800D Industrial Engines

KENR6241 August 2007

Disa Disass ssem embly bly and and Assembly 800D

Series

Industrial Engine

UK (Engine) (Engine) UL (Engi UL (Engine)

This document has been printed from SPI². Not for Resale

Important Safety Information M ost ac cid en ts tha tha t invo lve p rod uc t op erat erati ion , m ainten nten an ce an d rep air are are ca use d b y fai failure ure to ob ser se rve b asi as ic safet safety y rule s or p rec a uti ution s. A n ac cid en t ca n oft ofte n be b e avoi av oid ed b y rec o g nizing p oten oten tially ha zard zard ou s situa tion s be fore ore an a cc id en t oc cu rs. A p erson erson m ust b e alert ert to p oten oten tial ha zard zard s. Th is p e rson so n sh o u ld a lso h a ve th th e n e c e ssa ry tra in in g , skills an d to o ls to p e rfo rm th e se fu n c tio n s p ro p e rly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. S afet afety y p rec au tion s an d w arning s ar a re p rovid ed in thi this m an ua l an d on the p rod uc t. If the se h aza rd w arni arning s are are n ot he ed ed , b od ily injury ury or d ea th c ou ld oc cu r to yo u o r to o the r p erson erson s. T h e h a za rd s ar a re id e n tifie d b y th e “ S a fe ty A le rt S ym b o l”a n d fo llo w e d b y a “ S ig n a l W or o rd ”suc su c h a s “ D AN G ER” ,“ W A R N IN G ”o r “ C A U TIO TIO N ” . T h e S a fe ty A le rt “ W A R N IN G ”la b e l is sho sh o w n b e lo w .

Th e m e an ing o f this sa fe ty a le rt sym b o l is a s fol follow s:

Attention! Become Alert! Your Safety is Involved. Th e m e ssag ssa g e tha tha t ap p ea rs und u nd er the w arning exp lains the the ha zard zard an d ca n b e e ithe r w ritten or p ic to ria lly p re se n te d . O pe rati atio ns tha t m ay a y cau c au se p ro d uc t d am a g e a re id en tifie d b y “ N O TIC E ”lab els on o n th th e p ro d uc t an d in th is p u b lic a tio n .

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. T h e in fo rm a tio n , sp e c ific a tio n s, a n d illu str stra tio n s in th is p u b lic a tio n a re o n th e b a sis o f in fo rm a tio n th a t w a s ava a va ila b le a t th e ti tim e th th a t th e p u b lic a tio n w as w ritte n . T h e sp s p e c ific a tio n s, to rq u e s, p re ssu re s, m ea surem surem e nts, nts, ad justm ustm en ts, illustr ustrati ation s, an d othe othe r item s c an ch an g e a t an y tim e. Th ese ch an g es c an a ffe c t th e se s e rvic e th a t is g ive n to th th e p ro d u c t. O bta bta in th th e c o m p le te a n d m ost os t c u rre n t in fo rm ati atio n b e fo re yo u sta rt a n y jo b . P e rkin s de a le rs or P e rkin s d istrib u to rs h a ve th e m o st c u rre n t in fo rm a tio n ava av a ila b le .

When replaceme replacement nt parts are required required for this product Perkins recommends using Perkins replacement replacement parts. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.


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Table of Contents Disassembly and Assembly Section Fuel Priming Pump and Fuel Filter Base - Remove and Install ...................... .................................. ........................ ....................... ............... .... 4 Fuel Injection Lines - Remove and Install (Naturally Aspirated Engines) .... ............ ............ ............ ........ 5 Fuel Injection Lines - Remove and Install (Turbochar (Turbocharged ged Engines) ....................... ................................... ................ .... 7 Fuel Injection Injection Pump - Remove Remove ....................... .............................. ....... 9 Fuel Injection Pump - Remove (Fuel Injection Pumps With a Water Heated Heated Cold Start Device) Device) .............. .............. 11 Fuel Injection Pump - Install (Fuel Injection Pumps With a Water Heated Heated Cold Start Device) Device) ............. ............. 13 Fuel Injection Injection Pump - Install Install ....................... ................................ ......... 14 Fuel Injector - Remove and Install (Naturally Aspirated Engines) .... ............ ............ ............ ...... 16 Fuel Injector - Remove and Install (Turbocharged Engines) Engines) ........................ .................................... ....................... ....................... ............... ... 16 Turbocharg Turbocharger er - Remove .......................... ...................................... .............. .. 17 Turbocharg Turbocharger er - Install ........................... ....................................... ................. ..... 19 Exhaust Exhaust Manifold - Remove Remove and and Install Install ............... ............... 20 Inlet Manifold Manifold - Remove and Install Install ..................... ..................... 21 Inlet and Exhaust Valve Springs - Remove and Install ........................ .................................... ........................ ........................ ................... ....... 23 Inlet and Exhaust Exhaust Valves Valves - Remove Remove and Install .... 25 Engine Oil Oil Filter Base Base - Remove Remove and Install Install ........ 28 Engine Oil Cooler - Remove ................................. 29 Engine Oil Cooler - Install ..................................... 30 Engine Oil Relief Valve - Remove and Install ....... 31 Engine Oil Bypass Valve Valve - Remove and Install ..... 32 Engine Oil Pump - Remove .................................. 33 Engine Oil Pump - Install ...................................... 34 Water Water Pump - Remove and and Install ..................... ....................... .. 35 Water Temperature Regulator Housing - Remove and Install ...................... .................................. ........................ ........................ .................... ........ 37 Flywheel Flywheel - Remove .................................. .............................................. .............. 38 Flywheel Flywheel - Install ....................... ................................... ........................ ................ .... 39 Crankshaft Rear Seal - Remove and Install ......... 40 Crankshaft Wear Sleeve (Rear) - Remove and Install ........................ .................................... ........................ ........................ ................... ....... 42 Flywheel Flywheel Housing Housing - Remove Remove and and Install Install .............. .............. 43 Crankshaft Crankshaft Pulley - Remove Remove and Install Install ............... ............... 45 Crankshaft Front Seal - Remove and Install ......... 47 Front Cover - Remove and Install ......................... ......................... 48 Idler Gear - Remove and Install ............................ 48 Housing (Front) - Remove and Install ................... 51 Front Plate - Remove ................. ............................. ....................... ............... .... 52 Front Plate - Install ..................... ................................. ....................... ............... .... 53 Crankcase Breather - Remove and Install (Turbochar (Turbocharged ged Engines) ....................... ................................... .............. .. 54 Valve Mechanism Cover - Remove and Install ..... 55 Rocker Shaft and Pushrod - Remove ................... 56 Rocker Shaft - Disassembl Disassemble e ....................... ................................ ......... 57 Rocker Shaft - Assemble Assemble ....................... ................................... .............. .. 58 Rocker Shaft and Pushrod - Install ....................... 59 Cylinder Head - Remove ...................................... 60 Cylinder Cylinder Head - Install ....................... .................................. ................... ........ 62 Lifter Group - Remove and Install ......................... 64 Camshaft Camshaft - Remove Remove and Install ....................... ........................... .... 65

3 Table of Contents Contents

Camshaft Camshaft Gear - Remove and Install Install .................. .................. 66 Remove and and Install Install ................... ................... 67 Engine Oil Pan - - Remove Balancer Balancer - Remove ................................ ........................................... ............... .... 70 Balancer Balancer - Disassemble Disassemble ............................. ........................................ ........... 71 .......................................... ............... ... 72 Balancer Balancer - Assemble Assemble .............................. Balancer Balancer - Install ................................. ............................................ .................. ....... 73 Pistons and Connecting Rods - Remove .............. 74 Pistons Pistons and Connecting Conn ecting Rods - Disassemble ....... 75 Pistons and and Connecting Connecting Rods - Assemble ........... ........... 77 Pistons and Connecting Rods - Install .................. 80 Connecting Rod Bearings B earings - Remove (Connecting rods in position) ...................... .................................. ........................ ................. ..... 81 Connecting Rod Bearings - Install (Connecting rods in position) ....................... ................................... ........................ ........................ ............ 82 Crankshaft Main Bearings - Remove and Install (Crankshaft (Crankshaft in position) position) ........................ .................................... ............... ... 83 ............................................ ........... 87 Crankshaft - Remove Remove ................................. Crankshaft Crankshaft - Install ........................... ....................................... ..................... ......... 89 Crankshaft Crankshaft Gear Gear - Remove Remove and Install Install ................ ................ 92 ............................. .................. ...... 93 Bearing Clearance Clearance - Check ................. Coolant Temperature Sensor - Remove and Install ........................ .................................... ........................ ........................ ................... ....... 94 Engine Oil Pressure Pressure Sensor - Remove and Install ........................ .................................... ........................ ........................ ........................ ................. ..... 94 Glow Plugs - Remove Remove and Install Install ..................... ......................... .... 95 V-Belts - Remove and a nd Install ................................ 97 Fan - Remove and Install Install ...................... ................................. ............... .... 97 Alternator - Remove and Install ............. ............. . 98 Motor - Remove Remove and and Insta Install ll ..... ..... 100 Electric Starting Starting Motor

Index Section Index ....................... ................................... ........................ ....................... .................... ......... 101


4 Disassembly and Assembly Section

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Disassembly and Assembly Section i02748528

Fuel Priming Pump and Fuel Filter Base - Remove and Install Removal Procedure

Illustration 1

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Typical example

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

3. Drain fuel filter (4). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter/Water Seperator - Drain”. 4. Disconnect harness assembly (1) from fuel priming pump (2). 5. Disconnect the tube assemblies (not shown) from fuel filter base (3). 6. Remove bolts (5) and remove fuel fi lter base (3).

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Put identification marks on all hose assemblies and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This helps prevent fluid loss, and this helps to keep contaminants from entering the system. 1. Turn the fuel supply to the OFF position.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the assembly of the fuel priming pump and the fuel filter base is clean and free from damage. If necessary, replace any components that are damaged.

2. Turn the battery disconnect switch to the OFF position.

Illustration 2

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Typical example


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2. Position fuel filter base (3) on the mounting bracket. Install bolts (5) to the fuel filter base. Tighten the bolts to a torque of 35 N·m (26 lb ft). 3. Connect the tube assemblies for the fuel inlet and the fuel outlet (not shown) to fuel fi lter base (3). 4. If necessary, install a new fuel fi lter (4) to fuel fi lter base (3). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter/Water Seperator - Drain”. 5. Connect harness assembly (1) to fuel priming pump (2). 6. Turn the fuel supply to the ON position. 7. Turn the battery disconnect switch to the ON position. 8. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime”.

Illustration 3

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Typical example

i02748531

Fuel Injection Lines - Remove and Install (Naturally Aspirated Engines) Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 4

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Typical example

Note: Place identi fication marks on all tube assemblies for installation. Plug all lines and tube assemblies in order to prevent contamination. 1. Turn the fuel supply to the OFF position. 2. If necessary, loosen the dipstick tube (not shown).

3. Disconnect hose (4) from tube assembly (6). 4. Disconnect fuel injection lines (1) from fuel injectors (3). 5. Disconnect fuel injection lines (1) from fuel injection pump (5).



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Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are loosened. Use two wrenches in order to disconnect the fuel injection lines from the fuel injection pump. 6. Remove fuel injection lines (1). 7. Use suitable caps in order to plug the open ports of the fuel injection pump immediately. 8. Disconnect tube assembly (6) from fuel return line (2). 9. Remove banjo bolt (9) and sealing washers (10) from fuel injection pump (5). 10. Remove bolt (11) and remove tube assembly (6). 11. Remove nuts (7) from fuel injectors (3). Remove fuel return line (2) and sealing washers (8) from fuel injectors (3). 12. Use suitable caps in order to plug the open ports of the fuel injectors immediately.

Illustration 5

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Typical example

Installation Procedure Table 1

Required Tools Tool A

Part Number

Part Description

Qty

27610294

Injector Pipe Nut Tool

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 6

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Typical example

1. Remove the caps from fuel injectors (3) and install new sealing washers (8) to the fuel injectors. Note: Washers (8) have two small holes. The position of the holes is not important.


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2. Position fuel return line (2) onto fuel injectors (3). 3. Install nuts (7) onto each fuel injector. Tighten the nuts to a torque of 23 N·m (17 lb ft). 4. Position tube assembly (6) onto the engine. Loosely connect the tube assembly to fuel return line (2). 5. Install banjo bolt (9) and new sealing washers (10) to fuel injection pump (5). 6. Install bolt (11). Tighten the bolt to a torque of 11 N·m (97 lb in).

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Place identification marks on all tube assemblies for installation. Plug all lines and tube assemblies in order to prevent contamination. 1. Turn the fuel supply to the OFF position.

7. Tighten banjo bolt (9) to a torque of 18 N·m (13 lb ft). Tighten the nut to fuel return line (2) to a torque of 20 N·m (15 lb ft). 8. Remove the caps from the fuel injection pump. Install fuel injection lines (1) to fuel injection pump (5) and to fuel injectors (3). 9. Use Tooling (A) to tighten the nuts on fuel injection lines (1) to a torque of 30 N·m (22 lb ft). Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are tightened. 10. Connect hose (4) to tube assembly (6). 11. If necessar y, tighten the dipstick tube (not shown) to a torque of 9 N·m (80 lb in). 12. Turn the fuel supply to the ON position. 13. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for more information. i02748529

Fuel Injection Lines - Remove and Install (Turbocharged Engines)

Illustration 7

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Typical example

Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during per formance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.



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Part Number

Part Description

Qty

27610294

Injector Pipe Nut Tool

1


Illustration 8

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Typical example

2. If necessary, loosen the dipstick tube (not shown). 3. Disconnect fuel injection lines (1) from fuel injectors (3). 4. Disconnect fuel injection lines (1) from fuel injection pump (5). Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are loosened. Use two wrenches in order to disconnect the fuel injection lines from the fuel injection pump. 5. Remove clamps (4) and remove fuel injection lines (1).

Illustration 9

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Typical example

6. Use suitable caps in order to plug the open ports of the fuel injection pump and the fuel injectors immediately. 7. Disconnect tube assembly (6) from fuel injector (3). Disconnect tube assembly (6) from fuel injection pump (5). Remove bolts (7) and remove tube assembly (6). 8. Remove hoses (2) from fuel injectors (3).


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i02748534

Fuel Injection Pump - Remove Removal Procedure Table 3

Required Tools Tool

Part Number

A

-

Part Description Combination Puller

Qty 1

Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.

Illustration 10

g01324910

NOTICE Care must be taken to ensure that fl uids are contained during performance of inspection, maintenance, testing, adjusting andrepair of theproduct. Be prepared to collect the fl uid with suitable containers before opening any compartment or disassembling any component containing fluids.

Typical example

1. Install hoses (2) to fuel injectors (3).

Dispose of all fl uids according to local regulations and mandates.

2. Position tube assembly (6) onto the engine and install bolts (7). Tighten the bolts to a torque of 18 N·m (13 lb ft).

NOTICE Keep all parts clean from contaminants.

3. Connect tube assembly (6) to fuel injectors (3). Connect tube assembly (6) to fuel injection pump (5). 4. Remove the caps from fuel injectors and from the fuel injection pump. Loosely install fuel injection lines (1) to fuel injection pump (5) and to fuel injectors (3).

Contaminants may cause rapid wear and shortened component life. 1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

5. Install clamps (4). Tighten the clamps securely. 6. Use Tooling (A) to tighten the nuts on fuel injection lines (1) to a torque of 30 N·m (22 lb ft). Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are tightened. 7. If necessary, tighten the dipstick tube (not shown) to a torque of 9 N·m (80 lb in). 8. Turn the fuel supply to the ON position. 9. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for more information.



Illustration 11

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g01335768

Illustration 13

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Typical example

Typical example

2. Remove bolts (4).

6. Loosen bolt (7).

3. Remove plate (2) from front housing (1).

7. Remove fasteners (8), bolt (10) and bracket (9).

4. Remove O-ring seal (3) from plate (2).

8. Support fuel injection pump (6) and remove bolt (7). 9. Remove the assembly of housing (5) and fuel injection pump (6).

Illustration 12

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Timing marks on the gears

5. Ensure that Timing marks (X) on the teeth of the gears are aligned or make temporary marks on the gears for installation purposes.

Illustration 14

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Typical example

10. Remove O-ring seal (13) from housing (5). 11. Loosen nut (11).


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Note: Do not remove the nut at this time. 12. Use Tooling (A) to loosen gear (12). Remove nut (11) and gear (12).

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for more information.

13. If the original fuel injection pump will be installed, mark the flange of fuel injection pump (6) and housing (5). Remove nuts (15). Note: Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check” for the correct method of setting the fuel injection pump timing after installation. 14. Remove housing (5) from fuel injection pump (6). Remove O-ring seal (14) from housing (5). i02748532

Fuel Injection Pump - Remove (Fuel Injection Pumps With a Water Heated Cold Start Device)

Illustration 15

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Typical example

2. Loosen the hose clamps and disconnect hoses (1) and (4) from fuel injection pump (2). 3. Loosen the hose clamps and remove hose (3) from fuel injection pump (2). 4. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

Removal Procedure Table 4

Required Tools Tool

Part Number

A

-

Part Description Combination Puller

Qty 1

Start By: a. Remove the f uel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates. Illustration 16


g01366190

Typical example

5. Remove bolts (8). 6. Remove plate (6) from front housing (5). 7. Remove O-ring seal (7) from plate (6).



Illustration 17

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g01375914


8. Ensure that Timing marks (X) on the teeth of the gears are aligned or make temporary marks on the gears for installation purposes. Illustration 19

g01375949

Typical example

13. Remove O-ring seal (16) from housing (9). 14. Loosen nut (14). Note: Do not remove the nut at this time. 15. Use Tooling (A) to loosen gear (15). Remove nut (14) and gear (15). 16. If the original fuel injection pump will be installed, mark the flange of fuel injection pump (2) and housing (9). Remove nuts (18). Note: Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check” for the correct method of setting the fuel injection pump timing after installation. Illustration 18

g01375476

Typical example

17. Remove housing (9) from fuel injection pump (2). Remove O-ring seal (17) from housing (9).

9. Loosen bolt (10). 10. Remove fasteners (11), bolt (13) and bracket (12). 11. Support fuel injection pump (2) and remove bolt (10). 12. Remove the assembly of housing (9) and fuel injection pump (2).


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i02748536

Fuel Injection Pump - Install (Fuel Injection Pumps With a Water Heated Cold Start Device)

6. Install a new O-ring seal (16) to housing (9). Install gear (15) to fuel injection pump (2). Install nut (14) finger tight.

Installation Procedure NOTICE from contaminants. Keep all parts clean Contaminants may cause rapid wear and shortened component lif e. 1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”. Illustration 21

g01375476

Typical example

Illustration 22

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Illustration 20

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Typical example

2. Ensure that the mating surfaces of housing (9) and fuel injection pump (2) are clean and free from damage. 3. Install a new O-ring seal (17) to housing (9). 4. Position housing (9) on fuel injection pump (2). If the original fuel injection pump is installed, ensure that the appropriate marks on the flange of the fuel injection pump and the housing are aligned. Install nuts (18) fi nger tight.

7. Install the assembly of housing (9) and fuel injection pump (2) to the engine. Ensure that Timing marks (X) on the teeth of the gears are in the correct position. Install bolt (10) fi nger tight. 8. Position bracket (12) on fuel injection pump (2). Install fasteners (11) and bolt (13) fi nger tight. 9. Tighten nut (14) to a torque of 90 N·m (66 lb ft). Refer to Illustration 20.

5. Tighten nuts (18) to a torque of 18 N·m (13 lb ft).



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15. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. 16. Adjust the fuel injection pump timing. Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check”. End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. i02748535

Fuel Injection Pump - Install Illustration 23

g01366190

Typical example

Installation Procedure

10. Install a new O-ring seal (7) to plate (6).


11. Position plate (6) on front housing (5). Install bolts (8). Tighten the bolts to a torque of 18 N·m (13 lb ft).

Contaminants may cause rapid wear and shortened component life.

12. Tighten bolt (10) to a torque of 18 N·m (13 lb ft). Tighten bolt (13) to a torque of 18 N·m (13 lb ft). Tighten fasteners (11) to a torque of 35 N·m (26 lb ft). Refer to Illustration 21.

1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

Illustration 24

g01366198

Typical example

13. Install hose (3) to fuel injection pump (2). Tighten the hose clamps securely. 14. Connect hoses (1) and (4) to fuel injection pump (2). Tighten the hose clamps securely.

Illustration 25

g01335808

Typical example


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2. Ensure that the mating surfaces of housing (5) and fuel injection pump (6) are clean and free from damage. 3. Install a new O-ring seal (14) to housing (5).

8. Position bracket (9) on fuel injection pump (6). Install fasteners (8) and bolt (10) finger tight. 9. Tighten nut (11) to a torque of 90 N·m (66 lb ft). Refer to Illustration 25.

4. Position housing (5) on fuel injection pump (6). If the original f uel injection pump is installed, ensure that the appropriate marks on the flange of the fuel injection pump and the housing are aligned. Install nuts (15) fi nger tight. 5. Tighten nuts (15) to a torque of 18 N·m (13 lb ft). 6. Install a new O-ring seal (13) to housing (5). Install gear (12) to fuel injection pump (6). Install nut (11) finger tight.

Illustration 28

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Typical example

10. Install a new O-ring seal (3) to plate (2). 11. Position plate (2) on front housing (1). Install bolts (4). Tighten the bolts to a torque of 18 N·m (13 lb ft).

Illustration 26

g01375471

12. Tighten bolt (7) to a torque of 18 N·m (13 lb ft). Tighten bolt (10) to a torque of 18 N·m (13 lb ft). Tighten fasteners (8) to a torque of 35 N·m (26 lb ft). Refer to Illustration 26.

Typical example

13. Adjust the fuel injection pump timing. Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check”. End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.

Illustration 27

g01375914


7. Install the assembly of housing (5) and fuel injection pump (6) to the engine. Ensure that Timing marks (X) on the teeth of the gears are in the correct position. Install bolt (7) fi nger tight.



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i02748539

Fuel Injector - Remove and Install (Naturally Aspirated Engines)

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean the bore for the fuel injector in the cylinder head. Ensure that no debris enters the cylinder. Clean the threads on the body of the fuel injector.

Removal Procedure Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. NOTICE from contaminants. Keep all parts clean Contaminants may cause rapid wear and shortened component lif e. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

Illustration 30

g01325773

Typical example

2. Install new seat washers (1) into the bore for the fuel injector in the cylinder head. 3. Install fuel injectors (2) into the cylinder head. Use a deep socket to tighten fuel injectors (2) to a torque of 59 N·m (44 lb ft). End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. i02748538

Illustration 29

g01325773

Fuel Injector - Remove and Install (Turbocharged Engines)

Typical example

1. Use a deep socket to remove fuel injectors (2) from the cylinder head. 2. Remove seat washers (1).

Removal Pr ocedure Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.


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NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar tment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

Illustration 32

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Typical example

2. Install new seat washers (1) to the bores for the fuel injectors in the cylinder head. 3. Install fuel injectors (2) into the cylinder head. 4. Position clamps (4) onto fuel injectors (2) and install bolts (3). Tighten bolts (3) to a torque of 22 N·m (16 lb ft). End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. Illustrati on 31

g01325781

1. Remove bolts (3) and clamps (4) from fuel injectors (2).

i02748540

Turbocharger - Remove

2. Remove fuel injectors (2) from the cylinder head. 3. Remove seat washers (1).

Removal Procedure





Contaminants may cause rapid wear and shortened component life. 1. Clean the bores for the fuel injectors in the cylinder head. Ensure that no debris enters the cylinders. Clean the fuel injectors.

NOTICE Care must be taken to ensure that fl uids are contained during performance of inspection, maintenance, testing, adjusting andrepair of theproduct. Be prepared to collect the fl uid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.



Illustration 33

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g01336694

Typical example

1. Loosen hose clamps (6) and remove hose (4). Plug the connection on the inlet manifold with a suitable plug. 2. Remove bolts (5) and remove air pipe (3) from turbocharger (1). Remove gasket (2). 3. Plug the opening in the inlet manifold and the opening in the turbocharger with suitable plugs. Illustration 34

g01336699

Typical example

Illustration 35

g01337174

4. Follow Steps 4.a through 4.c in order to remove tube assembly (9) for the oil feed. a. Remove tube clamp (17) that secures tube assembly (9) to tube assembly (12). Note the position of the clamp.


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b. Remove banjo bolt (14) and sealing washers (15). Disconnect tube assembly (9) from adapter (16) in the cylinder block. Note: Do not allow adapter (16) to turn in the cylinder block when the banjo bolt is loosened. Use two wrenches in order to disconnect the tube assembly. c. Remove banjo bolt (7) and sealing washers (8). Remove tube assembly (9) from turbocharger (1). 5. Follow Steps 5 through 5.c in order to remove the tube assembly (12) for the oil drain. a. Remove bolts (13). Disconnect tube assembly (12) from tur bocharger (1). b. Remove joint (11). c. If necessary, loosen the hose clips and remove tube assembly (12) from the adapter in the cylinder block. 6. Remove the double nuts (not shown) that secure turbocharger (1) to the exhaust manifold. 7. Remove turbocharger (1) from the exhaust manifold. Remove gasket (10). 8. Plug the oil supply and the oil drain ports in the turbocharger and in the cylinder block with suitable plugs. i02748541

Illustration 36

g01336699

Typical example

Turbocharger - Install

2. Clean the mating surface of the exhaust manifold. Install a new gasket (10) over the studs. Apply Tooling (A) to the studs.


3. Position turbocharger (1) onto the exhaust manifold and install the double nuts. Tighten the nuts to a torque of 18 N·m (13 lb ft).

Table 5

Required Tools Part Number

Tool A

CV60889

Part Description Anti-Seize Compound

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect” for more information. If the turbocharger is worn, the complete turbocharger must be replaced.

Note: Do not allow the lower nuts to turn when the upper nuts are tightened. 4. Ensure that tube assemblies (9) and (12) are clean and free from damage. If necessary, replace the tube assemblies. 5. Remove the plugs from the ports in the turbocharger and from the cylinder block. 6. If necessary, install the lower end of tube assembly (12) to the adapter in the cylinder block. Position a new joint (11) onto tube assembly (12). Connect the tube assembly to turbocharger (1) and install bolts (13). Tighten the bolts to a torque of 9 N·m (80 lb in). If necessary, tighten the hose clips.



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7. Lubricate the bearings of turbocharger (1) with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant. 8. Install new sealing washers (8) and banjo bolt (7) to tube assembly (9). Position tube assembly (9) onto turbocharger (1). Tighten the banjo bolt fi nger tight. Install new sealing washers (15) and banjo bolt (14) to tube assembly (9). Connect the tube assembly to adapter (16) in the cylinder block. 9. Tighten banjo bolts (7) and (14) to a torque of 16 N·m (12 lb f t). Note: Do not allow adapter (16) to turn in the cylinder block.

11. Position a new joint (2) and air pipe (3) onto turbocharger (1). Install bolts (5). Tighten the bolts to a torque of 18 N·m (13 lb ft). 12. Remove the plugs from the connection on the inlet manifold and from the turbocharger. Install hose (4) and tighten hose clamps (6) securely. i02748542

Exhaust Manifold - Remove and Install Removal Procedure Start By: a. If the engine is equipped with a turbocharger, remove the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Remove”.

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. Illustration 37

g01337174

10. Install clamp (17) to tube assemblies (9) and (12). Tighten the fasteners securely.

NOTICE Keep all par ts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 39

g01333088

Exhaust manifold from a naturally aspirated engine

Illustration 38 Typical example

g01336694

1. Loosen bolts (1). Note: In order to prevent distortion of the exhaust manifold, Loosen the outer bolts first.


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2. Remove bolts (1) and remove exhaust manifold (2) from the cylinder head.

Note: Tighten the center bolts first. End By:

3. Remove gasket (3). a. If the engine is equipped with a turbocharger, install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install”.


Required Tools Tool

Part Number

A

-

Part Description Guide Stud (M8 x 1.25 by 100 mm)

i02748543

Qty 2

Inlet Manifold - Remove and Install Removal Procedure

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the exhaust manifold is clean and free from damage. Clean the joint surface of the cylinder head.

Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 40

g01333101

Exhaust manifold from a naturally aspirated engine

2. Install Tooling (A) to the cylinder head in positions (X). 3. Position a new exhaust manifold gasket (3) onto Tooling (A).

Illustration 41

g01333458

Typical example

Note: Ensure that the exhaust manifold gasket is correctly oriented. 4. Align exhaust manifold (2) with Tooling (A). Install the exhaust manifold to the cylinder head. 5. Install bolts (1) fi nger tight. 6. Remove Tooling (A). Install the remaining bolts (1) finger tight. 7. Tighten bolts (1) to a torque of 30 N·m (22 lb ft).



Illustration 42

KENR6241

g01333457

Typical example

Illustration 43

g01333458

Typical example

1. Loosen the hose clamps and disconnect the air hose (not shown) from connection (3). 2. For naturally aspirated engines, disconnect the hose for the crankcase breather (not shown) from inlet manifold (1). For turbocharged engines, remove the bolt that secures the hose for the crankcase breather (not shown) from the inlet manifold (1). 3. Remove bolts (6) from inlet manifold (1). Note the position of any brackets that are retained by the bolts for installation. Illustration 44

4. Remove inlet manifold (1) and gasket (5) from the cylinder head. 5. If necessary, remove bolts (4) and remove connection (3) from inlet manifold (1). Remove gasket (2).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all mating surfaces are clean and free from debris.

g01333457

Typical example

2. If necessary, position a new gasket (2) and connection (3) onto inlet manifold (1). Install bolts (4). Tighten the bolts to a torque of 11 N·m (97 lb in). Note: Ensure correct orientation of the connection. 3. Place a new gasket (5) in position on inlet manifold (1). 4. Position inlet manifold (1) on the cylinder head. 5. Install bolts (6). Ensure that bolts of different lengths are installed in the correct positions. Also ensure that any brackets that are retained by the bolts are installed in the correct positions. 6. Tighten bolts (6) to a torque of 18 N·m (13 lb ft). 7. For naturally aspirated engines, connect the hose for the crankcase breather (not shown) to inlet manifold (1).


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For turbocharged engines, install the bolt that secures the hose for the crankcase breather (not shown) to the inlet manifold (1). Tighten the bolt to a torque of 11 N·m (97 lb in). 8. Connect the air hose (not shown) to connection (3) and tighten the hose clamps securely. End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and install”.

Note: The following procedure should be adopted in order to remove the valve springs when the cylinder head is installed to the engine. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install” f or the procedure to remove the valve springs from a cylinder head that has been removed from the engine. Note: Ensure that the appropriate piston is at the top center position before the valve spring is removed. Failure to ensure that the piston is at the top center position may allow the valve to drop into the cylinder bore.

i02748544

Inlet and Exhaust Valve Springs - Remove and Install Removal Procedure Table 7


Tool A

21825666

B

27610235

Part Description Valve Spring Compressor Adapter

Qty 1 1

Start By: a. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”.

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine.

Illustration 45

g01358696

Typical example

1. Follow Steps 1.a through 1.d in order to position the appropriate piston at top center. a. Install Tooling (A) and (B) in position on the cylinder head in order to compress a valve spring for the appropriate piston. b. Use Tooling (A) in order to compress valve spring (3) and open the valve slightly. Note: Do not compress the spring so that the valve spring retainer (2) touches the valve stem seal. c. Carefully rotate the crankshaft until the piston touches the valve. Note: Do not use excessive force to turn the crankshaft. The use of force can result in bent valve stems. d. Continue to rotate the crankshaft and gradually release the pressure on Tooling (A) until the piston is at the top center position. The valve is now held in a position that allows the valve spring to be safely removed. NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.



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2. Use Tooling (A) in order to compress valve spring (3). Remove valve keepers (1). Note: Do not compress the valve spring so that the valve spring r etainer (2) touches the valve stem seal. 3. Slowly release the pressure on Tooling (A). 4. Remove valve spring retainer (2) and remove valve spring (3). NOTICE Do not turn the crankshaft while the valve springs are removed. Illustration 46

Note: If all valve springs require replacement the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 4 and 2 with 3. Ensure that all of the valve springs are installed before changing from one pair of cylinders to another pair of cylinders. 5. Remove Tooling (A) and (B).

Required Tools

A

21825666

B

27610235

Part Description Valve Spring Compressor Adapter

2. Install valve spring (3) onto the cylinder head. Position valve spring retainer (2) onto valve spring (3).

To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Table 8

Part Number

Typical example

Improper assembly of parts that are spring loaded can cause bodily injury.


Tool

g01358696

Qty 1 1

NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.


3. Install Tooling (A) and (B) in the appropriate position on the cylinder head in order to compress the valve spring.


4. Apply suf ficient pressure to Tooling (A) in order to install valve keepers (1).

NOTICE Do not turn the crankshaft while the valve springs are removed. 1. Inspect the valve springs for the correct length. Refer to Specifications, “Cylinder Head Valves ”.

Note: Do not compress the spring so that valve spring retainer (2) touches the valve stem seal. Install the valve spring keepers. 5. Carefully release the pressure on Tooling (A). Note: Ensure that the valve keepers are correctly seated.


KENR6241


The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves. 6. Remove Tooling (A). Ensure that all of the valves are secured in place by a valve spring and valve keepers. Rotate the crankshaft through about 45 degrees in order to clear the piston from the valve. Lightly strike the top of the valve with a soft hammer in order to ensure that the valve keepers are properly installed.

2. Place a temporary identi fication mark on the heads of the valves in order to identify the correct position. Note: Do not stamp the heads of the valves. Stamping or punching the heads of the valves could cause the valves to fracture.

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

End By: a. Install the rocker shaft assembly. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”.

NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.

i02748545

Inlet and Exhaust Valves Remove and Install Removal Procedure Table 9


Part Number

B

21825663 -

Part Description

Qty

Valve Spring Compressor

1

Seal Remover

1

Start By: a. Remove the cylinder head assembly. Refer to Disassembly and Assembly, “Cylinder Head Remove”.

Illustration 47

g01333469

Typical example

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean the bottom face of the cylinder head. Check the depth of the valves below the face of the cylinder head before the valve springs are removed. Refer to Speci fications, “Cylinder Head Valves” for the correct dimensions.



KENR6241

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean all components of the cylinder head assembly. Ensure that all ports, all coolant passages and all lubrication passages in the cylinder head are free from debris. Follow Steps 1.a through 1.e in order to inspect the components of the cylinder head assembly. Replace any components that are worn or damaged. a. Inspect the cylinder head for wear and for damage. Refer to Systems Operation, Testing and Adjusting, “Cylinder Head Inspect”.

g01333471


3. Use Tooling (A) in order to compress the appropriate valve spring (3). Remove valve keepers (1). Note: Do not compress the valve spring so that valve spring retainer (2) touches valve stem seal (4). 4. Remove Tooling (A). 5. Remove valve spring retainer (2). Remove valve spring (3).

b. Inspect the valve seats for wear and for damage. Refer to Speci fications, “Cylinder Head Valves” for further information. c. Inspect the valve guides for wear and for damage. Refer to Speci fications, “Cylinder Head Valves” and Systems Operation, Testing and Adjusting, “Valve Guide - Inspect” for further information. d. Inspect the valves for wear and for damage. Refer to Specifications, “Cylinder Head Valves”. e. Inspect the valve springs for the correct length. Refer to Specifications, “Cylinder Head Valves”.

6. Remove valve (5). 7. Use Tooling (B) to remove valve stem seal (4). 8. Repeat Steps 3 through 7 in order to remove the remaining inlet and exhaust valves.


Required Tools Tool A C

Part Number

Part Description

Qty

21825663

Valve Spring Compressor

1

27610261

Seal Installer

1

27610262

Valve Guide Driver

1 Illustration 49

g01333472

Typical example


KENR6241


2. Use Tooling (C) to install new valve stem seals (4) onto each of the valve guides.

Illustration 51

g01333469

Typical example Illustration 50

g01333471

Typical example

3. Lubricate the stem of valve (5) with clean engine oil. Install valve (5) in the appropriate position in the cylinder head. Check the depth of the valve below the face of the cylinder head. Refer to Systems Operation, Testing and Adjusting, “Valve Depth - Inspect” for more information. 4. Install valve spring (3) to the cylinder head. Position valve spring retainer (2) onto valve spring (3).

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.

5. Use Tooling (A) in order to compress valve spring (3). Install valve keepers (1). Note: Do not compress the spring so that valve spring retainer (2) touches valve stem seal (4).

The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves. 6. Remove Tooling (A). 7. Repeat Steps 3 to 6 for the remaining valves. 8. Place the cylinder head on a suitable support. Ensure that the heads of the valves are not obstructed. Gently strike the top of the valves with a soft hammer in order to ensure that valve keepers (1) are properly installed. End By: a. Install the cylinder head assembly. Refer to Disassembly and Assembly, “Cylinder Head Install”.



KENR6241

i02748546

Engine Oil Filter Base Remove and Install

1. Use Tooling (A) to remove engine oil filter (6) from engine oil fi lter base (5). Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change”. 2. Mark the orientation of engine oil fi lter base (5) for installation. Remove bolt (2).

Removal Procedure

Note: The engine oil filter base can be oriented in different positions.

Table 11

Required Tools Tool

Part Number

A

-

Part Description Strap Wrench

Qty

3. Remove bolt (4) and remove engine oil fi lter base (5) from the cylinder block. Plug the oil galleries in the cylinder block with suitable plugs.

1

4. Remove O-ring seal (1) from engine oil fi lter base (5).


5. Remove O-ring seal (3) from bolt (4).



NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

Illustration 53

g01333853

Typical example

1. Ensure that the engine oil filter base is clean and free from damage. Clean the mating surfaces of the cylinder block. 2. Install a new O-ring seal (1) to engine oil filter base (5). Install a new O-ring seal (3) to bolt (4). 3. Position engine oil filter base (5) against the cylinder block. Install bolt (4) finger tight. Illustration 52 Typical example

g01333853

4. Ensure the correct orientation of engine oil filter base (5). Install bolt (2) fi nger tight. Note: The engine oil filter base can be oriented in different positions.


KENR6241


5. Tighten bolt (4) to a torque of 50 N·m (37 lb ft). Tighten bolt (2) to a torque of 11 N·m (97 lb in). 6. Install a new engine oil fi lter (6). Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change” for the correct procedure. i02748547

Engine Oil Cooler - Remove Removal Procedure Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove”. Illustration 54

g01361343


Typical example


3. For turbocharged engines, remove crankcase breather (2). Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install”.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

4. Remove dipstick tube (1).

Dispose of all fl uids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. 2. Drain the engine lubricating oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change” for the procedure.



KENR6241

i02748549

Engine Oil Cooler - Install Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 55

g01333881

Typical example

5. Gradually loosen bolts (11). Note the position of any brackets that are secured by the bolts. 6. Support the assembly of engine oil cooler (3). Remove bolts (11) and remove the assembly of engine oil cooler (3) from the cylinder block. 7. Remove joint (5). 8. Remove O-ring seals (4) from the recesses in the cylinder block. Illustration 56

9. If necessary, follow Steps 9.a through 9.d in order to disassemble the engine oil cooler. a. Remove nuts (8). b. Remove cooler matrix (6) from cover (7). c. Remove O-ring seals (12) and (13). d. Remove plate (10) and joint (9) from cover (7).

g01333881

Typical example

1. If necessary, follow Steps 1.a through 1.e in order to assemble the engine oil cooler. a. Ensure that cooler matrix (6) is clean and free from damage. Ensure that cover (7) is clean and free from damage. b. Position new O-ring seals (12) and (13) onto cover (7).


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c. Install cooler matrix (6) to cover (7).

End By:

d. Install nuts (8). Tighten the nuts to a torque of 18 N·m (13 lb ft).

a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Install”.

e. Install joint (9) and plate (10).

i02748550

2. Clean the mating surface of the cylinder block. 3. Install new O-ring seals (4) to the recesses in the cylinder block. 4. Install two bolts (11) to the upper corners of the assembly of engine oil cooler (3). Install a new joint (5) to the assembly of engine oil cooler (3). 5. Install the assembly of engine oil cooler (3) to the cylinder block. Install the remaining bolts (11). Note: Ensure that any brackets that are secured by the bolts are installed in the correct location. 6. Tighten bolts (11) evenly to a torque of 18 N·m (13 lb ft).

Engine Oil Relief Valve Remove and Install Removal Procedure Table 12


Part Number -

Part Description Strap Wrench

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fl uids are contained during performance of inspection, maintenance, testing, adjusting andrepair of theproduct. Be prepared to collect the fl uid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

Illustration 57

g01361343

Typical example

7. Install dipstick tube (1). 8. For turbocharged engines, install crankcase breather (2). Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install”. 9. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. 10. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change” for the correct procedure.



Illustration 58

KENR6241

g01334417

Illustration 59

g01334417

Typical example

Typical example

1. If necessary, use Tooling (A) in order to remove engine oil filter (3). Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change”.

1. Install a new sealing washer (1) to engine oil relief valve (2).

2. Remove engine oil relief valve (2). 3. Remove sealing washer (1).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

2. Install engine oil relief valve (2) to the cylinder block. Tighten the engine oil relief valve to a torque of 49 N·m (36 lb ft). 3. If necessary, install a new engine oil fi lter (3). Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change” for the correct procedure. i02748551

Engine Oil Bypass Valve Remove and Install Removal Procedure Start By: a. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


KENR6241


NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar tment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates. 1. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”.

Illustration 61

g01334433

Typical example

2. Install a new sealing washer (2) to engine oil bypass valve (1). 3. Install engine oil bypass valve (1) to the cylinder block. Tighten the engine oil bypass valve to a torque of 69 N·m (51 lb ft). 4. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”. End By: Illustration 60

g01334433

Typical example

2. Remove engine oil bypass valve (1).

a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.

3. Remove sealing washer (2).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Inspect the components of the engine oil bypass valve for wear or damage. Check the valve and the valve seat for an abnormal contact pattern. Check the spring for weakness or damage. If necessary, replace the engine oil bypass valve.

i02748553

Engine Oil Pump - Remove Removal Procedure Start By: a. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.



KENR6241

i02748554

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar tment or disassembling any component containing fluids.

Engine Oil Pump - Install Installation Procedure Table 13



Part Number

21825617

Part Description Dial Indicator Group

Qty 1


Illustration 63

Illustration 62

g01334537

g01334869

1. Ensure that bushing (8) is free from wear or damage. Refer to Speci fications, “Engine Oil Pump” for more information. If necessary, replace the bushing.

1. Remove nut (5) and washer (4). 2. Remove gear (3) from the shaft of engine oil pump (1). 3. Remove bolts (6) and remove engine oil pump (1) from the cylinder block. 4. Remove O-ring seal (2).


KENR6241


i02748555

Water Pump - Remove and Install Removal Procedure Start By: a. If the engine is equipped with a fan, remove the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. If the engine is not equipped with a fan, remove the V-belt. Refer to Disassembly and Assembly, “V-belts - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 64

g01334537

2. Ensure that engine oil pump (1) is clean and free from wear or damage. Refer to Specifications, “Engine Oil Pump” for more information. If necessary, replace the engine oil pump. 3. Install a new O-ring seal (2) to engine oil pump (1). Lubricate the rotors of the engine oil pump with clean engine oil.

NOTICE Care must be taken to ensure that fl uids are contained during performance of inspection, maintenance, testing, adjusting andrepair of theproduct. Be prepared to collect the fl uid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

4. Align engine oil pump (1) with dowels (7). Install the engine oil pump to the cylinder block.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for more information.

5. Install bolts (6). Tighten the bolts to a torque of 11 N·m (97 lb in).

2. Loosen the hose clamp and disconnect the hose (not shown) from the water pump inlet.

6. Position oil pump gear (3) onto the shaft of engine oil pump (1). Ensure that the oil pump gear is aligned with the fl at on the shaft. Install washer (4) and nut (5). Tighten the nut to a torque of 33 N·m (24 lb ft). 7. Use Tooling (A) to check the backlash between oil pump gear (3) and the idler gear. Ensure that the backlash is within speci fied values. Refer to Specifications, “Gear Group (Front)” for further information. End By: a. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”.



KENR6241

1. Ensure that the mating surfaces of the water pump and the cylinder block are clean and free from damage. If the cover was removed, ensure that the mating surfaces of the cover are clean and free from damage.

Illustration 67 Illustration 65

Illustration 66

g01335205

g01335213

2. If necessary, align a new joint (6) and cover (7) with the holes in water pump (2). Install bolts (5). Tighten the bolts to a torque of 10 N·m (89 lb in).

g01335205

3. Loosen the hose clamp and disconnect hose (1) from water pump (2). 4. Remove bolts (4) and remove water pump (2). Do not remove bolts (5) at this time. Note: If necessary, gently tap the water pump with a soft faced hammer in order to loosen the water pump. 5. Remove joint (3). 6. If necessary, remove bolts (5), and remove cover (7). Remove joint (6).

Illustration 68

g01335213

3. Place water pump (2) in position and install bolts (4). Ensure that bolts of different lengths are installed in the correct positions. Tighten bolts (4) to a torque of 18 N·m (160 lb in).


4. Connect hose (1) and tighten the hose clamp.


5. Connect the hose (not shown) to the water pump inlet and tighten the hose clamp.



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6. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. End By: a. If the engine is equipped with a fan, install the fan. Refer to Disassembly and Assembly, “Fan Remove and Install”. If the engine is not equipped with a fan, install the V-belt. Refer to Disassembly and Assembly, “V-belts - Remove and Install”. i02748556

Water Temperature Regulator Housing - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 69

g01335249

Typical example

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure.

2. Remove bolts (1) and remove outlet connection (2). 3. Remove joint (3) and remove water temperature regulator (4). Note the orientation of the water temperature regulator for installation. 4. Loosen the hose clamp and disconnect hose (8) from water temperature regulator housing (6). 5. Remove bolts (7) and remove water temperature regulator housing (6) from the cylinder head. 6. Remove joint (5).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Inspect the water temperature regulator for wear, damage and correct operation. Refer to Systems Operation,Testing and Adjusting, “Water Temperature Regulator - Test” for more information. If necessary, replace the water temperature regulator.



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2. Ensure that the mating surfaces of the outlet connection, the water temperature regulator housing and the cylinder head are clean and free from damage.

5. Install water temperature regulator (4) to water temperature regulator housing (6). Ensure the correct orientation of the water temperature regulator. 6. Position a new joint (3) and outlet connection (2) onto water temperature regulator housing (6). 7. Install bolts (1). Tighten the bolts to 18 N·m (13 lb ft). 8. Connect hose (8) to water temperature regulator housing (6). Tighten the hose clamps securely. 9. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant -Change” for the correct procedure. i02748557

Flywheel - Remove Removal Procedure Table 14

Required Tools

Illustration 70

Tool

Part Number

A

-

g01335249

Typical example


Qty 2

3. Position bolts (7) and a new joint (5) onto water temperature regulator housing (6).

Start By:

4. Position water temperature regulator housing (6) onto the cylinder head. Tighten bolts (7) to a torque of 18 N·m (13 lb ft).

a. Remove the starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 71

g01335282

Orientation of the water temperature regulator


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i02748558

Flywheel - Install Installation Procedure Table 15

Required Tools

Illustration 72

Tool

Part Number

A

-

g01335288


Qty 2

Typical example

1. Make a temporary mark in order to show the orientation of the fl ywheel on the crankshaft. 2. Install a suitable lifting device to flywheel (2). The weight of the flywheel is approximately 23 kg (50 lb). 3. Remove two bolts (1) from Positions (X) on the flywheel.

NOTICE from contaminants. Keep all parts clean Contaminants may cause rapid wear and shortened component lif e.

Always wear protective gloves when handling parts that have been heated.

4. Install Tooling (A) in positions (X) on the fl ywheel. 5. Remove the remaining bolts (1) and remove flywheel (2).

Illustratio n 74

g01369129

Typical example

Illustration 73

g01360927

Typical example

6. Inspect r ing gear (3) and fl ywheel (2) for wear or damage. If the ring gear or the fl ywheel is worn or damaged, use new parts for replacement. 7. To remove ring gear (3) from flywheel (2), place the fl ywheel on a suitable support. Use a hammer and a punch in order to remove the ring gear from the flywheel.

1. If the ring gear was removed, follow Steps 1.a through 1.c in order to install ring gear (3) to flywheel (2). a. Identify the orientation of the new ring gear in order to install the ring gear correctly onto the flywheel. Note: The chamfered side of gear teeth (Y) must face toward the starting motor when the flywheel is installed. This will ensure the correct engagement of the starting motor. b. Heat ring gear (3) in an oven to a maximum temperature of 150°C (302°F) prior to installation.



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Note: Do not use a torch to heat the ring gear. c. Ensure that the orientation of ring gear (3) is correct and quickly install the ring gear onto flywheel (2).

End By: a. Install the starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”. i02748559

Crankshaft Rear Seal - Remove and Install Removal Procedure Table 16

Required Tools Illustration 75

g01335288

Typical example

2. Thoroughly clean the flywheel housing. Inspect the crankshaft rear seal for leaks. If there are any oil leaks replace the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”. 3. Ensure that the dowels are installed to the crankshaft. Install Tooling (A) to positions (X) in the crankshaft. 4. Install a suitable lifting device to flywheel (2). The weight of the flywheel is approximately 23 kg (50 lb). 5. Align flywheel (2) with Tooling (A). Install the flywheel to the crankshaft. Note: Ensure the correct orientation of the flywheel on the crankshaft. 6. Install bolts (1) finger tight. 7. Remove Tooling (A) and install the two remaining bolts (1).

Tool

Part Number

A

-

B

27610311

Part Description

Qty

Drill Bit (4.10 mm)

1

Slide Hammer Puller

1

Start By: a. Remove the fl ywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”. NOTICE Care must betaken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting andrepair of theproduct. Be prepared to collect the fl uid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

8. Remove the lifting device from the fl ywheel. 9. Use a suitable tool to prevent flywheel (2) from rotating. Tighten bolts (1) to a torque of 83 N·m (61 lb ft). 10. Check the concentricity of the flywheel. Refer to Systems Operation, Testing and Adjusting, “Flywheel - Inspect”.


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1. Ensure that the flange of the crankshaft and the inside of the fl ywheel housing are clean and free of damage. It is possible to reclaim a crankshaft flange that has a worn seal surface, or a damaged seal surface by installing a wear sleeve. Refer to Disassembly and Assembly, “Crankshaft Wear Sleeve (Rear) - Remove and Install” for more information.

g01335312


1. Use Tooling (A) to drill three evenly spaced holes in crankshaft rear seal (2). 2. Use Tooling (B) to carefully remove crankshaft rear seal (2) from fl ywheel housing (1). Alternate the position of Tooling (B) from one hole to another hole. This will allow you to evenly remove the crankshaft rear seal from the fl ywheel housing.

Illustration 77

g01335312

Typical example


Required Tools Tool

C

Part Number

Part Description

Qty

27610266

Oil Seal Installer

1

27610345

Oil Seal Locator

1

27610346

Bolt

1

28710476

Hard Washer

1

27610347

Bolt (M12 x 1.25 by 20 mm)

2

Illustration 78

g01368204

Sectional view of the crankshaft rear seal, the crankshaft and the installation tool


2. Apply a thin coat of clean engine oil to the lip of crankshaft rear seal (2).


3. Use Tooling (C) in order to install crankshaft rear seal (2), as follows: a. Align the locator with the dowels in crankshaft (3). Install the locator to the crankshaft. Ensure the correct orientation of the locator. Note: Check that the installer will slide freely over the locator.



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b. Carefully slide crankshaft rear seal (2) over the locator until the crankshaft rear seal contacts the rear of crankshaft (3). Note: Ensure that the lip of the crankshaft rear seal that is spring loaded is facing toward the flywheel housing.

Note: Wear sleeves are used to reclaim worn seal surfaces or damaged seal surfaces. Wear sleeves are not original equipment. The wear sleeve is supplied with a crankshaft rear seal that has a larger internal diameter than a standard crankshaft rear seal. A standard crankshaft rear seal cannot be used if a wear sleeve is installed.

c. Assemble the installer to the locator and install the bolt and the washer. Ensure that the face of the installer with the deep counterbore is toward crankshaft rear seal (2). d. Tighten the bolt until the installer bottoms out on the locator in order to pull crankshaft rear seal (2) into fl ywheel housing (1). e. Remove Tooling (C). End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”. i02748560

Crankshaft Wear Sleeve (Rear) - Remove and Install

g01384938

Illustration 79

1. Use Tooling (A) in order to remove crankshaft wear sleeve (1) from crankshaft (2).


Required Tools Tool


Part Number

Tool A

Part Number -

Part Description Puller

Qty

B

Oil Seal Installer

1

27610345

Oil Seal Locator

1

27610346

Bolt

1

28710476

Hard Washer

1

27610266

Bolt (M12 x 1.25 by 20 mm)

2

1

Start By: a. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Qty

27610266

Required Tools

Part Description

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Wear sleeves are used to reclaim worn seal surfaces or damaged seal surfaces. Wear sleeves are not original equipment. The wear sleeve is supplied with a crankshaft rear seal that has a larger internal diameter than a standard crankshaft rear seal. A standard crankshaft rear seal cannot be used if a wear sleeve is installed. 1. Ensure that the crankshaft is thoroughly clean and dry. Remove any areas of raised damage.


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2. Lubricate the inner surface of the crankshaft wear sleeve with clean engine oil.

i02748561

Flywheel Housing - Remove and Install Removal Procedure Table 20

Required Tools

Illustration 80

g01377790

Tool

Part Number

A

-

Sectional view of the crankshaft, the wear sleeve and the installation tool


Qty 2

Start By: 3. Use Tooling (A) in order to install the crankshaft wear sleeve, as follows: a. Align the locator with the dowels in crankshaft (2). Install the locator to the crankshaft. Ensure the correct orientation of the locator. Note: Check that the installer will slide freely over the locator. b. Carefully slide crankshaft wear sleeve (3) over the locator until the crankshaft wear sleeve contacts the rear of crankshaft (2). c. Assemble the installer to the locator and install the bolt and the washer. Ensure that the face of the installer with the deep counterbore is toward crankshaft wear sleeve (3).

a. Remove the fl ywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fl uids are contained during performance of inspection, maintenance, testing, adjusting andrepair of theproduct. Be prepared to collect the fl uid with suitable containers before opening any compartment or disassembling any component containing fluids.

d. Tighten the bolt until the installer bottoms out on the locator in order to pull crankshaft wear sleeve (3) onto crankshaft (2).


e. Remove Tooling (A).

1. Support the engine.

End By: a. Install the new crankshaft rear seal that was supplied with the crankshaft wear sleeve. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”.



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7. Remove joint (1). 8. Remove crankshaft rear seal (4) from flywheel housing (2).


Required Tools Tool

Part Number

A

-

Guide Stud (M10 x 1.25 by100 mm)

2

21825617

Dial Indicator Group

1

B

Part Description

Qty

NOTICE Keep all parts clean from contaminants. Illustration 81

g01335374


Typical example

1. Ensure that the mating surfaces of the cylinder block and the fl ywheel housing are clean and free from damage.

Illustration 82

g01366220

Typical example

2. Remove two bolts (5) from positions (X) on flywheel housing (2). 3. Install Tooling (A) to positions (X) on flywheel housing (2). 4. Attach a suitable lifting device to flywheel housing (2). The weight of the fl ywheel housing is approximately 32 kg (71 lb). 5. Remove the remaining bolts (5). 6. Carefully remove fl ywheel housing (2) from dowels (3) and from the cylinder block.

Illustration 83

g01335383

Typical example

2. Inspect dowels (3) in the cylinder block. If necessary, replace the dowels.

Note: If necessary, tap the flywheel housing with a soft faced hammer in order to separate the fl ywheel housing from the cylinder block.


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i02748562

Crankshaft Pulley - Remove and Install Removal Procedure Table 22

Required Tools Tool Illustration 84

g01335381

A

Part Number

27610267

B

-

Part Description

Qty

Socket

1

Puller Group

1

3. Install Tooling (A) to the cylinder block. 4. Install a new joint (1) to the cylinder block. 5. Install a suitable lifting device to fl ywheel housing (2). The weight of the flywheel housing is approximately 32 kg (71 lb). 6. Use the lifting device to align fl ywheel housing (2) with Tooling (A). Install the fl ywheel housing to the cylinder block.

Start By: a. Remove the V-belt. Refer to Disassembly and Assembly, “V-belts - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

7. Install bolts (5) finger tight. 8. Remove Tooling (A). Install the remaining bolts (5).

1. Use a suitable method to prevent the crankshaft from rotating.

9. Tighten bolts (5) to a torque of 35 N·m (26 lb ft). 10. Remove the lifting device. 11. Use Tooling (B) to check the alignment of the flywheel housing with the crankshaft. Refer to Systems Operation, Testing and Adjusting, “Flywheel Housing - Inspect”. 12. Install a new crankshaft rear seal (4). Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Install”. End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”.

Illustration 85

g01335388

Typical example



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g01335508


2. Use Tooling (A) in order to loosen nut (3). Note: Do not remove the nut at this time. 3. Install Tooling (B) to crankshaft pulley (2). Use Tooling (B) to loosen the crankshaft pulley. Remove Tooling (B). 4. Remove nut (3) and remove crankshaft pulley (2). g01368691

5. If necessary, remove woodruff key (1) from crankshaft (4).

Illustration 87


1. Ensure that the threads of crankshaft (4) and nut (3) are clean and free from damage. If necessary, install woodruff key (1) to the crankshaft.

Typical example

Table 23

Required Tools Tool

C

Part Number

1861108

Part Description POWERPART Silicon RTV Sealing and Jointing Compound

Qty

2. Apply a continuous bead of Tooling (C) around the threads of crankshaft (4) at position (X) approximately 10 mm (0.4 inch) from the shoulder of the crankshaft.

1


3. Install pulley (2) to crankshaft (4). 4. Use a suitable method to prevent the crankshaft from rotating. 5. Install nut (3). Tighten the nut to a torque of 490 N·m (361 lb ft). End By: a. Install the V-belt. Refer to Disassembly and Assembly, “V-belts - Remove and Install”.


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i02748563

Crankshaft Front Seal Remove and Install



Tool

Removal Procedure C

Table 24

27610268

Required Tools Tool

Part Number

A

-

B

27610311

Part Description

Part Description

Qty

Seal Installer Stud

1

Washer

1

Seal Installer Sleeve

1

Qty

Drill Bit (4.10 mm)

1

Slide Hammer Puller

1


Start By: a. Remove the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Ensure that the main lip is used in order to remove the crankshaft front seal. Do not damage the edge of the housing for the crankshaft front seal.

Illustratio n 89

g01335757

Typical example

1. Ensure that the bore in front housing (1) and the nose of the crankshaft are clean and free from damage. 2. Lubricate the outside diameter of a new crankshaft front seal (2) with clean engine oil. 3. Position crankshaft front seal (2) in the bore of front housing (1).

Illustration 88

g01335759

Typical example

1. Use Tooling (A) to drill three evenly spaced holes in crankshaft front seal (2). 2. Use Tooling (B) to carefully remove crankshaft front seal (2). Alternate the position of Tooling (B) from one hole to another hole. This will allow you to evenly remove the crankshaft front seal from front housing (1).

NOTICE Ensure that the lip of the crankshaft front seal that is spring loaded is facing toward the inside of the front housing and that it is square with the bore of the housing for the crankshaft front seal. 4. Use Tooling (C) to install crankshaft front seal (2) into front housing (1). 5. Remove Tooling (C) and check for correct installation of crankshaft front seal (2). 6. Apply clean engine oil to the lip of crankshaft front seal (2).



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End By: a. Install the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”. i02748564

Front Cover - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component lif e.

g01335768


1. Ensure that the mating surface of front housing (1) and plate (2) are clean and free from damage. 2. Install a new O-ring seal (3) to plate (2). 3. Position plate (2) onto front housing (1). 4. Install bolts (4) and tighten to 18 N·m (13 lb ft). i02748565

Idler Gear - Remove and Install Removal Procedure Table 26 Illustration 90

g01335768

Required Tools

Typical example


Part Number

Tool A

27610269

Part Description Idler Shaf t Puller

Qty 1

2. Remove plate (2) from front housing (1). 3. Remove O-ring seal (3) from plate (2).


Start By: a. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. b. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.


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NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar tment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates. 1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

g01337783


4. Remove bolt (2), washer (3), and plate (4). 5. Remove idler gear (5) from shaft (1).

Illustration 92

g01337345

Alignment of timing marks

2. Ensure that timing marks (X) on the gears are aligned. Refer to Illustration 92.

g01337810

Illustration 94 Extracting the shaft from the cylinder block

Alternatively, make temporary timing marks on the gears in order to show alignment. 3. Loosen the nuts on all rocker arms. Unscrew the adjusters on all rocker arms until all valves are fully closed. Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.

6. If necessary, follow Steps 6.a and 6.b in order to remove shaft (1). a. Make a temporary mark on the cylinder block in order to show the position of oil hole (Y). b. Use Tooling (A) to extract shaft (1) from the cylinder block.


Required Tools Tool B

Part Number

21825617

Part Description

Qty


1



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Illustration 96

g01337345

Alignme nt of timing marks

4. Lubricate shaft (1) with clean engine oil. Position idler gear (5) onto shaft (1). Ensure that timing marks (X) on the gears are aligned. Refer to Illustration 96. 5. Lubricate the bearing surface of plate (4) with clean engine oil. Install plate (4), washer (3), and bolt (2).

Illustration 95

g01364486

Typical example

1. If necessary, follow Steps 1.a and 1.b in order to install shaft (1). a. Align oil hole (Y) on shaft (1) with the temporary mark on the cylinder block. b. Use a soft faced hammer and a hard wooden drift to install shaft (1) into the cylinder block. Note: Install shaft (1) squarely into the cylinder block. Ensure that oil hole (Y) is aligned with the temporary mark and that the shoulder on the shaft is seated against the face of the cylinder block. 2. Ensure that plate (4) and idler gear (5) are clean and free from wear or damage. If necessary, replace any components that are worn or damaged. 3. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

Note: Ensure that the bearing surface of the plate is toward the idler gear. 6. Tighten bolt (2) to a torque of 34 N·m (25 lb ft). 7. Use a feeler gauge in order to check the end play of idler gear (2). Refer to Speci fications, “Gear Group (Front)” for more information. 8. Use Tooling (B) in order to inspect the backlash of the gear group. Refer to Systems Operation, Testing and Adjusting, “Gear Group - Inspect”. 9. Lightly lubricate all of the gears with clean engine oil. 10. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. 11. Adjust the engine valve lash. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Inspect/Adjust”. End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.


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i02748567

Housing (Front) - Remove and Install Removal Procedure Start By: a. Remove the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. b. Remove the alternator. Refer to Disassembly and Assembly, “Alternator - Remove and Install”. c. Remove the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”. d. Remove the fr ont cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install”. e. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Illustration 97

g01349330

Typical example

1. Remove bolts (2). 2. Remove front housing (4) from plate (6). Note: Avoid damage to crankshaft front seal (3) when the front housing is removed. 3. Remove joint (5). Note: It is not necessary to remove dowels (1).





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d. Install the alternator. Refer to Disassembly and Assembly, “Alternator - Remove and Install”. e. Install the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. i02748568

Front Plate - Remove Removal Procedure Start By: a. Remove the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump - Remove”. Illustration 98

g01349330

Typical example

1. Ensure that front housing (4) and the nose of the crankshaft are clean and free from damage. Clean the mating surface of plate (6). 2. Inspect crankshaft front seal (3) for wear or damage. If necessary, replace the crankshaft front seal. Refer to Disassembly and Assembly, “Crankshaft Front Seal - Remove and Install”. Apply clean engine oil to the lip of the crankshaft front seal.

b. Remove the idler gear. Refer to Disassembly and Assembly, “Idler Gear - Remove and Install”. c. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

3. Install a new joint (5) to plate (6). Ensure that the joint is correctly seated on dowels (1). 4. Align front housing (4) with dowels (1). Install the front housing to plate (6). Note: Ensure that the crankshaft front seal is not damaged when the front housing is installed. 5. Install bolts (2). Tighten the bolts to a torque of 18 N·m (13 lb ft). End By:

Illustration 99

a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.

1. Remove nut (3) and washer (2).

b. Install the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install”.

g01365310

2. Remove gear (1) from the shaft of engine oil pump (4).

c. Install the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”.


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Illustration 100


g01365307

Illustration 101

g01365307

Typical example

Typical example


1. Ensure that plate (7) and the mating surface of the cylinder block are clean and free from damage. Ensure that dowels (6) are located in the cylinder block.

4. Remove plate (7) from the cylinder block. 5. Remove joint (8).

2. Install a new joint (8) to the cylinder block. Note: It is not necessary to remove dowels (6). 6. If necessary, remove the bracket for the alternator (not shown) from plate (7). i02748569

3. Align plate (7) with dowels (6) and install the plate to the cylinder block. 4. Install bolts (5). Tighten the bolts to a torque of 12 N·m (106 lb in).

Front Plate - Install Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 102

g01365310

5. Position gear (1) onto the shaft of engine oil pump (4). Ensure that the gear is aligned with the fl at on the shaft. Install washer (2) and nut (3). Tighten the nut to a torque of 33 N·m (24 lb ft). 6. If necessary, Install t he bracket for the alternator (not shown) to plate (7).



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End By: a. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. b. Install the idler gear. Refer to Disassembly and Assembly, “Idler Gear - Remove and Install”. c. Install the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump - Install”. i02748570

Crankcase Breather - Remove and Install (Turbocharged Engines) g01344989

Removal Procedure

Illustration 103


1. Loosen the hose clamp and disconnect hose (3) from crankcase breather (1).


2. Loosen the hose clamp and disconnect hose (4) from crankcase breather (1).

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

Typical example

3. Remove bolts (2) and remove crankcase breather (1).



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Illustration 104


g01344989

Illustration 105

g01336694

Typical example

Typical example

1. Connect hose (4) to crankcase breather (1) and tighten the hose clamp.

1. If the engine is equipped with a turbocharger, follow Steps 1.a through 1.c in order to remove the air pipe.

2. Position crankcase breather (1) and install bolts (2). Tighten the bolts to a torque of 18 N·m (13 lb ft). 3. Connect hose (3) to crankcase breather (1) and tighten the hose clamp. i02748571

a. Loosen hose clamps (6) and remove hose (4). b. Remove bolts (5) and remove air pipe (3) from turbocharger (1). Remove gasket (2). c. Plug the opening in the inlet manifold and the opening in the turbocharger with suitable plugs.

Valve Mechanism Cover Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

Illustration 106

g01345049

2. Loosen the hose clamp and disconnect hose (10) from valve mechanism cover (8).



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3. Remove bolts (7). Remove valve mechanism cover (8) from the cylinder head. 4. Remove seal (9) from valve mechanism cover (8).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Thoroughly clean the valve mechanism cover. Clean the mating surfaces of the cylinder head.

Illustration 108

g01336694

Typical example

6. If the engine is equipped with a turbocharger, follow Steps 6.a through 6.c in order to install the air pipe. a. Remove the plugs from the inlet manifold and from the turbocharger. b. Position a new joint (2) and air pipe (3) onto turbocharger (1). Install bolts (5). Tighten the bolts to a torque of 18 N·m (13 lb ft). c. Install hose (4) and tighten hose clamps (6) securely. Illustration 107

g01345049

2. Install a new seal (9) to valve mechanism cover (8). Note: Ensure that the joint is fully seated into the groove of the valve mechanism cover. 3. Place valve mechanism cover (8) in position on the cylinder head. 4. Install bolts (7). Tighten the bolts to a torque of 12 N·m (106 lb in). 5. Connect hose (10) to valve mechanism cover (8) and tighten the hose clamp.

i02748572

Rocker Shaft and Pushrod Remove Removal Procedure Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


KENR6241


i02748573

Rocker Shaft - Disassemble Disassembly Pr ocedure Table 28

Required Tools Tool

Part Number

A

-

Part Description Retaining Ring Pliers

Qty 1

Start By: a. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”. Illustration 109

g01345395

Typical example

1. Loosen the nuts and adjustment screws (1) on all rocker arms.

Personal injury can result from being struck by parts propelled by a released spring force.


Make sure to wear all necessary protective equipment.

3. Progressively loosen bolts (3). Begin at the ends of the rocker shaft assembly and work toward the center.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Note: Damage to the rocker shaft may occur if the long bolts are loosened first. To avoid distortion of the rocker shaft assembly, each bolt should be loosened by a quarter of a turn at one time. Repeat the procedure until all bolts are loosened.


4. Remove bolts (3). 5. Remove rocker shaft assembly (2) from the cylinder head. 6. Place temporary identi fication marks on pushrods (4) and pads (6). Note: Identification will ensure that the pushrods and pads can be reinstalled in the correct position. Do not interchange the positions of used pushrods or pads. 7. Remove pushrods (4) from the cylinder head. Remove pads (6) from the valve stems.



KENR6241

i02748575

Rocker Shaft - Assemble Assembly Procedure Table 29

Required Tools Tool

Part Number

A

-

Part Description Retaining Ring Pliers

Qty 1

1. Ensure that all components are clean and free from wear or damage. Refer to Speci fications, “Rocker Shaft” for more information. If necessary, replace any components that are worn or damaged. Note: Ensure that all oil holes are free from blockages. 2. Lubricate all of the components with clean engine oil before assembly. Illustration 110

g01345402

1. Make an identi fication mark on each rocker arm assembly in order to show the location. Note the mark at position (X) for installation purposes. Note: The components must be reinstalled in the original location. Do not interchange components. 2. Use Tooling (A) to remove retaining rings (8). 3. Remove rocker arm assembly (5). 4. Remove pedestal (6) from rocker shaft (3). 5. Remove rocker arm assembly (7). 6. Remove spring (4). 7. Repeat Steps 3 through 6 in order to remove the remaining rocker arm assemblies from rocker shaft (3). 8. If necessary, remove nuts (1) and adjusters (2) from the rocker arms. Make a temporary identification mark on each adjuster in order to show the location. Illustration 111

Note: The components must be reinstalled in the original location. Do not interchange components.

g01345402

3. If necessary, install nuts (1) and adjusters (2) to rocker arm assemblies (5) and (7). If the original adjusters are reused, ensure that the adjusters are installed in the original positions.


KENR6241


4. Use Tooling (A) to install retaining ring (8) to the front end of rocker shaft (3). The front end of the rockershaft is identified by the mark at Position (X). Ensure that the mark at position (X) is upward. 5. Install rocker arm assembly (5) to rocker shaft (3). 6. Install bracket (6) to rocker shaft (3). Note: Ensure correct orientation of the bracket. Refer to Illustration 111. 7. Install rocker arm assembly (7) to rocker shaft (3).

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Illustration 112

g01345395

Typical example

8. Install spring (4) to rocker shaft (3). 9. Repeat Steps 5 through 8 in order to assemble the remaining components of the rocker shaft assembly. 10. Use Tooling (A) to install retaining ring (8) to the rear end of rocker shaft (3).

2. Apply clean engine lubricating oil to both ends of pushrods (4). Install the pushrods to the engine with the cup upward. Ensure that the pushrods are installed correctly in the socket of the valve lifters. Note: If the pushrods have been used, ensure that the pushrods are installed in original positions.

End By:

3. Lubricate the top of the valve stems with clean engine oil. Install caps (6) to the valve stems.

a. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”.

Note: If the caps have been used, ensure that the caps are installed in original positions. 4. Install rocker shaft (2) to the cylinder head.

i02748576

Rocker Shaft and Pushrod Install Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components are clean and free from wear or damage. Refer to Speci fications, “Rocker Shaft” for more information. Replace any components that are worn or damaged.

Note: Ensure that the ends of adjustment screws (1) are correctly seated in ends of pushrods (4). Also ensure that valve caps (6) are in position under the rocker arms. 5. Install bolts (3) to the rocker shaft. Tighten the bolts to a torque of 15 N·m (11 lb ft). Begin at the center of the rocker shaft assembly and work outward. Note: Damage to the rockershaft may occur if the short bolts are tightened first. 6. Install bolts (5) to the rocker shaft. Tighten the bolts to a torque of 15 N·m (11 lb ft). 7. Adjust the valve lash. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash Inspect/Adjust” for the correct procedure.



KENR6241

End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure.

i02748577

Cylinder Head - Remove Removal Procedure Table 30

Required Tools Tool

Part Number

A

-

Part Description Lifting Bracket

Qty 2

Start By: a. Remove the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold - Remove and Install”. Illustration 113

b. Remove the fuel injectors. Refer to Disassembly and Assembly, “Fuel Injectors - Remove and Install”. c. Remove the glow plugs. Refer to Disassembly and Assembly, “Glow Plugs - Remove and Install”. d. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”.

g01362487

Typical example

2. Disconnect hose (2) from water temperature regulator housing (1). 3. Remove breather hose (4). 4. If necessary, remove inlet manifold (3). Refer to Disassembly and Assembly, “Inlet Manifold Remove and Install”.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Illustration 114


g01001090

The cylinder head tightening sequence


KENR6241


Illustration 116

g01352734

9. Note the position of dowels (8) in the cylinder block. Do not remove the dowels unless the dowels are damaged. Illustration 115

g01346253

5. Gradually loosen cylinder head bolts (5) in reverse numerical order to the sequence that is shown in Illustration 114. This will prevent distortion of the cylinder head. 6. Remove cylinder head bolts (5) from cylinder head (6). 7. Attach Tooling (A) and a suitable lifting device to cylinder head (6). Carefully lift the cylinder head off the cylinder block. The weight of the cylinder head is approximately 34 kg (75 lb). Note: Do not use a lever to separate the cylinder head from the cylinder block. Take care not to damage the machined surfaces of the cylinder head during the removal procedure. Avoid contamination of the cylinder bores with coolant or with debris. Illustration 117

g01346658

NOTICE Place the cylinder head on a surface that will not scratch the face of the cylinder head.

Typical example

8. Remove gasket (7).

11. If necessary, remove water temperature regulator housing (1). Refer to Disassembly and Assembly, “Water Temperature Regulator Housing - Remove and Install”.

10. If necessary, remove bolts (11) and remove lifting bracket (10). Remove joint (9).



KENR6241

i02748578

Cylinder Head - Install Installation Procedure Table 31

Required Tools Tool

Part Number

Part Description

Qty

A

-

Lifting Bracket

2

B

-

Guide Stud (M12 x 1.75 by 100 mm)

2

C

-

Straight Edge

1


Illustration 119

Contaminants may cause rapid wear and shortened component life. 1. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Ensure that there is no debris in the cylinder bores, the coolant passages or the lubricant passages.

g01346658

Typical example

5. If necessary, install a new joint (9), lifting bracket (10) and bolts (11) to cylinder head (6). Tighten the bolts to a torque of 11 N·m (97 lb in).

2. Inspect the mating surface of the cylinder head for distortion. Refer to Specifications, “Cylinder Head” for more information.

Illustration 118

g01352861

3. Inspect dowels (8) for damage. If necessary, replace the dowels in the cylinder block. 4. Install Tooling (B) to the cylinder block. Refer to Illustration 118.

Illustration 120

g01346253

6. Align cylinder head gasket (7) with Tooling (B) and install the cylinder head gasket onto the cylinder block. Note: Ensure that the word UP on the cylinder head gasket is upward.


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7. Use Tooling (A) and a suitable lifting device to lift cylinder head (6). The weight of the cylinder head is approximately 34 kg (75 lb). Align cylinder head (6) with Tooling (B) and install the cylinder head to the cylinder block. Note: Ensure that the cylinder head is correctly seated on dowels (8). 8. Remove Tooling (B).

Illustration 123

g01362487

Typical example

Illustration 121

g01346700

9. Clean cylinder head bolts (5). Inspect the threads of the bolts. Use Tooling (C) in order to check the bolts. The bolts must be renewed if there is any visual reduction in the diameter over area (X). 10. Lubricate the threads and the shoulder of cylinder head bolts (5) with clean engine oil before installation. 11. Install cylinder head bolts (5) to cylinder head (6).

13. If necessary, install water temperature regulator housing (1). Refer to Disassembly and Assembly, “Water Temperature Regulator Housing - Remove and Install”. 14. Connect hose (2) to water temperature regulator housing (1). 15. If necessary, install inlet manifold (3). Refer to Disassembly and Assembly, “Inlet Manifold Remove and Install”. 16. Install breather hose (4). 17. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”. 18. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. End By: a. Install the glow plugs. Refer to Disassembly and Assembly, “Glow Plugs - Remove and Install”.

Illustration 122

g01001090

The cylinder head tightening sequence

b. Install the fuel injectors. Refer to Disassembly and Assembly, “Fuel Injectors - Remove and Install”.

12. Tighten cylinder head bolts (5) in numerical order to the sequence that is shown in Illustration 122. Tighten the cylinder head bolts to a torque of 118 N·m (87 lb ft).

c. Install the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold - Remove and Install”.



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i02748579

Lifter Group - Remove and Install

3. Repeat Steps 1 and 2 in order to remove the remaining lifters.


Required Tools


Tool

Part Number

A

-

Part Description Telescoping Magnet

Qty 1

Required Tools Tool

Part Number

A

-

Part Description Telescoping Magnet

Qty 1


Start By: a. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. If the engine is not equipped with a balancer, remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. b. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE It is strongly recommended that all lifters should be replaced when a new camshaft is installed. 1. Clean the lifters. Follow Steps 1.a through 1.c in order to inspect the lifters. Replace lifters that are worn or damaged. a. Inspect the seat of the pushrod in the lifter for visual wear or damage. b. Inspect the shank of the lifter for wear or damage. Refer to Speci fications, “Lifter Group” for more information. c. Inspect the face of the lifter that runs on the camshaft for visual wear or damage. 2. If the crankshaft is installed, rotate the crankshaft to access to the cylinder block in order to install lifters (1). 3. Lubricate lifters (1) with clean engine oil.

Illustration 124

g01343537

Typical example

1. If the crankshaft is installed, rotate the crankshaft in order to gain access to lifters (1). 2. Use Tooling (A) to remove lifters (1). Note: Make a temporary identification mark on each lifter in order to identify the correct location.

Illustration 125

g01343537

Typical example


KENR6241


4. Use Tooling (A) to install lifters (1) to the cylinder block. Ensure that used lifters are installed in the correct location. Note: The lifters should be free to rotate. 5. Repeat Steps 2 through 4 in order to install the remaining lif ters. End By: a. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. b. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”. If the engine is not equipped with a balancer, install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. i02748580

Camshaft - Remove and Install

g01349741


4. Ensure that gears (2) and (3) are marked in order to show alignment. Refer to Illustration 126. Note: Identification will ensure that the camshaft can be installed in the original position. 5. Remove bolts (1).

Removal Procedure Start By: a. Remove the f ront housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. NOTICE Keep all par ts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

g01350309


1. The engine should be mounted on a suitable stand and placed in the inverted position. 2. Rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No.1 Piston”. 3. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”.

NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed. 6. Carefully remove camshaft assembly (4) from the cylinder block. 7. If necessary, remove the camshaft gear. Refer to Disassembly and Assembly, “Camshaft Gear.Remove and Install”.



Tool A

21825617


Qty 1



KENR6241

4. Install bolts (1). Tighten the bolts to a torque of 12 N·m (106 lb in).

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the camshaft assembly is clean and free from wear or damage. If necessary, install the camshaft gear. Refer to Disassembly and Assembly, “Camshaft Gear.- Remove and Install”. 2. Lubricate the camshaft assembly with clean engine oil prior to installation.

5. Use Tooling (A) to check the backlash between gears (2) and (3). Ensure that the backlash for the gears is within speci fied values. Refer to the Specifications, “Gear Group (Front)” for further information. 6. Use Tooling (A) to check the end play for camshaft gear (3). Ensure that the end play is within specified values. Refer to the Speci fications, “Camshaft” for further information. 7. Lubricate the teeth of the gears with clean engine oil. End By: a. Install the f ront housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. b. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”. i02748582

Illustration 128

g01349741

Camshaft Gear - Remove and Install

Typical example

Removal Procedure Start By: a. Remove the camshaft assembly from the engine. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. NOTICE Keep all parts clean from contaminants.

Illustration 129

g01350309


Typical example

NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed. 3. Carefully install camshaft assembly (4) to the cylinder block. Ensure that the timing marks on gears (2) and (3) are in alignment and that the mesh of the gears is correct. Refer to Illustration 128.


KENR6241


Always wear protective gloves when handling parts that have been heated. 3. Raise the temperature of camshaft gear (1). Align the camshaft gear with woodruff key (3) and install the camshaft gear to camshaft (4). End By:

Illustration 130

g01350917

1. Place the camshaft assembly on a suitable support. Use a press to remove camshaft gear (1) from camshaft (4). 2. Remove thrust plate (2) and woodruff key (3) from camshaft (4). Note the orientation of the thrust plate for installation.

a. Install the camshaft assembly to the engine. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. i02748583

Engine Oil Pan - Remove and Install Removal Procedure for the Engine Oil Pan

Installation Procedure NOTICE Keep all parts clean from contaminants.


Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components of the camshaft assembly ar e clean and free from damage.

Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fl uids are contained during performance of inspection, maintenance, testing, adjusting andrepair of theproduct. Be prepared to collect the fl uid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

Illustration 131

g01350917

2. Install woodruff key (3) and thrust plate (2) to camshaft (4). Note: Ensure that the machined face of the thrust plate is toward the camshaft.



Illustration 132

KENR6241

g01347462

1. Remove oil drain plug (3). Drain the engine oil into a suitable container for storage or disposal.

Illustration 133

g01347459

The oil strainer for engines without a balancer

2. Remove sealing washer (2) from oil drain plug (3). 3. Remove bolts (4) from engine oil pan (1). 4. Carefully separate engine oil pan (1) from the cylinder block. Note: Avoid damage to the engine oil pan during removal.

Removal Procedure for the Oil Strainer NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 134

g01347461

The oil strainer for engines that are equipped with a balancer

1. Remove bolts (7). 2. Remove oil strainer (6). 3. Remove O-ring seal (5) from oil strainer (6).


KENR6241


Installation Procedure for the Oil Strainer NOTICE Keep all parts clean from contaminants.

4. Tighten bolts (7) to a torque of 18 N·m (13 lb ft).

Installation Procedure for the Engine Oil Pan Table 35


Required Tools Tool

1. Clean all mating mati ng surfaces thoroughly.

A

B

Part Number

21826038

21820117

Part Description

Qty

POWERPART Silicon Adhesive

1

POWERPART Threadlock and Nutlock

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component component life. 1. Ensure that the engine oil pan is clean and free from damage. Clean the mating surface of the cylinder block.

Illustration Illustration 135

g01347459

The oil strainer for engines without a balancer

Illustration 137


g01347462

g01347461 g01347461

The oil strainer for engines that are equipped with a balancer

2. Install a Install a new O-ring seal (5) to oil strainer (6). 3. Install oil strainer (6) and install bolts (7).



KENR6241

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component component life.


g01347865

The pattern of application of sealant to the engine oil pan.

2. Apply a continuous bead of Tooling (A) to the mating surface of engine oil pan (1) on the inside of the bolt holes. Refer to Illustration 138 for the correct pattern of application. application. The bead of Tooling (A) should be approximately 2 mm (0.080 inch) in diameter.

NOTICE Care Care must must be taken taken to ensur ensure e tha thatt fl uids are contained contained inspection, maintenance, maintenance, testduring performance performance of inspection, ing, ing, adjus adjusti ting ng andrepair andrepair of theproduc theproduct. t. Be prep prepare ared d to collect the fl uid with suitable containers before opentment or disassembling any compoing any compar tment nent containing fluids. Dispose of all fl uids according to local regulations and mandates. 1. Ensure that number one piston is at the top center position position on the compression stroke. Refer to Systems Operation, Testing Testing and Adjusting, Adjusting, “Finding Top Center Position for No. 1 Piston”.

3. Ensure that bolts (4) are clean and dry. Apply Tooling (B) to the threads of the bolts. 4. Position engine oil pan (1) onto the cylinder block and install bolts (4). 5. Tighten bolts (4) to a torque of 11 N·m (97 lb in). 6. Install a new sealing washer (2) to oil drain plug (3). 7. Install oil drain plug (3) to engine oil pan (1). Tighten the oil drain plug to a torque of 39 N·m (29 lb ft). 8. Fill the engine oil pan to the correct level. Refer to Operation Operation and Maintenance Maintenance Manual, Manual, “Engine Oil and Filter - Change” for the correct procedure. i02748584 i02748584

Balancer - Remove Removal Procedure Start By: a. Remove the engine oil pan and remove the oil strainer . Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.

Illustration 139

g01344508 g01344508

Note: If Note: If the balancer will be disassembled, loosen bolts (4) before the balancer is removed from the engine. 2. Support Support the weight of the balancer. balancer. The balancer balancer weighs approximately approximately 23 kg (51 lb). Remove bolts (3) and remove balancer (1) from the engine.


KENR6241


3. Do not remove dowels (2) unless the dowels are damaged. i02748586

Balancer - Disassemble Disassembly Procedure Table 36

Required Tools Tool

Part Number

A

-

Combination Puller

1

B

-

Retaining Ring Pliers

1

Bearing Installer Group

1

C

27610275

Illustration 141

Part Description

g01344528

Qty


Illustration 142

g01344665

Timing marks

1. Remove bolts (4) and washers (5). Use Tooling (A) in order to remove gears (6). Ensure that balancer shaft (10) is protected from damage. Note: Gears Note: Gears (6) have different Markings (X). Refer to Illustration 142. Identify the position of the gears for installation. installation. 2. Remove keys (7). Use Tooling (B) in order to remove retaining rings (8).


g01344515



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1. Ensure that all components of the balancer are clean and free f rom damage.

g01344533

Illustration 143

3. Carefully tap the assembly of bearing (9) and balancer shaft (10) forward until the shaft is clear of bushing (11). Refer to Illustration 143. 4. Use Tooling (A) in order to remove bearing (9) from balancer shaft (10). Note: Ensure that the balancer shaft is protected from damage. 5. Slide balancer shaft (10) back through bushing (11) until the shaft is clear of the balancer. 6. If necessary, use Tooling (C) in order to remove bushing (11) from balancer (1). i02748588

Balancer - Assemble

Illustration 144

g01344574

2. If new bushing (11) is installed to the balancer, follow Steps 2.a and 2.b. a. Align oil holes (Z) in bushing (11) to drilling (Y) in balancer (1). b. Use Tooling (C) to install bushing (11) to balancer (1). Ensure that the oil holes (Z) are correctly aligned to drilling (Y).

Assembly Procedure Table 37

Required Tools Tool

Part Number

B

-


1

Part Description

Qty

C

27610275

Bearing Installer Group

1

D

21820117

POWERPART Threadlock and Nutlock

1



KENR6241


g01344665

Illustration 146 Timing marks

7. Align gears (6) with keys (7) and install the gears to balancer shafts (10). Ensure that the gears are installed in the correct position. Illustration Illustration 145

g01344515

3. Use Tooling (C) in order to press bearings (9) into balancer (1). balancer (1). Note: Do Note: Do not press on the inner race of the bearing as this could could result in damage to the bearing.

Note: The Note: The gears have different Markings (X). The right hand gear is marked 1,1 and 2,2. The left hand gear is marked 2. Refer to Illustration 146. 8. Apply Tooling Tooling (D) to the threads threads of bolts (4). Install bolts (4) and washers (5). Tighten the bolts to a torque of 33 N·m (24 lb ft).

4. Use Tooling Tooling (B) to install install retaining rings (8). Note: Ensure Note: Ensure that the retaining rings are fully located into the grooves in the balancer. 5. Lubricate Lubricate balancer shafts (10) and bushing (11) with clean engine oil. Carefully Carefully install the balancer shafts to balancer to balancer (1). 6. Install keys (7).

i02748589

Balancer - Install Installation Procedure Table 38

Required Tools Tool F

Part Number

21825617


Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component component life.



KENR6241

g01344971

Illustration 149 Alignme nt of the timing marks


g01344665

Timing marks

2. Align dowels (2) with the holes in the cylinder block. Align mark 1,1 on gear (6) to mark 1 on crankshaft gear (12). Refer to Illustration 149. Position balancer (1) on the engine. The balancer weighs approximately 23 kg (51 lb). 3. Install bolts (3). Tighten the bolts to a torque of 30 N·m (22 lb ft). 4. Use Tooling (F) in order to check the backlash between gears (6). Refer to Speci fications, cations, “Gear Group (Front)”. 5. Use Tooling (F) in order to check the backlash between gears (6) and (12). Refer to Specifications, “Gear Group - Front” for further information. End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, “ Engine Oil Pan - Remove and Install”. i02748590

Pistons and Connecting Rods - Remove Removal Procedure Illustration Illustration 148

g01344983

1. Ensure that dowels (2) are seated in balancer (1). Ensure that marks 2,2 and 2 on gears (6) are aligned. Refer to Illustration 147.

Table 39


Part Number

27610274

Part art Description Ridge Reamer

Qty 1


KENR6241


Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Remove”. b. Remove the engine oil pan and remove the oil strainer. Refer to Disassembly and Assembly, “Engine Oil Pan Pan - Remove and Install”.

Note: Use Note: Use tape or rubber tubing on the connecting rod bolts to protect protect the crankshaft journals from damage. 7. Carefully push push the piston and the connecting rod assembly out of the cylinder bore. Lift the piston out of the top of the cylinder block. 8. Repeat Steps 2 through 7 in order to remove the remaining remaining pistons pistons and connecting rods.


i02748591

Pistons and Connecting Rods - Disassemble

1. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. 2. Rotate the crankshaft until the piston that is being removed is at the bottom center position. 3. Use Tooling (A) to remove the carbon ridge from the top inside surface of the cylinder bore.

Disassembly Procedure Table 40

Required Tools Tool

Part Number

A

-

Reta Retaiining ning Ring Ring Plier liers s

1

B

-

Ring Expander

1

Driver Group Group

1

C

27610275

Part Description

Qty

Start By: a. Remove the pistons and connecting rods. Refer to Disassembly Disassembly and Assembly, “Piston and Connecting Rods - Remove”. NOTICE ts clean from contaminants. Keep all par ts Contaminants may cause rapid wear and shortened component life. life.


g01352319

4. The connecting rod and the connecting rod cap have matching numbers (X) on the side. Note the location of the connecting rod for installation. If necessary, make a temporary mark on the connecting rod and the connecting rod cap in order to identify the cylinder number. 5. Remove nuts (2). 6. Remove connecting rod cap (1) from the connecting rod.

Illustration 151

g01359107

Piston from a naturally aspirated engine (X) Number (Y) Number



KENR6241

2. Place the piston and connecting rod assembly on a suitable surf ace with the connecting rod upward. Use Tooling (A) in order to remove retaining rings (4). 3. Remove piston pin (3) and connecting rod (1) from piston (2). Note: If the piston pin cannot be removed by hand, heat the piston to a temperature of 45 ± 5 °C (113 ± 9 °F). Do not use a torch to heat the piston.

Illustration 152

g01359108

Piston from a turbocharged engine (X) Number (Y) Number

1. Make a temporary mark on the components of the piston and connecting rod assembly. This will ensure that the components of each piston and connecting rod assembly can be reinstalled in the original cylinder. Note the correct orientation of the connecting rod in relation to the piston. Number (X) and number (Y) must be on the same side. Refer to Illustration 151. Do not interchange components.

Illustration 153

g01311807

Illustration 154

g00829406

Piston from a turbocharged engine

Illustration 155

g01351357


Typical example


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4. Place piston (2) on a suitable surface with the crown upward. Use Tooling (B) in order to remove compression rings (5) and (6), and oil control ring (7) from the piston. Note: Identify the orientation of the piston rings for installation.

7. Inspect piston pin bearing (12) for wear or damage. Refer to Specifications, “Pistons and Rings” for more information. If necessary, replace connecting rod (1) or replace piston pin bearing (12). If necessary, use Tooling (C) and a suitable press to remove piston pin bearing (12) from connecting rod (1). 8. Repeat Steps 1 through 7 in order to disassemble the remaining pistons and connecting rods. i02748593

Pistons and Connecting Rods - Assemble Assembly Procedure Table 41

Required Tools

Illustration 156

g01362961

Typical example

Tool

Part Number

A

-


1

B

-

Ring Expander

1

Driver Group

1

C

5. If necessary, remove nuts (11) and connecting rod cap (10) from connecting rod (1). 6. Remove the lower half of connecting rod bearing (9) from connecting rod cap (10). Remove the upper half of connecting rod bearing (8) from connecting rod (1). Keep the bearing shells together. NOTICE Removal of the piston pin bushing in the connecting rod must be carried out by personnel with the correct training. Also special machinery is required. For more information refer to your authorized Perkins distributor.

Illustration 157

27610275

Part Description

Qty

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components are clean and free from wear or damage. If necessary, replace any components that are worn or damaged. NOTICE Removal of the piston pin bushing in the connecting rod must be carried out by personnel with the correct training. Also special machinery is required. For more information refer to your authorized Perkins distributor.

g01351358



Illustration 158

KENR6241

g01352211

Illustration 160

g01359107

Piston from a naturally aspirated engine

2. If necessary, use Tooling (C) and a suitable press to install piston pin bearing (12) into connecting rod (1). Ensure that oil hole (Z) in the piston pin bearing is aligned with the oil hole at the top of the connecting rod.

(X) Number (Y) Number

Illustration 161

g01359108

Piston from a turbocharged engine (X) Number (Y) Number

4. Place piston (2) on a suitable surface with the crown downward. Ensure the correct orientation of the connecting rod in the piston. Number (X) and number (Y) must be on the same side. Refer to Illustration 160 or Illustration 161. Install connecting rod (1) and piston pin (3) to the piston. Note: If the piston pin cannot be installed by hand, heat the piston to a temperature of 45 ± 5 °C (113 ± 9 °F). Do not use a torch to heat the piston. Illustration 159

g01311807

Typical example

3. Lubricate piston pin bearing (12) and lubricate the bore for the piston pin in piston (2) with clean engine oil.

5. Use Tooling (A) in order to install retaining rings (4) to the piston pin bore in piston (2). Note: Ensure that the retaining rings are seated in the grooves in the piston. 6. Follow Steps 6.a through 6.e in order to install the piston rings to the piston.


KENR6241


Illustration 164

g00829406


b. Use Tooling (B) to install oil control ring (7) over the spring. Note: Ensure that the central wire is 180 degrees from the ring gap.

Illustration 162

g01351357

d. Use Tooling (B) to install top compression ring (5) into the top groove in the piston. The letter “T” must be upward.


Illustration 163

c. Use Tooling (B) to install intermediate compression ring (6) into the second groove in the piston. The letter “T” and the chamfer on the inner face of the ring must be upward.

g01352230

Piston from a turbocharged engine Illustration 165

a. Position the spring for oil control ring (7) into the oil ring groove in the piston. The central wire must be located inside the end of the spring.

g01359137

The correct position of the piston ring gaps (AA) Ring gap of the top compression ring (BB) Ring gap of the intermediate compression ring (CC) Ring gap of the oil control ring

e. Align the piston ring gaps to the positions that are shown in Illustration 165.



KENR6241

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the assemblies of the pistons and connecting rods are clean and free from damage. 2. Apply clean engine oil to the cylinder bore, to the piston rings, to the outer surface of the piston and to the connecting rod bearings. Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, “Bearing Clearance Check”. Apply clean engine oil to the connecting rod bearings during final assembly. g01362961


3. Rotate the crankshaft until the crankshaft pin is in the bottom center position. Lubricate the crankshaft pin with clean engine oil.

7. Install the upper half of connecting rod bearing (8) to connecting rod (1). 8. Install the lower half of connecting rod bearing (9) to connecting rod cap (10). 9. Repeat Steps 2 through 8 in order to assemble the remaining pistons and connecting rods. End By: a. Install the pistons and connecting rods. Refer to Disassembly and Assembly, “Piston and Connecting Rods - Install”. Illustration 167 i02748594

g01352295


Pistons and Connecting Rods - Install Installation Procedure Table 42

Required Tools Tool B

Part Number

21825491

Part Description Piston Ring Compressor

Qty 1 Illustration 168

g01359137

The correct position of the piston ring gaps (AA) Ring gap of the top compression ring (BB) Ring gap of the intermediate compression ring (CC) Ring gap of the oil control ring


KENR6241


4. Align the piston ring gaps to the positions that are shown in Illustration 168. Install Tooling (B) onto piston (3). Ensure that Tooling (B) is installed correctly and that the piston can easily slide from the tool.

10. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”.

Note: Use tape or rubber tubing on the connecting rod bolts to protect the crankshaft pin from damage. Ensure that the piston and the connecting rod assembly are installed in the correct cylinder.

a. Install the oil strainer and install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.

5. Carefully push the piston and the connecting rod assembly into the cylinder bore and onto the crankshaft pin. Note: Use tape or rubber tubing on the connecting rod bolts to protect the crankshaft pin from damage. Ensure that the piston and the connecting rod assembly are installed in the correct cylinder.

End By:

b. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. i02748595

Connecting Rod Bearings Remove (Connecting rods in position) Removal Procedure Start By: a. Remove the engine oil pan and remove the oil strainer. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. b. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 169

g01352319

Typical example

6. Remove the tape or rubber tubing on the connecting rod bolts. Install connecting rod cap (1). Note: Ensure that number (X) on the connecting rod cap matches number (X) on the connecting rod. Ensure that the numbers are on the same side.

Note: If all connecting rod bearings require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 4 and 2 with 3. Ensure that both pairs of the connecting rod bearings are installed before changing from one pair of cylinders to another pair of cylinders.. Refer to Disassembly and Assembly, “Connecting Rod Bearings - Install” for the correct procedure.

7. Install nuts (2). Tighten the nuts to a torque of 54 N·m (40 lb ft). 8. Ensure that the installed connecting rod assembly has tactile side play. Rotate the crankshaft in order to ensure that there is no binding. 9. Repeat Steps 2 through 8 in order to install the remaining pistons and connecting rods.



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i02748597

Connecting Rod Bearings Install (Connecting rods in position) Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 170

g01361963

Typical example

Note: The connecting rod and the connecting rod cap have matching numbers at position (X). Note the location of the connecting rod cap (5) for installation. 1. Rotate the crankshaft until the piston is at the bottom center position. Remove nuts (6) and remove connecting rod cap (5) from connecting rod (1).

1. Inspect the pins of the crankshaft for damage. Refer to Specifications, “Connecting Rod Bearing Journals” for more information. If the crankshaft is worn or damaged, replace the crankshaft or recondition the crankshaft. Refer to Disassembly and Assembly, “Crankshaft - Remove” and Disassembly and Assembly, “Crankshaft - Install”. 2. Ensure that the connecting rod bearings are clean and free from wear or damage. If necessary, replace the connecting rod bearings.

2. Remove lower connecting rod bearing (4) from connecting rod cap (5). Note: Use tape or rubber tubing on connecting rod bolts (2) in order to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals. 3. Carefully push connecting rod (1) into the cylinder bore. Remove upper connecting rod bearing (3) from the connecting rod.

Illustration 171

g01361963

Typical example

3. Clean the bearing surface of connecting rod (1) and connecting rod cap (5). 4. Install upper connecting rod bearing (3) to connecting rod (1). Lubricate the bearing surface of the connecting rod bearing with clean engine oil.


KENR6241

Note: Use tape or rubber tubing on connecting rod bolts (2) in order to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals. 5. Carefully pull connecting rod (1) against the crankshaft pin. 6. Install lower connecting rod bearing (4) to connecting rod cap (5). 7. Lubricate the pin of the crankshaft and lubricate lower connecting rod bearing (4) with clean engine oil. NOTICE When the connecting rod caps are installed, ensure that the identi fication marks are aligned. 8. Ensure that the numbers at position (X) on connecting rod cap (5) and on connecting rod (1) match. Install connecting rod cap (5). 9. Install nuts (6). Tighten the nuts evenly to a torque of 54 N·m (40 lb ft). 10. Repeat Steps 2 through 9 for the remaining connecting rod bearings. Note: If all connecting rod bearings require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 4 and 2 with 3. Ensure that both pairs of the connecting rod bearings are installed before changing from one pair of cylinders to another pair of cylinders. Refer to Disassembly and Assembly, “Connecting Rod Bearings - Remove” for the correct procedure. 11. Ensure that the installed connecting rod assemblies have tactile side play. Carefully rotate the crankshaft in order to ensure that there is no binding.


i02748598

Crankshaft Main Bearings Remove and Install (Crankshaft in position) Removal Procedure Start By: a. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. If the engine is not equipped with a balancer, remove the oil strainer. Refer to Disassembly and Assembly, “Engine Oil Pan Remove and Install”. b. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. NOTICE This procedure must only be used to remove and install the main bearing shells with the crankshaft in position. The removal procedure and the installation procedure must be completed for each pair of main bearing shells before the next pair of main bearing shells are removed. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the main bearing caps are marked for the correct location and orientation.

End By: a. If the engine is equipped with a balancer, Install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”. b. Install the oil strainer and the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.

Illustration 172

g01353474

Typical example



KENR6241

2. Remove bolts (1). Remove main bearing cap (2) from the cylinder block.

Note: The lower main bearing is a plain bearing that has no oil holes.

Note: Number five main bearing cap must be removed squar ely from the cylinder block. Do not twist the main bearing cap during removal as damage may result.

g01353517


5. Push out upper main bearing (6) with a suitable tool from the side opposite the locating tab. Carefully rotate the crankshaft while you push on the bearing. Remove upper main bearing (6) from the cylinder block. Keep the bearings t ogether.

Illustration 173

g01353478

Note: Do not damage the machined surfaces of the crankshaft during removal of the upper main bearing. The upper main bearing has a groove and two oil holes.

Number five main bearing cap

3. For number fi ve main bearing cap, remove lower thrust washers (4) and remove seals (3). Note: It is not possible to remove the upper thrust washer from the cylinder block with the crankshaft in position. If the upper thrust washer requires removal, the crankshaft must be removed. Refer to Disassembly and Assembly, “Crankshaft - Remove”.


Required Tools Tool

Part Number

Part Description

Qty

POWERPART Silicone Sealant Adhesive

1

27610013

Seal Installer

1

21825617


1

A

218260238

B

C

NOTICE This procedure must only be used to remove and install the main bearing shells with the crankshaft in position. The removal procedure and the installation procedure mustbe completed for each pair of main bearing shells before the next pair of main bearing shells are removed. Illustration 174

g01353475


4. Remove lower main bearing (5) from main bearing cap (2). Keep the main bearing and the main bearing cap together.


KENR6241


4. Install lower main bearing (5) into main bearing cap (2). Ensure that the locating tab for the lower main bearing is correctly seated into the slot in the bearing cap.


Note: The lower main bearing is a plain bearing that has no oil holes.

1. Ensure that the main bearings are clean and free from wear or damage. If necessary, replace the main bearings. 2. Clean the journal of the crankshaft. Inspect the journal of the crankshaft for damage. If necessary, replace the crankshaft or recondition the crankshaft. Refer to Disassembly and Assembly, “Crankshaft - Remove” for more information.

Illustration 178

g01353916

Number fi ve main bearing cap

5. For number fi ve main bearing cap, follow Steps 5.a through 5.c in order to install the lower thrust washers (4) to the main bearing cap.

Illustrati on 176

g01353517

Typical example

3. Lubricate the crankshaft journal and the upper main bearing (6) with clean engine oil. Slide the upper main bearing into position between the crankshaft journal and the cylinder block. Ensure that the locating tab for the upper main bearing is correctly seated in the slot in the cylinder block. Note: The upper main bearing has a groove and two oil holes.

Illustration 177

Note: It is not possible to install the upper thrust washer to the cylinder block with the crankshaft in position. If the upper thrust washer requires removal and installation, the crankshaft must be removed. Refer to Disassembly and Assembly, “Crankshaft Remove”. a. Ensure that lower thrust washers (4) are clean and free from wear or damage. If necessary, replace the thrust washers. Lubricate the thrust washers with clean engine oil. b. Install lower thrust washers (4) to main bearing cap (2). Ensure that holes (X) in the thrust washers are aligned with dowels (Y) in the main bearing cap. Ensure that the grooves in the thrust washers face toward the crankshaft.

g01353475




Illustration 179

KENR6241

g01354237

c. Ensure that the recess in the cylinder block for number fi ve main bearing cap is clean and dry. Apply a bead of Tooling (A) to the corners of the recess at positions (Z).

Illustration 181

g01354238

Typical example

8. Use Tooling (B) in order to push seals (3) fully into the grooves.

6. Lubricate the crankshaft journal and the lower main bearing with clean engine oil. Install main bearing cap (2) to the cylinder block. Ensure the correct orientation of the main bearing cap. The locating tab for the upper and the lower bearing should be on the same side of the engine.

Illustration 182

g01353474

Typical example

9. Lubricate the threads of bolts (1) with clean engine oil. Lubricate the underside of the heads of the bolts with clean engine oil. Illustration 180

g01359531

Typical example

7. Inject a small quantity of Tooling (A) into the two grooves in number fi ve main bearing cap. Position new seals (3) in the grooves. Ensure that rounded edges of the seals are outward. Push the first 25 mm (1 inch) of the seal into the grooves by hand.

10. Install bolts (1) to main bearing cap (2). Evenly tighten the bolts in order to pull the main bearing cap into position. Ensure that the main bearing cap is correctly seated. For number five main bearing cap, Ensure that the rear face of the main bearing cap is flush with the rear face of the cylinder block. Note: Do not tap the main bearing cap into position as the bearing may be dislodged.


KENR6241


11. Tighten bolts (1) to a torque of 103 N·m (76 lb ft).

Start By:

12. Rotate the crankshaft in order to ensure that there is no binding.

a. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”. b. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. If the engine is not equipped with a balancer, remove the oil strainer. Refer to Disassembly and Assembly, “Engine Oil Pan Remove and Install”. c. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”.

g01359530


13. Check the crankshaft end play. Refer to Specifications, “Crankshaft” for more information. Push the crankshaft toward the front of the engine. Install Tooling (C). Push the crankshaft toward the rear of the engine in order to measure the end play.

d. Remove the front plate. Refer to Disassembly and Assembly, “Front Plate - Remove”. NOTICE If the crankshaft has been reground or if thecrankshaft has been replaced, the height of the piston above the cylinder block must be inspected. It is necessary to remove the cylinder head in order to inspect the height of the piston above the cylinder block. NOTICE Keep all parts clean from contaminants.

End By: a. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”. If the engine is not equipped with a balancer, install the oil strainer and install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.


b. Install the fl ywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”.

Note: Use tape or rubber tubing on the connecting rod bolts to protect the crankshaft journals from damage.

i02748599

Crankshaft - Remove

Table 44


A

-

Part Description Lifting Sling

2. If necessary, remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head Remove”. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove”. If the cylinder head, the pistons and the connecting rods have not been removed, remove the connecting rod caps. Refer to Disassembly and Assembly, “Connecting Rod Bearings - Remove”. Carefully push the piston and connecting rod assemblies into the cylinder bores.

Removal Procedure

Tool

1. The engine should be mounted on a suitable stand and placed in the inverted position.

Qty 1



Illustration 184

KENR6241

g01359995

3. Ensure that bearing caps (2) are marked for the location and orientation. 4. Remove bolts (1) from bearing caps (2). 5. Remove bearing caps (2) from the cylinder block.

Illustration 186

g01359996

7. Attach a Tooling (A) and a suitable lifting device to crankshaft (3). Carefully lift the crankshaft out of the cylinder block. The weight of the crankshaft is approximately 32 kg (70 lb). Note: Do not damage the finished surfaces on the crankshaft.

Note: Number five main bearing cap must be removed squarely from the cylinder block. Do not twist the main bearing cap during removal as damage may result.

Illustration 187

g01359993

Typical example

8. Remove upper main bearings (7). Keep the upper main bear ings and the upper thrust washer with the respective main bearing caps. For number five main bearing, remove the upper thrust washer from the rear of the cylinder block. Illustration 185

g01359992

Note: The upper main bearings have a groove and two oil holes.


6. Remove lower main bearings (4) from main bearing caps (2). Keep the main bearings and the main bearing caps together. For number fi ve main bearing cap, remove lower thrust washers (5) and remove seals (6). Note: The lower main bearings are plain bearings with no oil holes.


KENR6241


i02748601

Crankshaft - Install Installation Procedure Table 45


Part Number

21826038

Part Description

Qty

POWERPART Silicone Sealant Adhesive

1 Illustration 188

B

27610013

Seal Installer

1

C

21825617


1

g01360029

Typical example


5. Install upper bearings (7) to the cylinder block. Ensure that the locating tabs for the upper bearings are seated in the slots in the cylinder block.


Note: The upper bearings have a groove and two oil holes.

Note: The engine should be mounted on a suitable stand and placed in the inverted position. 1. Clean the crankshaft and inspect the crankshaft for wear or damage. Refer to Speci fications, “Crankshaft” for more information. If necessary, replace the crankshaft or recondition the crankshaft.

6. Lubricate upper thrust washer (8). Install the upper thrust washer to the rear of the cylinder block with the oil grooves toward the outside. Ensure that holes (X) in the thrust washer are aligned with dowels (Y) in the cylinder block. 7. Lubricate upper bearings (7) with clean engine oil.

2. Ensure that the parent bores for the crankshaft bearings in the cylinder block are clean. Ensure that the thr eads for the bearing bolts in the cylinder block are clean and free from damage. 3. Clean the cr ankshaft bearings and the thrust washers. Inspect the bearings and the thrust washers for wear or damage. If necessary, replace the bearings and the thrust washers. Note: If the crankshaft bearings are replaced, check whether oversize bearings were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed. 4. Ensure that all of the lubrication passages are clean and free of debris.

Illustration 189

g01359996

Typical example

8. Attach Tooling (A) and a suitable lifting device to crankshaft (3). Carefully lift the crankshaft into the cylinder block. The weight of the crankshaft is approximately 32 kg (70 lb). Remove Tooling (A). Note: Do not damage any of the fi nished surfaces on the crankshaft. Do not damage the bearings.



Illustration 190

KENR6241

g01359992


9. Install lower bearings (4) to main bearing caps (2). Ensure that the locating tabs for the lower bearings are seated in the slots in the bearing caps. Note: The lower bearings are plain bearing with no oil holes. 10. For number fi ve main bearing cap, follow Steps 10.a through 10.c in order to install the lower thrust washers (5) to the main bearing cap.

Illustration 191

g01354237

c. Apply a bead of Tooling (A) to the corners of the recess in the cylinder block at positions (Z). 11. Lubricate the crankshaft journals and the lower main bearings with clean engine oil. Install main bearing caps (2) to the cylinder block. Ensure the correct orientation of the main bearing caps. The locating tab for the upper and the lower bearing should be on the same side of the engine. Note: For number fi ve main bearing cap, ensure that the rear face of the main bearing cap is fl ush with the rear face of the cylinder block.

a. Ensure that lower thrust washers (5) are clean and free from wear or damage. If necessary, replace the thrust washers. Lubricate the thrust washers with clean engine oil. b. Install lower thrust washers (5) to main bearing cap (2). Ensure that holes (X) in the thrust washers are aligned with dowels (Y) in the main bearing cap.

Illustration 192

g01359531

Typical example

12. Inject a small quantity of Tooling (A) into the two grooves in number fi ve main bearing cap. Position new seals (3) in the grooves. Ensure that rounded edges of the seals are outward. Push the first 25 mm (1 inch) of the seal into the grooves by hand.


KENR6241


Illustration 195

g01359530

Typical example

Illustration 193

g01354238

Typical example

13. Use Tooling (B) in order to push seals (3) fully into the grooves.

18. Check the crankshaft end play. Refer to Specifications, “Crankshaft” for more information. Push the crankshaft toward the front of the engine. Install Tooling (A). Push the crankshaft toward the rear of the engine in order to measure the end play. 19. If the crankshaft has been replaced or the crankshaft has been reconditioned, inspect the height of the pistons above the cylinder block. Refer to Systems Operation, Testing and Adjusting, “Piston Height - Inspect” for more information. First install the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. If the crankshaft has not been replaced or the crankshaft has not been reconditioned, install the connecting rod caps. Refer to Disassembly and Assembly, “Connecting Rod Bearings - Install”.

Illustration 194

g01353474

Typical example

14. Lubricate the threads of bolts (1) with clean engine oil. Lubricate the underside of the heads of the bolts with clean engine oil. 15. Install bolts (1) to main bearing caps (2). Evenly tighten the bolts in order to pull the main bearing caps into position. Ensure that the caps are correctly seated. Note: Do not tap the main bearing caps into position as the bearing may be dislodged. 16. Tighten bolts (1) to a torque of 103 N·m (76 lb ft). 17. Rotate the crankshaft in order to ensure that there is no binding.

End By: a. Install the front plate. Refer to Disassembly and Assembly, “Front Plate - Install”. b. Install the fl ywheel housing. Refer to Disassembly and Assembly, “Flywheel Housng - Remove and Install”. c. If the engine has a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer Install”. If the engine does not have a balancer, install the oil strainer and install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Install”. d. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Push Rod - Install”.



KENR6241

i02748602

Crankshaft Gear - Remove and Install

4. If necessary, remove the keys (not shown) from crankshaft (2).

Installation Procedure NOTICE Keep all parts clean from contaminants.

Removal Procedure

Contaminants may cause rapid wear and shortened component lif e.

Table 46

Required Tools Tool

Part Number

A

-

Part Description

Qty

Combination Puller

1

Start By: a. Remove the idler gear. Refer to Disassembly and Assembly, “Idler Gear - Remove and Install”. Note: In this procedure, the crankshaft gear is removed with the crankshaft in the engine. NOTICE Keep all parts clean from contaminants.

Illustration 197

Contaminants may cause rapid wear and shortened component life. 1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”. 2. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”.

g01344011

Typical example

1. If necessary, install the keys (not shown) to crankshaft (2).

Always wear protective gloves when handling parts that have been heated. 2. Raise the temperature of crankshaft gear (1) in an oven to 100 °C (212 °F). 3. Align the keyway in crankshaft gear (1) with the keys in crankshaft (2). Install crankshaft gear (1). Ensure that the crankshaft gear is seated squarely against the crankshaft. 4. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

Illustration 196

g01343991

5. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”.

Typical example

End By:

3. Use Tooling (A) to remove crankshaft gear (1) from crankshaft (2).

a. Install the idler gear. Refer to Disassembly and Assembly, “Idler Gear- Remove and Install”.


KENR6241


i02748526

• Ensure that the bearing locking tabs are properly seated in the tab grooves.

Bearing Clearance - Check

• The crankshaft must be free of oil at the contact points of Tooling (A).

Measurement Pr ocedure

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.

Table 47

Note: Do not allow Tooling (A) to extend over the edge of the bearing.

Required Tools Tool

Part Number

Part Description

Qty

-

Plastic Gauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch)

1

-

Plastic Gauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch)

1

-

Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)

1

-

Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)

1

A

2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. Note: Do not turn the crankshaft when Tooling (A) is installed. 3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 198.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Perkins does not recommend the checking of the actual clearances of the bearing shells particularly on small engines. This is because of the possibility of obtaining inaccurate results and of damaging the bearing shell or the journal surfaces. Each Perkins bearing shell is quality checked for speci fic wall thickness. Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch). NOTICE Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

Illustration 198

g01152855

Typical Example

4. Remove all of Tooling (A) before you install the bearing cap. Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Speci fications Manual, “Connecting Rod Bearing Journal” and Specifications Manual, “Main Bearing Journal” for the correct clearances.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered:

• Ensure that the backs of the bearings and the bores are clean and dry.



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i02748603

Coolant Temperature Sensor Remove and Install



Removal Procedure

Part Number

21820122

Part Description POWERPART Pipe Sealant

Qty 1

1. Ensure that the coolant temperature sensor is clean and free from damage.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

Illustration 200

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.

g01343990

Typical example

2. Apply a thin layer of Tooling (A) to the threads of coolant temperature sensor (1). 3. Install coolant temperature sensor (1) into the cylinder head. Tighten the coolant temperature sensor to a torque of 11 N·m (97 lb in). 4. Connect the harness assembly (not shown) to coolant temperature sensor (1). 5. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. i02748604

Illustration 199

g01343990

Typical example

2. Disconnect the harness assembly (not shown) from coolant temperature sensor (1). 3. Remove coolant temperature sensor (1) from the cylinder head.

Engine Oil Pressure Sensor Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


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NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar tment or disassembling any component containing fluids. Dispose of all fl uids according to local regulations and mandates.

Illustration 202

g01343988

Typical example

2. Apply a thin layer of Tooling (A) to the threads of engine oil pressure sensor (1). 3. Install engine oil pressure sensor (1) to the cylinder block. Use a deep socket in order to tighten the engine oil pressure sensor to a torque of 11 N·m (97 lb in). g01343988

Illustrati on 201 Typical example

1. Remove the harness assembly (not shown) from engine oil pressure sensor (1). 2. Use a deep socket in order to remove engine oil pressure sensor (1) from the cylinder block.

4. Connect the harness assembly (not shown) to engine oil pressure sensor (1). i02748605

Glow Plugs - Remove and Install

Installation Procedure Removal Procedure

Table 49


Part Number

21820122

Part Description

Qty

POWERPART Pipe Sealant

1

NOTICE Keep all par ts clean from contaminants.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn the battery disconnect switch to the OFF position.

Contaminants may cause rapid wear and shortened component life. 1. Ensure that the engine oil pressure sensor is clean and free from damage.



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g01343974

Illustration 203 Naturally aspirated engine

Illustration 205

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Naturally aspirated engine

g01343965

Illustration 204

Illustration 206

g01343965

Turbocharged engine

Turbocharged engine

2. Remove nuts (1) and bus bar (2).

2. Install glow plugs (3) to the cylinder head.

3. Use a deep socket in order to remove glow plugs (3) from the cylinder head.

3. For naturally aspirated engines, use a deep socket in order to tighten the glow plugs to a torque of 18 N·m (13 lb ft).


For turbocharged engines, use a deep socket in order to tighten the glow plugs to a torque of 25 N·m (18 lb ft).

Table 50


Part Number

27610296

Part Description

Torque Wrench

Qty 1


4. Position bus bar (2) onto glow plugs (3) and install nuts (1). Use Tooling (A) to tighten the nuts to a torque of 1.2 N·m (11 lb in). 5. Turn the battery disconnect switch to the ON position.

Contaminants may cause rapid wear and shortened component life. 1. Ensure that the threads of the glow plugs are clean and free from damage. Replace any damaged glow plugs.


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i02748606

V-Belts - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 208

g01343666

Typical example

1. Install V-belt (3) onto the pulleys. Note: A used V-belt should be installed in the original direction of rotation. 2. Adjust the tension of V-belt (3) by moving the alternator away from the engine. Use Tooling (A) in order to achieve the correct belt tension. Refer to Specifications, “Belt Tension Chart” for more information. g01343666


3. Tighten bolts (1), and (2) to a torque of 11 N·m (97 lb in). Tighten bolt (4), to a torque of 35 N·m (26 lb ft).

1. Loosen bolts (1), (2) and (4). Slide the alternator toward the engine.

i02748608

Fan - Remove and Install

2. Remove V-belt (3). Note: Mark the direction of rotation if the V-belt will be reused.

Removal Procedure


Start By:

Table 51

Required Tools Tool

Part Number

A

-

Part Description Belt Tension Gauge

Qty

a. Remove the V-Belt. Refer to Disassembly and Assembly, “V-Belts - Remove and Install”.

1




Illustration 209

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g01343637

Illustration 210

g01343637

Typical example

Typical example

1. Remove bolts (5) and plate (6).

2. Position fan pulley (3) onto water pump (4).

2. Remove fan (1). Note the orientation of the fan for installation.

3. If the engine is equipped with a spacer, position spacer (2) onto pulley (3).

3. If the engine is equipped with a spacer, remove spacer (2).

4. Install fan (1), plate (6), and bolts (5). Note: Ensure that the fan is correctly oriented.

4. Remove pulley (3) from water pump (4). 5. Tighten bolts (5) to a torque of 18 N·m (13 lb ft).

Installation Procedure 1. Ensure that all components are free from wear or damage. If necessary, replace any components that are worn or damaged.

End By: a. Install the V-Belt. Refer to Disassembly and Assembly, “V-Belts - Remove and Install”. i02748609

Alternator - Remove and Install Removal Procedure Start By: a. Remove the V-Belt. Refer to Disassembly and Assembly, “V-Belts - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


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1. Turn the battery disconnect switch to the OFF position.


2. Make temporary identi fication marks on the connections of the harness assembly.

Illustration 212

g01343570

Typical example

Illustration 211

g01343570

1. Position alternator (3) on bracket (6) and install bolt (5) finger tight.

Typical Example

2. Install bolt (1) and washer (2) fi nger tight. 3. Disconnect the harness assembly from alternator (3). 4. Loosen bolt (4). Remove bolt (1) and washer (2) from alternator (3). 5. Remove bolt (5) from alternator (3). Remove the alternator from alternator bracket (6).

3. Install the V-belt. Refer to Disassembly and assembly, “V-belts - Remove and Install” for the correct procedure. 4. Tighten bolts (1) and (4) to a torque of 11 N·m (97 lb in). Tighten bolt (5) to a torque of 35 N·m (26 lb ft). 5. Connect the harness assembly to alternator (3). 6. Turn the battery disconnect switch to the ON position.



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i02748611


Electric Starting Motor Remove and Install Removal Procedure

Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative ( ) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.

Illustration 214

g01343546

−

Placea Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. 1. Disconnect the battery. 2. Make temporary identi fication marks on the harness assemblies that are connected to the electric starting motor. Disconnect the harness assemblies from the electric starting motor.

Illustration 213

Typical example

1. If necessary, install studs (2). 2. Align electric starting motor (1) to studs (2). Install the electric starting motor. 3. Install nuts (3). Tighten the nuts to a torque of 35 N·m (26 lb ft). 4. Connect the harness assemblies to the electric starting motor. Refer to Specifications, “Electric Starting Motor” for the tightening torques of the terminal nuts. 5. Connect the battery.

g01343546

Typical example

3. Remove nuts (3) from electric starting motor (1). Note: Support the weight of the electric starting motor as the nuts are removed. 4. Remove electric starting motor (1). 5. If necessary, remove studs (2).


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101 Index Section

Index A Alternator - Remove and Install ............................. 98 Installation Procedure ........................................ 99 Removal Procedure ........................................... 98 B Balancer - Assemble ............................................. 72 Assembly Procedure.......................................... 72 Balancer - Disassemble......................................... 71 Disassembly Procedure ..................................... 71 Balancer - Install.................................................... 73 Installation Procedure ........................................ 73 Balancer - Remove................................................ 70 Removal Procedure ........................................... 70 Bearing Clearance - Check ................................... 93 Measurement Pr ocedure ................................... 93 C Camshaft - Remove and Install ............................. 65 Installation Procedure ........................................ 65 Removal Procedure ........................................... 65 Camshaft Gear - Remove and Install .................... 66 Installation Pr ocedure ........................................ 67 Removal Procedure ........................................... 66 Connecting Rod Bearings - Install (Connecting rods in position) ........................................................... 82 Installation Procedure ........................................ 82 Connecting Rod Bearings - Remove (Connecting rods in position) ................................................... 81 Removal Procedure ........................................... 81 Coolant Temperature Sensor - Remove and Install ................................................................... 94 Installation Procedure ........................................ 94 Removal Procedure ........................................... 94 Crankcase Breather - Remove and Install (Turbocharged Engines) ...................................... 54 Installation Procedure ........................................ 54 Removal Procedur e ........................................... 54 Crankshaft - Install................................................. 89 Installation Procedure ........................................ 89 Crankshaft - Remove............................................. 87 Removal Procedure ........................................... 87 Crankshaft Front Seal - Remove and Install.......... 47 Installation Procedure ........................................ 47 Removal Procedure ........................................... 47 Crankshaft Gear - Remove and Install .................. 92 Installation Procedure ........................................ 92 Removal Procedure ........................................... 92 Crankshaft Main Bearings - Remove and Install (Crankshaft in position)........................................ 83 Installation Procedure ........................................ 84 Removal Procedure ........................................... 83 Crankshaft Pulley - Remove and Install ................ 45 Installation Procedure ........................................ 46 Removal Procedure ........................................... 45

Crankshaft Rear Seal - Remove and Install .......... 40 Installation Procedure ........................................ 41 Removal Procedure ........................................... 40 Crankshaft Wear Sleeve (Rear) - Remove and Install ................................................................... 42 Installation Procedure ........................................ 42 Removal Procedure ........................................... 42 Cylinder Head - Install ........................................... 62 Installation Procedure ........................................ 62 Cylinder Head - Remove ....................................... 60 Removal Procedure ........................................... 60 D Disassembly and Assembly Section........................ 4 E Electric Starting Motor - Remove and Install ....... 100 Installation Procedure ...................................... 100 Removal Procedure ......................................... 100 Engine Oil Bypass Valve - Remove and Install ..... 32 Installation Procedure ........................................ 33 Removal Procedure ........................................... 32 Engine Oil Cooler - Install...................................... 30 Installation Pr ocedure ........................................ 30 Engine Oil Cooler - Remove.................................. 29 Removal Procedure ........................................... 29 Engine Oil Filter Base - Remove and Install.......... 28 Installation Procedure ........................................ 28 Removal Procedure ........................................... 28 Engine Oil Pan - Remove and Install..................... 67 Installation Procedure for the Engine Oil Pan.... 69 Installation Procedure for the Oil Strainer.......... 69 Removal Procedur e for the Engine Oil Pan....... 67 Removal Procedure for the Oil Strainer............. 68 Engine Oil Pressure Sensor - Remove and Install.. 94 Installation Procedure ........................................ 95 Removal Procedure ........................................... 94 Engine Oil Pump - Install....................................... 34 Installation Procedure ........................................ 34 Engine Oil Pump - Remove................................... 33 Removal Procedure ........................................... 33 Engine Oil Relief Valve - Remove and Install ........ 31 Installation Procedure ........................................ 32 Removal Procedure ........................................... 31 Exhaust Manifold - Remove and Install................. 20 Installation Procedure ........................................ 21 Removal Procedure ........................................... 20 F Fan - Remove and Install ...................................... 97 Installation Procedure ........................................ 98 Removal Procedure ........................................... 97 Flywheel - Install.................................................... 39 Installation Procedure ........................................ 39


102 Index Section

Flywheel - Remove................................................ 38 Removal Procedure ........................................... 38 Flywheel Housing - Remove and Install ................ 43 Installation Procedure ........................................ 44 Removal Procedure ........................................... 43 Front Cover - Remove and Install.......................... 48 Installation Procedure ........................................ 48 Removal Procedure ........................................... 48 Front Plate - Install ................................................ 53 Installation Procedure ........................................ 53 Front Plate - Remove ............................................ 52 Removal Procedure ........................................... 52 Fuel Injection Lines - Remove and Install (Naturally Aspirated Engines) ................................................ 5 Installation Procedure .......................................... 6 Removal Procedure ............................................. 5 Fuel Injection Lines - Remove and Install (Turbocharged Engines) ........................................ 7 Installation Procedure .......................................... 8 Removal Procedur e ............................................. 7 Fuel Injection Pump - Install .................................. 14 Installation Procedure ........................................ 14 Fuel Injection Pump - Install (Fuel Injection Pumps With a Water Heated Cold Start Device) ............. 13 Installation Procedure ........................................ 13 Fuel Injection Pump - Remove ................................ 9 Removal Procedure ............................................. 9 Fuel Injection Pump - Remove (Fuel Injection Pumps With a Water Heated Cold Start Device) .............. 11 Removal Procedure ............................................ 11 Fuel Injector - Remove and Install (Naturally Aspirated Engines) .............................................. 16 Installation Procedure ........................................ 16 Removal Procedure ........................................... 16 Fuel Injector - Remove and Install (Turbocharged Engines)............................................................... 16 Installation Procedure ........................................ 17 Removal Procedure ........................................... 16 Fuel Priming Pump and Fuel Filter Base - Remove and Install .............................................................. 4 Installation Procedure .......................................... 4 Removal Procedure ............................................. 4 G Glow Plugs - Remove and Install .......................... 95 Installation Procedure ........................................ 96 Removal Procedure ........................................... 95

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I Idler Gear - Remove and Install............................. 48 Installation Procedure ........................................ 49 Removal Procedure ........................................... 48 Important Safety Information ................................... 2 Inlet and Exhaust Valve Springs - Remove and Install ................................................................... 23 Installation Procedure ........................................ 24 Removal Procedure ........................................... 23 Inlet and Exhaust Valves - Remove and Install ..... 25 Installation Procedure ........................................ 26 Removal Procedure ........................................... 25 Inlet Manifold - Remove and Install ....................... 21 Installation Procedure ........................................ 22 Removal Procedure ........................................... 21 L Lifter Group - Remove and Install.......................... 64 Installation Procedure ........................................ 64 Removal Procedure ........................................... 64 P Pistons and Connecting Rods - Assemble ............ 77 Assembly Procedure.......................................... 77 Pistons and Connecting Rods - Disassemble ....... 75 Disassembly Procedure..................................... 75 Pistons and Connecting Rods - Install................... 80 Installation Procedure ........................................ 80 Pistons and Connecting Rods - Remove............... 74 Removal Procedur e ........................................... 74

R Rocker Shaft - Assemble....................................... 58 Assembly Procedure.......................................... 58 Rocker Shaft - Disassemble.................................. 57 Disassembly Procedure..................................... 57 Rocker Shaft and Pushrod - Install........................ 59 Installation Procedure ........................................ 59 Rocker Shaft and Pushrod - Remove.................... 56 Removal Procedure ........................................... 56 T

H Housing (Front) - Remove and Install.................... 51 Installation Procedure ........................................ 51 Removal Procedure ........................................... 51

Table of Contents..................................................... 3 Turbocharger - Install ............................................ 19 Installation Procedure ........................................ 19 Turbocharger - Remove ........................................ 17 Removal Procedure ........................................... 17


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103 Index Section

V V-Belts - Remove and Install ................................. 97 Installation Procedure ........................................ 97 Removal Procedure ........................................... 97 Valve Mechanism Cover - Remove and Install...... 55 Installation Procedure ........................................ 56 Removal Procedure ........................................... 55 W Water Pump - Remove and Install......................... 35 Installation Procedure ........................................ 36 Removal Procedure ........................................... 35 Water Temperature Regulator Housing - Remove and Install ................................................................... 37 Installation Procedure ........................................ 37 Removal Procedure ........................................... 37


800D Industrial Engines

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