R & R 04.10-00 Oil Pump - R & R 04.10-05 Oil Pick Up Tube and Bracket - R & R 04.10-06 Oil Transfer Tube - R & R 04.20-01 Oil Filter Housing - R & R 04.41-00 Oil Cooler Elements - R & R 04.70-00 Oil Pan & Gasket - R & R 05.10-00 Water Pump (Fresh Water or Engine Coolant) -R&R 05.20-04 Water/Oil Distribution Manifold - R & R 06.10-00 Exhaust Manifold - R & R (Each) 14.00-00 Engine Tune-Up
(Rev. 3/04)
12
OPER. NOS.
BASIC ENGINE
NO. OF CYL
01.10-00 Cylinder Block- R & R (Continued) NOT INCLUDED:
01.22-00 Engine Lifter Bracket - R & R 01.37-00 Belt Set - R & R 02.19-00 Electronic Control Module - R & R 02.33-00 Fuel Filter Assembly (Secondary) - R & R 02.70-00 Fuel System - Prime 03.10-00 Air Filter and Housing - R & R 04.20-00 Oil Filter Elements - R & R 04.40-02 Oil Cooler Elements - R & R (All) 04.70-01 Dipstick Tube & Adapter - R & R 05.20-00 Thermostat (Fresh Water or Engine) - R & R 05.30-02 Fan Hub Assembly - R & R 05.30-08 Fan Hub Mounting Bracket - R & R 05.60-00 Water Pump (Raw Water or Separate Circuit) -R&R 07.10-00 Alternator/Generator - R & R 07.30-00 Starter Motor and Drive Assembly R & R (One) 11.10-00 Engine Mount (Front Trunnion) - R & R 13.20-00 Engine Dynamometer Test Coolant or lube oil draining, filling, or disposal.
NOTES: (Requires)
Requires special lifting equipment to perform this operation. J 35791 Liner Remover J 41570 Injector Nozzle Puller Adapter J 41595 Flywheel Guide Studs J 42255 Cylinder Liner Installer & Hold Down J 42256 Piston Ring Compressor J 42258 Cam Follower Installer/Remover J 42259 Rear Crank Seal Installer 8V J 42261 Front Seal Installer J 42262 Engine Stand Adapter Plate (8V Only) J 42264 Camshaft Pilot, 17 in. Long J 43001 Front/Rear Crank Hub Installer/Remover J 43011 Piston Ring Pliers J 43028 Crankshaft Position Timing Tool J 43048 Main Bearing Guide Studs J 43394 Gearcase Alignment Tool 34.30025S MHUB ITH Hub Expansion Set J 43395 Engine Barring Tools
(Rev. 3/04)
13
OPER. NOS.
BASIC ENGINE
NO. OF CYL
08 12 16

-
C&I
-
GEN
-
MAR
-
01.10-01 Cylinder Block - R & R (From Short Block) INCLUDED:
01.30-00 Crankshaft (Engine Removed) - R & R 01.60-01 Cylinder Kit - R & R (Each Additional) 01.70-00 Camshaft - R & R
NOTES:
Engine removed time does not apply to marine.

01.10-02 Engine Stand - R & R INCLUDED: 08 12 16 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
All labor required to install and remove either a Short Block or Cylinder Block from engine work stand.
NOTES:
Requires special lifting equipment to perform this operation. With engine lifter brackets installed.
01.10-05 Steam Clean and Paint Engine 08 12 16 08 12 16 08 12 16 1.0 1.0 1.0 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 -
01.10-11 Cylinder Block - Pressure Test (Engine Removed)
01.19-00 General Operation NOTES:
01.20-00 Cylinder Head - R & R (One) INCLUDED:
01.80-00 Valve Mechanism - R & R 01.83-02 Pushrods - R & R 02.10-00 Injector Nozzle Assembly - R & R 02.50-10 Fuel Return Line Assembly - R & R 14.00-01 Valve Lash (Intake Exhaust) - Adjustment
NOT INCLUDED:
08 12 16
2.1 2.1 2.1
5.1 5.1 5.1
5.1 5.1 5.1
5.9 5.9 5.9
Removal of OEM Equipment 00.00-25 Coolant or Lube Oil - Drain & Refill 02.19-00 Electronic Control Module - R & R 03.10-02 Air Inlet Manifold - R & R 06.10-00 Exhaust Manifold - R & R (Each)
NOTES: (Requires)
J 41570 Injector Nozzle Puller Adapter
(Rev. 3/04)
14
OPER. NOS.
BASIC ENGINE
NO. OF CYL
08 12 16

10.6 14.0 18.0
C&I
16.0 21.0 27.0
GEN
16.0 21.0 27.0
MAR
27.0 35.0 45.0
01.20-01 Cylinder Head - R & R (All) INCLUDED:
01.80-00 Valve Mechanism - R & R 01.80-02 Pushrods - R & R 01.85-00 Rocker Cover - R & R 02.10-00 Injector Nozzle Assembly - R & R 02.10-02 High Pressure Fuel Tubes - R & R 02.50-10 Fuel Return Line Assembly - R & R 03.10-02 Air Inlet Manifold - R & R 03.50-00 Turbocharger - R & R 06.10-00 Exhaust Manifold - R & R (Each) 14.00-01 Valve Lash (Intake Exhaust) - Adjustment
NOT INCLUDED:
01.22-00 Engine Lifter Bracket - R & R 02.19-00 Electronic Control Module - R & R 03.70-05 Charge Air Cooler Coolant Piping - R & R Coolant or lube oil draining, filling, or disposal.
NOTES: (Requires)
J 41570 Injector Nozzle Puller Adapter J 43395 Engine Barring Tools

01.20-03 Valve Springs (Head Removed) - R & R (One Head) 08 12 16 08 12 16 0.3 0.3 0.3 0.3 0.3 0.3 -
01.20-04 Valve Seal (Head Removed) - R & R (One Head) INCLUDED:
01.20-03 Valve Springs (Head Removed) - R & R (One Head)

01.20-06 Cylinder Head - Pressure Test (One) NOT INCLUDED:
01.20-00 Cylinder Head - R & R

NOTES: (Requires)
08 12 16
0.3 0.3 0.3
0.3 0.3 0.3
0.3 0.3 0.3
0.3 0.3 0.3
J 42267 Cylinder Head Pressure Test Kit

01.22-00 Engine Lifter Bracket - R & R 08 12 16 08 12 16 0.4 0.4 0.4 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 -
(Rev. 3/04)
15
OPER. NOS.
BASIC ENGINE
NO. OF CYL
08 12 16

28.0 35.0 37.1
C&I
-
GEN
-
MAR
-
01.30-00 Crankshaft (Engine Removed) - R & R INCLUDED:
01.22-00 Engine Lifter Bracket - R & R 01.30-01 Crankshaft Front Drive Hub - R & R 01.30-02 Crankshaft Rear Drive Hub - R & R 01.31-00 Crankshaft Thrust Washers - R & R 01.32-00 Crankshaft Oil Seal (Front) - R & R 01.33-00 Crankshaft Oil Seal (Rear) - R & R 01.34-00 Gear Case Cover - R & R 01.34-02 Gear Case Cover (Lower Front) - R & R 01.35-00 Main Bearings - R & R (All) 01.36-00 Vibration Damper - R & R 01.37-00 Belt Set - R & R 01.38-00 Crankshaft Pulley - R & R 01.40-00 Flywheel - R & R 01.50-00 Flywheel Housing - R & R 01.60-02 Piston Cooling Jet - R & R (First One) 01.70-00 Camshaft - R & R 01.70-06 Cam Followers - R & R 01.80-00 Valve Mechanism - R & R 01.85-00 Rocker Cover - R & R 02.10-00 Injector Nozzle Assembly - R & R 02.10-02 High Pressure Fuel Tubes - R & R 02.11-00 Electronic Unit Pump - R & R (One) 02.18-00 Synchronous Reference Sensor or Timing Reference Sensor - R & R 02.18-05 Temperature or Pressure Sensor - R & R 02.19-00 Electronic Control Module - R & R 02.20-00 Fuel Pump and/or Coupling - R & R 02.33-00 Fuel Filter Assembly (Secondary) - R & R 02.50-00 Fuel Lines (Nozzle Holder) - R & R (One) 02.50-10 Fuel Return Line Assembly - R & R 03.10-02 Air Inlet Manifold - R & R 03.10-06 Charge Air Piping to Turbocharger - R & R 03.10-07 Charge Air Cooler Assembly - R & R 03.50-00 Turbocharger - R & R 03.51-00 Turbocharger Oil Supply Line - R & R (One) 03.52-00 Turbocharger Oil Drain - R & R (One) 03.70-05 Charge Air Cooler Coolant Piping - R & R
(Rev. 3/04)
16
OPER. NOS.
BASIC ENGINE
NO. OF CYL
01.30-00 Crankshaft (Engine Removed) - R & R (Continued)
04.10-00 Oil Pump - R & R 04.10-05 Oil Pick Up Tube and Bracket - R & R 04.10-06 Oil Transfer Tube - R & R 04.20-00 Oil Filter Elements - R & R 04.20-01 Oil Filter Housing - R & R 04.41-00 Oil Cooler Elements - R & R 04.70-00 Oil Pan & Gasket - R & R 04.70-01 Dipstick Tube & Adapter - R & R 05.20-04 Water/Oil Distribution Manifold - R & R 06.10-00 Exhaust Manifold - R & R (Each) 07.30-00 Starter Motor and Drive Assembly - R & R (One) Engine removed time does not apply to marine.
NOT INCLUDED:
01.10-05 Steam Clean and Paint Engine 01.34-03 Idler Gears - R & R 05.20-00 Thermostats (Fresh Water or Engine) - R & R 05.30-02 Fan Hub Assembly - R & R 05.60-00 Water Pump (Raw Water or Separate Circuit) -R&R 07.10-00 Alternator/Generator - R & R 11.10-00 Engine Mount (Front Trunnion) - R & R Coolant or lube oil draining, filling, or disposal.
NOTES: (Requires)
Requires special lifting equipment to perform this operation. J 43028 Crankshaft Position Timing Tool J 43048 Main Bearing Guide Studs J 41570 Injector Nozzle Puller Adapter J 41595 Flywheel Guide Studs J 42255 Cylinder Liner Installer & Hold Down J 42256 Piston Ring Compressor J 42258 Cam Follower Installer/Remover J 42261 Front Seal Installer J 43001 Front/Rear Crank Hub Installer/Remover J 43048 Main Bearing Guide Studs J 43394 Gearcase Alignment Tool J 43395 Engine Barring Tools
(Rev. 3/04)
17
OPER. NOS.
BASIC ENGINE
NO. OF CYL
08 12 16

1.5 1.5 1.5
C&I
3.1 3.1 3.1
GEN
3.1 3.1 3.1
MAR
3.1 3.1 3.1
01.30-01 Crankshaft Front Drive Hub - R & R NOT INCLUDED:
01.36-00 Vibration Damper - R & R 01.37-00 Belt Set - R & R 01.38-00 Crankshaft Pulley - R & R Belt guards - R & R
NOTES: (Requires)
J 42261 Front Seal Installer J 43001 Front/Rear Crank Hub Installer/Remover 34.30025S MHUB ITH Hub Expansion Set
01.30-02 Crankshaft Rear Drive Hub - R & R INCLUDED: 08 12 16 1.9 1.9 1.9 3.0 3.0 3.0 2.0 2.0 2.0 8.0 12.5 12.5
01.33-00 Crankshaft Oil Seal (Rear) - R & R 01.40-00 Flywheel - R & R

NOTES: (Requires)
J 41595 Flywheel Guide Studs J 43001 Front/Rear Crank Hub Installer/Remover 34.30025S MHUB ITH Hub Expansion Set
01.31-00 Crankshaft Thrust Washers - R & R INCLUDED: 08 12 16 0.5 0.5 0.5 0.9 0.9 0.9 0.8 0.8 0.8 1.0 1.0 1.0
Main Bearing Cap (See 01.35-01 Main Bearing - R & R) Inspect thrust washers. Check crankshaft endplay.
NOT INCLUDED:
04.10-00 Oil Pump - R & R 04.70-00 Oil Pan & Gasket - R & R Coolant or lube oil draining, filling, or disposal.
NOTES: (Requires)
J 43048 Main Bearing Guide Studs

01.32-00 Crankshaft Oil Seal (Front) - R & R INCLUDED: 08 12 16 2.9 2.9 2.9 6.5 6.5 6.5 6.5 6.5 6.5 8.5 8.5 8.5
01.30-01 Crankshaft Front Drive Hub - R & R 01.36-00 Vibration Damper - R & R 01.37-00 Belt Set - R & R 01.38-00 Crankshaft Pulley - R & R
NOT INCLUDED:
Belt guards - R & R

NOTES: (Requires)
J 43001 Front Seal Installer J 43001 Front/Rear Crank Hub Installer/Remover 34.30025S MHUB ITH Hub Expansion Set
(Rev. 3/04)
18
OPER. NOS.
BASIC ENGINE
NO. OF CYL
08 12 16

2.3 2.3 2.3
C&I
5.0 5.0 5.0
GEN
3.5 3.5 3.5
MAR
11.0 11.0 11.0
01.33-00 Crankshaft Oil Seal (Rear) - R & R INCLUDED:
01.40-00 Flywheel - R & R 01.30-02 Crankshaft Rear Drive Hub - R & R

NOTES: (Requires)
J 41595 Flywheel Guide Studs J 42259 Rear Crank Seal Installer 8V

01.34-00 Gear Case Cover - R & R INCLUDED: 08 12 16 5.0 5.0 5.0 9.9 9.9 9.9 9.9 9.9 9.9 16.0 18.0 18.0
01.30-01 Crankshaft Front Drive Hub - R & R 01.32-00 Crankshaft Oil Seal (Front) - R & R 01.36-00 Vibration Damper - R & R 01.37-00 Belt Set - R & R 01.38-00 Crankshaft Pulley - R & R 02.20-00 Fuel Pump and/or Coupling - R & R 05.10-00 Water Pump (Fresh Water or Engine Coolant) -R&R 05.20-04 Water/Oil Distribution Manifold - R & R
NOT INCLUDED:
01.34-03 Idler Gears - R & R 02.33-00 Fuel Filter Assembly (Secondary) - R & R 05.20-00 Thermostats (Fresh Water or Engine) - R & R 05.30-08 Fan Hub Mounting Bracket - R & R 05.60-00 Water Pump (Raw Water or Separate Circuit) -R&R 07.10-00 Alternator/Generator - R & R 11.10-00 Engine Mount (Front Trunnion) - R & R Coolant or lube oil draining, filling, or disposal.
NOTES: (Requires)
Requires special lifting equipment to perform this operation. J 42261 Front Seal Installer J 42257 Front Wear Sleeve Installer J 43001 Front/Rear Crank Hub Installer/Remover J 43394 Gearcase Alignment Tool 34.30025S MHUB ITH Hub Expansion Set
01.34-03 Idler Gears - R & R (Both) NOT INCLUDED: 08 12 16 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
01.34-00 Gear Case Cover - R & R
(Rev. 3/04)
19
OPER. NOS.
BASIC ENGINE
NO. OF CYL
08 12 16

2.3 2.4 3.5
C&I
8.0 10.0 12.0
GEN
8.0 10.0 12.0
MAR
12.0 20.0 25.0
01.35-00 Main Bearings - R & R (All) INCLUDED:
01.31-00 Crankshaft Thrust Washers - R & R 04.10-05 Oil Pick-Up and Bracket - R & R 04.70-00 Oil Pan & Gasket - R & R
NOT INCLUDED:
04.10-00 Oil Pump - R & R Coolant and Lube Oil - Drain & Refill.
NOTES: (Requires)
J 43048 Engine Bearing Guide Studs J 43395 Engine Barring Tools

01.35-01 Main Bearing - R & R (Each Set) NOT INCLUDED: 08 12 16 0.3 0.3 0.3 1.5 1.5 1.5 1.5 1.5 1.5 2.5 2.5 2.5
04.10-00 Oil Pump - R & R 04.10-05 Oil Pick Up Tube and Bracket - R & R 04.10-06 Oil Transfer Tube - R & R 04.70-00 Oil Pan & Gasket - R & R Coolant or lube oil draining, filling, or disposal.
NOTES: (Requires)
J 43048 Main Bearing Guide Studs

01.35-02 Rod Bearings - R & R (All) INCLUDED: 08 12 16 2.1 3.1 4.1 5.6 6.8 7.9 5.6 6.8 7.9 7.6 15.8 16.2
04.70-00 Oil Pan & Gasket - R & R

NOT INCLUDED:
Coolant or lube oil draining, filling, or disposal.

NOTES: (Requires)
J 43395 Engine Barring Tools

01.35-03 Rod Bearing - R & R (Each Set) NOT INCLUDED: 08 12 16 0.1 0.1 0.1 0.3 0.3 0.3 0.3 0.3 0.3 0.7 0.7 0.7
04.70-00 Oil Pan & Gasket - R & R Coolant or lube oil draining, filling, or disposal.
NOTES: (Requires)

01.36-00 Vibration Damper - R & R (All) INCLUDED: 08 12 16 0.8 0.8 0.8 5.0 6.0 8.0 5.0 6.0 8.0 8.0 12.0 12.0
01.37-00 Belt Set - R & R 01.38-00 Crankshaft Pulley - R & R

01.37-00 Belt Set - R & R INCLUDED:
Adjust required brackets. Check belt tension. Belt guards - R & R

NOTES: (Requires)
08 12 16
0.3 0.3 0.3
0.5 0.5 0.5
0.6 0.6 0.6
1.0 1.0 1.0
J 23586B Belt Tension Gage
(Rev. 3/04)
20
OPER. NOS.
BASIC ENGINE
NO. OF CYL
08 12 16

0.3 0.3 0.3
C&I
0.7 0.7 0.7
GEN
0.7 0.7 0.7
MAR
0.7 0.7 0.7
01.38-00 Crankshaft Pulley - R & R NOT INCLUDED:
01.37-00 Belt Set - R & R Belt guards - R & R

01.40-00 Flywheel - R & R INCLUDED:
08 12 16
Flywheel Mounted TRS Pulse Wheel, Centrifugal Mass, and Ring Gear - R & R
NOT INCLUDED:
08 12 16
0.4 0.4 0.4
2.0 2.0 2.0
1.5 1.5 1.5
3.0 3.0 3.0
02.18-00 Synchronous Reference Sensor or Timing Reference Sensor - R & R Transmission - R & R
NOTES: (Requires)
Requires special lifting equipment to perform this operation. J 41595 Flywheel Guide Studs
01.50-00 Flywheel Housing - R & R INCLUDED:
01.30-02 Crankshaft Rear Drive Hub - R & R 01.33-00 Crankshaft Oil Seal (Rear) - R & R 01.40-00 Flywheel - R & R 04.70-00 Oil Pan & Gasket - R & R 07.30-00 Starter Motor and Drive Assembly - R & R (One)
NOT INCLUDED:
08 12 16
4.0 4.6 5.2
9.3 9.3 9.8
7.3 7.3 7.8
15.5 16.0 16.5
01.34-03 Idler Gear - R & R 03.70-05 Charge Air Cooler Piping - R & R 11.10-01 Engine Mount (Rear) - R & R
NOTES: (Requires)
Requires special lifting equipment to perform this operation. J 41595 Flywheel Guide Studs J 42259 Rear Crank Seal Installer 8V J 43001 Front/Rear Crank Hub Installer/Remover 34.30025S MHUB ITH Hub Expansion Set
(Rev. 3/04)
21
OPER. NOS.
BASIC ENGINE
NO. OF CYL
08 12 16

6.3 6.3 6.3
C&I
14.0 14.0 14.0
GEN
14.0 14.0 14.0
MAR
20.5 22.5 22.5
01.50-01 Gear Case (Complete) - R & R INCLUDED:
01.34-00 Gear Case Cover - R & R 05.20-02 Thermostat Housing - R & R 05.30-08 Fan Mounting Bracket - R & R 07.10-00 Alternator/Generator - R & R 11.10-00 Engine Mount (Front Trunnion) - R & R
NOT INCLUDED:
01.34-03 Idler Gears - R & R 05.60-00 Water Pump (Raw Water or Separate Circuit) -R&R Coolant or lube oil draining, filling, or disposal. Removal of OEM equipment.
NOTES: (Requires)
J 42257 Front Wear Sleeve Installer J 42261 Front Seal Installer J 43001 Front/Rear Crank Hub Installer/Remover J 43394 Gearcase Alignment Tool 34.30025S MHUB ITH Hub Expansion Set
(Rev. 3/04)
22
OPER. NOS.
BASIC ENGINE
NO. OF CYL
08 12 16

8.4 8.4 8.4
C&I
11.5 12.5 13.5
GEN
11.5 12.5 13.5
MAR
13.0 15.0 18.0
01.60-00 Cylinder Kit - R & R (One) INCLUDED:
01.20-00 Cylinder Head - R & R 01.35-03 Rod Bearings - R & R (Each Set) 01.60-02 Piston Cooling Jet - R & R (First One) 01.80-00 Valve Mechanism - R & R 01.83-02 Pushrod - R & R 02.10-00 Injector Nozzle Assembly - R & R 03.10-02 Air Inlet Manifold - R & R 03.50-00 Turbocharger - R & R 04.10-00 Oil Pump - R & R (If needed) 04.70-00 Oil Pan & Gasket - R & R 06.10-00 Exhaust Manifold - R & R (Each) 14.00-01 Valve Lash (Intake / Exhaust) - Adjustment Disassemble kit, clean and measure ring grooves, replace piston rings, clean-up block bores, measure liner height and liner bores, and check piston ring end gap.
NOT INCLUDED:
02.19-00 Electronic Control Module - R & R Coolant or lube oil draining, filling, or disposal.
NOTES: (Requires)
Requires special lifting equipment to perform this operation. J 35791 Liner Remover J 41570 Injector Nozzle Puller Adapter J 42255 Cylinder Liner Installer & Hold Down J 43011 Piston Ring Pliers J 43395 Engine Barring Tools
01.60-01 Cylinder Kit - R & R (Each Additional) INCLUDED: 08 12 16 08 12 16 08 12 16 0.9 0.9 0.9 0.2 0.2 0.2 1.9 1.9 1.9 0.2 0.2 0.2 1.9 1.9 1.9 0.2 0.2 0.2 4.0 4.0 4.0 0.2 0.2 0.2 -
04.10-00 Oil Pump - R & R (If needed)

01.60-02 Piston Cooling Jet - R & R (One) DOES NOT INCLUDE:

(Rev. 3/04)
23
OPER. NOS.
01.70-00 Camshaft - R & R NOT INCLUDED:
BASIC ENGINE
NO. OF CYL
08 12 16

0.5 0.5 0.5
C&I
2.5 2.5 2.5
GEN
2.5 2.5 2.5
MAR
4.0 4.0 4.0
01.34-00 Gear Case Cover - R & R 01.50-00 Flywheel Housing - R & R 01.70-06 Cam Followers - R & R 02.11-00 Electronic Unit Pump - R & R (One)
NOTES: (Requires)
J 42264 Camshaft Pilot 17 in. Long J 43028 Crankshaft Position Timing Tool
01.70-06 Cam Followers - R & R (All) 08 12 16 08 12 16 0.3 0.4 0.5 0.6 0.8 0.8 0.6 0.8 0.9 -
01.80-00 Valve Mechanism - R & R (One Cylinder) INCLUDED:
This operation includes valve bridge and valve mechanism - R & R. 01.83-02 Pushrods - R & R 01.85-00 Rocker Cover - R & R (Each) 14.00-01 Valve Lash (Intake Exhaust) - Adjustment
NOTES: (Requires)
08 12 16
0.8 0.8 0.8
2.2 2.4 2.9
2.2 2.4 2.9
2.7 2.9 3.4

01.83-00 Valve Springs and/or Seals (Head Installed) - R & R (All Cylinders) INCLUDED: 08 12 16 1.6 2.4 3.2 4.8 7.2 9.6 4.8 7.2 9.6 4.8 7.2 9.6
01.80-00 Valve Mechanism - R & R 01.85-00 Rocker Cover - R & R 14.00-01 Valve Lash (Intake Exhaust) - Adjustment
NOTES: (Requires)

01.83-02 Push Rod - R & R (Each) NOT INCLUDED: 08 12 16 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
01.83-00 Valve Springs and/or Seals (Head Installed) R & R (One Cylinder) 01.85-00 Rocker Cover - R & R (Each)
01.85-00 Rocker Cover - R & R (Each)
08 12 16
0.2 0.2 0.2
0.2 0.2 0.2
0.2 0.2 0.2
0.2 0.2 0.2
(Rev. 3/04)
24
OPER. NOS.
01.85-01 Breather - R & R
BASIC ENGINE
NO. OF CYL
08 12 16 08 12 16 08 12 16

0.3 0.3 0.3 0.2 0.2 0.2 -
C&I
0.3 0.3 0.3 0.2 0.2 0.2 -
GEN
0.3 0.3 0.3 0.2 0.2 0.2 -
MAR
0.3 0.3 0.3 0.2 0.2 0.2 -
01.85-02 Breather Tube - R & R
Table 4
Basic Engine Operation Numbers
(Rev. 3/04)
25
Listed in Table 5 are the fuel system operation numbers.

NO. OF CYL
08 12 16

0.4 0.4 0.4
OPER. NOS.
FUEL SYSTEM
C&I
0.6 0.6 0.6
GEN
0.5 0.5 0.5
MAR
0.8 0.8 0.8
02.10-00 Injector Nozzle Assembly - R & R (Each) INCLUDED:
01.85-00 Rocker Cover - R & R (Each) 02.10-02 High Pressure Fuel Tube - R & R Check for leaks.
NOTES: (Requires)
J 41570 Injector Nozzle Puller Adapter

02.10-01 Each Additional Injector Nozzle Assembly 08 12 16 08 12 16 0.4 0.4 0.4 0.1 0.1 0.1 0.4 0.4 0.4 0.1 0.1 0.1 0.4 0.4 0.4 0.1 0.1 0.1 0.6 0.6 0.6 0.1 0.1 0.1
02.10-02 High Pressure Fuel Tube - R & R (Each) NOT INCLUDED:
02.10-00 Injector Nozzle Assembly - R & R Coolant draining, filling, or disposal.

NOTES: (Requires)
J 41570 Injector Nozzle Puller Adapter J 45648 Fuel Line Wrench Adapter
02.10-03 Fuel System - Pressure Test 08 12 16 08 12 16 08 12 16 08 12 16 1.0 1.0 1.0 0.5 0.5 0.5 0.7 1.0 1.3 0.8 1.1 1.3 1.0 1.0 1.0 0.7 0.7 0.7 2.1 2.1 2.1 2.0 2.0 2.0 0.9 0.9 0.9 0.6 0.6 0.6 2.0 2.0 2.0 1.9 1.9 1.9 1.0 1.0 1.0 0.7 0.7 0.7 3.5 3.5 3.5 3.0 3.0 3.0
02.10-04 Compression Test (Each Cylinder) NOT INCLUDED:
02.10-00 Injector Nozzle Assembly - R & R

02.10-05 Injector Harness (EUP) - R & R INCLUDED:
03.10-02 Air Inlet Manifold - R & R

02.11-00 Electronic Unit Pump - R & R (One) INCLUDED:
02.10-02 High Pressure Fuel Tube - R & R 03.10-02 Air Inlet Manifold - R & R
NOT INCLUDED:
02.19-00 Electronic Control Module - R & R 02.70-00 Fuel System - Prime

NOTES: (Requires)
(Rev. 3/04)
26
OPER. NOS.
FUEL SYSTEM
NO. OF CYL
08 12 16

0.2 0.2 0.2
C&I
0.5 0.5 0.5
GEN
0.4 0.4 0.4
MAR
0.5 0.5 0.5
02.11-01 Electronic Unit Pump - R & R (Each Additional) INCLUDED:
02.10-02 High Pressure Fuel Tube - R & R

NOT INCLUDED:

NOTES: (Requires)

02.18-00 Synchronous Reference Sensor or Timing Reference Sensor R&R 02.18-01 DDEC Sensor Harness - R & R NOT INCLUDED: 08 12 16 08 12 16 08 12 16 08 12 16 08 12 16 08 12 16 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.3 0.3 0.3 0.5 0.5 0.5 0.3 0.3 0.3 0.1 0.1 0.1 0.5 0.5 0.5 0.1 0.1 0.1 0.5 0.5 0.5 0.5 0.5 0.5 1.2 1.2 1.2 0.1 0.1 0.1 0.5 0.5 0.5 0.1 0.1 0.1 0.5 0.5 0.5 0.5 0.5 0.5 1.1 1.1 1.1 0.1 0.1 0.1 0.5 0.5 0.5 0.1 0.1 0.1 1.5 1.5 1.5 0.5 0.5 0.5 2.0 2.0 2.0

02.18-05 Temperature or Pressure Sensor - R & R (Each)
02.19-00 Electronic Control Modules (MDEC/DDEC) - R & R NOT INCLUDED:
01.22-00 Engine Lifter Bracket - R & R

02.19-01 Reprogram ECM or MDEC (Per Module)
02.20-00 Fuel Pump and/or Coupling - R & R INCLUDED:
02.50-00 Fuel Lines (Nozzle Holder) - R & R (One) Check for leaks.
NOT INCLUDED:
02.70-00 Fuel System - Prime

02.30-01 Fuel Filter Elements (Primary) - R & R (Set of 2) NOT INCLUDED:

02.33-00 Fuel Filter Assembly (Secondary) - R & R INCLUDED:
08 12 16 08 12 16
0.4 0.4 0.4 0.2 0.2 0.2
0.4 0.4 0.4 0.2 0.2 0.2
0.4 0.4 0.4 0.2 0.2 0.2
0.5 0.5 0.5 0.3 0.3 0.3
02.50-00 Fuel Lines (Nozzle Holder) - R & R (One)

NOT INCLUDED:
(Rev. 3/04)
27
OPER. NOS.
FUEL SYSTEM
NO. OF CYL
08 12 16

0.4 0.4
C&I
3.3 3.3
GEN
3.2 3.2
MAR
4.0 4.0
02.40-00 Fuel Manifold (Rail) - R & R INCLUDED:
02.19-00 Electronic Control Module - R & R 03.10-02 Air Inlet Manifold - R & R
02.40-01 Fuel Delivery Rail/Pressure Regulator - R & R INCLUDED:
02.10-02 High Pressure Fuel Tube - R & R (One Bank) 02.11-00 Electronic Unit Pump - R & R (One) 03.10-02 Air Inlet Manifold - R & R Drain fuel from fuel rail. Disconnect fuel lines.
NOT INCLUDED:
08 12 16
1.7 2.0 2.6
2.0 3.5 3.5
2.0 3.2 3.2
3.0 6.5 6.5
01.22-00 Engine Lifter Bracket - R & R 02.19-00 Electronic Control Module - R & R 02.70-00 Fuel System - Prime
NOTES:
8V time applies to fuel regulator only.

02.50-00 Fuel Lines (Nozzle Holder) - R & R (One) NOT INCLUDED: 08 12 16 08 12 16 08 12 16 08 12 16 08 12 16 0.2 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.4 0.5 0.5 0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.6 0.7 0.8 0.5 0.5 0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.6 0.7 0.8 0.5 0.5 0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.8 0.9 1.0 1.0 1.0 1.0 -

02.50-08 Fuel Lines (Nozzle Holder) - R & R (Each Additional)
02.50-10 Fuel Return Line Assembly - R & R (All)
02.70-00 Fuel System - Prime (Complete System)
02.99-00 General Operation) NOTES:
Table 5
Fuel System Operation Numbers
(Rev. 3/04)
28
Listed in Table 6 are the air system operation numbers.

NO. OF CYL
08 12 16

0.1 0.1 0.1
OPER. NOS.
AIR SYSTEM
C&I
0.4 0.4 0.4
GEN
0.3 0.3 0.3
MAR
1.0 1.0 1.0
03.10-00 Air Filter and Housing - R & R INCLUDED:
R & R piping and connections. Clean, inspect, and reassemble.

03.10-01 Air Filter Element - R & R (Each)
08 12 16 08 12 16
0.1 0.1 0.1 0.5 0.8 1.0
0.1 0.1 0.1 1.9 1.9 1.9
0.1 0.1 0.1 1.6 1.6 1.6
0.2 0.2 0.2 3.0 3.0 3.0
03.10-02 Air Inlet Manifold - R & R (Complete) NOT INCLUDED:
01.22-00 Engine Lifter Bracket - R & R 02.19-00 Electronic Control Module - R & R (One) 03.10-05 Charge Air Cooler Coolant Piping - R & R
03.10-03 Air Shutdown Mechanism - R & R NOT INCLUDED:
03.10-02 Air Inlet Manifold - R & R Charge Air Cooler Cover Only - R & R
NOTES:
08 12 16
0.1 0.1 0.1
0.2 0.2 0.2
0.2 0.2 0.2
0.2 0.2 0.2
Use this operation for air-inlet-manifold mounted air shutdown assembly.

03.10-05 Charge Air Cooler Coolant Piping - R & R (Each Section) NOT INCLUDED: 08 12 16 08 12 16 08 12 16 0.2 0.3 0.4 0.1 0.1 0.1 0.9 0.9 0.9 0.5 0.6 0.8 0.5 0.5 0.5 5.0 5.0 5.0 0.5 0.6 0.8 0.5 0.5 0.5 5.0 5.0 5.0 0.8 1.0 1.2 0.6 0.7 0.8 10.0 10.0 10.0

03.10-06 Charge Air Piping to Turbocharger - R & R NOT INCLUDED:
03.50-00 Turbocharger - R & R

03.10-07 Charge Air Cooler Assembly - R & R INCLUDED:
R & R piping and connections, clean, and visually inspect.

NOT INCLUDED:

03.10-08 Charge Air Cooler Cover - R & R INCLUDED: 08 12 16 0.3 0.3 0.3 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
R & R piping and connections.
(Rev. 3/04)
29
OPER. NOS.
AIR SYSTEM
NO. OF CYL
08 12 16

1.6 1.6 1.6
C&I
6.0 6.0 6.0
GEN
6.0 6.0 6.0
MAR
11.0 11.0 11.0
03.10-09 Charge Air Cooler Base - R & R INCLUDED:
03.10-07 Charge Air Cooler Assembly - R & R

NOT INCLUDED:
03.10-06 Charge Air Piping to Turbocharger - R & R 03.10-08 Charge Air Cooler Cover - R & R 03.50-00 Turbocharger - R & R Coolant or lube oil draining, filling, or disposal.
03.50-00 Turbocharger - R & R (One) INCLUDED: 08 12 16 1.0 1.0 1.0 2.0 2.0 2.0 1.5 1.5 1.5 4.0 4.0 4.0
03.51-00 Turbocharger Oil Supply Line - R & R (One) 03.52-00 Turbocharger Oil Drain - R & R (One)
NOT INCLUDED:
03.10-00 Air Cleaner and Adapter - R & R

03.50-02 Turbocharger Wastegate - R & R (One) 08 12 16 08 12 16 0.5 0.5 0.5 0.6 0.6 0.6 0.5 0.5 0.5 1.5 1.5 1.5 0.5 0.5 0.5 1.0 1.0 1.0 0.5 0.5 0.5 2.5 2.5 2.5
03.50-08 Turbocharger - R & R (Each Additional) INCLUDED:
03.51-00 Turbocharger Oil Supply Line - R & R (One) 03.52-00 Turbocharger Oil Drain - R & R (One)
NOT INCLUDED:
03.10-00 Air Cleaner and Adapter - R & R

03.51-00 Turbocharger Oil Supply Line - R & R (One) 08 12 16 08 12 16 08 12 16 08 12 16 08 12 16 0.1 0.1 0.1 0.3 0.3 0.3 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.2 0.2 0.2 0.4 0.4 0.4 0.2 0.2 0.2 0.3 0.3 0.3 0.2 0.2 0.2 0.4 0.4 0.4 0.2 0.2 0.2 0.3 0.3 0.3 0.3 0.3 0.3 0.5 0.5 0.5 -
03.51-02 Turbocharger Oil Supply Line - R & R (All)
03.52-00 Turbocharger Oil Drain - R & R (One)
03.52-01 Turbocharger Oil Drain - R & R (All)
Table 6
Air System Operation Numbers
(Rev. 3/04)
30
Listed in Table 7 are the lubricating system operation numbers.

NO. OF CYL
08 12 16

1.0 1.0 1.0
OPER. NOS.
04.10-00 Oil Pump - R & R INCLUDED:
LUBRICATING SYSTEM
C&I
1.8 1.8 1.8
GEN
1.6 1.6 1.6
MAR
2.0 2.0 2.0
04.10-01 Oil Pressure Relief Valve - R & R (Eight Cylinder Engines Only) 04.10-05 Oil Pick Up Tube and Bracket - R & R 04.10-06 Oil Transfer Tube - R & R
NOT INCLUDED:
04.10-02 Oil Pressure Relief Valve - R & R (12 and 16 Cylinder Engines) 04.70-00 Oil Pan & Gasket - R & R
04.10-01 Oil Pressure Relief Valve - R & R NOT INCLUDED: 08 12 16 08 12 16 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.2 0.4 0.4 0.4 0.2 0.2 0.2 0.4 0.4 0.4 0.2 0.2 0.2 0.5 0.5 0.5

04.10-05 Oil Pick Up Tube and Bracket - R & R NOT INCLUDED:
04.70-00 Oil Pan & Gasket - R & R 04.70-01 Dipstick Tube & Adapter - R & R
04.10-06 Oil Transfer Tube - R & R NOT INCLUDED:

04.20-00 Oil Filter Elements - R & R NOT INCLUDED:
08 12 16 08 12 16 08 12 16
0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
0.4 0.4 0.4 0.2 0.2 0.2 1.0 1.0 1.0
0.4 0.4 0.4 0.2 0.2 0.2 0.9 0.9 0.9
0.5 0.5 0.5 0.2 0.2 0.2 1.3 1.3 1.3

04.20-01 Oil Filter Housing - R & R NOT INCLUDED:
04.20-00 Oil Filter Elements - R & R Coolant or lube oil draining, filling, or disposal.
04.41-00 Oil Cooler Elements - R & R NOT INCLUDED:

04.41-01 Oil Cooler Housing - R & R NOT INCLUDED:
08 12 16 08 12 16
0.5 0.5 0.5 0.6 0.6 0.6
0.6 0.6 0.6 0.8 0.8 0.8
0.6 0.6 0.6 0.7 0.7 0.7
1.0 1.0 1.0 1.2 1.2 1.2
03.10-05 Charge Air Cooler Coolant Piping - R & R 04.20-01 Oil Filter Housing - R & R 04.41-05 Oil Cooler Housing Cover - R & R Coolant or lube oil draining, filling, or disposal.
04.41-05 Oil Cooler Housing Cover - R & R NOT INCLUDED:
08 12 16
0.4 0.4 0.4
0.5 0.5 0.5
0.5 0.5 0.5
0.6 0.6 0.6
(Rev. 3/04)
31
OPER. NOS.
LUBRICATING SYSTEM
NO. OF CYL
08 12 16

1.3 1.9 2.5
C&I
2.5 2.5 3.0
GEN
2.0 2.0 3.0
MAR
2.5 3.0 3.5
04.70-00 Oil Pan & Gasket - R & R INCLUDED:
04.70-01 Dipstick Tube & Adapter - R & R

NOT INCLUDED:
Lube Oil - Drain & Refill

NOTES:

04.70-01 Dipstick Tube & Adapter - R & R 08 12 16 08 12 16 0.3 0.3 0.3 0.4 0.4 0.4 0.4 0.4 0.4 0.5 0.5 0.5 -
Table 7
Lubricating System Operation Numbers
(Rev. 3/04)
32
Listed in Table 8 are the cooling system operation numbers.

NO. OF CYL
08 12 16 08 12 16 08 12 16 08 12 16

0.4 0.4 0.4 0.8 0.8 0.8
OPER. NOS.
COOLING SYSTEM
C&I
2.2 2.2 2.2 1.2 1.2 1.2 1.9 1.9 1.9 1.6 1.6 1.6
GEN
2.0 2.0 2.0 1.0 1.0 1.0 1.9 1.9 1.9 1.5 1.5 1.5
MAR
2.5 2.5 2.5 1.5 1.5 1.5 1.9 1.9 1.9 2.0 2.0 2.0
05.10-00 Water Pump (Fresh Water or Engine Coolant) - R & R NOT INCLUDED:

05.10-02 Cooling System - Flush
05.10-03 Cooling System - Reverse Flush (When Needed) 05.20-00 Thermostat - R & R INCLUDED:
02.33-00 Fuel Filter Assembly (Secondary) - R & R 05.30-08 Fan Hub Mounting Bracket - R & R Coolant or lube oil draining, filling, or disposal.
NOTES:
Engine removed time does not apply to the marine engine configuration.
05.20-01 Thermostat Housing Seal (Engine) - R & R (Each) 08 12 16 08 12 16 0.4 0.4 0.4 0.6 0.6 0.6 1.0 1.0 1.0 0.8 0.8 0.8 1.0 1.0 1.0 0.7 0.7 0.7 2.0 2.0 2.0 1.0 1.0 1.0
05.20-02 Thermostat Housing - R & R INCLUDED:
02.33-00 Fuel Filter Assembly (Secondary) - R & R 05.30-08 Fan Hub Mounting Bracket - R & R Coolant or lube oil draining, filling, or disposal.
NOTES:
Engine removed time does not apply to the marine engine configuration.
05.20-04 Water/Oil Distribution Manifold - R & R NOT INCLUDED: 08 12 16 0.6 0.6 0.6 3.0 3.0 3.0 2.5 2.5 2.5 8.0 8.0 8.0
02.33-00 Fuel Filter Assembly (Secondary) - R & R 05.20-00 Thermostat - R & R 05.20-01 Thermostat Housing Seal - R & R 05.20-02 Thermostat Housing - R & R 05.30-08 Fan Hub Mounting Bracket - R & R Coolant or lube oil draining, filling, or disposal.
(Rev. 3/04)
33
OPER. NOS.
COOLING SYSTEM
NO. OF CYL
08 12 16 08 12 16 08 12 16

0.2 0.2 0.2
C&I
3.5 3.5 3.5 1.5 1.5 1.5 1.9 1.9 1.9
GEN
3.0 3.0 3.0 1.3 1.3 1.3 1.5 1.5 1.5
MAR
-
05.30-00 Radiator Assembly - R & R
05.30-01 Fan - R & R
05.30-02 Fan Hub Assembly - R & R NOT INCLUDED:
01.37-00 Belt Set - R & R 05.30-01 Fan - R & R

05.30-04 Belt Tensioner and Bracket - R & R NOT INCLUDED:
01.37-00 Belt Set - R & R

NOTES: (Requires)
08 12 16
0.1 0.1 0.1
1.5 1.5 1.5
1.4 1.4 1.4
Belt Tension Gage

05.30-05 Cooling System - Pressure Check 08 12 16 08 12 16 0.5 0.5 0.5 0.4 0.4 0.4 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 -
05.30-08 Fan Hub Mounting Bracket - R & R NOT INCLUDED:
05.30-02 Fan Hub Assembly - R & R 05.30-04 Belt Tensioner and Bracket - R & R
05.60-00 Water Pump (Raw Water or Separate Circuit) - R & R INCLUDED:

05.99-00 General Operation Use this operation for work performed in this group which is not covered by an operation number.
08 12 16 08 12 16
0.3 0.3 0.3 -
2.5 2.5 2.5 -
2.5 2.5 2.5 -
3.0 3.0 3.0 -
Table 8
Cooling System Operation Numbers
(Rev. 3/04)
34
Listed in Table 9 are the exhaust system operation numbers.

NO. OF CYL
08 12 16

0.2 0.3 0.4
OPER. NOS.
EXHAUST SYSTEM
C&I
1.4 1.6 1.8
GEN
1.4 1.6 1.8
MAR
2.6 2.9 3.2
06.10-00 Exhaust Manifold - R & R (Each) INCLUDED:
Drain water from manifold.

NOT INCLUDED:
03.50-00 Turbocharger - R & R

06.10-01 Exhaust Manifold - R & R (All) INCLUDED: 08 12 16 08 12 16 0.4 0.6 0.8 2.8 3.2 3.6 2.8 3.2 3.6 5.2 5.8 6.4 -
Refer to Group 06.10-00 for details.

Table 9
Exhaust System Operation Numbers
Listed in Table 10 are the electrical instruments operation numbers.

NO. OF CYL
08 12 16 08 12 16 08 12 16 08 12 16

0.1 0.1 0.1 0.4 0.4 0.4 0.2 0.2 0.2 -
OPER. NOS.
ELECTRICAL INSTRUMENTS
C&I
1.5 1.5 1.5 1.8 1.8 1.8 -
GEN
1.5 1.5 1.5 1.8 1.8 1.8 -
MAR
2.0 2.0 2.0 2.0 2.0 2.0 -
07.10-00 Alternator/Generator - R & R NOT INCLUDED:
01.37-00 Belt Set - R & R

07.30-00 Starter Motor and Drive Assembly - R & R
07.30-01 Starter Solenoid (Starter Removed) - R & R
Table 10
Electrical Instruments Operation Numbers
(Rev. 3/04)
35
Listed in Table 11 are the engine mounting operation numbers.

NO. OF CYL
08 12 16

0.2 0.2 0.2
OPER. NOS.
ENGINE MOUNTING
C&I
1.4 1.4 1.4
GEN
1.3 1.3 1.3
MAR
1.5 1.5 1.5
11.10-00 Engine Mount (Front Trunnion) - R & R NOT INCLUDED:
01.36-00 Vibration Damper - R & R 01.37-00 Belt Set - R & R

08 12 16
Table 11
Engine Mounting Operation Numbers
Listed in Table 12 are the miscellaneous operation numbers.

NO. OF CYL
08 12 16 08 12 16 08 12 16 08 12 16 08 12 16

0.5 0.5 0.5 0.2 0.2 0.2 0.3 0.3 0.3 0.5 0.5 0.5 -
OPER. NOS.
MISCELLANEOUS
C&I
0.7 0.7 0.7 0.2 0.2 0.2 0.6 0.6 0.6 1.0 1.0 1.0 -
GEN
0.6 0.6 0.6 0.2 0.2 0.2 0.5 0.5 0.5 1.0 1.0 1.0 -
MAR
2.0 2.0 2.0 0.3 0.3 0.3 1.0 1.0 1.0 1.5 1.5 1.5 -
12.40-00 Air Compressor - R & R NOT INCLUDED:

12.40-03 Air Compressor Hose - R & R
12.40-05 Air Compressor Drive - R & R
12.50-00 Hydraulic Pump (Power Steering) - R & R
Table 12
Miscellaneous Operation Numbers
(Rev. 3/04)
36
Listed in Table 13 are the engine performance test operation numbers.

NO. OF CYL
08 12 16

3.0 3.5 4.0
OPER. NOS.
ENGINE PERFORMANCE TEST
C&I
-
GEN
-
MAR
-
13.20-00 Engine Dynamometer Test INCLUDED:
Set-up and warm engine. Perform basic engine run-in. Complete dyno test report, and remove engine from dyno.
13.21-00 Repair Validation NOTES:
Use this operation for repairs that do not affect driveability, such as: Sensors, water pump, front cover, ECM/MDEC, air compressor, starter, alternator, tensioner, accessory drive, belts, manifolds, flywheel housing, fuel lines, gaskets, seals, etc...
13.22-00 Engine Performance Test NOTES:
08 12 16
0.2 0.2 0.2
0.2 0.2 0.2
0.2 0.2 0.2
0.2 0.2 0.2
Use this operation to check engine performance by equiptment operation test under load when necessary to test the engine without using a chassis dynamometer.
13.22-05 Engine Performance Test (Load Box Method)
08 12 16
1.0 1.0 1.0
1.0 1.0 1.0
2.0 2.0 2.0
08 12 16 08 12 16 08 12 16
0.5 0.5 0.5 0.3 0.3 0.3 -
0.5 0.5 0.5 0.3 0.3 0.3 -
0.3 0.3 0.3 -
13.22-10 Test Run (Check for Leaks)
Table 13
Engine Performance Test Operation Numbers
(Rev. 3/04)
37
Listed in Table 14 are the engine tune-up operation numbers.

NO. OF CYL
08 12 16

0.9 1.1 1.6
OPER. NOS.
14.00-00 Engine Tune-Up INCLUDED:
ENGINE TUNE-UP
C&I
1.9 2.1 2.6
GEN
1.9 2.1 2.6
MAR
2.4 2.6 3.1
01.85-00 Rocker Cover - R & R 14.00-01 Valve Lash (Intake Exhaust) - Adjustment
14.00-01 Valve Lash (Intake / Exhaust) - Adjustment
08 12 16 08 12 16
0.7 0.9 1.4 -
1.7 1.9 2.4 -
1.7 1.9 2.4 -
2.2 2.4 2.9 -
Table 14
Engine Tune-Up Operation Numbers
(Rev. 3/04)
38

Labot T Guide 2000 Usa

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TABLE OF CONTENTS

SERIES 2000 LABOR TIME GUIDE

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

Procedure for Development of Labor Time Manual

ELEMENTS OF TIME MANUAL

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

Service Outlet Action

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

SERIES 2000 LABOR OPERATION INDEX (ALPHABETICAL)

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

Series 2000 Labor Operation Index

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

SERIES 2000 OPERATION NUMBERS

SERVICE LEVELS ENG REM

13.22-00 Engine Performance Test R & R radiator, fan, and guard.

Requires special lifting equipment to perform this operation.

Refer to Group 00.00-01 for details.

Requires special lifting equipment to perform this operation.

R & R radiator, fan, and guard.

Requires special lifting equipment to perform this operation.

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

SERVICE LEVELS ENG REM

00.00-25 Coolant or Lube Oil - Drain & Refill INCLUDED:

Disposal of removed coolant and lube oil.

R & R of any filters.

Engine Assembly Operation Numbers

Listed in Table 4 are the basic engine operation numbers.

SERVICE LEVELS ENG REM

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

SERVICE LEVELS ENG REM C&I GEN MAR

01.10-00 Cylinder Block- R & R (Continued)

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE

SERVICE LEVELS ENG REM C&I GEN MAR

01.10-00 Cylinder Block- R & R (Continued) NOT INCLUDED:

All information subject to change without notice.

12SE2000 0403 Copyright 2004 DETROIT DIESEL CORPORATION

SERIES 2000 LABOR TIME GUIDE