Disassembly & Assembly 4006-8 TRS_KENR6945-00

KENR6945 May 2009

Disassembly and Assembly 4006 TRS Gas and 4008 TRS Gas Industrial Engines SG61-Up (Engine) SG81-Up (Engine)

SAFETY.CAT.COM

i03602780

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. 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. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar 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. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar 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 become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. 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 Gas Pressure Regulator - Remove (Zero Pressure Regulator) ............................................................. 5 Gas Pressure Regulator - Install (Zero Pressure Regulator) ............................................................. 6 Fuel Control Actuator - Remove and Install (Throttle Governor) .............................................................. 7 Fuel Control Valve - Remove and Install (Main Fuel Adjuster) .............................................................. 10 Governor - Remove (Governor Control Unit) ........ 12 Governor - Remove (Ignition Control Unit) ........... 14 Governor - Install (Governor Control Unit) ............ 15 Governor - Install (Ignition Control Unit) ............... 16 Spark Plugs - Remove and Install ....................... 17 Spark Plugs - Remove and Install (Multitorch) ..... 19 Carburetor - Remove ........................................... 21 Carburetor - Disassemble .................................... 21 Carburetor - Assemble ......................................... 22 Carburetor - Install ............................................... 23 Air Cleaner - Remove and Install .......................... 25 Turbocharger - Remove ........................................ 26 Turbocharger - Install ............................................ 28 Exhaust Manifold - Remove and Install ............... 30 Exhaust Elbow - Remove and Install ................... 35 Inlet Manifold - Remove ....................................... 36 Inlet Manifold - Install ........................................... 37 Inlet and Exhaust Valves - Remove and Install .... 39 Engine Oil Line - Remove and Install (Engine Oil Rail) ..................................................................... 41 Engine Oil Filter Base - Remove .......................... 44 Engine Oil Filter Base - Install .............................. 45 Engine Oil Cooler - Remove ................................. 47 Engine Oil Cooler - Disassemble ......................... 49 Engine Oil Cooler - Assemble .............................. 50 Engine Oil Cooler - Install ..................................... 50 Engine Oil Relief Valve - Remove and Install (Engine Oil Pressure Regulator) ...................................... 53 Engine Oil Relief Valve - Remove and Install (Engine Oil Cooler) ........................................................... 54 Engine Oil Pump - Remove .................................. 57 Engine Oil Pump - Disassemble ........................... 58 Engine Oil Pump - Assemble ................................ 59 Engine Oil Pump - Install ...................................... 61 Water Pump - Remove ......................................... 62 Water Pump - Disassemble ................................. 63 Water Pump - Assemble ...................................... 64 Water Pump - Install ............................................. 65 Water Temperature Regulator Housing - Remove and Install (Thermostat Housing) ............................... 66 Auxiliary Water Pump - Remove (Gilkes Raw Water Pump) ................................................................. 68 Auxiliary Water Pump - Disassemble (Gilkes Raw Water Pump) ....................................................... 70 Auxiliary Water Pump - Assemble (Gilkes Raw Water Pump) ................................................................. 72 Auxiliary Water Pump - Install (Gilkes Raw Water Pump) ................................................................. 75 Aftercooler - Remove ........................................... 76

3 Table of Contents

Aftercooler - Disassemble ..................................... 78 Aftercooler - Assemble ......................................... 79 Aftercooler - Install (Air Charge Cooler) ................ 80 Engine Support (Front) - Remove and Install (Backplate) .......................................................... 82 Flywheel - Remove ............................................... 83 Flywheel - Install ................................................... 85 Crankshaft Rear Seal - Remove and Install ......... 86 Flywheel Housing - Remove and Install .............. 88 Vibration Damper - Remove and Install (Damper and Plate) ................................................................... 90 Vibration Damper - Remove and Install ............... 93 Vibration Damper and Pulley - Remove and Install (Single Vibration Damper) ................................... 95 Crankshaft Front Seal - Remove and Install ......... 99 Gear Group (Front) - Remove ............................ 101 Gear Group (Front) - Install ................................ 102 Housing (Front) - Remove (Timing Case) ........... 104 Housing (Front) - Install (Timing Case) ............... 105 Crankcase Breather - Remove and Install ......... 107 Valve Mechanism Cover - Remove and Install (Rocker Box Cover) ........................................... 110 Valve Mechanism Cover Base - Remove and Install (Rocker Box) ...................................................... 111 Rocker Arm and Shaft - Remove ......................... 113 Rocker Arm - Disassemble .................................. 114 Rocker Arm - Assemble ....................................... 115 Rocker Arm and Shaft - Install ............................. 117 Cylinder Head - Remove ..................................... 118 Cylinder Head - Install ........................................ 120 Lifter Group - Remove (Cam Followers) ............. 123 Lifter Group - Disassemble (Cam Followers) ...... 124 Lifter Group - Assemble (Cam Followers) .......... 124 Lifter Group - Install (Cam Followers) ................. 125 Camshaft - Remove ............................................ 126 Camshaft - Install ................................................ 127 Camshaft Bearings - Remove ............................. 128 Camshaft Bearings - Install ................................. 128 Engine Oil Pan - Remove .................................. 129 Engine Oil Pan - Install ...................................... 131 Cylinder Liner - Remove ..................................... 133 Cylinder Liner - Install ......................................... 134 Piston Cooling Jets - Remove and Install ........... 136 Pistons and Connecting Rods - Remove ............ 138 Pistons and Connecting Rods - Disassemble ..... 139 Pistons and Connecting Rods - Assemble ......... 140 Pistons and Connecting Rods - Install ................ 143 Crankshaft Main Bearings - Remove and Install ........................................................................... 145 Crankshaft - Remove (Eight Cylinder TRS Engines) ............................................................ 146 Crankshaft - Remove (Six Cylinder TRS Engines) ............................................................ 147 Crankshaft - Install (Six Cylinder TRS) ............... 148 Crankshaft - Install (Eight Cylinder TRS Engines) ............................................................ 151 Crankshaft Gear - Remove and Install .............. 153 Bearing Clearance - Check ................................. 154 Engine Sensors - Remove and Install (Knock Sensor) ............................................................. 155 Engine Sensors - Remove and Install (Exhaust Temperature Thermocouple) ............................. 156

4 Table of Contents

Engine Sensors - Remove and Install (High Inlet Manifold Pressure Shutdown Sensor) .............. 157 Coolant Temperature Switch - Remove and Install ................................................................. 159 Engine Oil Pressure Switch - Remove and Install ........................................................................... 160 Engine Oil Pressure Switch - Remove and Install (Alternator Warning Lamp) ................................ 161 Engine Speed Sensor - Remove and Install (Overspeed Sensor) .......................................... 162 Engine Speed Sensor - Remove and Install (Camshaft Timing Sensor) ................................ 163 Engine Speed Sensor - Remove and Install (Engine Speed for Governor Control) ............................. 165 Boost Pressure Sensor - Remove and Install (Boost Pressure and Temperature Sensor) .................. 166 Ignition Wiring Harness - Remove and Install (Ignition Wiring Harness Rail) ......................................... 166 Alternator - Remove and Install (Battery Charging Alternator) ......................................................... 169 Alternator - Remove and Install (Battery Charging Alternator Drive) ................................................ 171 Electric Starting Motor - Remove and Install ..... 173

Index Section Index ................................................................... 176

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5 Disassembly and Assembly Section

Disassembly and Assembly Section i03401440

Gas Pressure Regulator Remove (Zero Pressure Regulator)

3. Loosen hose clamp. Disconnect plastic hose assembly (7) and position the plastic hose assembly away from the zero pressure regulator. 4. Disconnect harness assembly (5) from fuel control valve (4). 5. Disconnect hose assembly (3) from zero pressure regulator (2). 6. Remove nuts (10) from fuel control valve (4).

SMCS Code: 1270-011

7. Remove nuts from clamp (1) and remove the clamp.

Removal Procedure

Note: Support the weight of the zero pressure regulator.

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

8. Remove the assembly of zero pressure regulator (2) and fuel control valve (4) from the support bracket and carburetor (6). 9. Remove gasket (9) (not shown).

NOTICE Comply with the local official gas regulations regarding isolating the gas supply. 1. Turn the gas supply valve to the OFF position.

Illustration 2

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10. If necessary, remove zero pressure regulator (2) from tube assembly (11) and tube assembly (12). Follow Step 10.a through Step 10.c in order to remove zero pressure regulator (2). a. Mount the assembly of zero pressure regulator (2) and fuel control valve (4) in a bench vise.

Illustration 1

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2. Disconnect gas inlet hose from connection (8) from zero pressure regulator (2).

b. Make a temporary mark on tube assembly (11) so that the tube assembly can be reinstalled in the original orientation. Remove tube assembly (11) from zero pressure regulator (2).


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c. Make a temporary mark on tube assembly (12) so that the tube assembly can be reinstalled in the original orientation. Remove zero pressure regulator (2) from tube assembly (12). i03401441

Gas Pressure Regulator Install (Zero Pressure Regulator) SMCS Code: 1270-012

Installation Procedure Table 1

Required Tools Tool

Part Number

A

-

Part Description Loctite 577 Pipe Sealant

Qty 1

Illustration 4

g01816934

2. If necessary, Install tube assembly (11) and tube assembly (12) to zero pressure regulator (2). Follow Step 2.a through Step 2.f in order to install tube assemblies to zero pressure regulator (2).

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components of the zero pressure regulator are clean and free from damage. Ensure that all tube assemblies are free from restriction. Clean the gasket surface of the carburetor.

a. Mount tube assembly (12) for fuel control valve (4) in a bench vise. b. Apply a bead of Tooling (A) to threads in Position (A) on tube assembly (12). c. Install zero pressure regulator (2) onto tube assembly (12). Note: Ensure that the zero pressure regulator and the tube assembly are installed in the correct orientation. d. Mount the zero pressure regulator (2) in a bench vise. e. Apply a bead of Tooling (A) to threads at Position (A) on tube assembly (11). f. Install tube assembly (11) to zero pressure regulator (2). Note: Ensure that the tube assembly is installed in the correct orientation.

Illustration 3

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Illustration 6

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9. Tighten the nuts for clamp (1) to a torque of 47 N·m (35 lb ft). Ensure that the tube assembly is seated in Position (B). Illustration 5

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10. Connect gas inlet hose to connection (8) to zero pressure regulator (2).

3. Position a new gasket (9) (not shown) onto carburetor (6).

11. Connect harness assembly (5) to fuel control valve (4).

4. Position the assembly of zero pressure regulator (2) and fuel control valve (4) onto the support bracket and carburetor (6).

12. Connect hose assembly (3) to zero pressure regulator (2).

Note: Support the weight of the zero pressure regulator. 5. Install clamp (1) to the assembly of zero pressure regulator (2) and fuel control valve (4). Install the nuts to clamp (1) finger tight. 6. Install nuts (10) to fuel control valve (4) and tighten nuts finger tight. 7. Ensure that the assembly of zero pressure regulator (2) and fuel control valve (4) is installed in the correct orientation. 8. Tighten nuts (10) to fuel control valve (4). Tighten the nuts to a torque of 25 N·m (18 lb ft).

13. Connect plastic hose assembly (7) and tighten hose clamp securely. 14. Turn the gas supply valve to the ON position. i03401444

Fuel Control Actuator Remove and Install (Throttle Governor) SMCS Code: 1909-010-AQ; 1909-010

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


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NOTICE Comply with the local official gas regulations regarding isolating the gas supply. 1. Turn the gas supply valve to the OFF position.

4. Remove the nuts and bolts (10) from tube assembly (6). 5. Remove tube assembly (6) from air charge cooler and throttle governor (14). 6. Remove gasket (9) (not shown) and O-ring seal (11) (not shown). 7. Disconnect harness assembly (8) from throttle governor (14). 8. Remove nuts (13) from throttle governor (14). 9. Remove throttle governor (14) from the inlet manifold. Remove O-ring seal (12) (not shown).

Illustration 7

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2. Loosen nuts on clamp (2) on zero pressure regulator (1). Remove nuts and bolts (3) from bracket (4). Note: Support the weight of the zero pressure regulator. 3. Remove nuts (5) and remove bracket (4) from the air charge cooler.

Illustration 9

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10. Remove spacer (15) and O-ring seal (16) from the inlet manifold. 11. If necessary, remove studs (17) from the inlet manifold.

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 throttle governor are clean and free from damage. Ensure that the tube assembly is free from restriction. Clean the gasket surface of the air charge cooler, spacer and the inlet manifold. Illustration 8

g01826573

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8. Install tube assembly (6) onto air charge cooler and throttle governor (14). 9. Install the nuts and bolts (10) to tube assembly (6) hand tight. 10. Connect harness assembly (8) to throttle governor (14).

Illustration 10

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Illustration 12

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11. Install bracket (4) to the tube assembly. Install nuts (5) hand tight. 12. Install nuts and bolts (3) to bracket (4) for zero pressure regulator (2) hand tight. Tighten nuts on clamp (2) hand tight.

Illustration 11

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2. If necessary, install studs (17) from the inlet manifold. Tighten studs securely. 3. Install a new O-ring seal (16) to the inlet manifold and install spacer (15). 4. Install a new O-ring seal (12) (not shown) to throttle governor (14). 5. Position throttle governor (14) onto inlet manifold. Install nuts (13) to the throttle governor hand tight. 6. Install a new O-ring seal (11) (not shown) to tube assembly (6). 7. Position a new gasket (9) onto air charge cooler.

Illustration 13

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1. Turn the gas supply valve to the OFF position.

Illustration 14

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13. Tighten nuts (13) to a torque of 47 N·m (35 lb ft). 14. Tighten the nuts and bolts (10) to a torque of 47 N·m (35 lb ft). 15. Tighten nuts (5) to a torque of 47 N·m (35 lb ft). 16. Tighten the nuts and bolts (3) to a torque of 47 N·m (35 lb ft). 17. Tighten the nuts for clamp (2) to a torque of 47 N·m (35 lb ft). Ensure that tube assembly (18) is seated in Position (B). 18. Turn the gas supply valve to the ON position. i03401445

Fuel Control Valve - Remove and Install (Main Fuel Adjuster) SMCS Code: 1715-010; 1909-010


Illustration 15

2. Disconnect gas inlet hose from connection (8) on zero pressure regulator (2). 3. Loosen hose clamp on plastic hose assembly. Disconnect plastic hose assembly (7) and position the plastic hose assembly away from the zero pressure regulator. 4. Disconnect harness assembly (5) from fuel control valve (4). 5. Disconnect hose assembly (3) from zero pressure regulator (2). 6. Remove nuts (10) from fuel control valve (4). 7. Remove nuts from clamp (1) and remove the clamp. Note: Support the weight of the fuel control valve and zero pressure regulator. 8. Remove the assembly of zero pressure regulator (2) and fuel control valve (4) from the support bracket and carburetor (6). 9. Remove gasket (9) (not shown).

NOTICE Comply with the local official gas regulations regarding isolating the gas supply.

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Illustration 16

Illustration 17

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Illustration 18

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10. Mount the assembly of fuel control valve (4) in a vise. 11. Make a temporary mark on tube assembly (11) so that the tube assembly can be reinstalled in the original orientation. Remove tube assembly (11) from fuel control valve (4).


Required Tools Tool

Part Number

A

-

Part Description Loctite 577 Pipe Sealant

Qty 1

1. Ensure that all components of the fuel control valve are clean and free from damage. Ensure that all tube assembly is free from restriction. Clean the gasket surface of the carburetor.

2. Mount tube assembly (11) for the fuel control valve (4) in a vise. 3. Apply a bead of Tooling (A) to threads in Position (A) on tube assembly (11). 4. Install fuel control valve (4) to tube assembly (11). Note: Ensure that the fuel control valve and tube assembly are installed in the correct orientation.


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7. Install clamp (1) to the assembly of zero pressure regulator (2) and fuel control valve (4). Install the nuts to clamp (1) hand tight. 8. Install nuts (10) to fuel control valve (4) and tighten nuts hand tight. 9. Ensure that the assembly of zero pressure regulator (2) and fuel control valve (4) is installed in the correct orientation. 10. Tighten nuts (10) for fuel control valve (4) to a torque of 25 N·m (18 lb ft). 11. Tighten the nuts for clamp (1) to a torque of 47 N·m (35 lb ft). Ensure that the tube assembly is seated in Position (B). 12. Connect harness assembly (5) to fuel control valve (4). 13. Connect hose assembly (3) to zero pressure regulator (2). 14. Connect plastic hose assembly (7) and tighten hose clamp for plastic hose assembly securely. Illustration 19

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15. Connect gas inlet hose to connection (8) for zero pressure regulator (2). Tighten hose for the connection securely. 16. Turn the gas supply valve to the ON position. i03401446

Governor - Remove (Governor Control Unit) SMCS Code: 1264-011

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 20

g01824554

5. Position a new gasket (9) (not shown) onto carburetor (6). 6. Position the assembly of zero pressure regulator (2) and fuel control valve (4) onto the support bracket and carburetor (6). Note: Support the weight of the zero pressure regulator and the fuel control valve.

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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. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Illustration 22

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4. Remove screws (7) from cover (8) for the governor control unit. 5. Remove allen head bolts (9) and remove governor control unit (10). Remove washers (11) (not shown).

Illustration 21

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1. Turn the battery disconnect switch to the OFF position. 2. Disconnect harness assembly (1), harness assembly (2) and harness assembly (3) from the governor control unit. 3. Disconnect harness assembly (4) from customer harness assembly. Remove bolts (5) from clips. Remove screws (6) from fuses. Position the wire harness away from the governor control unit. Illustration 23

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6. Remove nuts (12) and remove bolts (13). Remove mounting bracket (15). 7. Remove rubber mounting (14) from mounting bracket (15). 8. Remove nuts (17) and remove rubber mounting (16) from mounting bracket (15).


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i03534440

Governor - Remove (Ignition Control Unit) SMCS Code: 1264-011

Removal Procedure

Illustration 24

g01861393

9. If necessary, remove mounting bracket (21) from the inlet manifold. Follow Step 9.a through Step 9.c in order to remove the mounting bracket from the inlet manifold. a. Remove ignition control unit. Refer to Disassembly and Assembly, “Governor Remove (Ignition Control Unit)” for the correct procedure. b. Remove nuts and bolts (20) and remove mounting bracket (21). c. Remove the nuts and bolts (18) from the inlet manifold and remove mounting brackets (19) from the inlet manifold.

Illustration 25

g01862553

1. Turn the battery disconnect switch to the OFF position. 2. Disconnect harness assembly (1), harness assembly (2) and harness assembly (3). 3. Remove screw (6) and remove grounding wire. Position the harness assembly away from ignition control unit. 4. Remove nuts and bolts (4). Remove ignition control unit (5) from the mounting bracket.

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Illustration 26


g01862653

5. Remove nuts (9) and nuts (7). Remove mounting bracket (13) from mounting bracket (12). 6. Remove rubber mountings (8) from mounting bracket (13). Remove nuts (11) and remove rubber mountings (10) from mounting bracket (13). 7. If necessary, remove the electronic control unit and the mounting bracket (12). Refer to Disassembly and Assembly, “Governor Remove (Electronic Control Unit)” for the correct procedure. i03401447

Governor - Install (Governor Control Unit) SMCS Code: 1264-012

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

Illustration 27

g01861393

1. If necessary, install mounting bracket (21) to the inlet manifold. Follow Step 1.a through Step 1.b in order to install the mounting bracket to the inlet manifold. a. Position mounting brackets (19) onto the inlet manifolds. Install bolts (18) and tighten the bolts hand tight. Position mounting brackets (21) onto mounting brackets (19). Install nuts and bolts (20). Tighten the nuts and bolts hand tight. Tighten bolts (18) to a torque of 47 N·m (35 lb ft). Tighten nuts and bolts (20) to a torque of 47 N·m (35 lb ft). b. Install ignition control unit. Refer to Disassembly and Assembly, “Governor Install (Ignition Control Unit)” for the correct procedure.


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7. Position cover (8) onto the governor control unit. Install screws (7) and tighten screws securely.

Illustration 28

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2. Install rubber mountings (14) to mounting bracket (15). Tighten rubber mounting securely. 3. Install rubber mounting (16) and install nuts (17). Tighten nut (17) to a torque of 25 N·m (18 lb ft). 4. Install mounting bracket (15) to mounting bracket (21). Install nuts (13) and nuts (12). Tighten nuts to a torque of 25 N·m (18 lb ft).

Illustration 30

g01859657

8. Connect harness assembly (1), harness assembly (2) and harness assembly (3). 9. Position clips for harness assemblies. Install bolts (5) and tighten the bolts securely. Position fuses and install screws (6). Tighten screws securely. Connect harness assembly (4) to customer harness assembly. 10. Turn the battery disconnect switch to the OFF position. i03535840

Governor - Install (Ignition Control Unit) SMCS Code: 1264-012

Installation Procedure 1. If necessary, install the electronic control unit and mounting plate (12). Refer to Disassembly and Assembly, “Governor Remove (Electronic Control Unit)” for the correct procedure. Illustration 29

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5. Position governor control unit (10) onto the mounting bracket. Position washers (11) (not shown) between the governor control unit and the mounting bracket. 6. Install allen head bolts (9). Tighten the allen head bolts to a torque of 9 N·m (80 lb in).

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6. Turn the battery disconnect switch to the ON position. i03401449

Spark Plugs - Remove and Install SMCS Code: 1114-010; 1555-010

Removal Procedure Table 3

Required Tools

Illustration 31

g01862653

2. Install rubber mounting (8) to mounting bracket (13). Install rubber mounting (10) to mounting bracket (13) and install nuts (11). Tighten nuts to a torque of 25 N·m (18 lb ft).

Tool

Part Number

A

484/45

Part Description Spark plug Socket

Qty 1


3. Install mounting bracket (13) onto mounting plate (12). Install nuts (7) and nuts (9). Tighten nuts to a torque of 25 N·m (18 lb ft).

Illustration 33

Illustration 32

g01862553

4. Position ignition control unit (5) onto mounting bracket. Install nuts and bolts (4). Tighten nuts and bolts to a torque of 25 N·m (18 lb ft). 5. Position the grounding wire onto the mounting bracket. Install bolt (6) and tighten the bolt securely. Install harness assembly (1), harness assembly (2) and harness assembly (3).

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Illustration 35

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Illustration 36

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Illustration 34

1. Remove high tension lead (2) from ignition coil (1). 2. Remove seal (3) for high tension lead (2) from valve mechanism cover (4). Remove high tension lead (2) from spark plug (5) (not shown). 3. Use Tooling (A) to remove spark plug (5) (not shown) from the cylinder head.


Required Tools Tool

Part Number

A

484/45


Qty 1


1. Install a new sealing washer (6) to spark plug (5). 2. Use Tooling (A) to install spark plug (5) (not shown) to the cylinder head. 3. Tighten spark plug (5) to a torque of 50 N·m (30 lb ft).

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g01833385

Illustration 37

Illustration 38

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Illustration 39

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4. Install high tension lead (2) to ignition coil (1). 5. Install seal (3) for high tension lead (2) to valve mechanism cover (4). i03496842

Spark Plugs - Remove and Install (Multitorch) SMCS Code: 1114-010; 1555-010


Required Tools Tool

Part Number

A

484/49


Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE The Multitorch spark plugs fitted to the Perkins 4000 TRS series engines are unique to Perkins, they are designed for the specific combustion chamber and must not be replaced with alternatively sourced Multitorch plugs. Damage may occur resulting in engine failure.

1. Remove high tension lead (2) from ignition coil (1). 2. Remove seal (3) for high tension lead (2) from valve mechanism cover (4). 3. Use Tooling (A) to remove multitorch spark plug (5) (not shown) from the cylinder head.


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Required Tools Tool

Part Number

A

484/49


Qty 1


Illustration 41

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1. Install a new sealing washer (6) to multitorch spark plug (5). 2. Use Tooling (A) to install multitorch spark plug (5) (not shown) to the cylinder head. Illustration 40

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3. Tighten multitorch spark plug (5) to a torque of 50 N·m (30 lb ft).

Illustration 42

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4. Install high tension lead (2) to ignition coil (1).

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5. Install seal (3) for high tension lead (2) to valve mechanism cover (4). i03401450

Carburetor - Remove SMCS Code: 1266-011

Removal Procedure Start By: a. Remove the air cleaner. Refer to Disassembly and Assembly, “Air Cleaner - Remove and Install”. NOTICE Comply with the local official gas regulations regarding isolating the gas supply. 1. Turn the gas supply valve to the OFF position.

Illustration 44

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6. Loosen hose clamp (10) and remove air cleaner adapter (11) from carburetor (5). 7. Position air cleaner adapter (11) away from carburetor (5). 8. Remove nuts (8) and remove carburetor (5) from turbocharger adapter (7). 9. Remove carburetor (5). 10. Remove gasket (9) (not shown). i03401452

Carburetor - Disassemble SMCS Code: 1266-015

Disassembly Procedure Illustration 43

g01817934

2. Remove nuts (4) (not shown) from fuel control valve (2). 3. Loosen clamps (1). Position fuel control valve (2) away from carburetor (5). Temporarily tighten the nuts on clamps (1) to a torque of 47 N·m (35 lb ft). Note: Support the weight of the assembly of the fuel control valve and zero pressure regulator. 4. Remove gasket (3) (not shown). 5. Disconnect hose assembly (6) from carburetor (5).

Start By: a. Remove the carburetor. Refer to Disassembly and Assembly, “Carburetor - Remove” for the engine that is being serviced. Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.


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g01818715

Illustration 45

1. Remove grub screws (2) from carburetor (1). 2. Remove venturi (5) from the body of carburetor (1). Note: Make a temporary mark on the venturi so that the venturi can be reinstalled in the original orientation. Misalignment of the venturi will affect the mixture of the air and the mixture of the gas. Misalignment of the venturi will affect engine performance.

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

3. Remove O-ring seal (3) and O-ring seal (4) from the body of carburetor (1). i03401453

Carburetor - Assemble SMCS Code: 1266-016

Assembly Procedure Table 7

Required Tools Tooling

Part Number

A

21820221

Description POWERPART Rubber Grease

Qty 1

Illustration 46

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Illustration 47

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1. Use Tooling (A) to lubricate a new O-ring seal (3) and a new O-ring seal (4). 2. Install the new O-ring seal (3) and the new O-ring seal (4) to the body of carburetor (1) in Position (A). 3. Install venturi (5) from the body of carburetor (1). Note: Ensure that the venturi is installed in the correct orientation. Misalignment of the venturi will affect the mixture of the air and the mixture of the gas. Misalignment of the venturi will affect engine performance. 4. Install grub screws (2) from carburetor (1) and tighten securely. End By: a. Install the carburetor. Refer to Disassembly and Assembly, “Carburetor - Install” for the engine that is being serviced.

i03401451

Carburetor - Install SMCS Code: 1266-012

Installation Procedure 1. Ensure that all components of the carburetor are clean and free from damage. Ensure that the carburetor is free from restriction. Clean the gasket surface of the carburetor, fuel control valve and the turbocharger adapter.


KENR6945

6. Install nuts (4) (not shown) onto fuel control valve (2) and tighten the nuts finger tight. 7. Tighten the nuts (not shown) on fuel control valve (2) to a torque of 25 N·m (18 lb ft).

Illustration 48

g01817994

Illustration 50

g01829773

8. Tighten the nuts on clamps (1) to a torque of 47 N·m (35 lb ft). Ensure that the tube assembly is seated in Position (B). 9. Ensure that the assembly of fuel control valve (4) is installed in the correct orientation. 10. Connect hose assembly (6) to carburetor (5). Tighten hose assembly (6) securely. 11. Loosely install air cleaner adapter (11) to carburetor (5).

Illustration 49

g01817934

2. Position a new gasket (9) (not shown) onto carburetor (5). Install carburetor (5) onto turbocharger adapter (7). 3. Install nuts (8) to carburetor (5) and tighten the nuts hand tight. 4. Position a new gasket (3) (not shown) onto carburetor (5). 5. Loosen clamps (1) and position fuel control valve (2) onto carburetor (5). Note: Support the weight of the assembly of the fuel control valve and zero pressure regulator.

12. Install the air cleaners. Refer to Disassembly and Assembly, “Air Cleaner - Remove and Install”. 13. Tighten hose clamp (10) securely. 14. Turn the gas supply valve to the ON position.

KENR6945


i03401454

Air Cleaner - Remove and Install SMCS Code: 1051-010-HG


Illustration 52

g01825253

5. If necessary, remove air cleaner bracket (6) from the air charge cooler. Follow Step 5.a through Step 5.c in order to remove air cleaner bracket (5). a. Attach a suitable lifting device in order to remove air cleaner bracket (5). The weight of the air cleaner bracket is approximately 8 kg (17 lb). b. Remove bolts (5) from air cleaner bracket (6). c. Use the suitable lifting device to remove air cleaner bracket (6) from the air charge cooler. Illustration 51

g01825133

1. Loosen bolts (3) and loosen hose clamp (2) from air cleaner (1). 2. Attach a suitable lifting device in order to support the weight of air cleaner (1). The weight of the air cleaner is approximately 15 kg (33 lb). 3. Use the lifting device in order to remove air cleaner (1) from the mounting bracket. Note: Make a temporary mark on air cleaner (1) so that the air cleaner can be reinstalled in the original orientation. 4. Remove straps (4) from air cleaner (1).



KENR6945

3. Use the lifting device in order to position air cleaner (1) onto the mounting bracket. 4. Carefully push air cleaner (1) onto the hose and align the air cleaner with the mounting bracket. 5. Install straps (4) to air cleaner (1). 6. Install nuts and bolts (3). Tighten the nuts and bolts to a torque of 47 N·m (35 lb ft). Note: Ensure that air cleaner (1) is reinstalled in the original orientation. 7. Tighten hose clamp (2) securely. i03401456

Turbocharger - Remove Illustration 53

g01825253

1. If necessary, install air cleaner bracket (6) to the air charge cooler. Follow Step 1.a through Step 1.c in order to install air cleaner bracket (6). a. Attach a suitable lifting device in order to install air cleaner bracket (6). The weight of the air cleaner bracket is approximately 8 kg (17 lb). b. Use the suitable lifting device to position air cleaner bracket (6) onto the air charge cooler. c. Install bolts (5) to air cleaner bracket (6). Tighten the bolts to a torque of 41 N·m (30 lb ft).

SMCS Code: 1052-011

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 fluids according to local regulations and mandates. 1. Remove the exhaust elbow. Refer to Disassembly and Assembly, “Exhaust Elbow - Remove and Install”.

Illustration 54

g01825133

2. Use a suitable lifting device to support the weight of air cleaner (1). The weight of the air cleaner is approximately 15 kg (33 lb).

KENR6945


7. Remove gland (8) and remove O-ring seals (7). 8. Remove gland (9) and remove O-ring seals (10). Note: Mark the location and orientation of glands for assembly purposes.

Illustration 55

g01830999

Illustration 57

g01831053

Note: Mark the position of bracket for the tube assembly for the turbocharger oil line for installation purpose.

Illustration 58

g01831776

3. Remove bolts (3) and remove bracket (4) from elbow (5) and tube assembly (6).

9. Loosen hose clamps (17) for turbocharger (13) and the adapter for the carburetor.

4. Remove the nuts and bolts (11) from tube assembly (6).

10. Remove allen head bolts (15) and disconnect tube assembly (14) from turbocharger (13). Remove gasket (16).

Illustration 56

g01831468

2. Remove bolts (2) from bracket (1).

5. Remove gasket (12) (not shown). 6. Remove elbow (5) and tube assembly (6) from the turbocharger and air charge cooler.

Note: Plug all open ports in order to prevent the entry of dirt.


KENR6945

11. Remove allen head bolts (22) and disconnect tube assembly (21) from turbocharger (13). Remove gasket (20). Note: Plug all open ports in order to prevent the entry of dirt. 12. Use a suitable lifting device to support the weight of turbocharger (13). The weight of the turbocharger is approximately 35 kg (77 lb). 13. On six cylinder engines, remove nuts (19) and remove turbocharger (13). On eight cylinder engines, remove the nuts and bolts (19) and remove turbocharger (13). 14. Remove gasket (18) (not shown). 15. If necessary, remove the studs that are on six cylinder engines from the turbocharger adapter.

i03401457

Turbocharger - Install

Illustration 59

g01832637

2. Loosen V-band clamp (23) and V-band clamp (24). Ensure that the housings are free to rotate on the body of turbocharger (13). If necessary, remove the V-band clamps and clean the mating surfaces of the turbocharger. Lubricate the mating surfaces with Tooling (B) and install the V-band clamps. 3. If necessary, install new studs that are on six cylinder engines for the turbocharger adapter. Tighten the studs securely.

SMCS Code: 1052-012


Required Tools Tool

Part Number

A

21820221

B

CV60889

Part Description

Qty

POWERPART Rubber Grease

1

POWERPART Anti-Sieze Compound

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” for more information. Ensure that all pipes are clean and free from restrictions.

Illustration 60

g01831776

KENR6945


12. Install a new gasket (16) onto tube assembly (14) and connect tube assembly onto turbocharger (13). Install allen head bolts (15). Tighten allen head bolts (15) to a torque of 47 N·m (35 lb ft). Note: A new filter gasket must be installed to oil supply line for the turbocharger. This gasket must be installed at a major overhaul of the engine. The filtered gasket must be removed after the engine has been operated for one hour. The filter gasket must be replaced with a new standard gasket.

Illustration 61

g01831053

4. On six cylinder engines, position a new gasket (19) (not shown) onto studs for the turbocharger adapter.

Illustration 62

g01832637

Illustration 63

g01426578

5. Use a suitable lifting device to support the weight of turbocharger (13). The weight of the turbocharger is approximately 35 kg (77 lb). 6. Install turbocharger (13) onto the turbocharger adapter. On six cylinder engines, install nuts (19) and tighten nuts (19) to a torque of 58 N·m (43 lb ft). 7. On eight cylinder engines, install turbocharger (13) onto the turbocharger adapter. 8. Position a new gasket (19) (not shown) between the turbocharger adapter and the turbocharger. Install the nuts and bolts (19) and tighten the nuts and bolts (19) to a torque of 58 N·m (43 lb ft). 9. Tighten hose clamps (17) for turbocharger (13) and the adapter for the carburetor. Tighten the hose clamps to a torque of 9 N·m (80 lb in). 10. Install a new gasket (20) onto tube assembly (21) and connect tube assembly onto turbocharger (13). Install allen head bolts (22). Tighten allen head bolts (22) to a torque of 47 N·m (35 lb ft). Note: Remove the plug from ports and remove the plug from tube assembly. 11. Remove the plug from the oil inlet port. Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.

Seating the v-band clamps on the turbocharger

13. Tighten V-band clamps (23) and V-band clamps (24) on turbocharger (13) to a torque of 9 N·m (80 lb in). Lightly tap the V-band clamps with a soft faced hammer in order to seat the V-band clamps. Again, tighten the V-band clamps to a torque of 9 N·m (80 lb in). Repeat this Step until the V-band clamps are secure.


KENR6945

18. Position a new gasket (12) (not shown) between air charge cooler and tube assembly (6). 19. Install the nuts and bolts (11) to tube assembly (6). Tighten the nuts and bolts hand tight. 20. Install bolts (2) onto bracket (1). Tighten bolts hand tight. Note: The bracket for the tube assembly for the turbocharger oil line must be correctly installed. 21. Position bracket (4) onto elbow (5) and tube assembly (6). Install bolts (3) and tighten bolts hand tight. 22. Tighten the nuts and bolts (11) to a torque of 47 N·m (35 lb ft). 23. Tighten bolts (2) and bolts (3) to a torque of 41 N·m (30 lb ft). Illustration 64

g01831468

24. Install the exhaust elbow. Refer to Disassembly and Assembly, “Exhaust Elbow - Remove and Install”. 25. Prime the engine oil system. Refer to Operation and Maintenance Manual, “Before Starting the Engine” for the correct procedure. i03401458

Exhaust Manifold - Remove and Install SMCS Code: 1059-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Illustration 65

g01830999

14. Install new O-ring seals (7) to gland (8). Lubricate the O-ring seals with Tooling (A). 15. Install new O-ring seals (10) to gland (9). Lubricate the O-ring seals with Tooling (A). 16. Install gland (8) to elbow (5). Install gland (9) to tube assembly (6). Assemble elbow (5) onto tube assembly (6). Note: Install the gland so that the machined end of the bore is located in the turbocharger. 17. Install elbow (5) and tube assembly (6) to the turbocharger and air charge cooler.

Contaminants may cause rapid wear and shortened component life. NOTICE The exhaust manifolds should be removed as individual sections. If the exhaust manfold is removed as a complete assembly, damage to the bellows may occur. Note: It is possible to remove individual sections of an exhaust manifold without removing the complete manifold.

KENR6945


Manifold Front and Center Sections

6. Remove nuts and bolts (13) and remove blanking plate (12). 7. Remove gasket (14) (not shown) and bracket (15) from exhaust manifold (9). Note: Mark the location and orientation of the brackets for installation. 8. Remove nuts and bolts (16) from exhaust manifold (9). 9. Remove the bolts and spacers (10) from exhaust manifold (9) and remove the exhaust manifold from the cylinder heads. 10. Remove gaskets (11) (not shown) and gasket (17) (not shown).

Illustration 66

g01836237

1. Loosen hose clamp (3) (not shown) and remove plastic hose assembly (4) from tube assembly (8). 2. Loosen hose clamp (6). Remove the nut and bolt (7) (not shown). 3. Remove nuts from clamp (2) and remove tube assembly (8) from the crankcase breather. 4. Remove nuts (5) and remove heat shield (1) from the exhaust manifold.

Illustration 68

g01836455

11. Remove nuts and bolts (19). Remove exhaust bellow (18) from the exhaust manifold. Remove bracket (21) from the exhaust manifold. Note: Mark the location and orientation of the brackets for installation. 12. Remove gasket (20) (not shown). 13. Repeat Step 5 through Step 13 in order to remove the remaining front sections of the exhaust manifold or the remaining center sections of the exhaust manifold.

Illustration 67

g01836333

5. If necessary, remove the exhaust temperature thermocouple. Refer to Disassembly and Assembly, “Engine Sensors - (Exhaust Temperature Thermocouple) Remove and Install”.

Manifold Rear Sections 1. Remove the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Remove”.


KENR6945

2. If necessary, remove the exhaust temperature thermocouple. Refer to Disassembly and Assembly, “Engine Sensors - (Exhaust Temperature Thermocouple) Remove and Install”.

Note: If installation of a complete manifold is necessary, begin the installation procedure at the rear of the engine and work toward the front.

Manifold Rear Sections 1. Ensure that the gasket surfaces of the exhaust manifolds and the cylinder heads are clean and free from damage. Ensure that the bellows are clean and free from damage.

g01836614

Illustration 69

3. Remove nuts and bolts (23) and remove exhaust bellow (22) from exhaust manifold (26). Remove gasket (28) (not shown). 4. Remove bolts (29) and remove bracket (30). Remove adapter (27). Remove gasket (31) (not shown). Note: Mark the location and orientation of the brackets for installation. 5. Remove bolts and spacers (24) from exhaust manifold (26) and remove the exhaust manifold from the cylinder heads. 6. Remove gaskets (25) (not shown).

Required Tools

A

CV60889

Part Description POWERPART Anti-Sieze Compound

2. Position new gaskets (25) (not shown) onto cylinder head. 3. Position exhaust manifolds (26) on the cylinder head. Install the spacers and bolts (24) hand tight. 4. Position a new gasket (31) (not shown) onto exhaust manifolds (26). Position adapter (27) and bracket (30) onto the exhaust manifold.

5. Apply Tooling (A) to the threads of bolts (29) and install bolts (29) hand tight.

Table 9

Part Number

g01836614

Note: Ensure the correct location and orientation of the brackets on installation.

Installation Procedure

Tool

Illustration 70

Qty 1


6. Position gasket (28) (not shown) onto exhaust bellow (22).

KENR6945

Illustration 71


g01837054

Illustration 72

g01836455

Illustration 73

g01837054

7. Install the exhaust bellow to exhaust manifold (26). Note: Ensure that Arrow (X) is toward the turbocharger. 8. Apply Tooling (A) to the threads of nuts and bolts (23). Install nuts and bolts (23) hand tight. Note: New nuts must be installed to the bolts. 9. Tighten bolts (24) to a torque of 70 N·m (50 lb ft). 10. Tighten bolts (29) to a torque of 58 N·m (43 lb ft). 11. Tighten nuts and bolts (23) to a torque of 58 N·m (43 lb ft). 12. Install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install”. 13. If necessary, install the exhaust temperature thermocouple. Refer to Disassembly and Assembly, “Engine Sensors - (Exhaust Temperature Thermocouple) Remove and Install”.

Manifold Front and Center Sections 1. Ensure that the gasket surfaces of the exhaust manifolds and the cylinder heads are clean and free from damage. Ensure that the bellows are clean and free from damage.

2. Position a new gasket (20) (not shown) onto exhaust bellow (18). 3. Position exhaust bellow (18) onto the exhaust manifold. Note: Ensure that Arrow (X) is toward the turbocharger. 4. Install bracket (21) onto the exhaust manifold. Note: Ensure the correct location and orientation of the brackets on installation. 5. Apply Tooling (A) to the threads of nuts and bolts (19). Install the nuts and bolts hand tight.


KENR6945

Note: New nuts must be installed to the bolts. 6. Tighten nuts and bolts (19) to a torque of 58 N·m (43 lb ft).

16. Tighten nuts and bolts (13) to a torque of 70 N·m (50 lb ft). 17. Repeat Step 1 through Step 17 in order to install the remaining center sections of the exhaust manifold or the remaining front sections of the exhaust manifold. 18. If necessary, install the exhaust temperature thermocouple. Refer to Disassembly and Assembly, “Engine Sensors - (Exhaust Temperature Thermocouple) Remove and Install”.

Illustration 74

g01836333

7. Position new gaskets (11) (not shown) onto the cylinder heads. 8. Position exhaust manifold (9) onto the cylinder heads. Install the spacers and bolts (10) to exhaust manifold (9) hand tight. Illustration 75

9. Install a new gasket (17) (not shown) between exhaust manifold (9) and the exhaust bellow. 10. Apply Tooling (A) to the threads of nuts and bolts (19). Install nuts and bolts (16) hand tight. Note: New nuts must be installed to the bolts. 11. Tighten bolts (10) to a torque of 70 N·m (50 lb ft). 12. Tighten nuts and bolts (16) to a torque of 58 N·m (43 lb ft). 13. Position a new gasket (18) (not shown) onto blanking plate (12). 14. Install blanking plate (12) to exhaust manifold (9) and position bracket (15) onto the exhaust manifold. Note: Ensure the correct location and orientation of the brackets on installation. 15. Apply Tooling (A) to the threads of nuts and bolts (13). Install nuts and bolts (13) hand tight. Note: New nuts must be installed to the bolts.

g01836237

19. Position heat shield (1) onto the exhaust manifold. Install nuts (5) and tighten the nuts to a torque of 44 N·m (32 lb ft). 20. Install tube assembly (8) to the crankcase breather. Install the nut and bolt (7) (not shown). Install nuts to clamp (2). 21. Tighten the nut and bolt (7) (not shown) securely . Tighten nuts on clamp (2) securely. Tighten hose clamp (6) securely. 22. Install plastic hose assembly (4) to tube assembly (8) and tighten hose clamp (3) (not shown) securely.

KENR6945


i03401459

Exhaust Elbow - Remove and Install


SMCS Code: 1061-010-E4

Removal Procedure 1. Ensure that the exhaust elbow is clean and free from damage.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Disconnect the exhaust system from the exhaust elbow. Note: Ensure that the exhaust system is adequately supported.

Illustration 76

Illustration 77

g01824713

Illustration 78

g01428427

g01824713

2. Make a temporary mark on exhaust elbow (1) and turbocharger (3) so that the exhaust elbow can be reinstalled in the original orientation. 3. Use a suitable lifting device to support the weight of exhaust elbow (1). The weight of the exhaust elbow is approximately 15 kg (33 lb). 4. Loosen band clamp (2) and use the suitable lifting device in order to remove exhaust elbow (1) from turbocharger (3).

Seating the V-band clamp on the turbocharger

2. Use a suitable lifting device to lift exhaust elbow (1) into the position onto turbocharger (3). The weight of the exhaust elbow is approximately 15 kg (33 lb). 3. Position V-band clamps (2) onto exhaust elbow (1) and turbocharger (3).


KENR6945

4. Tighten V-band clamps (2) to a torque of 9 N·m (80 lb in). Lightly tap the V-band clamps with a soft faced hammer in order to seat the V-band clamps. Again, tighten the V-band clamp to a torque of 9 N·m (80 lb in). Note: Ensure the correct orientation of the exhaust elbow. 5. Connect the exhaust systems to the exhaust elbows. i03401460

Inlet Manifold - Remove SMCS Code: 1058-011

Removal Procedure NOTICE Keep all parts clean from contaminants.

Illustration 80

Contaminants may cause rapid wear and shortened component life.

1. Remove nuts and bolts (2) and remove blanking plate (3) from inlet manifold (1). Remove gasket (7) (not shown).

Note: It is possible to remove individual sections of an inlet manifold without removing the complete manifold. If removal of a complete manifold is necessary, use a suitable lifting device.

Front Inlet Manifolds

g01834597

2. Remove nuts and bolts (5) from the bracket and inlet manifold (1) and center sections of inlet manifold (4). 3. Support inlet manifold (1). Remove bolts (8) from inlet manifold (1). 4. Remove assembly of inlet manifold from the cylinder heads. Remove gaskets (9) and gasket (6). 5. For eight cylinder engines, remove the nuts and bolts from the assembly of the inlet manifold. Remove the inlet manifold and the gasket.

Illustration 79

g01834596

KENR6945


Inlet Manifold Center Section

4. Support inlet manifold (4) and remove bolts (14). Remove inlet manifold (4) from cylinder heads. 5. Remove gasket (12) (not shown) and gaskets (14) (not shown).

Inlet Manifold Rear Section 1. To remove the rear section of the inlet manifold to the engine, refer to Disassembly and Assembly, “Aftercooler - Remove ” for the correct procedure. i03401461

Inlet Manifold - Install SMCS Code: 1058-012

Installation Procedure Illustration 81

g01834896

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: If the inlet manifold is installed as a complete assembly, use a suitable lifting device to lift the inlet manifold. The inlet manifold should only be installed as a complete assembly if the inlet manifold has not been disassembled.

Inlet Manifold Rear Section 1. Ensure that the gasket surfaces of the inlet manifold and the cylinder heads are clean and free from damage. 2. To install the rear section of the inlet manifold to the engine, refer to Disassembly and Assembly, “Aftercooler - Install ” for the correct procedure. Illustration 82

g01834953

1. Remove the tube assembly and the harness assembly from the fuel control actuator (throttle governor). Refer to Disassembly and Assembly, “Fuel Control Actuator (Throttle Governor) Remove and Install” for the correct procedure. 2. Remove nuts and bolts (10) from the bracket for the electronic control unit on inlet manifold (4). Remove electronic control unit (11) from the inlet manifold and position the electronic control unit away from the inlet manifold. 3. Remove the nuts and bolts (13) from inlet manifold (4).

Inlet Manifold Center Section 1. Ensure that the gasket surfaces of the inlet manifolds and the cylinder heads are clean and free from damage.


KENR6945

7. Install the tube assembly and the harness assembly to the fuel control actuator (throttle governor). Refer to Disassembly and Assembly, “Fuel Control Actuator (Throttle Governor) Remove and Install” for the correct procedure. 8. Position electronic control unit (11) onto the inlet manifold. Install nuts and bolts (10) to the bracket for the electronic control unit and inlet manifold (4) hand tight. 9. Tighten nuts and bolts (10) to a torque of 47 N·m (35 lb ft).

Front Inlet Manifolds

Illustration 83

Illustration 84

g01834953

Illustration 85

g01834597

Illustration 86

g01834596

g01834896

2. Position new gaskets (15) (not shown) on the cylinder heads. 3. Position inlet manifold (4) onto the cylinder heads. Install bolts (14) to inlet manifold (4) hand tight. 4. Position new gaskets (12) (not shown) between inlet manifolds. 5. Install the nuts and bolts (13) to inlet manifold (4) hand tight. 6. Tighten bolts (14) to a torque of 47 N·m (35 lb ft). Tighten nuts and bolts (13) to a torque of 47 N·m (35 lb ft).

KENR6945


1. For eight cylinder engines, assemble the inlet manifolds together. Install a new gasket between the inlet manifolds. Install the nuts and bolts to the inlet manifolds and tighten finger tight. 2. Position new gaskets (9) onto cylinder head. Position assembly of the inlet manifold onto the cylinder heads.

2. Place a temporary identification 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.

3. Install bolts (8) to inlet manifold (1) hand tight. 4. Position a new gasket (6) between the inlet manifolds. Install nuts and bolts (5) to the bracket and inlet manifold (1) and center sections of inlet manifold (4) hand tight. 5. Tighten bolts (8) to a torque of 47 N·m (35 lb ft). 6. Tighten nuts and bolts (5) to a torque of 47 N·m (35 lb ft). 7. Position a new gasket (7) (not shown) onto blanking plate (3). Install blanking plate (3) to inlet manifold (1) and install nuts and bolts (2). Tighten nuts and bolts (3) to a torque of 47 N·m (35 lb ft).

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.

i03401462

Inlet and Exhaust Valves Remove and Install SMCS Code: 1105-010


Required Tools Part Number

Tool A

Illustration 87

Part Description

T6253/243 Valve Spring Compressor

Qty 1

Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Remove”. 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 Specifications, “Cylinder Head Valves” for the correct dimensions.

g01865782


KENR6945

1. Clean all components of the cylinder head assembly. Ensure that all ports, and all passages in the cylinder head are free from debris. Follow Step 1.a through Step 1.e in order to inspect the components of the cylinder head assembly. a. Inspect the cylinder head for wear and for damage. Refer to Systems Operation, Testing and Adjusting, “Cylinder Head Inspect”. b. Inspect the valve seats for wear and for damage. Refer to Specifications, “Cylinder Head Valves” for further information. c. Inspect the valve guides for wear and for damage. Refer to Specifications, “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”. 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. g01865783

Illustration 88

e. Inspect the valve springs for the correct length. Refer to Specifications, “Cylinder Head Valves”.

3. Use Tooling (A) in order to compress the appropriate valve spring (3). Remove valve collets (1). 4. Remove Tooling (A). 5. Remove cap (2). Remove valve spring (3). 6. Remove valve (5). Remove valve stem seals (4). Note: Valve stem seals are only installed on the inlet valves. 7. Repeat Step 3 through Step 6 in order to remove the remaining valves.


Required Tools Tool A

Part Number

Part Description

T6253/243 Valve Spring Compressor

Qty 1


Illustration 89

g01865783

2. Install the new valve stem seals (4). Lubricate the stem of valve (5) with clean engine oil. Install the valve in the appropriate position in the cylinder head.

KENR6945


Note: Valve stem seals are only installed on the inlet valves. 3. Install valve spring (3) to the cylinder head. Position cap (2) on the valve spring.

End By: a. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. i03401464

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

Engine Oil Line - Remove and Install (Engine Oil Rail)

Make sure to wear all necessary protective equipment.

SMCS Code: 1307-010

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

Removal Procedure

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

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 fluids according to local regulations and mandates.

Illustration 90

g01453609

4. Use Tooling (A) in order to compress valve spring (3). Install valve collets (1).

NOTICE Comply with the local official gas regulations regarding isolating the gas supply. 1. Turn gas supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position.

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. 5. Remove Tooling (A). 6. Repeat Step 2 through Step 5 in order to install the remaining valves. 7. Place the cylinder head on a suitable support. Ensure that the heads of the valves are not obstructed. Gently tap the top of the valves with a soft hammer in order to ensure that the valve collets are properly installed.

3. Disconnect the ignition wiring harness. Refer to Disassembly and Assembly , “Ignition Wiring Harness” for more information.


Illustration 91

KENR6945

g01837915

4. Remove the bolt from clip (2) (not shown). Disconnect the tube assembly (1) from the valve mechanism cover base and the connection on the engine oil rail. 5. Remove bolts from clamps for tube assembly (3). 6. Disconnect tube assembly (3) from the engine oil rail. Disconnect tube assembly (4) from the engine oil rail and cylinder head.

g01842773

Illustration 93

8. If necessary, follow Step 8.a through Step 8.b in order to remove brackets (8) and connection (7) from the engine oil rail. a. Remove the nuts and bolts (9) and remove brackets (8) from the engine oil rail. Note: Mark the bracket before removal in order to ensure correct orientation. b. Remove connection (7) from the engine oil rail.


Required Tools Tool

Part Number

A

21820121

Part Description POWERPART Hydraulic Threadseal

Qty 1


Illustration 92

g01842555

Items have been removed for clarity.

7. Remove bolts (5) and remove engine oil rail (6) from cylinder head.

KENR6945

Illustration 94


g01842773

1. If necessary, follow Step 8.a through Step 8.b in order to install brackets (8) and connection (7) to the engine oil rail. a. Position brackets (8) onto the engine oil rail and install the nuts and bolts (9). Tighten the nuts and bolts hand tight. b. Apply Tooling (A) to the threads of connection (7) and install connection (7) to the engine oil rail. Tighten the connection securely.

Illustration 96

g01837915

3. Connect tube assembly (4) to the cylinder head and to the connection on the engine oil rail. 4. Connect tube assembly (1) to the valve mechanism cover base and to the connection on the engine oil rail. Position clip (2) (not shown) and loosely install the bolt. 5. Connect tube assembly (3) to the connection on the engine oil rail. 6. Tighten tube assembly (1), tube assembly (2) and tube assembly (3) securely. 7. Tighten the bolt for clip (2) to a torque of 41 N·m (30 lb ft). 8. Tighten bolts (5) for the bracket to a torque of 47 N·m (35 lb ft). 9. Tighten bolts for the bracket to the engine oil rail to a torque of 25 N·m (18 lb ft). 10. Connect the ignition wiring harness. Refer to Disassembly and Assembly , “Ignition Wiring Harness” for more information. 11. Turn the battery disconnect switch to the ON position. 12. Turn gas supply to the ON position.

Illustration 95

g01842555

2. Position engine oil rail (6) onto cylinder head. Install bolts (5). Tighten bolts hand tight.


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i03401465

Engine Oil Filter Base Remove SMCS Code: 1306-011


Required Tools Tool

Part Number

A

-

Part Description Strap Wrench

Qty 1


Illustration 98

g01808194

2. Use Tooling (A) to remove engine oil filters (1) from engine oil filter base (2). Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change” for the correct procedure. 3. Remove bolts from tube clips (3) and clip (5). Remove tube clips (3) and clip (5) from tube assembly (3). 4. Disconnect tube assembly (4) from engine oil filter base (2).

1. If the engine oil filter base is equipped with an oil pressure switch, disconnect the harness assembly from the oil pressure switch.

Illustration 97

g01808193

Illustration 99

g01808338

5. Remove bolts (7) from tube assembly (6). 6. Remove O-ring seal (8) (not shown) from tube assembly (6).

KENR6945


Illustration 101

g01808533

2. Install Tooling (B) to the engine cylinder block.

g01808454

Illustration 100

7. Remove bolts (9) from engine oil filter base (2). Remove engine oil filter base (2) from the engine cylinder block. 8. Remove gasket (10) (not shown). 9. If the engine oil filter base is equipped with an oil pressure switch (11) remove oil pressure switch (11) from engine oil filter base (2). i03401466

Engine Oil Filter Base - Install SMCS Code: 1306-012


Illustration 102

g01808454

Illustration 103

g01808338

Table 14

Required Tools Tool

Part Number

B

-

Part Description Guide Stud M10 by 75 mm

Qty 2

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components of the engine oil filter base are clean and free from damage. Ensure that all oil passages are free from restriction. Clean the gasket surface of the cylinder block.


KENR6945

3. If the engine oil filter base is equipped with an oil pressure switch (11) install oil pressure switch (11) to engine oil filter base (2). Tighten oil pressure switch (11) securely. 4. Install new O-ring seal (8) (not shown) to tube assembly (6). 5. Install a new gasket (10) (not shown). Note: Ensure the correct orientation of the gasket. 6. Install engine oil filter base (2) onto the engine cylinder block and install bolts (9) hand tight. Remove Tooling (B) and install the remaining bolts. 7. Install bolts (10) to tube assembly (8) hand tight.

Illustration 105

g01808194

10. Connect tube assembly (4) to engine oil filter base (2). Tighten tube assembly securely. 11. Install bolts to tube clip (5) and clips (3) to tube assembly (3). Tighten bolts for the tube clips securely.

Illustration 104

g01808674

The bolt tightening sequence for the engine oil filter base

8. Tighten bolts (7) for tube assembly (8) to a torque of 47 N·m (35 lb ft). Tighten the bolts in the sequence that is shown in Illustration 104. 9. Tighten bolts (9) for engine oil filter base (2) to a torque of 47 N·m (35 lb ft). Tighten the bolts in the sequence that is shown in Illustration 104.

Illustration 106

g01808193

12. Install new engine oil filters (1) to engine oil filter base (2). Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change” for the correct procedure. 13. If the engine oil cooler is equipped with an oil pressure switch, connect the harness assembly to the oil pressure switch.

KENR6945


i03401469

Engine Oil Cooler - Remove SMCS Code: 1378-011

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.

Illustration 108

g01810005

Illustration 109

g01810434

Dispose of all fluids according to local regulations and mandates.

Illustration 107

g01479573

Typical example

1. Drain the coolant from the cooling system into a suitable container. Refer to Operation and Maintenance Manual, “Cooling System Coolant Change” for the correct procedure. Open tap (2) and drain the coolant from engine oil cooler (1).

2. Remove bolts (4) and bolts (6). Remove tube assembly (5) from engine oil cooler (1). Remove O-ring seal (3) (not shown) and O-ring seal (7) (not shown). 3. Remove bolts (9) and bolts (11). Remove tube assembly (10) and remove O-ring seal (12) (not shown) and gasket (8) (not shown). 4. Remove valve (13) and gasket (14) (not shown).


Illustration 110

KENR6945

g01810098

Illustration 112

g01810006

8. Use a suitable lifting device to support the weight of engine oil cooler (1). The weight of the engine oil cooler is approximately 45 kg (100 lb). 9. Remove bolts (25) and bolts (26) from engine oil cooler (1). Note: For six cylinder engines, position the bracket for tube assembly for oil feed away from the engine oil cooler. 10. Carefully pry engine oil cooler (1) from the dowels on the cylinder block. Use the suitable lifting device to remove engine oil cooler (1) from the cylinder block.

Illustration 111

g01811594

5. Loosen hose clamps (19). Remove bolts (16). Remove tube assembly(18) from engine oil cooler (1). Remove gasket (17) (not shown). 6. Remove hose assembly (15) from engine oil cooler (1). 7. Remove nuts and bolts (21). Remove bolts (23). Remove elbow (22) from the engine oil cooler. Remove gasket (20) (not shown) and gasket (24) (not shown).

Illustration 113

g01810233

11. If necessary, remove connection (28) from engine oil cooler (1). Follow Step 11.a through Step 11.c in order to remove the connection. a. Remove bolts (27). b. Remove connection (28) from engine oil cooler (1).

KENR6945


c. Remove O-ring seal (29) (not shown). 12. Drain the oil from the engine oil cooler into a suitable container.

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 fluids according to local regulations and mandates.

Illustration 114

g01810355

13. Remove bolts (30). Remove bracket (32) from engine oil cooler (1). Do not remove dowel pins (34). Note: Mark the position of the bracket for installation purpose.

Illustration 115

g01811721

14. Remove bolts (31). Remove bracket (33) from engine oil cooler (1). Do not remove dowel pins (34).

1. Remove bolts (1) and bolts (5). Remove cover (2) and cover (6) from the engine oil cooler.

Note: Mark the position of the bracket for installation purpose.

Note: If necessary, tap the covers with a soft faced hammer in order to loosen the covers.

i03401471

2. Remove O-ring seal (3). Remove gasket (4) (not shown).

Engine Oil Cooler Disassemble SMCS Code: 1378-015

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

Illustration 116

g01811722

3. Carefully tap the rear face of tubestack (8) with a soft faced hammer in order to drive the tubestack from the housing of the engine oil cooler. Note: Use a block of wood in order to protect the tubestack. 4. Remove gasket (7).


KENR6945

i03401472

Engine Oil Cooler - Assemble

4. Install bolts (5). Tighten the bolts to a torque of 40 N·m (30 lb ft).

SMCS Code: 1378-016

5. Place a new O-ring seal (3) in position and install cover (2).

Assembly Procedure

6. Install bolts (1). Tighten the bolts to a torque of 40 N·m (30 lb ft).

NOTICE Keep all parts clean from contaminants.

7. Pressure test the engine oil cooler for leaks. Refer to Systems Operation, Testing and Adjusting, “General Information - Cooling System” for the correct procedure.


End By: 1. Ensure that all parts of the engine oil cooler are clean and free from damage. Note: If the tubestack is still contaminated with limescale or with sludge after cleaning, then the tubestack must be replaced. Do not use a contaminated tubestack. The use of a contaminated tubestack could lead to engine failure.

a. Install the engine oil cooler. Refer to Disassembly and Assembly, “Engine Oil Cooler - Install”. i03401470

Engine Oil Cooler - Install SMCS Code: 1378-012


Required Tools Tool

Part Number

A

-


Qty 2

NOTICE Keep all parts clean from contaminants. Illustration 117

g01811722

Contaminants may cause rapid wear and shortened component life. 1. Ensure that the engine oil cooler and the pipes are clean and free from damage or restrictions.

Illustration 118

g01811721

2. Place a new gasket (7) in position and push tubestack (8) into the housing of the engine oil cooler. 3. Place a new joint (4) (not shown) in position and install cover (6).

Illustration 119

g01810355

KENR6945


2. Install bracket (32) to engine oil cooler (1). Bracket (32) should be correctly positioned onto dowel pins (34). Install bolts (30). Tighten the bolts to a torque of 47 N·m (35 lb ft). 3. Install bracket (33) to engine oil cooler (1). Bracket (33) should be correctly positioned onto dowel pins (34). Install bolts (31). Tighten the bolts to a torque of 47 N·m (35 lb ft).

Illustration 122

Illustration 120

g01810233

4. If necessary, Install connection (28) to engine oil cooler (1). Follow Step 4.a through Step 4.c in order to install the connection. a. Install a new O-ring seal (29) (not shown) to connection (28). b. Install connection (28) to engine oil cooler (1). c. Install bolts (27) and tighten the bolts to a torque of 47 N·m (35 lb ft).

g01810006

5. Install Tooling (A) to the cylinder block. 6. Attach a suitable lifting device to engine oil cooler (1). The weight of the engine oil cooler is approximately 45 kg (100 lb). 7. Use a suitable lifting device to position engine oil cooler (1) onto Tooling (A). Align the engine oil cooler with the dowel pins in the cylinder block and install the engine oil cooler to the cylinder block. 8. Install bolts (25) and bolts (26) to engine oil cooler (1). Note: For six cylinder engines, position the bracket for tube assembly for oil feed onto the bracket from the engine oil cooler. 9. Remove Tooling (A) from the cylinder block. Install remaining bolts (25) and bolts (26) to engine oil cooler (1). 10. Tighten bolts (25) and bolts (26) to a torque of 47 N·m (35 lb ft).

Illustration 121

g01810839

Illustration 123

g01810842


KENR6945

17. Install tube assembly (5) to engine oil cooler (1). Install bolts (4) and bolts (6) finger tight. 18. Tighten bolts (9) to a torque of 47 N·m (35 lb ft). 19. Tighten bolts (6) to a torque of 47 N·m (35 lb ft). 20. Tighten bolts (4) to a torque of 47 N·m (35 lb ft).

Illustration 124

g01810434

11. Install Tooling (A) to the cylinder block. 12. Install a new gasket (14) (not shown) and install valve (13).

Illustration 125

Illustration 126

g01811594

Illustration 127

g01810098

g01810005

13. Install a new gasket (8) (not shown) to valve (13). 14. Install a new O-ring seal (12) (not shown) to tube assembly (10). Install tube assembly (10) to Tooling (A). 15. Install bolts (11) finger tight. Remove Tooling (A) and install bolts (9) finger tight. 16. Install a new O-ring seal (3) (not shown) and a new O-ring seal (7) (not shown) to tube assembly (5).

21. Position gasket (24) (not shown) on the engine oil cooler. Position gasket (20) (not shown) on elbow (22). 22. Position elbow (22) on the engine oil cooler and install nuts and bolts (21) hand tight. Install bolts (23) hand tight. Tighten nuts and bolts (16) to a torque of 47 N·m (35 lb ft).

KENR6945


Tighten bolts (23) to a torque of 47 N·m (35 lb ft). 23. Position a new gasket (17) (not shown) onto tube assembly (18). Install tube assembly (18) to engine oil cooler (1) and onto the elbow on the water pump. Install bolts (16) hand tight. Tighten hose clamps (18) securely. Tighten bolts (16) to a torque of 47 N·m (35 lb ft). 24. Install hose assembly (15) to engine oil cooler (1) and tighten securely. 25. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. 26. Ensure that the engine oil pan is filled to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil Level - Check” for the correct procedure. g01811853

Illustration 128 i03401474

Engine Oil Relief Valve Remove and Install (Engine Oil Pressure Regulator) SMCS Code: 1315-010


Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 1. Carefully loosen bolts (6). Remove the bolts and remove plate (5). Note: The spring force will be released suddenly when the bolts are removed. 2. Remove spring seat (2) and spring (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.

3. Remove plunger (1). 4. Remove gasket (3).



Required Tools Tool A

Part Number

Part Description

Qty

-

Bolts M8 by 50 mm

2

-

Nuts M8

2


KENR6945

Note: The plunger must slide freely in the bore. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components of the engine oil pressure regulator are clean and free from damage.

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.

3. Place spring seat (2), gasket (3) and plate (6) into position. Use Tooling (A) in order to temporarily hold the plate in place. Refer to Illustration 130. Using of temporary nuts and bolts to install the plate to the engine oil pressure regulator 4. Tighten the nuts on Tooling (A) evenly in order to compress spring (4). 5. Remove one nut and bolt from Tooling (A). Install bolt (6) hand tight. Remove the remaining nut and bolt from Tooling (A). Install the remaining bolt (6). 6. Tighten bolts (6) to a torque of 25 N·m (18 lb ft). 7. Run the engine in order to carry out final adjustment of the engine oil pressure regulator. Refer to Systems Operation, Testing and Adjusting, “General Information - Lubrication System” for the correct procedure. i03401473

Engine Oil Relief Valve Remove and Install (Engine Oil Cooler) SMCS Code: 1315-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 129

g01811853


Illustration 130

g01811854

2. Lubricate plunger (1) with clean engine oil. Install the plunger and spring (4) into the bore for the relief valve in the engine oil pump.

KENR6945

Illustration 131


g01821493

Illustration 133

g01821553

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 4. If necessary, follow Step 4.a through Step 4.d in order to remove the components from the assembly of valve (13). a. Remove plug (15) from the assembly of valve (13).

Illustration 132

g01821494

Note: The spring force will be released when the plug is removed.

1. Remove bolts (4) and bolts (6). Remove tube assembly (5) from engine oil cooler (1). Remove O-ring seal (3) (not shown) and O-ring seal (7) (not shown).

b. Remove sealing washer (16) from plug (15).

2. Remove bolts (9) and bolts (11). Remove tube assembly (10) and remove O-ring seal (12) (not shown) and gasket (8) (not shown).

d. Remove plunger (18) from the assembly of valve (13).

3. Remove valve (13) and gasket (14) (not shown).

c. Remove spring (17) from the assembly of valve (13).


KENR6945


Note: The plunger must slide freely in the bore for the relief valve.

Table 17

b. Install spring (17) to the assembly of valve (13).

Required Tools Tool

Part Number

A

21820117

B

-

Part Description

Qty

POWERPART Threadlock and Nutlock

1

Guide Stud M10 by 75 mm

2

Note: Ensure that the spring is properly located inside the plunger and the cap. c. Install a new sealing washer (16) to plug (15). Apply Tooling (A) to the threads of the plug. d. Install plug (15) to the assembly of valve (13). Tighten plug (15) to a torque of 25 N·m (18 lb ft).

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all the components of the oil relief valve is clean and free from damage.

Illustration 134

Illustration 135

g01929414

Illustration 136

g01821494

g01821553

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 2. If necessary, follow Step 2.a through Step 2.d in order to install the components to the assembly of valve (13). a. Install plunger (18) to the assembly of valve (13).

3. Install Tooling (B) to the cylinder block. 4. Install a new gasket (14) (not shown) and install valve (13) onto Tooling (B).

KENR6945


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 fluids according to local regulations and mandates. NOTICE Comply with the local official gas regulations regarding isolating the gas supply. 1. Turn the gas supply valve to the “OFF” position.

Illustration 137

g01821493

5. Install a new O-ring seal (12) (not shown) to tube assembly (10). Install tube assembly (10) to Tooling (B).

2. Drain the engine oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change.” for the correct procedure.

6. Install bolts (11) finger tight. Remove Tooling (B) and install bolts (9) finger tight. 7. Install a new O-ring seal (3) (not shown) and a new O-ring seal (7) (not shown) to tube assembly (5). 8. Install tube assembly (5) to engine oil cooler (1). Install bolts (4) and bolts (6) finger tight. 9. Tighten bolts (9) to a torque of 47 N·m (35 lb ft). 10. Tighten bolts (4) and (6) to a torque of 40 N·m (30 lb ft). 11. Ensure that the engine oil pan is filled to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil Level - Check” for the correct procedure. i03401475

Engine Oil Pump - Remove SMCS Code: 1304-011 Illustration 138


g01813916

3. Place a suitable container below the engine oil pump. Disconnect hose assembly (1) from engine oil pump (2) and allow the oil to drain. Note: Cap all open ports and tube assemblies. 4. If necessary, remove the oil relief valve. Refer to Disassembly and Assembly, “Engine Oil Relief Valve (Oil Relief Valve) - Remove and Install”.


KENR6945

5. Remove bolts (5) and bolts (9). Remove tube assembly (8) and remove O-ring seals (3) (not shown) from the tube assembly. Note: Cap all open ports and tube assemblies.

Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump Remove ”.

6. Remove O-ring seals (4) (not shown). Remove spacer (6) (not shown) from suction pipe. Remove O-ring seals (7) (not shown) from suction pipe.


Note: Cap all open ports.

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 fluids according to local regulations and mandates. Note: The overhaul of the engine oil pump is a specialist operation that should only be attempted by trained personnel with the correct equipment. A service exchange engine oil pump is available from your authorized Perkins distributor.

g01814973

Illustration 139

7. Support the weight of engine oil pump (2). The weight of the engine oil pump is approximately 32 kg (71 lb). 8. Remove nuts (10). Carefully slide engine oil pump (2) along the retaining studs and remove the engine oil pump. 9. Remove gasket (14) (not shown). i03401478

Engine Oil Pump - Disassemble SMCS Code: 1304-015 g01836190

Disassembly Procedure

Illustration 140

Table 18

1. The weight of the engine oil pump is approximately 32 kg (71 lb).

Required Tools Tool

Part Number

A

-

Part Description Combination Puller

Qty 1

Note: Mark the gear in order to ensure correct orientation. 2. Use a suitable tool in order to prevent the gear from rotating. Remove nut (4) and washer (3).

KENR6945


3. Use Tooling (A) to pull gear (2) from the shaft of engine oil pump (5). Remove key (1).

8. Remove inner rotor (15) from assembly of shaft (14). Remove key (13) from shaft (14). 9. If necessary, remove bushing (10) and bushing (16). Use a suitable tool in order to remove the bushing from the engine oil pump. Note: Do not remove dowels (17) from the engine oil pump unless the dowels are damaged. 10. In order to remove the engine oil pressure regulator, refer to Disassembly and Assembly, “Engine Oil Relief Valve (Engine Oil Pressure Regulator) - Remove and Install” for the correct procedure. i03401479

Engine Oil Pump - Assemble SMCS Code: 1304-016

Illustration 141

g01836214


Required Tools Tool

Part Number

Part Description

Qty

B

21820117


1

-

Bolts M10 by 200 mm

3

-

M10 Nuts

3

-

M10 Flat Washers

6

C


Illustration 142

g01836293

4. Remove nuts (6) and remove plate (7). Remove gasket (8). 5. Remove the body of engine oil pump (9) from the body of engine oil pump (5). Remove gasket (11). Note: Temporarily mark both rotors in order to ensure that the components are assembled correctly. 6. Remove outer rotor (12). 7. Remove the following items as an assembly. Shaft (14), Inner rotor (15), and key (13).

Note: The overhaul of the engine oil pump is a specialist operation that should only be attempted by trained personnel with the correct equipment. A service exchange engine oil pump is available from your authorized Perkins distributor. 1. Ensure that all components of the engine oil pump are clean and free from wear or damage. Check the clearance between the outer rotor of the engine oil pump and the body of the engine oil pump. Check the clearance between the outer rotor and the inner rotor. Check the end play of the rotors. Refer to the Specifications, “Engine Oil Pump” for more information.


Illustration 143

KENR6945

g01836293

2. If necessary,use a suitable tool in order to install the bushing. Install bushing (10) to engine oil pump (9) and bushing (16) to the engine oil pump (5). Note: Ensure that oil holes are correctly aligned.

Illustration 144

g01836754

6. Install Tooling (C) in Position (A). Then hand tighten Tooling (C). 7. Ensure that the shaft of the engine oil pump is free to rotate.

3. Install key (13) to shaft (14). Install inner rotor (15) onto shaft assembly. Lubricate bushing (16) and install shaft assembly into the body of the assembly of engine oil pump (5). 4. Lubricate the inner rotor with clean engine oil and lubricate the outer rotor with clean engine oil. Install outer rotor (12) into assembly. NOTICE The end play of the engine oil pump is controlled by the gasket. Always assemble a new POWERPART gasket to the engine oil pump. Failure to use a new POWERPART gasket may result in serious damage to the engine. 5. Install a new gasket (11) onto the body of assembly of the engine oil pump (5). Lubricate bushing (10). Install the body of engine oil pump (9) onto the body of engine oil pump (5).

Illustration 145

g01836214

8. Install a new gasket (8). Install plate (7) and install nuts (6). Tighten nuts (6) to a torque of 25 N·m (18 lb ft).

KENR6945


i03401477

Engine Oil Pump - Install SMCS Code: 1304-012


Required Tools Tool

Part Number

A

21820117

Part Description

Qty


1


Illustration 146

g01836190

9. Install key (1) to the shaft of the engine oil pump. Install gear (2) onto the shaft of the assembly of the engine oil pump. Install washer (3).

Contaminants may cause rapid wear and shortened component life. 1. Ensure that the engine oil pump is clean and free from damage. Ensure that the pipes are clean and free from restriction.

Note: Ensure that the orientation of the gear is correct. 10. Apply Tooling (B) to the threads of nut (4)and install the nut. 11. Use a suitable tool in order to prevent gear (2) from rotating. Tighten nut (4) to a torque of 237 N·m (175 lb ft). Note: Ensure that the gear is not damaged during the tightening of the nut. Ensure that the shaft is free to rotate. 12. If necessary, install the engine oil pressure regulator. Refer to Disassembly and Assembly, “Engine Oil Relief Valve (Engine Oil Pressure Regulator) - Remove and Install” for the correct procedure. Note: Remove Tooling (C) before installing the engine oil pump.

Illustration 147

End By:

Note: If necessary, remove the three clamping bolts from the body of the engine oil pump.

a. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install ”.

g01814973

2. Install a new gasket (11) (not shown) to the support plate. 3. Support the weight of engine oil pump (2). The weight of the engine oil pump is approximately 32 kg (71 lb). 4. Carefully slide engine oil pump (2) along the retaining studs and install the engine oil pump.


KENR6945

5. Install nuts (10) to the studs. Tighten nuts (10) to a torque of 47 N·m (35 lb ft).

16. Turn the gas supply to the “ON” position. 17. Prime the engine oil system. Refer to Operation and Maintenance Manual, “Before Starting the Engine ” for the correct procedure. i03401480

Water Pump - Remove SMCS Code: 1361-011

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. Illustration 148

g01813916

6. Remove caps from ports on the engine oil pump and remove caps from hose assembly. Connect hose assembly (1) to engine oil pump (2). Tighten hose assembly (1) securely. 7. Install a new O-ring seal (7) (not shown) and install spacer (6). 8. Install new O-ring seal (4) (not shown). 9. Install new O-ring seal (3) (not shown) to tube assembly (8). 10. Position tube assembly (8) onto engine oil pump (2). Install bolts (9) and tighten hand tight. 11. Apply Tooling (A) to the threads of bolts (5). Install bolts (5) and tighten hand tight. 12. Tighten bolts (9) to a torque of 47 N·m (35 lb ft). 13. Tighten bolts (5) to a torque of 47 N·m (35 lb ft). 14. If necessary, install the oil relief valve. Refer to Disassembly and Assembly, “Engine Oil Relief Valve (Oil Relief Valve) - Remove and Install”. 15. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil Level - Check” for the correct procedure.

Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container. Refer to Operation and Maintenance Manual, “Cooling System Coolant Change” for the correct procedure. 2. If necessary, remove the alternator. Refer to Disassembly and Assembly, “Alternator Remove and Install (Alternator Drive)” for more information.

KENR6945


i03401482

Water Pump - Disassemble SMCS Code: 1361-015

Disassembly Procedure Table 21

Required Tools Tool

Part Number

A

-

Part Description

Qty

Circlip Pliers

1

Start By: a. Remove the water pump. Refer to Disassembly and Assembly, “Water Pump - Remove”.

Illustration 149

g01841094


Illustration 150

g01841095

3. Loosen the hose clamps and disconnect hose (7) from elbow connection (4). 4. Remove bolts (3) and remove connection (4) from water pump (1). Remove gasket (6) (not shown). 5. Loosen the hose clamps and loosen hose (2) from the elbow connection on water pipe (1). 6. Loosen hose clamp (9) on elbow connection (10). Remove bolts (11) and remove elbow connection (10) from water pump (1). 7. Remove gasket (12) (not shown).

Illustration 151

8. Remove bolts (8) and remove water pump (1). Remove gasket (5) (not shown).

1. Separate body (1) from bearing housing (5).

g01842553


KENR6945

Note: If necessary, tap the body with a soft faced hammer in order to separate the body from the bearing housing. 2. Remove O-ring seal (3). 3. Mount gear (7) in a suitable bench vise in order to prevent the shaft from rotating. Note: Ensure that the gear is protected by soft vise jaws. 4. Remove nut (9) and washer (8). Remove gear (7) and remove the key from shaft (10).

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the components of the water pump are clean and free from damage. Note: A repair kit for the water pump is available from your authorized Perkins Distributor. All components in the repair kit should be used when a water pump is overhauled.

5. Use Tooling (A) in order to remove circlip (12) from bearing housing (5). 6. Position bearing housing (5) on a suitable support with impeller (2) upward. Use a suitable mandrel and a press in order to press the assembly of shaft (10) and bearings (13) from the impeller and from the bearing housing. 7. Remove carbon seal (11) from impeller (2). Remove counterface (4) from bearing housing (5). 8. Remove seal (14) from bearing housing (5). Remove the snap rings from the bearing housing. Note: The snap rings retain the bearings in the bearing housing. 9. Position the assembly of shaft (10) and bearings (13) on a suitable support. Use a suitable mandrel and a press in order to press the bearings from the shaft. Remove spacer (6). Note: Shims may be installed between the bearings and the spacer. i03401483

Water Pump - Assemble

Table 22

Required Tools

A

-

B C

Part Description

2. Place shaft (10) on a suitable support and press on the inner race of bearing (13) until the bearing is against the shoulder of the shaft. Install spacer (6) to the shaft. Press on the inner race of second bearing (13) until the bearing is against the spacer.

3. Install a new seal (14) to bearing housing (5). Install the seal with the spring toward the bearings. Lubricate the lip of the seal with clean engine oil.

Assembly Procedure

Part Number

g01842553

Note: If shims were installed between the bearings, install the shims before installing the second bearing.

SMCS Code: 1361-016

Tool

Illustration 152

Qty

Circlip Pliers

1

21820117


1

21820221


1

4. Install new snap rings to bearing housing (5). Install the assembly of shaft (10) and bearings (13) to the bearing housing. Use Tooling (A) to install circlip (12). 5. Position the key on the shaft and install gear (7). 6. Apply Tooling (B) to the threads on shaft (10). Install washer (8) and nut (9) to the shaft.

KENR6945

7. Mount gear (7) in a suitable bench vise in order to prevent the shaft from rotating. Tighten the nut to a torque of 230 N·m (175 lb ft). Note: Ensure that the gear is protected by soft vise jaws. 8. Lubricate counterface (4) with a solution of de-mineralised water and 4% Cylam lubricant. Use the tool that is supplied with the repair kit in order to install the counterface to bearing housing (5). Note: After the counterface has been installed, the bearing housing should be left for ten minutes in order to allow the Cylam lubricant to evaporate. 9. Lubricate the internal bore of carbon seal (11) with a solution of de-mineralised water and 4% Cylam lubricant. Position carbon seal (11) on shaft (10). Use the tool that is supplied with the repair kit to install the carbon seal to the shaft. Note: After the carbon seal has been installed, pressure should be maintained on the carbon seal for ten minutes in order to hold the carbon seal in position against the counterface until the Cylam lubricant has evaporated.


i03401481

Water Pump - Install SMCS Code: 1361-012


Required Tools Tool

Part Number

A

-


Qty 2

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the water pump and the water pipe are clean and free from damage. Clean the gasket surface of the timing case.

10. Position bearing housing (5) on a suitable support with gear (7) downward. Press impeller (2) onto shaft (10). Press the impeller onto the shaft until the face of the impeller is flush with the end of the shaft. Note: After the impeller has been installed, ensure that the shaft is free to rotate and that the impeller is concentric to the bearing housing. 11. Lubricate a new O-ring seal (3) with Tooling (C). Install the O-ring seal to bearing housing (5). 12. Install body (1) to bearing housing (5). Note: After the body has been installed, ensure that the impeller is free to rotate without touching to the body. End By: a. Install the water pump. Refer to Disassembly and Assembly, “Water Pump - Install”.

Illustration 153

g01841094


KENR6945

13. If necessary, install the alternator. Refer to Disassembly and Assembly, “Alternator Remove and Install (Alternator Drive)” for more information. 14. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. i03401484

Water Temperature Regulator Housing - Remove and Install (Thermostat Housing) SMCS Code: 1393-010

Removal Procedure Illustration 154

g01841095

2. Install Tooling (A) to the timing case. Note: Install Tooling (A) to inner bolt holes for the water pump. 3. Position a new gasket (5) (not shown) on the timing case. 4. Lubricate the gear on water pump (1) with clean engine oil. Align the water pump with Tooling (A) and install the water pump to the timing case. Note: Ensure that the gear on the water pump is aligned with the idler gear. Ensure that the water pump is correctly seated on the timing case. 5. Install bolts (8) hand tight. Remove Tooling (A) and install remaining bolts (8). 6. Tighten bolts (8) to a torque of 47 N·m (35 lb ft). 7. Position a new gasket (6) (not shown) onto water pump (1). Install elbow connection (4) and install bolts (3). 8. Tighten bolts (3) to a torque of 47 N·m (35 lb ft). 9. Install hose (7) onto the elbow connection and tighten the hose clamps securely. 10. Position gasket (12) (not shown) on water pump (1). 11. Install elbow connection (10) to water pump (1) and hose (2). Install bolts (11). Tighten the bolts to a torque of 47 N·m (35 lb ft). 12. Tighten hose clamps (9) and hose clamp for hose (2) securely.

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 fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container. Refer to Operation and Maintenance Manual, “Cooling System Coolant Change” for the correct procedure.

KENR6945


c. Remove bolts (12) and remove washers (14). d. Remove thermostats (15). 4. Disconnect harness assembly (2) from the coolant temperature switch. 5. Remove nuts and bolts (4) from rail (6). Remove nuts (8) from tube assembly (9). 6. Remove thermostat housing (15) from rail (6) and tube assembly (9). 7. Remove O-ring seal (5) (not shown) and O-ring seal (7) (not shown).

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 thermostat housing are clean and free of wear or damage. Illustration 155

g01842674

Illustration 156

g01842675

2. Loosen hose clamp (3) and disconnect hose (1) from cover (11). 3. If necessary, follow Step 3.a through Step 3.d in order to remove the thermostats. a. Remove nuts (10). Remove cover (11) from thermostat housing (16). b. Remove gasket (13).

Illustration 157

g01842674


KENR6945

9. Connect hose (1) to cover (11) and tighten hose clamp (3) securely. 10. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct filling procedure. i03524401

Auxiliary Water Pump Remove (Gilkes Raw Water Pump) SMCS Code: 1371-011


g01842675


2. Install a new O-ring seal (7) (not shown) to tube assembly (9). Install a new O-ring seal (5) (not shown) to rail (6).


3. Position thermostat housing (16) onto tube assembly (9) and rail (6).


4. Install nuts and bolts (4) to rail (6) and tighten the nuts and bolts hand tight. 5. Install nuts (8) to tube assembly (9) and tighten the nuts hand tight. 6. Tighten nuts (8) to a torque of 47 N·m (35 lb ft). Tighten nuts and bolts (4) to a torque of 47 N·m (35 lb ft). 7. Connect the harness assembly to coolant temperature switch (2). 8. If necessary, follow Step 8.a through Step 8.e in order to install the thermostats. a. Check the thermostats for correct operation. Refer to Systems Operation, Testing and Adjusting, “Water Temperature Regulator Test” for the procedure to test the thermostats. b. Install thermostats (15) to thermostat housing (16). c. Install bolts (12) and washers (14). Tighten the bolts to a torque of 47 N·m (35 lb ft). d. Position a new gasket (13) on thermostat housing (16). Install cover (11). e. Install nuts (10) and tighten the nuts to a torque of 47 N·m (35 lb ft).

Dispose of all fluids according to local regulations and mandates. 1. Turn the battery disconnect switch to the OFF position. 2. Drain the raw water from the raw water cooling system.

KENR6945

Illustration 159


g01866334

Illustration 161

g01866474

8. Disconnect tube assembly (14) from auxiliary water pump (4) and the engine cylinder block. 9. Use a suitable lifting device to support the weight of auxiliary water pump (4). The weight of the auxiliary water pump is approximately 28 kg (62 lb). 10. Remove bolt (13) from auxiliary water pump (4). Remove the nuts and bolts (16) from auxiliary water pump (4). 11. Use the suitable lifting device to remove auxiliary water pump (4) from the backplate. 12. Remove gasket (15) (not shown).

Illustration 160

g01866335

3. Remove bolts on clamps (3) for tube assembly (2). 4. Remove bolts (9) for tube assembly. Remove O-ring seal (10). 5. Remove bolts (11) for tube assembly. Remove O-ring seal (12). 6. Remove tube assembly clamp (5) and remove sealing gasket (6) (not shown). Remove tube assembly clamp (7) and remove sealing gasket (8) (not shown). 7. Position tube assembly (1) and tube assembly (2) away from auxiliary water pump (4).

13. If necessary, remove the adapter plate from the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Disassemble” for the correct procedure.


KENR6945

i03524404

Auxiliary Water Pump Disassemble (Gilkes Raw Water Pump)

Note: This procedure will require two trained personnel. 3. Remove nut (4) and locking tab (3). 4. Remove gear (2) from auxiliary water pump (1). Remove the key from the shaft of the auxiliary water pump.

SMCS Code: 1371-015


Required Tools Tooling

Part Number

Description

A

T6253/121

Pegged Socket

1

B

T6253/258

Circlip Pliers

1

Qty

Start By: a. Remove the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 163

g01867113

5. Remove nuts (7) and remove adapter plate (5) from auxiliary water pump (1). 6. Remove gasket (6) (not shown). 7. If necessary, remove studs (8) from adapter plate (5).

Illustration 162

g01867093

1. Mount auxiliary water pump (1) in a bench vise. Use a suitable tool in order to prevent gear (2) from rotating. 2. Release locking tab (3). Use Tooling (A) to remove nut (4) from the shaft of auxiliary water pump (1).

Illustration 164

g01867273

KENR6945

Illustration 165


g01870193

8. Remove the nuts and bolts (10) from V-band clamps (11) and remove the V-band clamps. 9. Remove suction housing (13) from auxiliary water pump (1). Note: Mark the position of suction housing for assembly purpose. 10. Remove cavity plate (19) from suction housing (13). Note: Note the orientation of cavity plate for installation purpose.

Illustration 166

g01868037

14. Remove shims (27) and remove fibre spacer (25). 15. Remove cavity plate (24). Note: Note the orientation of cavity plate for installation purpose.

11. Remove O-ring seal (12) and remove spacer (14) from auxiliary water pump (1).

16. Remove bolts (20). Use a suitable tool in order to remove delivery housing (21) from bearing housing (26) for the auxiliary water pump.

12. Remove split pin (16). Remove nut (15) and washer (18).

17. Use a suitable drift in order to remove the track for ceramic seal (22) from delivery housing (21).

13. Use a suitable puller in order to remove impeller (17) from the shaft of auxiliary water pump (1). Remove the key from the shaft of the auxiliary water pump.

Illustration 167

g01868035

18. Remove oil seal (35) from bearing housing (26).


KENR6945

19. Place bearing housing (26) in a suitable press with Position (X) in the vertical position. Press shaft (32) from bearing housing (26). 20. Place shaft (32) in a suitable press with Position (Y) in the vertical position. Press collar (34) and bearing (33) from the shaft. 21. Use Tooling (B) in order to remove circlips (28) and circlips (31) from bearing housing (26). 22. Use a suitable drift in order to remove bearing track (30) from bearing housing (26). 23. Place bearing housing (26) in a suitable press with bearing (29) in the downward position. Use the suitable press in order to remove bearing (29) from bearing housing (25). i03524406

Auxiliary Water Pump Assemble (Gilkes Raw Water Pump)

Illustration 168

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

SMCS Code: 1371-016

2. Use a suitable press in order to install bearing track (30) to bearing housing (26).

Assembly Procedure

3. Use a suitable press in order to install bearing (29) to bearing housing (26).

Table 25

Required Tools Description

g01868035

Tooling

Part Number

A

T6253/121

Pegged Socket

1

B

T6253/258

Circlip Pliers

1

C

21820117


1

Qty


4. Install circlip (28) and circlip (31) to bearing housing (26). 5. Position bearing (33) onto shaft (32). Place shaft (32) and bearing (33) on a suitable press with Position (X) in the vertical position. Press on the inner face of the bearing until the bearing is against the shoulder of the shaft. 6. Position collar (34) onto shaft (32). Place shaft (32) and collar (34) on a suitable press with Position (X) in the vertical position. Press on the inner face of the collar until the collar is against the shoulder of bearing (33). 7. Place bearing housing (26) in a suitable press with bearing (29) facing in the downward position. Place the inner race of bearing (29) onto a suitable support. 8. Position shaft (32) into bearing (29) and bearing housing (26). Position shaft (32) with Position (Y) of the shaft in the vertical position. Press the shaft into the bearing housing until the shoulder of the shaft is against bearing (29). Note: Bearing (33) must align correctly with the track for bearing (30).

KENR6945


9. Lubricate bearing (33) and bearing (29) with clean engine oil. Use a suitable tool in order to install oil seal (35) into bearing housing (26).

Illustration 169

Illustration 170

g01867273

Illustration 171

g01870193

g01868037

10. Use a suitable tool in order to install the track for ceramic seal (22) to delivery housing (21). Note: Take care on installation of the track for ceramic seal (22) to delivery housing (21). 11. Mount bearing housing (26) in a bench vise with the shaft for the impeller in the vertical position. 12. Position delivery housing (21) onto bearing housing (26) for the auxiliary water pump. Install bolts (20) finger tight. 13. Install a new seal (23) onto the shaft for the impeller. Note: Take care on installation of seal (23). Ensure the correct orientation of the seal. 14. Install cavity plate (24). Ensure that cavity plate is correctly located in delivery housing (21). 15. Install fibre spacer (25). Install shims (27). 16. Tighten bolts (20) to a torque of 47 N·m (35 lb ft).

17. Use a suitable press in order to install impeller (17) to the shaft of the auxiliary water pump. Install the key to the shaft of the auxiliary water pump. Position impeller (17) onto the shaft of auxiliary water pump (1). Position the shaft of the auxiliary water pump on a suitable support in the vertical position. Press impeller (17) onto auxiliary water pump (1) until the impeller contacts the shoulder of the shaft. 18. Position washer (18) onto the shaft of the impeller. Apply Tooling (C) to the treads of the shaft of the impeller. Install nut (15). Tighten the nut to a torque of 135 N·m (100 lb ft). 19. If necessary, tighten nut (15) in a clockwise direction in order to enable split pin (16) to be installed. 20. Install spacer (14) to auxiliary water pump (1) and install a new O-ring seal (12). 21. Install cavity plate (19) to suction housing (13).


KENR6945

Note: Ensure the orientation of cavity plate. 22. Position suction housing (13) onto auxiliary water pump (1).

25. If necessary, install studs (8) to adapter plate (5). Apply Tooling (C) to the thread of the studs and install the studs to adapter plate (5). Tighten studs securely. 26. Position a new gasket (6) (not shown) onto adapter plate (5). 27. Position adapter plate (5) onto auxiliary water pump (1). Install nuts (7) and tighten the nuts to a torque of 25 N·m (18 lb ft).

Illustration 172

g01870293

Seating the V-band clamps on the auxiliary water pump

23. Install V-band clamps (11) to the auxiliary water pump. Install the nuts and bolts (10). Note: Connections (A) must be correctly aligned. 24. Tighten V-band clamps (11) on auxiliary water pump (1) to a torque of 25 N·m (18 lb ft). Lightly tap the V-band clamps with a soft faced hammer in order to seat the V-band clamps. Again, tighten the V-band clamps to a torque of 25 N·m (18 lb ft). Repeat this Step until the V-band clamps are secure.

Illustration 174

g01867093

28. Mount auxiliary water pump (1) in a bench vise. Use a suitable tool in order to prevent gear (2) from rotating. 29. Position a new locking tab (3) onto the shaft for auxiliary water pump (1). 30. Install nut (4) to the shaft of auxiliary water pump (1). Tighten the nut to a torque of 163 N·m (120 lb ft). Note: This procedure will require two trained personnel. 31. If necessary, tighten nut (4) in a clockwise direction In order to enable locking tab (3) to be engaged into the nut. End By: a. Install the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Install”.

Illustration 173

g01867113

KENR6945


i03524403

Auxiliary Water Pump - Install (Gilkes Raw Water Pump) SMCS Code: 1371-012

8. Tighten the nuts and bolts (16) to a torque of 47 N·m (35 lb ft). 9. Remove the suitable lifting device from auxiliary water pump (4). 10. Connect tube assembly (14) to auxiliary water pump (4) and the engine cylinder block. Tighten the tube assembly securely.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean the gasket surfaces of the auxiliary water pump and the backplate. 2. If necessary, install the adapter plate to the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Assemble” for the correct procedure.

Illustration 175

Illustration 176

g01866335

Illustration 177

g01866334

g01866474

3. Position a new gasket (15) (not shown) onto the backplate. 4. Attach a suitable lifting device to auxiliary water pump (4). The weight of the auxiliary water pump is approximately 28 kg (62 lb). 5. Use the suitable lifting device to install auxiliary water pump (4) onto the backplate. 6. Install bolts (13) to auxiliary water pump (4) hand tight. Install the nuts and bolts (16) to auxiliary water pump (4) hand tight. 7. Tighten bolts (13) to a torque of 47 N·m (35 lb ft).

11. Install a new O-ring seal (12) to the tube assembly. Install bolts (11) for tube assembly finger tight. 12. Install a new O-ring seal (10) to the tube assembly. Install bolts (9) for tube assembly finger tight.


KENR6945

13. Position a new sealing gasket (8) (not shown) onto auxiliary water pump (4). Position tube assembly (2) onto auxiliary water pump (4). Install V-band clamp (7) and tighten the nut and the bolt for V-band clamp (7) hand tight. 14. Position a new sealing gasket (6) (not shown) onto auxiliary water pump (4). Position tube assembly (2) onto auxiliary water pump (4). Install V-band clamp (5) and tighten the nut and the bolt for V-band clamp (5) hand tight. 15. Install bolts for clamps (3) for tube assembly (2). Tighten bolts (3) securely. 16. Tighten bolts (11) and bolts (9) to a torque of 47 N·m (35 lb ft). 17. Tighten the nut and the bolt for V-band clamp (5) to a torque of 25 N·m (18 lb ft). 18. Tighten the nut and the bolt for V-band clamp (7) to a torque of 25 N·m (18 lb ft).

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 fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container. Refer to Operation and Maintenance Manual, “Cooling System Coolant Change” for the correct procedure. Remove the plug and drain the coolant from the aftercooler. 2. Remove tube assembly from air charge cooler assembly to the throttle governor. Refer to Disassembly and Assembly Manual, “Fuel Control Actuator (Throttle Governor) Remove and Install” for the correct procedure.

19. Turn the battery disconnect switch to the ON position. 20. Fill the raw water cooling system. 21. Run the engine and check for leakage at the auxiliary water pump and at the tube assemblies. i03401485

Aftercooler - Remove SMCS Code: 1063-011

Removal Procedure Start By: a. Remove the air cleaners. Refer to Disassembly and Assembly, “Air Cleaner - Remove and Install”. b. Remove the gas pressure regulator. Refer to Disassembly and Assembly, “Gas Pressure Regulator Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 178

g01828318

KENR6945


9. Remove gasket (13) (not shown). 10. Loosen screws (12) and disconnect harness assembly (10) from the terminal block of the high inlet manifold pressure shutdown sensor. Note: Make a temporary mark on the terminal block and on the harness assembly. 11. Loosen gland nut (11) and remove harness assembly (10) from the high inlet manifold pressure shutdown sensor. 12. Remove harness connection (14) (not shown) from the boost pressure and the temperature sensor.

Illustration 179

g01828133

3. Loosen bolts for the clamps for the tube assemblies (3). 4. Remove bolts (1) from tube assemblies (3). Remove gaskets (4) (not shown). 5. Position tube assemblies (3) away from air charge cooler assembly (2). 6. Remove the nuts and bolts (5). Position tube assembly (6) away from air charge cooler assembly (2). 7. Remove gasket (7) (not shown). Illustration 181

g01828154

13. Use a suitable lifting device to support the weight of the air charge cooler assembly. The weight of the air charge cooler assembly is approximately 50 kg (110 lb). 14. Remove bolts (16) and remove nuts and bolts (17). Note: Mark the position and the orientation of the bracket that is installed on the six cylinder engine. Remove the bracket . Also, mark the position and the orientation of the manifolds on the air charge cooler. 15. Remove gaskets (15) (not shown) and remove gasket (18) (not shown).

Illustration 180

g01831469

8. Loosen screws (8) and remove cover (9) from the hgh inlet mnifold pessure shutdown sensor.


KENR6945

i03494320

Aftercooler - Disassemble SMCS Code: 1063-015

Disassembly 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 fluids according to local regulations and mandates.

Illustration 183

g01831016

1. Place the assembly of the air charge cooler on a suitable stand. If necessary, remove bolt (1) and remove the boost pressure and the temperature sensor (2). Remove O-ring seal (6) (not shown). 2. Remove bolts (5). Disconnect tube assembly (3). Remove high inlet manifold pressure shutdown sensor (4). 3. Remove allen head bolts (10). Remove the washer and nut (9). Note: Note the position of the stud and nut (9) for installation purpose. 4. Remove plate assembly (8) from the inlet manifold. Remove gasket (7) (not shown). Illustration 182

g01831015

KENR6945


i03496260

Aftercooler - Assemble SMCS Code: 1063-016

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

Illustration 184

g01831017

5. Remove allen head bolts (11) and remove plate (12). Remove gasket (13). Note: Mark the position of the plate and the orientation of the plate. Also, note the position of all nuts and the allen head bolts.

1. Ensure that the air charge cooler is clean and free from damage. Check the fins on the outside of the water tubes. Remove any deposits of carbon from the fins. Check the inside of the water tubes for deposits of limescale. If necessary, use a chemical solution in order to remove the deposits of limescale. Clean the gasket surfaces of the inlet manifold and the air pipes. Note: Ensure that any chemical solution that is used to remove the deposits of limescale is suitable for use with aluminum components.

Illustration 186 Illustration 185

g01831033

g01832676

2. Place the air charge cooler on a suitable stand.

6. Remove nuts and allen head bolts (16). Remove allen head bolts (15).

3. Position gasket (13) onto inlet manifold (8).

7. Remove manifold (17) and gasket (14) (not shown).

4. Position plate (12) onto the assembly of the inlet manifold. Install allen head bolts into Position (B). Tighten the allen head bolts hand tight.

Note: Do not remove the end plates from the air charge cooler.

5. Install allen head bolts (11) in Position (A). Tighten all the allen head bolts to a torque of 19 N·m (14 lb ft).


KENR6945

10. Install the nuts and allen head bolts (16). Install allen head bolts (15). Tighten allen head bolts (15) to a torque of 19 N·m (14 lb ft). Tighten the nuts and allen head bolts (16) to a torque of 19 N·m (14 lb ft). i03401486

Aftercooler - Install (Air Charge Cooler) SMCS Code: 1063-012

Installation Procedure NOTICE Keep all parts clean from contaminants.

Illustration 187

g01832833


6. Position air charger cooler (2) onto inlet manifold (8). Note: Ensure correct orientation of the air charger cooler. 7. Install allen head bolts (10). Install nuts (9) onto studs. Tighten the allen head bolts to a torque of 19 N·m (14 lb ft). Tighten the nuts to a torque of 19 N·m (14 lb ft).

Illustration 189

Illustration 188

g01833513

8. Position gasket (14) onto the assembly of air charger cooler (2). 9. Ensure correct orientation of manifold (17). Align manifold (17) to the assembly of air charger cooler (2).

g01828154

KENR6945

Illustration 190


g01831469

Illustration 191

g01828133

Illustration 192

g01828318

1. Position gasket (18) (not shown) onto the manifold and position gasket (15) (not shown) onto the manifold. 2. Use a suitable lifting device to lift the assembly of the air charge cooler into position. The weight of the air charge cooler assembly is approximately 50 kg (110 lb). 3. Install bolts (16) and tighten bolts finger tight. 4. Install nuts and bolts (17) and tighten bolts finger tight. 5. Tighten bolts (16) to a torque of 47 N·m (35 lb ft). Tighten nuts and bolts (17) to a torque of 47 N·m (35 lb ft). 6. Install harness assembly (14) (not shown). 7. Install harness assembly (10) to the high inlet manifold pressure shutdown sensor. 8. Install harness assembly (10) to connections on the terminal block. Ensure that the temporary marks on harness assembly are correctly installed to the terminal block. Tighten screws (12) securely. Tighten gland nut (11) securely. 9. Position gasket (13) (not shown) onto cover (9). Position cover (9) onto the high inlet manifold pressure shutdown sensor and install screws (8). Tighten the screws securely.

10. Position a new gasket (7) (not shown). Position tube assembly (6) and install the nuts and bolts (5) finger tight. 11. Position a new gasket (4) (not shown). Position tube assemblies and install bolts (1) finger tight. 12. Tighten nuts and bolts (5) to a torque of 47 N·m (35 lb ft). Tighten bolts (1) to a torque of 47 N·m (35 lb ft). 13. Tighten the bolts for the clamps on tube assemblies (3).


KENR6945

14. Install tube assembly from air charge cooler assembly to the throttle governor. Refer to Disassembly and Assembly Manual, “Fuel Control Actuator (Throttle Governor) Remove and Install” for the correct procedure. 15. 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 gas pressure regulator. Refer to Disassembly and Assembly, “Gas Pressure Regulator Remove”. b. Remove the air cleaners. Refer to Disassembly and Assembly, “Air Cleaner - Remove and Install”. i03401781

Engine Support (Front) Remove and Install (Backplate)

g01847393

Illustration 193

3. Use a suitable lifting device to support the weight of backplate (1). The weight of the backplate is approximately 45 kg (100 lb).

SMCS Code: 1154-010-FR

4. Remove bolts (2).

Removal Procedure

5. Separate backplate (1) from the crankcase. Use the lifting device in order to remove the backplate.

Start By:

6. Remove gasket (3) (not shown).

a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”.


b. Remove the timing gears. Refer to Disassembly and Assembly, “Gear Group (Front) - Remove”. NOTICE Keep all parts clean from contaminants.

Table 26

Required Tools Tool

Part Number

A

-

Part Description Guide Studs M10 by 100 mm

Qty 2



1. If necessary, remove the auxiliary water pump. Refer to Disassembly and Assembly, “Auxilary Water Pump - Remove”.


2. Ensure that the engine is adequately supported.

1. Ensure that the gasket surface of the crankcase and the backplate are clean.

KENR6945


i03401782

Flywheel - Remove SMCS Code: 1156-011


Required Tools Tool

Part Number

A

T6253/157

B

-

Part Description

Qty

Support Studs Flywheel and Damper

2

Bolt M12 by 100mm

2

Start By: Illustration 194

g01847394

2. Install Tooling (A) to Positions (X) on the crankcase.

a. Remove the engine speed sensor. Refer to Disassembly and Assembly, “Engine Speed Sensor - (Engine Speed for Governor Control) Remove and Install”.

3. Align gasket (3) (not shown) with Tooling (A). Install the gasket to the crankcase.

b. Remove the overspeed sensor. Refer to Disassembly and Assembly, “Engine Speed Sensor - (Overspeed Sensor) Remove and Install”.

4. Use a suitable lifting device to lift backplate (1) into position. The backplate weighs approximately 45 kg (100 lb). Install the backplate to the crankcase.

c. Remove the electric starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”.

Note: Ensure that the backplate is seated on the dowels in the crankcase.


5. Install bolts (2) hand tight. Ensure that gasket (3) (not shown) protrudes below the base of the backplate. Tighten bolts (2) to a torque of 47 N·m (35 lb ft).


6. Remove Tooling (A) and remove excess material from gasket (3) (not shown). The gasket should be flush with the base of the backplate.

1. Make a temporary mark in order to show the position of the flywheel on the crankshaft.

7. If necessary, install the auxiliary water pump. Refer to Disassembly and Assembly, “Auxilary Water Pump - Install”. End By: a. Install the timing gears. Refer to Disassembly and Assembly, “Gear Group (Front) - Install”. b. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”. Illustration 195

g01454176


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8. Inspect the starter ring gear for wear or damage. If necessary, follow Step 8 through Step 8.a in order to remove the starter ring gear. Note: Identify the orientation of the teeth on the ring gear.

Illustration 196

g01454178

2. Follow Step 2.a and Step 2.b in order to prevent the flywheel from rotating. a. Install a suitable bolt (1) to flywheel (4). b. Position a suitable piece of wood (3) between bolt (1) and the floor. 3. Loosen bolts (2). Remove two bolts (2) and install Tooling (A) in place of the bolts. Remove remaining bolts (2).

Illustration 198

g01454182

Typical example

a. Drill a hole through ring gear (5) between two of the teeth.

4. Install Tooling (B) into the threaded holes in flywheel (4). Tighten Tooling (B) evenly in order to push the flywheel off the crankshaft. Note: Push the flywheel off the crankshaft until there is sufficient clearance in order to install a suitable sling to the flywheel.

Illustration 199

g01454184

Typical example

b. Use a hammer and a chisel in order to split ring gear (5). Remove the ring gear from the flywheel.

Illustration 197

g01454180

5. Pass a suitable sling through the center of flywheel (4). Attach the sling to a suitable lifting device and support the weight of the flywheel. The weight of the flywheel is approximately 160 kg (350 lb). 6. Continue to tighten Tooling (B) until the flywheel has been pushed off the crankshaft. 7. Use the lifting device in order to remove flywheel (4).

KENR6945


i03401783

Flywheel - Install SMCS Code: 1156-012

d. Ensure that the orientation of ring gear (5) is correct and quickly install the ring gear to flywheel (4). Note: Ensure that the ring gear is seated on the shoulder of the flywheel.


2. 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”.

Table 28

Required Tools Tool

Part Number

A

T6253/157


2

C

CV60889

Anti-Seize Compound

1

Part Description

Qty


Illustration 201

Always wear protective gloves when handling parts that have been heated. 1. If the starter ring gear required replacement, follow Step 1.a through Step 1.d in order to install a new ring gear.

g01577716

3. Pass a suitable sling through the center of flywheel (4). Attach the sling to a suitable lifting device and support the weight of the flywheel. The weight of the flywheel is approximately 160 kg (350 lb). 4. Install Tooling (A) to the crankshaft. 5. Use the lifting device in order to position flywheel (4) onto Tooling (A). Note: Ensure the correct orientation of the flywheel. Push the flywheel toward the crankshaft until there is sufficient clearance in order to remove the sling from the flywheel. 6. Remove the lifting device and the sling from flywheel (4).

Illustration 200

g01454200

Typical example

a. Lay flywheel (4) on a horizontal surface. b. Identify the orientation of the teeth on new ring gear (5). Note: The chamfered side of the ring gear teeth must face toward the starting motor when the flywheel is installed. c. Heat ring gear (5) in an oven to a maximum temperature of 250 °C (482 °F).

7. Apply Tooling (C) to the threads of bolts (2). Apply Tooling (C) to the underside of the heads of bolts (2). Install bolts (2) to flywheel (4). Tighten the bolts evenly in order to pull the flywheel onto the crankshaft. 8. Remove Tooling (A) and install the remaining bolts (2) hand tight.


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11. Check the run out of the flywheel. Refer to Specifications, “Flywheel” for further information. End By: a. Install the electric starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”. b. Install the overspeed sensor. Refer to Disassembly and Assembly, “Engine Speed Sensor - (Overspeed Sensor) Remove and Install”. Illustration 202

g01454201

c. Install the engine speed sensor. Refer to Disassembly and Assembly, “Engine Speed Sensor - (Engine Speed for Governor Control) Remove and Install”. i03401784

Crankshaft Rear Seal - Remove and Install SMCS Code: 1161-010


Required Tools

Illustration 203

g01926062

The tightening sequence for the flywheel bolts

9. Follow Step 9.a and Step 9.b in order to prevent the flywheel from rotating.

Tool

Part Number

A

27610311

Part Description Slide Hammer Puller

Qty 1

Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”.

a. Install a suitable bolt (1) to flywheel (4).


b. Position a suitable piece of wood (3) between bolt (1) and the floor.


10. Use the following method in order to tighten the flywheel bolts to the correct torque. a. Tighten bolts (2) hand tight, in the sequence that is shown in Illustration 203. b. Tighten bolts (2) to a torque of 135 N·m (100 lb ft) in the sequence that is shown in Illustration 203. c. Tighten bolts (2) to a torque of 337 N·m (250 lb ft) in the sequence that is shown in Illustration 203.


KENR6945


g01454205

Illustration 204

1. Use a 4 mm (1/8 inch) drill in order to make three equally spaced holes in crankshaft rear seal (1). Note: Ensure that debris does not enter the crankcase. 2. Screw Tooling (A) firmly into one of the holes. Use Tooling (A) to dislodge crankshaft rear seal (1). When the crankshaft rear seal begins to move, unscrew Tooling (A). Install Tooling (A) in the next hole. Repeat the process using each hole, until the crankshaft rear seal is removed.


Required Tools Tool B

Part Number

Part Description

Qty

T6253/140 Rear Oil Seal Insertion Kit

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Do not lubricate the crankshaft rear seal or the crankshaft. The crankshaft seal should be installed dry. 1. Inspect the rear of the crankshaft for damage. Ensure that the crankshaft is clean and dry.

Illustration 205

g01454208

2. Ensure that Tooling (B) is clean, dry and free from damage. Install Tooling (B) (oil seal locator) to the rear of the crankshaft. 3. Position a new crankshaft rear seal (1) on Tooling (B) (oil seal locator). Note: A new crankshaft rear seal is supplied with a plastic sleeve. The plastic sleeve should be aligned with the chamfer on Tooling (B) (oil seal locator). 4. Push crankshaft rear seal (1) squarely over Tooling (B) (oil seal locator). The plastic sleeve will be forced out of the crankshaft rear seal. Discard the plastic sleeve. Push the crankshaft rear seal up to the flywheel housing. 5. Install Tooling (B) (outer sleeve). Lubricate the face of the washer with clean engine oil and install the nut. 6. Tighten the nut on Tooling (B) until the crankshaft rear seal is pushed into the bore in the flywheel housing. 7. Remove Tooling (B). End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”.


KENR6945

i03401785

Flywheel Housing - Remove and Install SMCS Code: 1157-010


Required Tools Tool

Part Number

A

-

Part Description Guide Studs M10 by 100 mm

Qty 2

Start By: a. Remove the engine speed sensor. Refer to Disassembly and Assembly, “Engine Speed Sensor - Remove and Install”. b. Remove the overspeed sensor. Refer to Disassembly and Assembly, “Engine Speed Sensor (Overspeed) - Remove and Install”. c. Remove the starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”. d. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”.

Illustration 206

g01848254

1. Remove bolts (2) and bolts (3). 2. Use a suitable hoist to lift the rear of the engine. The weight of the engine is approximately 2040 kg (450 lb). Raise the rear of the engine so that there is a distance of 10 mm (0.4 inch) between flywheel housing (1) and the base frame. Note: Ensure that the engine is supported.

e. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - 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 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 fluids according to local regulations and mandates.

Illustration 207

g01848255

3. Use a suitable lifting device to support the weight of flywheel housing (1). The flywheel housing weighs approximately 150 kg (330 lb). 4. Remove bolts (4) from Positions (X). Install Tooling (A) to Positions (X).

KENR6945


5. Remove remaining bolts (4). 6. Separate flywheel housing (1) from the crankcase. 7. Use the lifting device to remove the flywheel housing.

Note: The flywheel housing should be installed within ten minutes of applying Tooling (C). Application of Tooling (C) to the rear of the crankcase

8. Use a suitable drift to remove the crankshaft rear seal from the flywheel housing.


Required Tools Tool

Part Number

Part Description

Qty

A

-

Guide Studs M10 by 100 mm

2

B

-

Loctite 518

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the gasket surfaces of the flywheel housing and the crankcase are clean and free from damage. Ensure that the oil galleries in the engine cylinder block are free from debris or restrictions.

Illustration 209

g01848255

3. Install Tooling (A) to Positions (X) in the crankcase. 4. Use a suitable lifting device to lift flywheel housing (1) into position. The flywheel housing weighs approximately 150 kg (330 lb). 5. Align flywheel housing (1) with Tooling (A) and install the flywheel housing to the crankcase. Note: Ensure that the flywheel housing is seated on the dowels in the crankcase. 6. Install bolts (4) hand tight. Remove Tooling (A). Install the remaining bolts. 7. Ensure that the bottom face of the flywheel housing is aligned with the bottom face of the crankcase. The bottom face of the flywheel housing should be aligned with the bottom face of the crankcase within 0.10 mm (0.004 inch). 8. Tighten bolts (4) to a torque of 47 N·m (35 lb ft).

Illustration 208

g01848256

2. Apply a fine bead of Tooling (B) to the rear of the crankcase. Refer to Illustration 208 for the correct pattern of application. Ensure that camshaft Bore (Y) and oil Holes (Z) are not contaminated with Tooling (B).


KENR6945

i03538581

Vibration Damper - Remove and Install (Damper and Plate) SMCS Code: 1205-010


Required Tools

Illustration 210

Tool

Part Number

A

T6253/209A

B

T6253/209

-

g01848260

C

9. Use a suitable hoist to lower the rear of the engine onto the base frame. Install bolts (2) and bolts (3). Tighten the bolts securely. 10. Install a new crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”. End By:

Part Description

Qty

Retaining Plate

1

Crankshaft Adapter Extractor

1

Nuts and Bolts M12 by 125 mm

3

High Tensile Bolts -

Heavy Duty Flat Washers

3


a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Install”. b. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”. c. Install the starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”. d. Install the overspeed sensor. Refer to Disassembly and Assembly, “Engine Speed Sensor (Overspeed) - Remove and Install”. e. Install the engine speed sensor. Refer to Disassembly and Assembly, “Engine Speed Sensor - Remove and Install”.

Illustration 211

g01868053

1. Install a suitable lifting device to plate assembly (1) in order to support the weight of the assembly. 2. Remove nuts and bolts from position (X). 3. Remove bolts (2) and remove plate (3).

KENR6945


Note: Support the weight of vibration damper assembly on removal of bolts (2).

g01868662


g01868553

9. Remove bolts (5). Use a suitable lifting device in order to remove damper (6). The weight of the damper is 38 kg (85 lb).

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. 4. Install Tooling (A) to the crankshaft. Install Tooling (B) and Tooling (C). Lubricate the threads of the forcing bolt with clean engine oil. Tighten the forcing bolt in order to pull adapter (4) off the crankshaft. Note: The adapter will be released from the crankshaft with considerable force. 5. Remove Tooling (C) and remove Tooling (B). 6. Remove Tooling (A).

g01868674

Illustration 214

Note: Support the weight of vibration damper assembly on removal of Tooling (A).

10. Remove the remaining nuts and bolts (7). Remove adapter (4) from plate (1). The weight of plate is 22 kg (50 lb).

7. Use a suitable lifting device in order to move plate assembly (1) from the crankshaft. The weight of the assembly is 76 kg (168 lb).


8. Lay the assembly on a flat surface.

Required Tools Tool

Part Number

E

CV60889

Part Description POWERPART Anti-Seize Compound

Qty 1


KENR6945

4. Use the following method in order to tighten the damper bolts to the correct torque.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the nose of the crankshaft and the bore of the adapter are clean, dry and free from damage. Ensure that the casing of the damper is free from damage.

a. Tighten bolts (7) hand tight, in the sequence that is shown in Illustration 216. b. Tighten bolts (7) to a torque of 160 N·m (118 lb ft) in the sequence that is shown in Illustration 216.

Note: If a new damper is installed, the casing should be painted in order to prevent corrosion. 2. Inspect the crankshaft front seal for leaks. If there are any oil leaks, replace the crankshaft front seal. Refer to Disassembly and Assembly, “Crankshaft Front Seal - Remove and Install”.

Illustration 217

g01868662

5. By using a suitable lifting device, install damper (6) onto assembly (1). Install new bolts (5). a. Tighten bolts (5) hand tight, in the sequence that is shown in Illustration 216.

Illustration 215

g01868674

3. Position adapter (4) on the front of plate (1). Install new nuts and bolts (7). Apply Tooling (E) to the threads of bolts (7).

Illustration 216 The tightening sequence for the damper bolts

g01867315

b. Tighten bolts (5) to a torque of 160 N·m (118 lb ft) in the sequence that is shown in Illustration 216.

KENR6945


g01868753

Illustration 218

Illustration 219

g01868013

6. By using a suitable lifting device, install assembly (1) onto the crankshaft. Apply tooling (E) to the threads of bolts (2). Install plate (3) and install bolts (2).

1. Remove the guard that covers the damper.

7. Tighten bolts (2) to a torque of 340 N·m (250 lb ft). Repeat this Step until a torque of 340 N·m (250 lb ft) has been achieved.

3. Remove bolts (1) and remove plate (2).

2. Install Tooling (A). Use a suitable lifting device in order to support the weight of the assembly.

Note: Support the weight of vibration damper assembly on removal of bolts (1).

i03538580

Vibration Damper - Remove and Install SMCS Code: 1205-010


Required Tools Tool

Part Number

Part Description

Qty

A

T6253/214

Damper Lifting Tool

1

B

T6253/209A

Retaining Plate

1

C

T6253/209


1


Illustration 220

g01868014

4. Install Tooling (B) to the nose of the crankshaft.


KENR6945

Installation Procedure 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. 5. Install Tooling (C) to adapter (3). Lubricate the threads of the forcing bolt with clean engine oil. Tighten the forcing bolt in order to pull adapter (3) off the crankshaft. Note: The adapter will be released from the crankshaft with considerable force.

Table 36

Required Tools Tool

Part Number

A

T6253/214

D

CV60889

Qty

Damper Lifting Tool

1

POWERPART Anti-Seize Compound

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the nose of the crankshaft and the bore of the adapter are clean, dry and free from damage. Ensure that the casing of the damper is free from damage.

6. Remove Tooling (C). 7. Remove Tooling (B). Note: Support the weight of vibration damper assembly on removal of Tooling (B). 8. Using a suitable lifting device and Tooling (A) in order to remove the assembly of damper (4) and adapter (3). Lay the assembly of the damper and the adapter on a flat surface with the adapter downward. The weight of the assembly is approximately 54 kg (119 lb).


Illustration 222

Illustration 221

Part Description

g01868015

9. Remove bolts (5) and remove adapter (3) from damper (4).

g01868015

3. Apply Tooling (D) to the threads of bolts (5). Position adapter (3) on the front of damper (4) and install bolts (5).

KENR6945


8. Tighten bolts (1) to a torque of 340 N·m (250 lb ft). Repeat this Step until a torque of 340 N·m (250 lb ft) has been achieved. 9. Install the guard for the damper. i03401786

Vibration Damper and Pulley Remove and Install (Single Vibration Damper) SMCS Code: 1205-010 Illustration 223

g01867315

Removal Procedure

The tightening sequence for the damper bolts

4. Use the following method in order to tighten the damper bolts to the correct torque. a. Tighten bolts (5) hand tight, in the sequence that is shown in Illustration 223. b. Tighten bolts (5) to a torque of 160 N·m (118 lb ft) in the sequence that is shown in Illustration 223.

Table 37

Required Tools Tool

Part Number

Part Description

Qty

A

T6253/157


2

B

T6253/214

Damper Lifting Tool

1

C

T6253/209A

Retaining Plate

1

D

T6253/209


1

Start By: a. Remove the V-belts from the fan drive. Refer to OEM. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 224

g01868013

5. Install Tooling (A) and a suitable lifting device to the assembly of damper (4) and adapter (3). The weight of the damper and the adapter is approximately 54 kg (119 lb). 6. Use the lifting device in order to position the assembly of the adapter and damper onto the crankshaft. 7. Apply Tooling (D) to the threads of bolts (1). Install plate (2) and bolts (1). Remove Tooling (B).


Illustration 225

KENR6945

g01866373

1. Remove bolts (2). Use a suitable lifting device in order to remove pulley (1). The weight of the pulley is approximately 25 kg (55.11550 lb).

Illustration 227

g01866495

3. Install Tooling (B). Use a suitable lifting device in order to support the weight of the assembly. 4. Remove bolts (5) and remove plate (6). Note: Support the weight of vibration damper assembly on removal of bolts (1).

Illustration 226

g01866413

2. Remove bolts (3). Use a suitable lifting device in order to remove the adapter for pulley (4). The weight of this adapter is approximately 25 kg (55.11550 lb).

Illustration 228

g01866753

5. Install Tooling (C) to the nose of the crankshaft.

KENR6945


Installation Procedure 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.

Table 38

Required Tools Tool

Part Number

Part Description

Qty

A

T6253/157


2

B

T6253/214

Damper Lifting Tool

1

E

CV60889


1

6. Install Tooling (D) to adapter (7). Lubricate the threads of the forcing bolt with clean engine oil. Tighten the forcing bolt in order to pull adapter (7) off the crankshaft.


Note: The adapter will be released from the crankshaft with considerable force.


7. Remove Tooling (D).

1. Ensure that the nose of the crankshaft and the bore of the adapter are clean, dry and free from damage. Ensure that the casing of the damper is free from damage.

8. Remove Tooling (C). Note: Support the weight of vibration damper assembly on removal of Tooling (B). 9. Using a suitable lifting device and Tooling (B) in order to remove the assembly of damper (8) and adapter (7). Lay the assembly of the damper and the adapter on a flat surface with the adapter downward. The weight of the assembly is approximately 95 kg (210 lb).

Illustration 229

g01866858

10. Remove bolts (9) and remove adapter (7) from damper (8).


Illustration 230

g01866858

3. Apply Tooling (E) to the threads of bolts (9). Position adapter (7) on the front of damper (8) and install bolts (9).


KENR6945

8. Tighten bolts (5) to a torque of 340 N·m (250 lb ft). Repeat this Step until a torque of 340 N·m (250 lb ft) has been achieved.

Illustration 231

g01867315

The tightening sequence for the damper bolts

4. Use the following method in order to tighten the damper bolts to the correct torque. a. Tighten bolts (9) hand tight, in the sequence that is shown in Illustration 231. b. Tighten bolts (9) to a torque of 160 N·m (118 lb ft) in the sequence that is shown in Illustration 231.

Illustration 232

Illustration 233

g01867134

9. Install Tooling (A) into the adapter for the damper. Align adapter (4) to Tooling (A) and slide adapter (4) onto Tooling (A).

g01866495

5. Install Tooling (B) and a suitable lifting device to damper (7). The weight of the damper and the adapter is approximately 120 kg (265 lb). 6. Use the lifting device in order to position the assembly of the adapter and damper onto the crankshaft. 7. Apply Tooling (E) to the threads of bolts (5). Install plate (6) and bolts (5). Remove Tooling (B).

Illustration 234

g01866413

10. Apply Tooling (E) to the threads of bolts (3). Install bolts (3). Remove Tooling (A). Install the remaining bolts.

KENR6945


End By: a. Install the V-belts to the fan drive. Refer to OEM. i03401788

Crankshaft Front Seal Remove and Install SMCS Code: 1160-010


g01867214

Table 39

Required Tools

11. Use the following method in order to tighten the damper bolts to the correct torque. a. Tighten bolts (3) hand tight, in the sequence that is shown in Illustration 235. b. Tighten bolts (3) to a torque of 160 N·m (118 lb ft) in the sequence that is shown in Illustration 235. c. Tighten bolts (3) to a torque of 340 N·m (250 lb ft) in the sequence that is shown in Illustration 235.

Tool

Part Number

A

27610311

Part Description Slide Hammer Puller

Qty 1

Start By: a. Remove the damper from the crankshaft. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - 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. Dispose of all fluids according to local regulations and mandates.

Illustration 236

g01866373

12. Apply Tooling (E) to the threads of bolts (2). Install pulley (1) and install bolts (2). Tighten the bolts to a torque of 85 N·m (62 lb ft). Note: Check the alignment of pulley (1) with the pulley on the fan drive. Ensure that the pulleys are aligned. After the engine has been run for the appropriate length of time check the tightness of the bolts that secure the pulley.


KENR6945

g01861573

Illustration 237

1. Use a 4 mm (1/8 inch) drill in order to make three equally spaced holes in crankshaft front seal (1). Note: Ensure that debris does not enter the crankcase. 2. Screw Tooling (A) firmly into one of the holes. Use Tooling (A) to dislodge crankshaft front seal (1). When the crankshaft front seal begins to move, unscrew Tooling (A). Install Tooling (A) in the next hole. Repeat the process using each hole, until the crankshaft front seal is removed.


Required Tools Tool B

Part Number

Part Description

T6253/141 Front Oil Seal Insertion Kit

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Do not lubricate the crankshaft front seal or the crankshaft. The crankshaft front seal should be installed dry. 1. Inspect the nose of the crankshaft for damage. Ensure that the crankshaft is clean and dry.

Illustration 238

g01861574

2. Ensure that Tooling (B) is clean, dry and free from damage. Install Tooling (B) (oil seal locator) to the nose of the crankshaft. 3. Position a new crankshaft front seal (1) on Tooling (B) (oil seal locator). Note: A new crankshaft front seal is supplied with a plastic sleeve. The plastic sleeve should be seated over the chamfer on Tooling (B) (oil seal locator). 4. Push crankshaft front seal (1) squarely over Tooling (B) (oil seal locator). The plastic sleeve will be forced out of the crankshaft front seal. Push the crankshaft front seal up to the timing case. Discard the plastic sleeve. 5. Install Tooling (B) (outer sleeve). Lubricate the face of the washer with clean engine oil and install the nut. 6. Tighten the nut on Tooling (B) until the crankshaft front seal is pushed into the bore in the timing case. 7. Remove Tooling (B). End By: a. Install the damper to the crankshaft. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”.

KENR6945


i03401789

Gear Group (Front) - Remove SMCS Code: 1206-011

Removal Procedure Start By: a. Remove the rocker assemblies. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove”. b. Remove the timing case. Refer to Disassembly and Assembly, “Housing (Front) - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 240

g01855214

2. Remove bolts (2). 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.

3. Carefully remove camshaft gear (1) from the camshaft. 4. Do not remove dowel (3) from the camshaft unless the dowel is damaged.


Illustration 241

g01855753

5. Remove bolts (6) and remove plate (5). Illustration 239

g01854918

Alignment of the timing marks

1. Align the timing marks on the gears. Refer to Illustration 239.

6. Remove idler gear (4). 7. If necessary, remove allen head bolts (8) and remove hub (7) from the backplate.


KENR6945

i03401790

Gear Group (Front) - Install SMCS Code: 1206-012


Required Tools Tool

Part Number

A

21825617

Part Description

Qty

Dial Indicator Group

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 243

g01856977

3. Inspect idler gears (4) for wear or damage. Check the inside diameter of the bushes. Refer to Specifications, “Gear Group (Front)” for more information. If necessary, use a suitable mandrel in order to press the old bush out of the idler gear. Press a replacement bush into the gear. Note: A replacement bush is supplied with the inside diameter that is finished to the correct size. 4. Lubricate the hub with clean engine oil. Position idler gear (4) on the hub. Note: Ensure that the idler gear is correctly meshed with the crankshaft gear and with the oil pump gear. 5. Lubricate plate (5) with clean engine oil. Position the plate and install bolts (6). Tighten the bolts to a torque of 47 N·m (35 lb ft). Illustration 242

g01856933

1. Inspect hub (7) for wear or damage. Check the outside diameter of the hubs. Refer to Specifications, “Gear Group (Front)” for more information. 2. Position hub (7) on the backplate. Position the oil hole in the hub in Position (A). Refer to Illustration 242. Install allen head bolts (7). Tighten the allen head bolts to a torque of 47 N·m (35 lb ft).

KENR6945

Illustration 244


g01856993

Checking the end play and the backlash of an idler gear

6. Use feeler gauges in order to check the end play of the idler gears. Use Tooling (A) in order to check the backlash between the idler gears and the crankshaft gear. Refer to Specifications, “Gear Group (Front)” for more information.

Illustration 245 Alignment of the timing marks

Illustration 246

g01855214

7. Align the timing marks on gears (1) with the timing marks on the crankshaft gear. Refer to Illustration 245. Align the hole in the camshaft gear with dowel (3) in the nose of the camshaft. Position the camshaft gear on the camshaft. 8. Install bolts (2). Tighten the bolts to a torque of 150 N·m (110 lb ft).

g01854918

Illustration 247

g01857053

Checking end play of the camshaft

9. Use Tooling (A) in order to check the end play of the camshaft. Use Tooling (A) in order to check the backlash between the camshaft gear and the crankshaft gear. Refer to Specifications, “Gear Group (Front)” for more information. 10. Lubricate all gears with clean engine oil.


KENR6945

End By: a. Install the timing case. Refer to Disassembly and Assembly, “Housing (Front) - Install”. b. Install the rocker assemblies. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install”.

Note: It is possible to remove the timing case without removing the engine oil pan. The bolts that secure the engine oil pan to the timing case should be removed so that the engine oil pan can be lowered. The gasket should then be separated from the timing case.

i03401791

Housing (Front) - Remove (Timing Case) SMCS Code: 1151-011

Removal Procedure Start By: a. Remove the water pumps. Refer to Disassembly and Assembly, “Water Pump - Remove”. b. Remove the damper from the crankshaft. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”. c. Remove the camshaft speed sensor from timing case. Refer to Disassembly and Assembly, “Engine Speed Sensor (Camshaft) - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 248

g01857913

3. Use a suitable lifting device to support the weight of timing case (3). The timing case weighs approximately 90 kg (200 lb). 4. Remove bolts (4) from timing case (3).

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 fluids according to local regulations and mandates. 1. If necessary, remove tube assembly from the water temperature regulator and the elbow on the water pump. Refer to Disassembly and Assembly, “Water Temperature Regulator - Remove and Install” for the correct procedure. 2. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove” for the correct procedure.

Note: Note the position of the bolts of different length for installation purpose. 5. Remove the nuts and bolts (1) from timing case (3). Note: Note the position of nuts and bolts of different length for installation purpose. 6. Separate timing case (3) from the backplate. Use the suitable lifting device in order to remove the timing case. 7. Remove gasket (2) (not shown). 8. Use a suitable drift to remove the crankshaft front seal from the timing case.

KENR6945


NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the gasket surface of the timing case and the backplate are clean.

g01870499

Illustration 249

9. If necessary, remove adapter (6) from timing case (3). Follow Step 9.a through Step 9.d in order to remove the adapter from the timing case. a. Remove nuts and washers (5) from adapter (6). b. Remove adapter (6) from timing case (3). g01870499

c. Remove gasket (7).

Illustration 250

d. If necessary, remove studs (8) from timing case (3).

2. If necessary, install adapter (6) to timing case (3). Follow Step 2.a through Step 2.d in order to install the adapter to the timing case.

i03401792

Housing (Front) - Install (Timing Case)

a. If necessary, install studs (8) to timing case (3). Apply Tooling (C) to the threads of studs (8). Install the studs to the timing case and tighten the studs securely.

SMCS Code: 1151-012

b. Position gasket (7) onto timing case (3).


c. Install adapter (6) to timing case (3).

Table 42

d. Install nuts and washers (5) to adapter (6). Tighten nuts finger tight.

Required Tools Tool

Part Number

A

-

B C

Part Description

Qty


2

T6253/354

Seal Carrier Alignment Tool

1

21820117


1


KENR6945

6. Use a suitable lifting device to lift timing case (3) into position. The timing case weighs approximately 90 kg (200 lb). Install the timing case. Note: Ensure that the timing case is seated on the dowels in the backplate. 7. Install bolts (4) hand tight. Remove Tooling (A) and install the remaining bolts (4) hand tight. Note: Ensure that bolts of different lengths are installed in the correct positions. Ensure that gasket (2) (not shown) protrudes below the base of the timing case. 8. Install the nuts and bolts (1) to timing case (3) hand tight. Note: Ensure that the nuts and bolts of different lengths are installed in the correct positions. Illustration 251

g01857733

9. Tighten bolts (4) to a torque of 47 N·m (35 lb ft).

3. Ensure that dowels (9) are correctly located in the engine cylinder block and backplate. 4. Install Tooling (A) to Positions (X) on the backplate. 5. Align gasket (2) (not shown) with Tooling (A). Install the gasket to the backplate.

Tighten the nuts and bolts (1) to a torque of 47 N·m (35 lb ft). Remove excess material from gasket (2) (not shown). The gasket should be flush with the base of the timing case. 10. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Install” for the correct procedure.

Illustration 253

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11. If necessary, Install Tooling (B) to timing case (3) in order to align the adapter to the timing case. Tighten nuts and washers (5) to a torque of 25 N·m (18 lb ft).

Illustration 252

g01857913

12. Install a new crankshaft front oil seal. Refer to Disassembly and Assembly, “Crankshaft Front Oil Seal - Remove and Install”.

KENR6945


13. If necessary, install tube assembly from the water temperature regulator and the elbow on the water pump. Refer to Disassembly and Assembly, “Water Temperature Regulator - Remove and Install” for the correct procedure. End By: a. Install the damper to the crankshaft. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”. b. Install the water pumps. Refer to Disassembly and Assembly, “Water Pump - Install”. c. Install the camshaft speed sensor from timing case. Refer to Disassembly and Assembly, “Engine Speed Sensor (Camshaft) - Remove and Install”. i03401793

Crankcase Breather - Remove and Install SMCS Code: 1317-010


Illustration 254

g01837993

1. Loosen hose clamp (1) (not shown) and disconnect plastic hose assembly (2) from tube assembly (4). 2. Remove nuts (3) from the clamp for the tube assembly. 3. Loosen hose clamp (6). Remove the nut and bolt (5) (not shown) from tube assembly (4) and the tube assembly from crankcase breather (11). 4. Disconnect hose assembly (10) from crankcase breather (11) and the inspection cover. 5. Loosen hose clamp (7) and hose clamp (9). Disconnect tube assembly (8) from crankcase breather (11).


Illustration 255

g01838075


KENR6945

6. Support crankcase breather (11). Remove bolts (14) from the crankcase breather. 7. Remove bracket (13), heat shield (14) and crankcase breather (11). 8. If necessary, disassemble the crankcase breather. Refer to Operation and Maintenance Manual, “Engine Crankcase Breather - Clean” for the correct procedure.

Illustration 257

g01839653

10. If necessary, follow step10.a through step 10.c in order to remove the inspection cover from the engine cylinder block and studs from the inspection cover. a. Remove bolts and washers (24) and remove inspection cover (25) from the engine cylinder block. Illustration 256

g01839533

9. If necessary, follow step11.a through step 11.c in order to remove brackets from the engine cylinder block and the assembly of breather tube from the inspection cover. a. Remove bolts (15) and remove bracket (16).

Note: Mark the position and orientation of the inspection cover for installation purpose. b. Remove O-ring seal (22). c. If necessary, remove studs (25) from inspection cover (23).

Note: Note the position and orientation of bracket for installation purpose. b. Remove bolts (17) and remove bracket (18). Note: Note the position and orientation of bracket for installation purpose. c. Remove nuts (20) and remove the assembly of breather tube (19). Remove O-ring seal (21) (not shown).

Illustration 258

g01839533

KENR6945


11. If necessary, follow step11.a through step 11.c in order to Install brackets to the engine cylinder block and the assembly of the breather tube to the inspection cover. a. Remove bolts (15) and remove bracket (16). Note: Note the position and orientation of bracket for installation purpose. b. Remove bolts (17) and remove bracket (18).

b. Install a new O-ring seal (22) to inspection cover (25). c. Position inspection cover (25) onto the engine cylinder block. Install bolts and washers (24). Note: Ensure the correct orientation when the inspection cover is installed. d. Tighten bolts and washers (24) to a torque of 47 N·m (35 lb ft).

Note: Note the position and orientation of bracket for installation purpose. c. Remove nuts (20) and remove the assembly of breather tube (19). Remove O-ring seal (21) (not shown).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. If necessary, assemble the crankcase breather. Refer to Operation and Maintenance Manual, “Engine Crankcase Breather - Clean” for the correct procedure. Illustration 260

g01839533

3. If necessary, follow step3.a through step 3.d in order to Install brackets to the engine cylinder block and assembly of the breather tube to the inspection cover. a. Install a new O-ring seal (21) (not shown) to assembly of breather tube (19). Position assembly of breather tube (19) onto the inspection cover. b. Install nuts (20) to the assembly of breather tube (19). Tighten nuts to a torque of 47 N·m (35 lb ft). c. Position bracket (16) onto the engine cylinder block. Install bolts (15). Tighten bolts to a torque of 47 N·m (35 lb ft).

Illustration 259

g01839653

2. If necessary, follow step2.a through step 2.d in order to install the inspection cover to the cylinder block and install studs to the inspection cover. a. If necessary, install studs (25) to inspection cover (23) and tighten studs securely.

Note: Ensure the correct orientation when the bracket is installed. d. Position bracket (18) onto the engine cylinder block. Install bolts (17). Tighten bolts to a torque of 47 N·m (35 lb ft). Note: Ensure the correct orientation when the bracket is installed.


KENR6945

8. Tighten hose clamp (6) securely. Install nuts (3) to the clamp for the tube assembly. Tighten the nuts securely. 9. Connect plastic hose assembly (2) to tube assembly (4) and tighten hose clamp (1) (not shown) securely. 10. Connect hose assembly (10) to crankcase breather (11) and the inspection cover. Tighten hose assembly (10) securely. i03401794

Valve Mechanism Cover Remove and Install (Rocker Box Cover) SMCS Code: 1107-010 Illustration 261

g01838075

4. Install bolts (14) to crankcase breather (11) and position heat shield (14) and bracket (13) onto the crankcase breather. 5. Install crankcase breather (11) to brackets on the engine cylinder block. Install bolts (14) and tighten bolts to a torque of 47 N·m (35 lb ft).

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 fluids according to local regulations and mandates.

Illustration 262

g01837993

6. Connect tube assembly (8) to crankcase breather (11). Tighten hose clamp (7) and hose clamp (9) securely. 7. Connect tube assembly (4) to crankcase breather (11). Install the nut and bolt (5) (not shown). Tighten bolts to a torque of 47 N·m (35 lb ft).

KENR6945

Illustration 263


g01865457

Illustration 264

g01865457

1. Remove allen head bolts (2), washers (3) and curved washers (4).

2. Remove the protective backing from gasket (3) (not shown) and install the gasket to cover (1).

2. Remove cover (1).

3. Position cover (1) on the rocker box. Install allen head bolts (2), washers (3) and curved washers (4).

Note: If necessary, carefully tap the cover with a soft faced hammer in order to loosen the cover. 3. Remove gasket (5) (not shown) from cover (1).


Note: Position curved washers (4) below washers (3). 4. Tighten allen head bolts (2) evenly to a torque of 47 N·m (35 lb ft).

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the cover is clean and dry. Ensure that the gasket surface of the rocker box is clean and free from damage.

i03401796

Valve Mechanism Cover Base Remove and Install (Rocker Box) SMCS Code: 1120-010

Removal Procedure Start By: a. Remove the rocker assembly. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


KENR6945


Note: If necessary, carefully tap the rocker box with a soft faced hammer in order to loosen the rocker box. 5. Remove gasket (5) (not shown).


g01865746

Illustration 267

6. Remove O-ring seal (7). 7. If necessary, remove stud (8) from the cylinder head. Illustration 265

g01865743

1. Remove bolt (3). Loosen pipe (2) at both ends. Allow the oil to drain from the oil rail. 2. Disconnect the pipe from rocker box (1). Note: Cap the pipes and the connections on the rail.

Note: In order to remove stud (8), first drain the coolant to a level that is below the cylinder head. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure.


Required Tools Tool

Part Number

Part Description

Qty

A

21820117


1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 266

g01865745

3. Remove allen head bolts and washers (4). 4. Remove rocker box (1).

1. Ensure that the rocker box is clean and free from damage. Ensure that the gasket surface of the cylinder head is clean.

KENR6945


4. Position a new gasket (5) (not shown) on the cylinder head. 5. Align rocker box (1) with the dowels in the cylinder head and install the rocker box. 6. Install allen head bolts and washers (4). Tighten the allen head bolts to a torque of 70 N·m (50 lb ft).

Illustration 268

g01865746

2. If stud (8) for the rocker assembly was removed from the cylinder head, follow Step 2.a through Step 2.c in order to install the stud. a. Ensure that the threads of stud (8) are clean and dry. Ensure that the holes for the stud in the cylinder head are clean and dry. b. Apply Tooling (A) to the threads of stud (8). Note: Apply the Tooling to the end of the studs that have the short thread. c. Install stud (8) to the cylinder head. Tighten the studs to a torque of 47 N·m (35 lb ft). Note: Ensure that the coolant is filled to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure.

Illustration 270

g01865743

7. Connect pipe (2) to rocker box (1). Tighten the nuts at both ends of the pipe securely. 8. Install bolt (3) to the pipe clip. Tighten the bolt to a torque of 40 N·m (30 lb ft). End By: a. Install the rocker assembly. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install”. i03401798

3. Position a new O-ring seal (7) in the recess in the cylinder head.

Rocker Arm and Shaft Remove SMCS Code: 1102-011

Removal Procedure Start By: a. Remove the cover from the rocker box. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.

Illustration 269

g01865745


KENR6945

3. Remove bridge piece (4) and bridge piece (5) from the rocker box.


4. Remove pushrod (6) (not shown) and pushrod (7).

Contaminants may cause rapid wear and shortened component life. Note: Make temporary identification marks on the rocker assembly, on the bridge pieces and on the pushrods in order to show the location.

5. Repeat Step 1 through Step 4 in order to remove the remaining rocker assemblies. i03401800

Rocker Arm - Disassemble SMCS Code: 1123-015

Disassembly Procedure Start By: a. Remove the rocker assembly. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Rocker Arm and Shaft Assembly Illustration 271

g01864439

1. Make a temporary identification mark on each rocker arm and shaft assembly in order to show the location. Note: The components must be reinstalled in the original location and orientation. Do not interchange used components.

Illustration 272

g01864441

1. Remove nut (3) and allen head bolt (1). 2. Carefully remove rocker assembly (2) from the rocker box. Illustration 273

g01865273

KENR6945


2. Remove rocker arm assembly (3) from rocker shaft (4). Remove spacer (2) from rocker shaft (4). Remove rocker arm assembly (1) from rocker shaft (4).

i03401801

Rocker Arm - Assemble SMCS Code: 1123-016


Required Tools Tool

Part Number

Part Description

Qty

A

-

Loctite Activator

1

B

-

Loctite 603

1

NOTICE Keep all parts clean from contaminants. Illustration 274

g01865274

3. If necessary, remove nuts (5) and adjusters (6) from the rocker arms.


Bridge Piece

Bridge Piece

1. Inspect the bridge piece for wear or damage. Inspect the clearance between the bridge piece and the guide pillar in the cylinder head. Inspect the nut and the adjuster for damage and free from wear. Note: The components must be installed in the original location and orientation. Do not interchange used components.

Illustration 275

g01865275

1. If necessary, remove nut (9) and adjuster (8) from bridge piece (10). 2. Inspect pad (7) for wear or damage. If the pad is worn or damaged, use a suitable press in order to remove the pad from bridge piece (10). Illustration 276

g01865415


Illustration 277

KENR6945

g01865275

2. If the pad on the bridge piece required replacement, follow Step 2.a through Step 2.d in order to install a new pad.

Illustration 278

g01865274

2. If necessary, install adjusters (6) and install nuts (5) to the rocker arms.

a. Ensure that new pad (7) and the bore in bridge piece (10) are clean and dry. b. Apply Tooling (A) to Stem (X) on the pad and to Bore (Y) in the bridge piece. c. Apply Tooling (B) to Bore (Y) in the bridge piece. Note: Ensure that the top face of the bridge piece is not contaminated with Tooling (B). d. Install pad (7) to bridge piece (10). Note: Position the bridge piece with the pad upward. Allow Tooling (B) to cure for 2 hours before installing the bridge piece. 3. Install adjuster (8) and nut (9) to bridge piece (10).

Rocker Arm and Shaft Assembly 1. Check the rocker arms for wear or damage. Check the rocker shaft for wear or damage. Refer to Specifications, “Valve Mechanism” for more information. Ensure that the oil holes in the rocker shaft are free from restriction. Check that the nuts and the adjusters are free from damage. Note: The components must be installed in the original location and orientation. Do not interchange used components.

Illustration 279

g01865273

3. Lubricate rocker shaft (4) with clean engine oil. Install rocker arm assembly (1), spacer (2) and rocker arm assembly (3) to rocker shaft (4). End By: a. Install the rocker assembly. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install”.

KENR6945


i03401799

Rocker Arm and Shaft - Install SMCS Code: 1102-012

2. Apply clean engine oil to both ends of the pushrods. Install pushrod (6) (not shown) and pushrod (7) to the engine with the cup upward. Ensure that the ball end of each pushrod is correctly seated in the cam follower.


3. Lubricate the posts for the bridge pieces and lubricate the valves with clean engine oil.


4. Install bridge piece (4) and bridge piece (5).


5. Equalize the bridge pieces. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Adjust”.

1. Ensure that all components are clean and free from wear or damage. Replace any components that are worn or damaged.

6. Position rocker assembly (2) onto the rocker box. Note: Ensure that the rocker assembly is aligned with the dowels in the rocker box. Ensure that the adjustment screws are properly seated in the ends of the pushrods. 7. Install nut (1) and allen head bolt (3). Evenly tighten the nut and the allen head bolt in order to pull the rocker assembly into position.

Illustration 280

g01864441

Illustration 282

g01916697

8. Tighten nut (1) and allen head bolt (3) to a torque of 122 N·m (90 lb ft). 9. Recheck the torque of allen head bolts (6). Tighten the allen head bolts (6) to a torque of 70 N·m (50 lb ft). 10. Adjust the engine valve lash. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Adjust” for the correct procedure. Adjust the fuel injector timing.

Illustration 281

g01864439


KENR6945

End By: a. Install the cover to the rocker box. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. i03401802

Cylinder Head - Remove SMCS Code: 1100-011


Required Tools Tool

Part Number

Part Description

T6253/237

Cylinder head Lifting Tool

1

-

Bolts M10 by 70 mm

2

A

Qty

Illustration 283

g01865394

Typical example

Start By: a. Remove the spark plug. Refer to Disassembly and Assembly, “Spark Plug - Remove and Instal ”. b. Remove the oil line. Refer to Disassembly and Assembly, “Engine Oil Line- Remove and Install”. c. Remove the appropriate sections of the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold - Remove and Install”. d. Remove the appropriate sections of the inlet manifold. Refer to Disassembly and Assembly, “Inlet Manifold - Remove”. NOTICE Keep all parts clean from contaminants.

2. Follow Step 2.a through Step 2.c in order to remove the appropriate sections of the coolant rail. Note: The coolant rail can be removed as an assembly or as individual sections. To remove the front section, first loosen the thermostat housing. To remove the center section, first remove the rear section. a. Remove bolts (1). Remove nuts and bolts (2). b. Remove coolant rail (4). c. Remove O-ring seal (3). Remove gasket (5). 3. Remove the appropriate rocker box. Refer to Disassembly and Assembly, “Valve Mechanism Cover Base - Remove and Install”.

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 fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container. Refer to Operation and Maintenance Manual, “Cooling System Coolant Change” for the correct procedure.

Illustration 284

g01622284

Marking of the cylinder head bolts (X) After the first removal, reuse the bolt. (Y) After the second removal, reuse the bolt. (Z) After the third removal, renew the bolt.

4. Before removing the cylinder head bolts, the heads of the bolts should be marked with a dot from a center punch. Any bolts that have two dots before removal should not be reused.

KENR6945

Illustration 285


g01864053

Illustration 287

g01864200

7. Attach Tooling (A) to cylinder head (8). Carefully lift the cylinder head off the cylinder block. The weight of the cylinder head is approximately 40 kg (88 lb).

Illustration 286

g01511134

The cylinder head tightening sequence

5. Gradually loosen cylinder head bolts (6) in reverse numerical order to the sequence that is shown in Illustration 286. 6. Remove cylinder head bolts (6) and spacers (7) from cylinder head (8).

Illustration 288

g01454324

8. Remove retainer (9) from cylinder head (8). Remove O-ring seal (10) from the retainer.


KENR6945

i03403561

Cylinder Head - Install SMCS Code: 1100-012


Required Tools Tool

Illustration 289

g01865196

A

Part Number

Part Description

T6253/237

Cylinder head Lifting Tool

1

-

Bolts M10 by 70 mm

2


1


1

Loctite Copper Sealant

1

9. Remove O-ring seals (11), (12), (14), (15) and (16).

B

CV60889

10. Remove flame ring (13).

C

21820221

D

5920

Qty

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Thoroughly clean the gasket surface of the cylinder head and the crankcase. Ensure that there is no debris in the cylinder bores, the coolant passages or the lubricant passages.

Illustration 290

g01865213

11. Remove allen head bolt (19) and remove clamp (21). 12. Remove sleeve (17) from cylinder head (8). Remove O-ring seals(18). Remove sealing washer (20).

Illustration 291

g01879793

KENR6945

Illustration 292


g01879776

2. Install new O-ring seals (18) to sleeve (17). Apply Tooling (C) to O-ring seals. 3. Apply a bead of Tooling (D) to sleeve (17) in Position (X). Position a new sealing washer (20) onto the sleeve. 4. Install sleeve assembly (17) into cylinder head (8). Install clamp (21) and install allen head bolt (19). Tighten the allen head bolt to a torque of 136 N·m (100 lb ft).

Illustration 293

Illustration 294

g01454331

7. Install a new O-ring seal (10) to retainer (9). Install the retainer to cylinder head (8). Refer to Illustration 294 for the correct orientation of the retainer. Note: Use petroleum jelly in order to hold the retainer in position.

g01865196

5. Install flame ring (13). 6. Install new O-ring seals (11), (12), (14), (15) and (16). Note: Use petroleum jelly in order to hold the O-ring seals in position.

Illustration 295

g01864200

8. Attach Tooling (A) to cylinder head (8). Carefully, lift the cylinder head into position. The weight of the cylinder head is approximately 40 kg (88 lb). Note: Ensure that the cylinder head is aligned with the dowels in the crankcase. Ensure that the retainer and the O-ring seal are not dislodged.


Illustration 296

KENR6945

g01622284

Marking of the cylinder head bolts (X) After the first removal, reuse the cylinder head bolt. (Y) After the second removal, reuse the cylinder head bolt. (Z) After the third removal, renew the cylinder head bolt.

9. Inspect the cylinder head bolts for previous use. Refer to Illustration 296. If necessary, replace the cylinder head bolts.

Illustration 299

g01511134

10. Apply Tooling (B) to Threads (X) of cylinder head bolts (6). Apply Tooling (B) to the faces of washers (7). 11. Install cylinder head bolts (6) and spacers (7) to cylinder head (8).

Illustration 297

g01454332

12. Tighten cylinder head bolts (6) according to the following procedure: a. Tighten the cylinder head bolts hand tight in the sequence that is shown in Illustration 299. b. Tighten the cylinder head bolts to a torque of 135 N·m (100 lb ft) in the sequence that is shown in Illustration 299. c. Tighten the cylinder head bolts to a torque of 270 N·m (200 lb ft) in the sequence that is shown in Illustration 299. d. Tighten the cylinder head bolts to a torque of 540 N·m (400 lb ft) in the sequence that is shown in Illustration 299. e. Tighten the cylinder head bolts to a torque of 725 N·m (530 lb ft) in the sequence that is shown in Illustration 299.

Illustration 298

g01864053

13. Install the rocker box to the cylinder head. Refer to Disassembly and Assembly, “Valve Mechanism Cover Base - Remove and Install”.

KENR6945


c. Install the oil rail. Refer to Disassembly and Assembly, “Engine Oil Line- Remove and Install”. d. Install the spark plug. Refer to Disassembly and Assembly, “Spark Plug - Remove and Install ”. i03401804

Lifter Group - Remove (Cam Followers) SMCS Code: 1209-011


Illustration 300

g01865394


Typical example

14. Follow Step 14.a through Step 14.d in order to install the sections of the coolant rail to the cylinder head. Note: The coolant rail can be installed as an assembly or as individual sections. If a front section is installed, ensure that the thermostat housing is secured. Refer to Disassembly and Assembly, “Water Temperature Regulator Housing - Remove and Install” for more information.


a. Install O-ring seal (3) to coolant rail (4). Install gaskets (5) to the cylinder head. b. Install coolant rail (4) to the cylinder head. Position the heat shield on the coolant rail. c. Install bolts (1) finger tight. Install nuts and bolts (2) finger tight. d. Tighten bolts (1) to a torque of 47 N·m (35 lb ft). Tighten nuts and bolts (2) to a torque of 47 N·m (35 lb ft). 15. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. End By: a. Install the appropriate sections of the inlet manifold. Refer to Disassembly and Assembly, “Inlet Manifold - Install”. b. Install the appropriate sections of the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold - Remove and Install”.

Illustration 301

g01855773

1. If necessary, remove the crankcase breather. Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install”.


KENR6945

2. Remove bolts (2) and remove cam follower (1). Remove gasket (3) (not shown). The weight of the cam follower is approximately 16 kg (35 lb). Note: Do not remove dowels from the crankcase unless the dowels are damaged. 3. If necessary, remove the dowels. i03401806

Lifter Group - Disassemble (Cam Followers) SMCS Code: 1209-015

Disassembly Procedure Start By: a. Remove the cam followers. Refer to Disassembly and Assembly, “Lifter Group - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

g01857514

Illustration 303

4. Remove shaft (7). Remove cam follower (8) and spacer (9) from body (4). Remove cam follower (10) from body (4). 5. Remove shims (6) (not shown) from each assembly. Note the position of each shim. Make an identification mark on each component of the cam follower in order to show the location. Note: The components must be reinstalled in the original location and orientation. Do not interchange used components. i03401808

Lifter Group - Assemble (Cam Followers) SMCS Code: 1209-016


Required Tools

Illustration 302

g01857047

1. Make a temporary mark on shaft (7) for the correct installation. 2. Remove allen head bolt (2) and remove jet (3). 3. Remove allen head bolt (1) and allen head bolt (5) for body (4).

Tool

Part Number

Part Description

Qty

A

21820117


1


KENR6945


4. Ensure that both cam followers can rotate freely. Set the end play for both cam followers. Apply Tooling (A) to the threads of the grub screw. Install grub screw (1) and tighten securely. Refer to specifications, “Camshaft” for information on end play. 5. Install jet (3) and install allen head bolt (2). Tighten the allen head bolt securely. End By: a. Install the cam followers. Refer to Disassembly and Assembly, “Lifter Group - Install”. i03401805

Lifter Group - Install (Cam Followers) Illustration 304

g01857514

1. Ensure that all components are clean and free from damage. Note: The components must be reinstalled in the original location and orientation. Do not interchange used components. 2. Align cam follower (8) to body (4). Install the appropriate shim and install shaft (7). Align spacer (9) and install the appropriate shim. Install shaft (7). Align cam follower (10) and install the appropriate shim. Install shaft (7) into body (4).

SMCS Code: 1209-012

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. If necessary, install new dowels into the crankcase. 2. Ensure that the cam followers are clean and free from damage. Clean the gasket surface of the crankcase. Note: Ensure that debris does not enter the crankcase. 3. Lubricate the lobes of the camshaft and the rollers of the cam followers with clean engine oil.

Illustration 305

g01857047

3. Ensure correct alignment of shaft (7). Apply Tooling (A) to the threads of allen head bolts (5). Install allen head bolts (5) into body (4). Tighten the allen head bolts to a torque of 67 N·m (50 lb ft).


KENR6945


g01855773

Illustration 306

4. Install new gasket (3) (not shown). Align the cam follower to the dowels in the crankcase. Install cam follower (1). 5. Install bolts (2). Tighten the bolts to a torque of 50 N·m (37 lb ft).

Illustration 307

g01858958

1. Remove allen head bolts (1) and thrust plate (2). 2. Ensure that Tooling (A) is clean and free from burrs. Install Tooling (A) to the nose of camshaft (3).

6. If necessary, install the crankcase breather. Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install”. i03401809

Camshaft - Remove SMCS Code: 1210-011


Required Tools Tool

Part Number

Part Description

A

T6253/142

Camshaft Guide Tool

Qty 1

Start By: a. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. b. Remove the cam followers. Refer to Disassembly and Assembly, “Lifter Group - Remove”. c. Remove the camshaft gear. Refer to Disassembly and Assembly, “Gear Group (Front) - Remove”.

Illustration 308

g01858973

3. Use a long wooden drift in order to push on Tooling (A). Carefully push camshaft (3) out of the rear of the engine. Use a suitable sling in order to support the camshaft during the removal procedure. 4. Lift the camshaft from the engine. The weight of the camshaft is approximately 70 kg (155 lb). Place the camshaft on a suitable support. If necessary, remove Tooling (A) from the camshaft.

KENR6945


g01859034

Illustration 309

5. Remove bolts (4) and remove cover (5).

i03401810

Camshaft - Install Installation Procedure Table 49

6. When camshaft (3) is in the correct position, remove Tooling (A).

Required Tools

A

T6253/142

Part Number Camshaft Guide Tool

4. Use a suitable lifting device in order to lift the camshaft into position. The weight of the camshaft is approximately 70 kg (155 lb). 5. Align Tooling (A) with the rear camshaft bearing. Carefully push camshaft (3) into the engine. Use a suitable sling in order to support the camshaft during the installation procedure.

SMCS Code: 1210-012

Part Number

g01858973

3. Ensure that Tooling (A) is clean and free from burrs. Install Tooling (A) to the nose of camshaft (3).

6. Remove O-ring seal (6) from cover (5).

Tool

Illustration 310

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the camshaft is clean and free from wear or damage. Refer to Specifications, “Camshaft” for more information. 2. Inspect the camshaft bearings for wear or damage. If necessary, replace the camshaft bearings. Refer to Disassembly and Assembly, “Camshaft Bearings - Remove ” and Disassembly and Assembly, “Camshaft Bearings - Install ” for the correct procedures.

Illustration 311

g01858958

7. Position thrust plate (2) and install allen head bolts (1). Tighten the allen head bolts to a torque of 47 N·m (35 lb ft).


KENR6945


g01859034

Illustration 312

8. Position a new O-ring seal (6) onto cover (5). 9. Position cover (5) onto the cylinder block. Install bolts (4). Tighten the bolts to a torque of 27 N·m (20 lb ft). End By: a. Install the camshaft gear. Refer to Disassembly and Assembly, “Gear Group (Front) - Install”. b. Install the cam followers. Refer to Disassembly and Assembly, “Lifter Group - Install”. c. Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. i03401811

Camshaft Bearings - Remove SMCS Code: 1211-011

T6253/199

Camshaft Bearing Removal/Fitting Tool

A

2. Tighten the nut on Tooling (A) in order to pull camshaft bearing (1) from the crankcase.

SMCS Code: 1211-012

Required Tools Part Description

Note: Ensure that Tooling (A) is correctly aligned with the camshaft bearing and with the crankcase.

Camshaft Bearings - Install

Table 50

Part Number

1. Lubricate the threads on Tooling (A) with clean engine oil. Install Tooling (A) to the appropriate camshaft bearing.

i03401813

Removal Procedure

Tool

g01859303

Illustration 313

Qty 1

Start By: a. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove”.


Required Tools Tool

Part Number

Part Description

A

T6253/199

Camshaft Bearing Removal/Fitting Tool

Qty 1

KENR6945


Note: The camshaft bearing should be installed with Joint (X) in the twelve o'clock position. The locking tabs should face toward left side of the engine. View the engine from rear.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean the bearing housing in the crankcase. Ensure that the oil holes are free from debris. Lubricate the bearing housing with clean engine oil.

Illustration 316

g01637630

Alignment of the oil groove

3. Tighten the nut on Tooling (A) in order to pull camshaft bearing (1) into the crankcase. Install the camshaft bearing so that bearing is central in the bearing housing. Ensure that oil groove (Y) is aligned with the oil hole in the crankcase. End By: a. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Install”. i03401814

Engine Oil Pan - Remove SMCS Code: 1302-011 Illustration 314

g01859303


Illustration 315

g01859333

2. Position new camshaft bearing (1) on Tooling (A). Lubricate the threads on Tooling (A) with clean engine oil. Assemble Tooling (A).



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Engine Oil Pan 1. Drain the engine oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change.” for the correct procedure.

5. Remove the dipstick and tube (13) from engine oil pan (9). 6. Remove bolts (10) (not shown) from solenoid mounting bracket (11) for the starting motor. Position the solenoid mounting bracket for the starting motor away from the engine oil pan. Note: Note the position of any bracket. 7. Remove bolts (12) from engine oil pan (9). Note: Note the position of bolts of different lengths for installation purposes.

Illustration 317

g01819934

2. Remove bolts (5) and bolts (7). 3. Remove pipe (7) from engine oil pump (1) and the engine oil pan. Remove O-ring seal (8) (not shown). 4. Remove O-ring seal (4) (not shown) and spacer (3) (not shown). Remove O-ring seal (2) (not shown).

Illustration 319

g01820033

8. Support the weight of engine oil pan (9). The weight of the engine oil pan is approximately 60 kg (130 lb). 9. Lower engine oil pan (9) and then remove the engine oil pan. Remove gasket (14).

Illustration 318

g01820157

KENR6945


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

Suction Pipe and Strainer 1. Ensure that the components of the engine oil pan and suction pipe are clean and free from damage.

g01820393

Illustration 320

1. Remove bolts (15) and loosen the nuts on clamp (16). 2. Remove suction pipe (17) and strainer (18) from engine oil pan (9). i03401815

Engine Oil Pan - Install

Illustration 321

SMCS Code: 1302-012

g01820393

2. Install suction pipe (17) and strainer (18) to engine oil pan (9).


3. Install bolts (15) finger tight. Tighten bolts (15) to a torque of 47 N·m (35 lb ft).

Table 52

Required Tools

4. Tighten the nuts on clamp (16) to a torque of 25 N·m (18 lb ft).

Tool

Part Number

A

21820221


1

5. Ensure that suction pipe (17) and strainer (18) are installed correctly in the engine oil pan.

B

21820518

POWERPART Gasket and Flange Sealant

1

Engine Oil Pan

C

-


2

1. Ensure that the gasket surfaces of the engine oil pan and the crankcase are clean.

D

21820117


1

Part Description

Qty


Illustration 322

KENR6945

g01820713

Illustration 324

g01820157

Note: If a new gasket has been installed to the timing case, to the back plate or to the flywheel housing, ensure that the gasket is flush with the crankcase.

3. Position a new gasket (14) on oil pan (9).

2. Apply Tooling (B) to the face of the crankcase at Positions (X) and Positions (Y). Install Tooling (C) to each end of the crankcase.

4. Use a suitable lifting device to lift engine oil pan (9) into position. The weight of the engine oil pan is approximately 60 kg (130 lb). Align the engine oil pan with Tooling (C). Carefully install the engine oil pan.

Note: Ensure the correct orientation of the gasket.

5. Install bolts (12) finger tight to engine oil pan (9). 6. Remove Tooling (C) and install remaining bolts (12) finger tight to engine oil pan (9). 7. Position solenoid mounting bracket (11) for the starting motor and install bolts (10) (not shown) finger tight. 8. Tighten bolts (12) and bolts (10) to a torque of 47 N·m (35 lb ft). 9. Install the dipstick and tube (13) to engine oil pan (9). Tighten tube (13) securely.

Illustration 323

g01820033

KENR6945


i03401816

Cylinder Liner - Remove SMCS Code: 1216-011


Required Tools Tool

Part Number

A

SE253

B

T6253/152

Part Description

Qty

Engine Turning Tool

1

Liner Extractor

1

Start By:

Illustration 325

g01819934

10. Apply Tooling (A) to a new O-ring seal (2), a new O-ring seal (4) and a new O-ring seal (8). 11. Position a new O-ring seal (2) (not shown) and install spacer (3) (not shown) onto engine oil pan. Position a new O-ring seal (4) (not shown) onto spacer (3) (not shown).

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

13. Install bolts (7) to engine oil pump (1) hand tight.


14. Apply Tooling (D) to the threads of bolts (5). Install bolts (5) hand tight.


12. Position a new O-ring seal (2) (not shown) onto pipe (7). Install pipe (7) onto engine oil pump (1) and engine oil pan.

15. Tighten bolts (7) to a torque of 47 N·m (35 lb ft). 16. Tighten bolts (5) to a torque of 41 N·m (30 lb ft). 17. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil and Filter- Change” for the correct procedure. 18. Prime the engine oil system. Refer to Operation and Maintenance Manual, “Before Starting the Engine ” for the correct procedure.

1. Use Tooling (A) in order to rotate the crankshaft. Rotate the crankshaft until there is sufficient clearance in order to install Tooling (B).


Illustration 326

KENR6945

g01844363

2. Follow Step 2.a through Step 2.c in order to assemble Tooling (B) to the cylinder liner. a. Position the lower clamping plate in the bottom of the cylinder liner. Position the upper clamping plate in the top of the cylinder liner. b. Install the bolts to the clamping plates. Tighten the bolts securely. c. Locate the frame in the cylinder head bolt holes. Lubricate the threads with clean engine oil. 3. Tighten the forcing bolt on Tooling (B) in order to pull cylinder liner (1) from the crankcase. Note: A small quantity of coolant and accumulated debris will be released when the liner is removed from the crankcase. Ensure that the crankshaft is protected from the debris. 4. Lift Tooling (B) and the cylinder liner from the crankcase. The weight of Tooling (B) and the cylinder liner is approximately 45 kg (100 lb). Remove the cylinder liner from Tooling (B).

g01844493

Illustration 327

5. Remove O-ring seals (2) from cylinder liner (1). i03401817

Cylinder Liner - Install SMCS Code: 1216-012


Required Tools Tool

Part Number

C

21820221

D

-

Qty


1

Loctite 638

1

Liner Clamp Kit

1

-

Cylinder Head Bolts

2

-

Spacers

2

T6253/200 E

Part Description


KENR6945


1. Clean the interior of the crankcase. Ensure that the seat for the cylinder liner is clean, dry and free from rust or sealant. Ensure that the cylinder liner is clean and dry. If a used cylinder liner is installed, ensure that the cylinder liner is free from rust or sealant.

Illustration 328

g01454704

Illustration 330

2. Install new O-ring seals (2) to cylinder liner (1).

g01454329

6. Install Tooling (E). Note: Install Tooling (E) so that the Tooling does not foul the dowels in the crankcase. 7. Use Tooling (E) to push cylinder liner (1) into the crankcase. When the cylinder liner is correctly seated, tighten the bolts to a torque of 5 N·m (45 lb in). Allow Tooling (D) to cure for three hours before removing Tooling (E). Note: When the cylinder liner is correctly seated, the top of the cylinder liner will sit below the face of the crankcase. 8. Check Dimension (X). Dimension (X) ............................ 2.07 to 2.20 mm (0.082 to 0.087 inch) End By:

Illustration 329

g01454706

3. Apply Tooling (C) to Bore (Z) in the crankcase. 4. Apply Tooling (D) to Face (Y) on the crankcase. 5. Carefully install liner (1) to the crankcase. Push the liner into the crankcase by hand until the O-ring seals make contact with the bottom of the crankcase. Note: When the O-ring seals make contact with the bottom of the crankcase, resistance will be felt.

a. Install the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”.


KENR6945

i03401818

Piston Cooling Jets - Remove and Install SMCS Code: 1331-010


Required Tools Tool

Part Number

A

SE253

Part Description Engine Turning Tool

Qty 1

Start By: a. Remove the engine oil coolers. Refer to Disassembly and Assembly, “Engine Oil Cooler - Remove”. Illustration 331

g01845960


2. Remove bolt (3) and remove plate (2).


3. Rotate cooling jet (1) clockwise by 90 degrees. Rotate into Position (C). Withdraw the cooling jet from the crankcase.

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 fluids according to local regulations and mandates. 1. Use Tooling (A) in order to rotate the crankshaft so that the piston of the appropriate cylinder is at the top center position.

Illustration 332

g01846153

4. Remove O-ring seal (4). Remove plug (5) and remove O-ring seal (6).

KENR6945



1. lubricate the O-ring seal with clean engine oil. Install O-ring seal (4).

Table 56

Required Tools Tool

Part Number

A

SE253

B

T9142/21

Part Description

Qty

Engine Turning Tool

1

Drift

1

2. Install cooling jet (1) into Position (C). Rotate the cooling jet counterclockwise by 90 degrees.


Illustration 335

g01846294

3. Install bolt (3). Install Tooling (B). By using Tooling (B), install the cooling jet into the crankcase. Remove tooling (B) and bolt (3). 4. lubricate the O-ring seal with clean engine oil. Install O-ring seal (6) onto plug (5). Install the assembly into the cooling jet. Illustration 333

g01846153

5. Install plate (2) and install bolt (3). Tighten bolt (3) to a torque of 47 N·m (35 lb ft). End By: a. Install the engine oil coolers. Refer to Disassembly and Assembly, “Engine Oil Cooler - Install”. b. Install the Aftercooler. Refer to Disassembly and Assembly, “Aftercooler- Remove and Install”.

Illustration 334

g01845960


KENR6945

i03401819

Pistons and Connecting Rods - Remove SMCS Code: 1225-011


Required Tools Tool

Part Number

A

SE253

B

T6253/295

Part Description

Qty

Engine Turning Tool

1

Suction Cup

1

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

Illustration 336

g01848396

Illustration 337

g01848353

Illustration 338

g01848354

b. Remove the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. If necessary, remove the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Remove” for more information. 2. Use Tooling (A) to rotate the crankshaft to a convenient position. 3. Remove the carbon ridge from the top of the cylinder liner bore. Remove the carbon from the piston crown.

KENR6945


i03401821

Pistons and Connecting Rods - Disassemble SMCS Code: 1225-015


Required Tools

Illustration 339

g01848233

4. Remove bolts (3) and remove inspection cover (2). Remove O-ring seal (1). Note: The connecting rod and connecting rod cap have an etched Number (X) on the side. The number on connecting rod (6) and the number on connecting rod cap (5) must match. Ensure that the connecting rod and the connecting rod cap are marked for the correct location. If necessary, make a temporary mark on the connecting rod and the connecting rod cap in order to identify the cylinder number. 5. Use Tooling (A) to carefully rotate the crankshaft. Rotate the crankshaft until the appropriate piston is just after the top center position. 6. Remove connecting rod bolts (4) and connecting rod cap (5) from connecting rod (6). 7. Position Tooling (B) onto the crown of piston (7). Carefully expand Tooling (B) into the recess of the piston. Note: Ensure that Tooling (B) is installed to the piston securely. 8. Use Tooling (B) in order to remove the piston assembly from the cylinder liner bore. Note: Be careful not to damage the cylinder liner or the crankshaft journal during the removal of the piston assembly. 9. Temporarily install connecting rod cap (5) and connecting rod bolts (4) to connecting rod (6) in order to keep the bearing shell in position.

Tool

Part Number

C

T6253/258

Circlip Pliers

1

D

T6253/256

Piston Ring Pliers

1

E

T6253/159

Small End Bush Tool

1

Part Description

Qty

Start By: a. Remove the pistons and the connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Make a temporary mark on the components of the piston and connecting rod assembly in order to show the location and the orientation. This will ensure that the components of each piston and connecting rod assembly can be reinstalled in the original cylinder. Do not interchange used components.


KENR6945

6. Remove piston pin (11) and connecting rod (1) from piston (12). Note: If the piston pin cannot be removed by hand, heat the piston to a temperature of 45 ± 5 °C (113 ± 9 °F). Note the orientation of the connecting rod to the piston.

Illustration 340

g01584454

g01850173

Illustration 342

Typical example

2. Remove connecting rod bolts (3) and connecting rod cap (2) from connecting rod (1). 3. Remove lower bearing shell (6) from connecting rod cap (2). Remove upper bearing shell (5) from connecting rod (1).

7. Inspect small end bush (13) for wear or for damage. Refer to Specifications, “Pistons and Rings” for more information. If the small end bush is damaged or worn beyond the specified limits, use Tooling (E) in order to remove the small end bush from connecting rod (1). i03401822

Pistons and Connecting Rods - Assemble SMCS Code: 1225-016


Required Tools

Illustration 341

g01850121

4. Use Tooling (D) in order to remove compression rings (7) and (8), and oil control ring (9) from piston (12). Note: Identify the position and the orientation of the compression rings and the oil control ring. 5. Use Tooling (C) to remove circlips (10) from piston (12).

Tool

Part Number

C

T6253/258

Circlip Pliers

1

D

T6253/256

Piston Ring Pliers

1

E

T6253/159

Small End Bush Tool

1

Part Description

Qty

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Follow Step 1.a through Step 1.e in order to inspect the pistons and the connecting rods.

KENR6945


a. Carefully remove the carbon deposits from the piston. Visually check the piston for cracks, signs of seizure or other damage. b. Inspect piston ring grooves for wear. Refer to Specifications, “Pistons and Rings” for more information. c. Carefully remove the carbon deposits from the piston rings. Inspect the piston rings for wear or damage. Install the piston rings into the cylinder liner bore and check the clearance between the ends of the piston rings. Refer to Specifications, “Pistons and Rings” for more information. d. Check that the piston pin is free from wear or damage. Refer to Specifications, “Pistons and Rings” for more information. e. Check that the connecting rod is free from cracks. Inspect the connecting rod for wear and for distortion. Refer to Specifications, “Connecting Rod” for more information. If the connecting rod requires replacement, ensure that the weight of the new connecting rod is the same weight as the original connecting rod.

Illustration 343

Illustration 344

g01850121

Illustration 345

g01854913

g01850173

2. If the small end bush required replacement, use Tooling (E) in order to install small end bush (13) to connecting rod (1). Note: A replacement small end bush is supplied, finished to the correct size.

The correct orientation of the piston and connecting rod (1) Connecting rod assembly (X) Camshaft (Y) Piston cooling jet (Z) Cut out for the piston cooling jet.


KENR6945

d. Use Tooling (D) to install top compression ring (7) into the top groove in piston (12). The identification “TOP” must be upward. e. Position the piston ring gaps at 120 degrees away from each other.

Illustration 346

g01850197

The location and orientation of the piston rings (7) Top compression ring (8) Intermediate compression ring (9) Oil control ring (12) Piston

3. Lubricate the small end bush and the bores in the piston with clean engine oil.

Illustration 347

g01584454

Illustration 348

g01622255

4. Ensure the correct orientation of the connecting rod and install connecting rod (1) to piston (12). Refer to illustration 345 for more information. Lubricate piston pin (11) with clean engine oil. Slide the piston pin into position. Note: If the piston pin cannot be installed by hand, heat the piston to a temperature of 45 ± 5 °C (113 ± 9 °F). 5. Use Tooling (C) to install new circlips (10). Ensure that the circlips are seated into the grooves. 6. Follow Steps 6.a through 6.e in order to install the piston rings to the piston. a. Position the spring for oil control ring (9) into the oil ring groove in piston (12). The central wire must be located inside the end of the spring. b. Use Tooling (D) to install oil control ring (9) over the spring. Note: Ensure that the central wire is 180 degrees from the ring gap. c. Use Tooling (D) to install intermediate compression ring (8) into the second groove in piston (12). The identification “TOP” must be upward.

Location of the bearing tab

7. Install upper bearing shell (5) to connecting rod (1). Install lower bearing shell (6) to connecting rod cap (2). Ensure that the bearings are correctly seated and that the tabs are located in the slots. Refer to illustration 348. 8. Temporarily install connecting rod cap (2) to connecting rod (1) in order to keep the bearings in position. Loosely install new connecting rod bolts (3). End By: a. Install the pistons and the connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”.

KENR6945


i03401820

Pistons and Connecting Rods - Install SMCS Code: 1225-012

Note: Ensure that Tooling (B) is installed to the piston securely. 3. Apply clean engine oil to the cylinder liner bore, to the piston rings and to the outer surface of the piston. 4. Lubricate the bearing shells and lubricate the crankshaft pin with clean engine oil. Lubricate the threads and the underside of the heads of the new connecting rod bolts with clean engine oil.


Required Tools Tool

Part Number

A

SE253

B

Part Description

Qty

Engine Turning Tool

1

T6253/295

Suction Cup

1

F

T6253/139

Piston Ring Compression Tool

1

G

SE671K

30 Degree Indicator Socket Tool

1


Note: Install the bearing shells dry when clearance checks are performed. Refer to Disassembly and Assembly, “Bearing Clearance - Check” for the correct procedure. Apply clean engine oil on the big end bearings for final assembly. 5. Ensure that the gaps for the piston rings are at 120 degrees away from each other. Position Tooling (F) onto the piston in order to compress the piston rings. Carefully position the piston and the connecting rod into the cylinder liner bore. Note: Ensure that Tooling (F) is installed correctly and that the piston can easily slide from the tool. Ensure that the piston and the connecting rod are installed in the correct cylinder.


g01851986

1. Installation of the piston and connecting rod assembly require two trained personnel. Use Tooling (A) to carefully rotate the crankshaft. Rotate the crankshaft until the appropriate crankshaft pin is just after the top center position. 2. Position Tooling (B) onto the crown of piston (7). Carefully expand Tooling (B) into the recess of the piston. Remove the connecting rod bolts and the connecting rod cap from the connecting rod.

g01854979

(X) Camshaft (Y) Piston cooling jet (Z) Cut out for the piston cooling jet. (6) Connecting rod

6. Ensure that the piston is correctly oriented. Refer to illustration 350. 7. Carefully push the piston and the connecting rod into the cylinder liner bore. At the same time, guide the connecting rod onto the pin of the crankshaft. Take care not to displace the bearing shells.


KENR6945

Note: Be careful not to damage the cylinder liner, the bearing shells or the crankshaft during installation of the piston and the connecting rod. 8. Remove Tooling (F).

Illustration 351

g01852121

Illustration 353

g01852318

Typical example

11. Use the following method in order to tighten the connecting rod bolts to the correct torque. a. Tighten connecting rod bolts (4) to a torque of 110 N·m (82 lb ft). b. Install Tooling (G) to connecting rod bolt (4). Apply light pressure to the wrench. Set the leading edge of Tooling (G) in line with the center of the connecting rod. Turn connecting rod bolt (4) through 30 degrees. The trailing edge of Tooling (G) is now in line with the center of the connecting rod.

Illustration 352

g01848353

9. The connecting rod and connecting rod cap have an etched Number (X) on the side. The number on connecting rod (6) and the number on connecting rod cap (5) must match. Position connecting rod cap (5) on the connecting rod.

c. Reposition Tooling (G) so that the leading edge of Tooling (G) is in line with the center of the connecting rod. Turn connecting rod bolt (4) through an additional 30 degrees. The trailing edge of Tooling (G) is now in line with the center of the connecting rod.

NOTICE Discard all used connecting rod bolts. 10. Install the new connecting rod bolts (4) to connecting rod cap (5) hand tight.

Illustration 354

g01852353

Using feeler gauges to check the side float of the connecting rods

KENR6945


12. Check the side float of the connecting rods. Connecting rod side float ........... 0.36 to 0.69 mm (0.014 to 0.027 inches)

Illustration 356

g01329038

1. Remove upper main bearings (1) from the crankcase. Note: The upper main bearings have a groove and two oil holes.

Illustration 355

g01848396

13. Install O-ring seal (1) and inspection plate (2). Install bolts (3). Tighten bolts to a torque of 47 N·m (35 lb ft). End By: a. Install the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install”. Illustration 357

b. Install the cylinder heads. Refer to Disassembly and Assembly, “Cylinder Head - Install”. i03401823

Crankshaft Main Bearings Remove and Install SMCS Code: 1203-010

Removal Procedure Start By: a. Remove the crankshaft and the thrust washers. Refer to Disassembly and Assembly, “Crankshaft - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

g01329039

2. Remove lower main bearings (2) from the main bearing caps. Note: The lower main bearings are plain bearings that have no oil holes.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Inspect the main bearings for wear or for damage. Refer to Specifications, “Crankshaft” for more information. If necessary, replace the main bearings. Note: If the engine is undergoing a major overhaul, the main bearings and the main bearing bolts should be replaced.


KENR6945

i03476540

Crankshaft - Remove (Eight Cylinder TRS Engines) SMCS Code: 1202-011

Removal Procedure Start By:

Illustration 358

g01329039

a. Remove the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install”.

2. Install lower main bearings (2) to the main bearing caps.

b. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove”.

Note: The lower main bearings are plain bearings that have no oil holes.

c. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove”. d. Remove the back plate. Refer to Disassembly and Assembly, “Engine Support (Front) - Remove and Install”. e. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 359

g01329038

3. Install upper main bearings (1) to the crankcase. Note: The upper main bearings have a groove and two oil holes. End By: a. Install the crankshaft and the thrust washers. Refer to Disassembly and Assembly, “Crankshaft - Install”.

1. The engine should be placed in the inverted position. The weight of the engine is approximately 2040 kg (4500 lb). Note: Place the engine on a suitable surface in order to avoid damage to the machined faces of the crankcase.

KENR6945

Illustration 360


g01853913

2. Rotate the crankshaft so that the center balance weights are in the horizontal position. 3. Remove allen head bolts (3). Note: Check the marking on each bearing cap.

Illustration 362

g01854055

Typical example

7. Attach a suitable sling and a lifting device to crankshaft (5). Attach the sling around the center balance weights of the crankshaft. The weight of the crankshaft is approximately 356 kg (785 lb). 8. Carefully lift crankshaft (5) out of the crankcase. Place the crankshaft on a suitable support.

4. Remove main bearing bolts (1). 5. Remove main bearing caps (2).

9. Remove the crankshaft main bearings. Refer to Disassembly and Assembly, “Crankshaft Main Bearings - Remove and Install”. i03401824

Crankshaft - Remove (Six Cylinder TRS Engines) SMCS Code: 1202-011

Removal Procedure Start By: Illustration 361

g01431403

6. Remove thrust washers (4) from the crankcase.

a. Remove the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install”.

Note: The crankshaft has two thrust washers. The thrust washers are located on each side of the rear main bearing. Note the orientation of the thrust washers.

b. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove”. c. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove”. d. Remove the back plate. Refer to Disassembly and Assembly, “Engine Support (Front) - Remove and Install”.


KENR6945

e. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. NOTICE Keep all parts clean from contaminants.

5. Remove thrust washers (3) from the crankcase. Note: The crankshaft has two thrust washers. The thrust washers are located on each side of the rear main bearing.

Contaminants may cause rapid wear and shortened component life. 1. The engine should be placed in the inverted position. The weight of the engine is approximately 2040 kg (4500 lb). Note: Place the engine on a suitable surface in order to avoid damage to the machined faces of the crankcase.

g01855273

Illustration 365

6. Attach a suitable sling and a lifting device to crankshaft (4). Attach the sling around the center balance weights of the crankshaft. The weight of the crankshaft is approximately 270 kg (595 lb). 7. Carefully lift crankshaft (4) out of the crankcase. Place the crankshaft on a suitable support.

Illustration 363

g01855194

2. Rotate the crankshaft so that the center balance weights are in the horizontal position.

8. Remove the crankshaft main bearings. Refer to Disassembly and Assembly, “Crankshaft Main Bearings - Remove and Install”. i03401826

3. Remove main bearing bolts (1).

Crankshaft - Install (Six Cylinder TRS)

4. Remove main bearing caps (2).

SMCS Code: 1202-012


Required Tools

Illustration 364

g01855276

Tool

Part Number

A

21825617

Part Description Dial Indicator

Qty 1

KENR6945


NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Inspect the crankshaft for wear and for damage. Refer to Specifications, “Crankshaft” for more information. 2. Install the main bearings to the crankcase and to the main bearing caps. Refer to Disassembly and Assembly, “Crankshaft Main Bearings - Remove and Install”. Note: Install the main bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, “Bearing Clearance - Check” for the correct procedure. Apply clean engine oil on the face of the main bearings for final assembly.

Illustration 366

Illustration 367

g01855276

5. Lubricate thrust washers (3) with clean engine oil. Install the thrust washers to the crankcase. Note: The crankshaft has two thrust plates. The thrust washers are located on each side of the rear main bearing. Install the thrust washers with the grooves toward the crankshaft.

g01855273

3. Attach a suitable sling and a lifting device to crankshaft (4). Attach the sling around the center balance weights of the crankshaft. The weight of the crankshaft is approximately 270 kg (595 lb). 4. Carefully lift crankshaft (4) into the crankcase. Note: The crankshaft should be installed with the center balance weights in the horizontal position.

Illustration 368

g01855194


KENR6945

c. Tighten main bearing bolts (1) to a torque of 540 N·m (400 lb ft) in the sequence that is shown in Illustration 370. d. Tighten main bearing bolts (1) to a torque of 783 N·m (580 lb ft) in the sequence that is shown in Illustration 370. e. Ensure that the crankshaft rotates freely.

Illustration 369

g01331451

Identification of the main bearing caps

6. The crankcase and main bearing cap have a Number (X) on the bottom. The number on main bearing cap (2) must match the corresponding number on the crankcase. Install the main bearing caps to the crankcase. 7. Lubricate the underside of the head and the threads of main bearing bolts (1) with clean engine oil. Install the main bearing bolts finger tight.

Illustration 371

g01331447

Checking the end play of the crankshaft

9. Use Tooling (A) to check the crankshaft end play. Crankshaft end play (new thrust washers) .. 0.13 to 0.51 mm (0.005 to 0.020 inch) Maximum crankshaft end play (service limit) ................................... 0.55 mm (0.025 inch) End By: a. Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”.

Sequence for tightening main bearing bolts (1)

b. Install the back plate. Refer to Disassembly and Assembly, “Engine Support (Front) - Remove and Install”.

8. Use the following method in order to tighten the main bearing bolts to the correct torque.

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

Illustration 370

g01333139

a. Tighten main bearing bolts (1) to a torque of 135 N·m (100 lb ft) in the sequence that is shown in Illustration 370.

d. Install the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”.

b. Tighten main bearing bolts (1) to a torque of 270 N·m (200 lb ft) in the sequence that is shown in Illustration 370.

e. Install the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install”.

KENR6945


Crankshaft - Install (Eight Cylinder TRS Engines)

3. Attach a suitable sling and a lifting device to crankshaft (5). Attach the sling around the center balance weights of the crankshaft. The weight of the crankshaft is approximately 356 kg (785 lb).

SMCS Code: 1202-012

4. Carefully lift crankshaft (5) into the crankcase.


Note: The crankshaft should be installed with the center balance weights in the horizontal position.

i03476541

Table 62

Required Tools Tool

Part Number

A

21825617

Part Description Dial Indicator

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Inspect the crankshaft for wear and for damage. Refer to Specifications, “Crankshaft” for more information. 2. Install the main bearings to the crankcase and to the main bearing caps. Refer to Disassembly and Assembly, “Crankshaft Main Bearings - Remove and Install”.

Illustration 373

g01431403

5. Lubricate thrust washers (4) with clean engine oil. Install the thrust washers to the crankcase. Note: The crankshaft has two thrust plates. The thrust washers are located on each side of the rear main bearing. Install the thrust washers with the grooves toward the crankshaft.

Note: Install the main bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, “Bearing Clearance - Check” for the correct procedure. Apply clean engine oil on the face of the main bearings for final assembly.

Illustration 374

Illustration 372 Typical example

g01854055

g01853913


KENR6945

b. Tighten main bearing bolts (1) to a torque of 270 N·m (200 lb ft) in the sequence that is shown in Illustration 376. c. Tighten main bearing bolts (1) to a torque of 540 N·m (400 lb ft) in the sequence that is shown in Illustration 376. d. Tighten main bearing bolts (1) to a torque of 783 N·m (580 lb ft) in the sequence that is shown in Illustration 376.

Illustration 375

g01331451

Identification of the main bearing caps

6. The crankcase and main bearing cap have a Number (X) on the bottom. The number on main bearing cap (2) must match the corresponding number on the crankcase. Install the main bearing caps to the crankcase. 7. Lubricate the underside of the head and the threads of main bearing bolts (1) with clean engine oil. Install the main bearing bolts finger tight. 8. Lubricate the underside of the head and the threads of allen head bolts (3) with clean engine oil. Install the allen head bolts finger tight.

Illustration 377

g01854273

Sequence for tightening the side allen head bolts

e. Tighten allen head bolts (3) to a torque of 168 N·m (124 lb ft) in the sequence that is shown in Illustration 377. f. Ensure that the crankshaft rotates freely.

Illustration 376

g01854235

Sequence for tightening main bearing bolts (1)

9. Use the following method in order to tighten the main bearing bolts to the correct torque. a. Tighten main bearing bolts (1) to a torque of 135 N·m (100 lb ft) in the sequence that is shown in Illustration 376.

KENR6945


i03401827

Crankshaft Gear - Remove and Install SMCS Code: 1204-010-GE


Required Tools Tool

Part Number

A

-

Part Description Puller

Qty 1

Start By:

Illustration 378

g01331447

Checking the end play of the crankshaft

10. Use Tooling (A) to check the crankshaft end play. Crankshaft end play (new thrust washers) .. 0.13 to 0.51 mm (0.005 to 0.020 inch)

a. Remove the timing gears. Refer to Disassembly and Assembly, “Gear Group (Front) - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Maximum crankshaft end play (service limit) ................................... 0.55 mm (0.025 inch) End By: a. Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. b. Install the back plate. Refer to Disassembly and Assembly, “Engine Support (Front) - Remove and Install”. c. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Install”. d. Install the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”. e. Install the piston cooling jets . Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install”.

Illustration 379

g01454825

1. Ensure that Timing Mark (X) is upward. 2. Use Tooling (A) in order to pull crankshaft gear (2) from crankshaft (1).



KENR6945

i02748526

Bearing Clearance - Check SMCS Code: 1203-535; 1219-535

Measurement Procedure Table 64

Required Tools Tool

Illustration 380

g01454833

1. Heat crankshaft gear (1) in an oven to 250 °C (480 °F).

Part Number

2. Align Timing Mark (X) on crankshaft gear (2) with Timing Mark (X) on crankshaft (1). Install the crankshaft gear to the crankshaft. Note: Ensure that the crankshaft gear is seated against the shoulder on the crankshaft.

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

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

Part Description


End By: a. Install the timing gears. Refer to Disassembly and Assembly, “Gear Group (Front) - Install”.

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 specific 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. 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.

KENR6945


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

• The crankshaft must be free of oil at the contact points of Tooling (A). 1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap. Note: Do not allow Tooling (A) to extend over the edge of the bearing. 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.

i03554966

Engine Sensors - Remove and Install (Knock Sensor) SMCS Code: 1718-010; 1906-010; 1907-010; 1912-010; 1917-010; 1921-010; 1922-010; 1923-010; 1924-010; 1925-010; 1929-010


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 381.

Illustration 382

Illustration 381

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 Specifications Manual, “Connecting Rod Bearing Journal” and Specifications Manual, “Main Bearing Journal” for the correct clearances.

g01880138

1. Disconnect harness assembly (2) from knock sensor (1). 2. Remove bolt (3) from knock sensor (1). Remove knock sensor (1) from the engine cylinder block. Note: Note the orientation of the knock sensor for installation purpose. 3. If necessary, follow Step 1 through Step 5 in order to remove the remaining knock sensors from the engine cylinder block.


KENR6945


i03401840

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Incorrect installation of the knock sensors may lead to poor operation of the engine control system. Subsequently lead to engine damage.

Engine Sensors - Remove and Install (Exhaust Temperature Thermocouple) SMCS Code: 1718-010; 1906-010; 1907-010; 1912-010; 1917-010; 1921-010; 1922-010; 1923-010; 1924-010; 1925-010; 1929-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Thermocouples can be installed in the exhaust manifolds on some engines. There is a thermocouple for each cylinder. This procedure can be used to remove the thermocouple. This procedure can be used to Install the thermocouple.

Illustration 383

g01880138

1. Ensure that the engine cylinder block is clean and free from debris in the mounting position of the knock sensor. 2. Position knock sensor (1) onto the engine cylinder block. Note: Ensure the correct orientation of the knock sensor. 3. Install bolt (3) to the knock sensor. Tighten the bolts to a torque of 30 N·m (22 lb ft). 4. Connect harness assembly (2) to knock sensor (1). 5. If necessary, follow Step 1 through Step 5 in order to install the remaining knock sensors to the engine cylinder block.

Illustration 384

g01860836

2. Disconnect harness assembly (1). 3. Disconnect the gland nut from thermocouple (2). 4. Remove thermocouple (2) from adapter (4). 5. If necessary, remove adapter (3) from exhaust manifold (4).

KENR6945



i03535760

Table 65

Required Tools Tool

Part Number

A

CV60889

Part Description POWERPART Anti-Sieze Compound

Qty 1


Engine Sensors - Remove and Install (High Inlet Manifold Pressure Shutdown Sensor) SMCS Code: 1718-010; 1906-010; 1907-010; 1912-010; 1917-010; 1921-010; 1922-010; 1923-010; 1924-010; 1925-010; 1929-010


Illustration 385

g01860836

1. If necessary, install adapter (3) to exhaust manifold (4). Apply Tooling (A) to the threads of adapter (3). Install the adapter to the exhaust manifold and tighten the adapter securely. 2. Install thermocouple (2) to adapter (3). Tighten the gland nut for the thermocouple securely. 3. Connect harness assembly (1).

Illustration 386

g01863674

1. Loosen screws (2) and remove cover (3) from high inlet manifold pressure shutdown sensor (1). Remove gasket (4) (not shown). 2. Loosen gland nut (5). Loosen screws (6) and disconnect harness assembly (7) from high inlet manifold pressure shutdown sensor (1).


KENR6945

g01863673

Illustration 387

3. Disconnect tube assembly (9) from high inlet manifold pressure shutdown sensor (1). 4. Remove nuts (10) and remove the high inlet manifold pressure shutdown sensor from the inlet manifold. 5. If necessary, remove adapter (11) from the inlet manifold. 6. If necessary, remove adapter (8) from the high inlet manifold pressure shutdown sensor.

Installation Procedure Required Tools Part Number

A

21820121


g01863673

1. If necessary, install adapter (11) to the inlet manifold. Apply Tooling (A) to the threads of adapter (11). Install adapter (11) to the inlet manifold and tighten securely. 2. If necessary, install adapter (8) to the high inlet manifold pressure shutdown sensor. Apply Tooling (A) to the threads of adapter (8). Install adapter (8) to the high inlet manifold pressure shutdown and tighten securely. 3. Position high inlet manifold pressure shutdown sensor (1) onto the inlet manifold. Install nuts (10) finger tight. 4. Connect tube assembly (9) to high inlet manifold pressure shutdown sensor (1) finger tight.

Table 66

Tool

Illustration 388

Qty 1


5. Tighten nuts (10) to a torque of 9 N·m (80 lb in). Tighten tube assembly (9) securely.

KENR6945


1. Drain the coolant from the cooling system to a level that is below the coolant temperature switch. Use a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.

Illustration 389

g01863674

6. Connect harness assembly to high inlet manifold pressure shutdown sensor (1). Tighten screw (6) securely. Tighten gland nut (5) securely. 7. Position a new gasket (4) (not shown) onto cover (3). Install cover (3) to high inlet manifold pressure shutdown sensor (1) and tighten screws (2) securely. i03401841

g01861336

Illustration 390

2. Disconnect harness assembly (1) from coolant temperature switch (3). 3. Remove coolant temperature switch (3) from thermostat housing (2).

Coolant Temperature Switch Remove and Install

4. Remove sealing washer (4) (not shown) from coolant temperature switch (3).

SMCS Code: 1906-010


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 fluids according to local regulations and mandates.

Table 67

Required Tools Tool

Part Number

A

21820121


Qty 1



KENR6945


Illustration 391

g01861336

1. Install a new sealing washer (4) (not shown) to coolant temperature switch (3). Apply Tooling (A) to the threads of coolant temperature switch (3). 2. Install coolant temperature switch (3) into thermostat housing (2). Tighten the coolant temperature switch to a torque of 30 N·m (22 lb ft). 3. Connect harness assembly (1) to coolant temperature switch (3).

g01860833

Illustration 392

4. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. i03401843

Engine Oil Pressure Switch Remove and Install SMCS Code: 1924

1. Disconnect harness assembly (4) from engine oil pressure switch (3). 2. Remove engine oil pressure switch (3) from adapter (2). 3. If necessary, remove adapter (2) from the engine cylinder block. Follow Step 3.a through Step 3.b in order to remove the adapter from the engine cylinder block.

Removal Procedure

a. Remove adapter (2) from the engine cylinder block.


b. Remove sealing washer (1).



Required Tools Tool

Part Number

A

21820121


Qty 1

KENR6945


i03401842

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. If necessary, Install adapter (2) to the engine cylinder block. Follow Step 3.a through Step 3.b in order to install the adapter to the engine cylinder block.

Engine Oil Pressure Switch Remove and Install (Alternator Warning Lamp) SMCS Code: 1924

Removal Procedure

a. Install a new sealing washer (1) to adapter (2).


b. Apply Tooling (A) to the threads of adapter (2). Install adapter (2) to the engine cylinder block.


c. Tighten the adapter to a torque of 47 N·m (35 lb ft).


Illustration 393

g01860833

2. Apply Tooling (A) to the threads of oil pressure switch (3). Install engine oil pressure switch (3) to adapter (2). Tighten the engine oil pressure switch to a torque of 9.5 N·m (84 lb in). 3. Connect harness assembly (4) to engine oil pressure switch (3).

Illustration 394

g01860834

1. Disconnect harness assembly (1) from engine oil pressure switch (2). 2. Remove engine oil pressure switch (2) from engine oil filter base(3).


KENR6945


i03401844

Table 69

Required Tools Tool

Part Number

A

21820121

Part Description

Qty

POWERPART Hydraulic Threadseal

1

SMCS Code: 1907-010; 5626-010

Removal Procedure


Illustration 395

Engine Speed Sensor Remove and Install (Overspeed Sensor)


g01860834 g01859306

1. Apply Tooling (A) to the threads of oil pressure switch (2). Install engine oil pressure switch (2) to engine oil filter base (3). Tighten the engine oil pressure switch to a torque of 9.5 N·m (84 lb in).

Illustration 396

2. Connect harness assembly (1) to engine oil pressure switch (2).

2. Loosen locknut (4) and remove engine overspeed speed sensor (3) from flywheel housing (2).

1. Disconnect harness assembly (1) from engine overspeed speed sensor (3).


Required Tools Tool

Part Number

A

SE253

Part Name Engine cranking device

Qty 1


KENR6945


1. Refer to Operation and Maintenance Manual, “Speed Sensor - Clean/Inspect” for the correct procedure.

i03530361

Engine Speed Sensor Remove and Install (Camshaft Timing Sensor) SMCS Code: 1907-010; 5626-010


Illustration 397

g01859306

2. Install tooling (A) to flywheel housing (2). 3. Use tooling (A) in order to rotate the engine. Align one tooth of the flywheel ring gear to the center position of the tapped hole in flywheel housing (2). 4. Install the engine overspeed speed sensor (3) into flywheel housing (2). Screw the engine overspeed speed sensor until the engine speed sensor just touches the tooth of the flywheel ring gear. Unscrew the engine overspeed speed sensor In a counterclockwise direction by half a turn. This will give a clearance of 0.5 to 0.8 mm (0.02 to 0.03 inch). 5. Tighten locking nut (4) to a torque of 22 N·m (16 lb ft). Note: Ensure that engine overspeed speed sensor (3) does not turn when locking nut (4) is torqued. 6. Remove tooling (A) from flywheel housing (2). 7. Connect harness assembly (1) to engine overspeed speed sensor (3).

Illustration 398

g01859354

1. Disconnect harness assembly (1) from engine camshaft timing sensor (2). 2. Loosen locknut (3) and remove engine camshaft timing sensor (2) from adapter plate (6) on timing case (8). Remove sealing washer (4). 3. If necessary, remove adapter plate (6) from timing case(8). Follow Step 3.a through Step 3.c in order to remove the adapter plate. a. Remove nuts (7) from adapter (6). b. Remove adapter (6) from timing case (8). c. Remove gasket (5) (not shown).


KENR6945


Required Tools Tool

Part Number

A

SE253

Part Name

Qty

Engine cranking device

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Refer to Operation and Maintenance Manual, “Speed Sensor - Clean/Inspect” for the correct procedure. Illustration 400

g01861514

4. Use tooling (A) in order to rotate the engine. Align one magnet (9) on the camshaft gear to the center position of tapped Hole (B) in adapter plate (5). 5. Install engine camshaft timing sensor (2) into adapter plate (5). Screw the engine camshaft timing sensor until the engine camshaft timing sensor just touches the magnet on the camshaft gear. Unscrew the engine camshaft timing sensor In a counterclockwise direction by half a turn. This will give a clearance of 0.5 to 0.8 mm (0.02 to 0.03 inch). 6. Tight locking nut (3) to a torque of 22 N·m (16 lb ft).

Illustration 399

g01859354

2. If necessary, install adapter plate (6) to timing case (8). Follow Step 2.a through Step 2.c in order to install the adapter plate. a. Position a new gasket (5) (not shown) onto timing case (8). b. Install adapter (6) onto timing case (8). c. Install nuts (7) to adapter (6). Tighten nuts 22 N·m (16 lb ft). 3. Install tooling (A) to the flywheel housing.

Note: Ensure that engine camshaft timing sensor (2) does not turn when locking nut (3) is torqued. 7. Remove tooling (A) from the flywheel housing. 8. Connect harness assembly (1) to engine camshaft timing sensor (2).

KENR6945


i03401845


Engine Speed Sensor Remove and Install (Engine Speed for Governor Control)

Contaminants may cause rapid wear and shortened component life. 1. Refer to Operation and Maintenance Manual, “Speed Sensor - Clean/Inspect” for the correct procedure.

SMCS Code: 1907-010; 5626-010


Illustration 402

g01859003

2. Install tooling (A) to flywheel housing (2). 3. Use tooling (A) in order to rotate the engine. Align one tooth of the flywheel ring gear to the center position of the tapped hole in flywheel housing (2). g01859003

Illustration 401

1. Disconnect harness assembly (1) from engine speed sensor (3). 2. Loosen locknut (4) and remove engine speed sensor (3) from flywheel housing (2).


4. Install engine speed sensor (3) into flywheel housing (2). Screw the engine speed sensor until the engine speed sensor just touches the tooth of the flywheel ring gear. Unscrew the engine speed sensor In a counterclockwise direction by half a turn. This will give a clearance of 0.5 to 0.8 mm (0.02 to 0.03 inch). 5. Tighten locking nut (4) to a torque of 22 N·m (16 lb ft).

Table 72

Note: Ensure that engine speed sensor (3) does not turn when locking nut (4) is torqued.

Required Tools Tool

Part Number

A

SE253

Part Name Engine cranking device

Qty 1

6. Remove tooling (A) from flywheel housing (2). 7. Connect harness assembly (1) to engine speed sensor (3).


KENR6945

i03401846


Boost Pressure Sensor Remove and Install (Boost Pressure and Temperature Sensor)


SMCS Code: 1917-010


Illustration 404

g01862655

1. Lubricate a new O-ring seal (3) (not shown) with Tooling (A). Install the O-ring seal to boost pressure and temperature sensor (1). 2. Install boost pressure and temperature sensor (1) to inlet manifold (4). 3. Install nut (2). Tighten the nut to a torque of 9 N·m (80 lb in). g01862655

Illustration 403

1. Disconnect harness assembly (5) from boost pressure and temperature sensor (1).

4. Connect harness assembly (5) to boost pressure and temperature sensor (1). i03401860

2. Remove nut (2) from boost pressure and temperature sensor (1). 3. Remove boost pressure and temperature sensor (1) from inlet manifold (4). 4. Remove O-ring seal (3) (not shown) from boost pressure and temperature sensor (1).

Installation Procedure Required Tools Part Number

A

21820221

Part Description POWERPART Rubber Grease

SMCS Code: 1408-010


Table 73

Tool

Ignition Wiring Harness Remove and Install (Ignition Wiring Harness Rail)

Qty 1


KENR6945


5. Disconnect the customer connection. NOTICE Comply with the local official gas regulations regarding isolating the gas supply. 1. Turn the gas supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position.

Illustration 405

g01837973

Illustration 406

g01840754

3. Disconnect coil leads (5). 4. Disconnect harness assembly (1) from the control box. Remove cable straps. Note: Note the position of cable straps that have been removed.

6. Disconnect harness assembly (3) from knock sensors (4). 7. Use a suitable lifting device to support the weight of the ignition wiring harness rail. The weight of the ignition wiring harness rail is approximately 25 kg (55 lb). Remove nuts (2) and remove the ignition wiring harness rail from mounting brackets.

Illustration 407

g01839674

Illustration 408

g01838013

8. If necessary, remove ignition coils (11) from ignition wiring harness rail (12). Follow Step 8.a through Step 8.d in order to remove the ignition coils from the ignition wiring harness rail. a. Remove cover (6) from ignition coils (11).


KENR6945

b. Remove nuts (8) from ignition coils (11). c. Remove harness assembly (8) from ignition coils (11).

1. If necessary, install ignition coils (11) to ignition wiring harness rail (12). Follow Step 8.a through Step 8.d in order to install the ignition coils to the ignition wiring harness rail.

d. Remove bolts (9) and spacers (10). Remove coil (11) from ignition wiring harness rail (12).

a. Position ignition coil (11) onto ignition wiring harness rail (12). b. Install bolts (9) and spacers (10) to ignition coil (11). Tighten the bolts to a torque of 25 N·m (18 lb ft).


c. Install harness assembly (8) onto ignition coils (11). Install nuts (7) to ignition coils (11) and tighten the nut securely. d. Install cover (6) to ignition coils (11).

Illustration 409

g01838013

Illustration 411

g01837973

2. Use a suitable lifting device to support the weight of the ignition wiring harness rail. The weight of the ignition wiring harness rail is approximately 25 kg (55 lb). Position ignition wiring harness rail onto the mounting brackets. 3. Install nuts (2) and tighten the nuts to a torque of 25 N·m (18 lb ft). 4. Connect coil lead (3) and connect harness assembly (1) to the control box.

Illustration 410

g01839674

KENR6945


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. 2. Make temporary identification marks on the harness assemblies that are connected to the alternator. Disconnect the harness assemblies from the alternator.

Illustration 412

g01840754

5. Connect harness assembly (5) to knock sensor (4). 6. Install new cable straps to harness assembly. Connect the customer connection. 7. Turn the battery disconnect switch to the ON position. 8. Turn the gas supply to the ON position. i03401864

Alternator - Remove and Install (Battery Charging Alternator)

Illustration 413

SMCS Code: 1405-010

4. Loosen the nut and bolt (1).

Removal Procedure

5. Loosen the nut and bolt (5).

g01871990

3. Remove bolts (6) and guard (4).

6. Push alternator (2) toward the engine. Slide belt (3) from the pulley of the alternator. 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. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

7. Remove the nut and bolt (5) from the alternator. 8. Remove the nut and bolt (1) from the alternator. Note: Support the weight of the alternator on removal of the nut and bolt (1). 9. Remove alternator (2) from the mounting bracket. 10. If necessary, follow Step 10.a through Step 10.c in order to remove the pulley from the alternator.


Illustration 414

KENR6945

g01871991

a. Remove grub screws (8) from pulley (7).

Illustration 416

g01871991

a. Ensure that the mating surface of the two halves of pulley (7) are clean, dry and free from damage. Align the halves of the pulley. Lightly lubricate grub screws (8) with clean engine oil. Install the grub screws to the pulley finger tight. b. Install pulley (7) to the alternator. c. Tighten grub screws (8). Tighten the grub screws alternately and tighten the grub screws evenly to a torque of 22 N·m (15 lb ft). d. Tap the outer half of pulley (7) with a soft faced hammer in order to seat the two halves of the pulley.

Illustration 415

g01871992

b. Lubricate one screw (8) with clean engine oil. Install the grub screw into the jacking hole in pulley (7). Tighten the grub screw until the center of the pulley is released from the shaft of the alternator. c. Remove the pulley from the shaft of the alternator. Remove grub screw (8) from pulley (7) and separate the two halves of the pulley.

Note: Use a block of wood in order to prevent damage to the pulley. e. Again, tighten grub screws (8) to a torque of 22 N·m (15 lb ft). Note: Ensure that the pulley is seated against the shoulder on the shaft of the alternator.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. If necessary, follow Step 1.b through Step 1.d in order to install the pulley for the alternator.

Illustration 417

g01871990

KENR6945


2. Position alternator (2) on the mounting bracket and push the alternator toward the engine. Slide belt (3) over the pulley of the alternator. Ensure that the belt is correctly aligned. Install the nut and bolt (1) hand tight. Install the nut and bolt (5) hand tight. 3. Ensure that the belt tension is correct. Refer to Operation and Maintenance Manual, “Belts Inspect/Adjust/Replace”. Tighten the nut and bolt (1) to a torque of 47 N·m (35 lb ft). Tighten the nut and bolt (5) to a torque of 47 N·m (35 lb ft). 4. Position guard (4) and install bolts (6). Tighten the bolts to a torque of 47 N·m (35 lb ft). 5. Connect the harness assemblies to the alternator. 6. Turn the battery disconnect switch to the ON position. Note: After the engine has been run for the appropriate length of time check the tightness of the grub screws that secure the alternator pulley. Refer to Operation and Maintenance Manual, “Alternator Pulley - Check.” for more information.

Illustration 418

g01871655

1. Remove bolt (2) and remove guard (1). 2. Remove the alternator. Refer to Disassembly and Assembly, “Alternator (Battery Charging Alternator) - Remove and Install” for the correct procedure.

i03401863

Alternator - Remove and Install (Battery Charging Alternator Drive) SMCS Code: 1405-010


Illustration 419


5. Remove the drive belt from pulley (13).

3. Remove bolts (4) and remove bracket (3). 4. Remove bolt (5) and remove link (5).

g01871656


Illustration 420

KENR6945

g01871657

Illustration 422

g01871657

1. If necessary, follow Step 1.a through Step 1.c in order to install the seal for the drive shaft. a. Press a new seal (9) into housing (8) so that the seal is flush with the outer face of the housing. Ensure that the seal spring is inward. b. Lubricate seal (9) with clean engine oil. Position a new gasket (10) (not shown) and install housing (8). Note: Ensure that the lip of the seal is not damaged as the seal is installed. Illustration 421

g01871658

6. Remove grub screws (12) from pulley (13). 7. Lubricate one grub screw (12) with clean engine oil. Install the grub screw into the jacking hole in pulley (13). Tighten the grub screw until the center of the pulley is released from the shaft. 8. Remove pulley (13) and key (7) from the shaft of the engine water pump. Remove grub screw (12) from the pulley and separate the two halves of the pulley. 9. If necessary, follow Step 1.a through Step 1.c in order to remove the seal for the drive shaft. a. Remove bolts (10). b. Remove housing (8) and gasket (11) (not shown). c. Remove seal (9) from housing (8).


c. Install bolts (10). Tighten the bolts to a torque of 25 N·m (18 lb ft). 2. Install key (7) to the drive shaft. 3. Ensure that the mating surface of the two halves of pulley (13) are clean, dry and free from damage. Align the halves of the pulley. Lightly lubricate grub screws (12) with clean engine oil. Install the grub screws to the pulley finger tight. 4. Install pulley (13) to the shaft of the engine water pump. 5. Tighten grub screws (12). Tighten the grub screws alternately and tighten the grub screws evenly to a torque of 22 N·m (15 lb ft). 6. Tap the outer half of pulley (13) with a soft faced hammer in order to seat the two halves of the pulley. 7. Again, tighten grub screws (12) to a torque of 22 N·m (15 lb ft). 8. Position the drive belt onto pulley (13).

KENR6945


i03401865

Electric Starting Motor Remove and Install SMCS Code: 1453-010

Removal Procedure

Accidental engine starting can cause injury or death to personnel working on the equipment.

Illustration 423

g01871656

9. Position bracket (3) and install bolts (4). Tighten the bolts to a torque of 47 N·m (35 lb ft). 10. Position link (6) and install bolt (5) hand tight. 11. Install the alternator. Refer to , “Alternator (Battery Charging Alternator) - Remove and Install” for the correct procedure. Note: After the engine has been run for the appropriate length of time check the tightness of the grub screws that secure the pulley. Refer to Operation and Maintenance Manual, “Alternator Pulley - Check.” for more information.

Illustration 424

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. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. 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. 2. Place identification marks on all of the harness assemblies that are connected to the solenoids and to the electric starting motors.

g01871655

1. Install bolt (2) and tighten the bolts to a torque of 47 N·m (35 lb ft).

Illustration 425

g01861654


KENR6945

3. Disconnect harness assembly (3) and harness assembly (5) from electric starting motor (2). 4. Disconnect harness assembly (4) from electric starting motor (2). 5. Attach a suitable sling and a lifting device to the upper electric starting motor (2). The weight of the electric starting motor is approximately 26 kg (57 lb). 6. Remove nuts (1). Use the lifting device to remove electric starting motor (2) from the flywheel housing.

Illustration 427

g01862597

1. If necessary, install the solenoid and the bracket to the engine oil pan. Follow Step 1.a through Step 1.c in order to install the solenoid and the bracket to the engine oil pan. a. Position bracket (8) onto the engine oil pan. Install bolts (7) and tighten the bolts to a torque of 47 N·m (35 lb ft). b. Position solenoid (12) onto bracket (8). Install the nuts and bolts (9) and tighten the bolts to a torque of 9 N·m (80 lb in). Illustration 426

g01862597

7. If necessary, remove the solenoid and the bracket from the engine oil pan. Follow Step 1.a through Step 7.c in order to remove the solenoid and the bracket from the engine oil pan.

c. Connect harness assembly (6), harness assembly (10) and harness assembly (11) to solenoid (12). Tighten nuts for the harness assemblies securely.

a. Disconnect harness assembly (6), harness assembly(10) and harness assembly (11) from solenoid (12). b. Remove the nuts and bolts (9) and remove solenoid (12) from bracket (8). c. Remove bolts (7) and remove bracket (8) from the engine oil pan.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 428

g01861654

KENR6945

2. Attach a suitable sling and a lifting device to the lower electric starting motor (2). The weight of the electric starting motor is approximately 26 kg (57 lb). 3. Use the lifting device to install electric starting motor (2) to the flywheel housing. Install nuts (1). Tighten the nuts to a torque of 85 N·m (60 lb ft). 4. Connect harness assembly (3) and harness assembly (5) to electric starting motor (2). Tighten nuts for the harness assemblies securely. 5. Connect harness assembly (4) to electric starting motor (2). Tighten nuts for the harness assembly securely. 6. Turn the battery disconnect switch to the OFF position.


176 Index Section

KENR6945

Index A Aftercooler - Assemble .......................................... 79 Assembly Procedure.......................................... 79 Aftercooler - Disassemble ..................................... 78 Disassembly Procedure ..................................... 78 Aftercooler - Install (Air Charge Cooler) ................ 80 Installation Procedure ........................................ 80 Aftercooler - Remove............................................. 76 Removal Procedure ........................................... 76 Air Cleaner - Remove and Install........................... 25 Installation Procedure ........................................ 25 Removal Procedure ........................................... 25 Alternator - Remove and Install (Battery Charging Alternator Drive)................................................. 171 Installation Procedure ...................................... 172 Removal Procedure ......................................... 171 Alternator - Remove and Install (Battery Charging Alternator) .......................................................... 169 Installation Procedure ...................................... 170 Removal Procedure ......................................... 169 Auxiliary Water Pump - Assemble (Gilkes Raw Water Pump) .................................................................. 72 Assembly Procedure.......................................... 72 Auxiliary Water Pump - Disassemble (Gilkes Raw Water Pump)........................................................ 70 Disassembly Procedure ..................................... 70 Auxiliary Water Pump - Install (Gilkes Raw Water Pump) .................................................................. 75 Installation Procedure ........................................ 75 Auxiliary Water Pump - Remove (Gilkes Raw Water Pump) .................................................................. 68 Removal Procedure ........................................... 68 B Bearing Clearance - Check ................................. 154 Measurement Procedure ................................. 154 Boost Pressure Sensor - Remove and Install (Boost Pressure and Temperature Sensor)................... 166 Installation Procedure ...................................... 166 Removal Procedure ......................................... 166 C Camshaft - Install................................................. 127 Installation Procedure ...................................... 127 Camshaft - Remove............................................. 126 Removal Procedure ......................................... 126 Camshaft Bearings - Install ................................. 128 Installation Procedure ...................................... 128 Camshaft Bearings - Remove ............................. 128 Removal Procedure ......................................... 128 Carburetor - Assemble .......................................... 22 Assembly Procedure.......................................... 22 Carburetor - Disassemble...................................... 21 Disassembly Procedure ..................................... 21

Carburetor - Install................................................. 23 Installation Procedure ........................................ 23 Carburetor - Remove............................................. 21 Removal Procedure ........................................... 21 Coolant Temperature Switch - Remove and Install ................................................................. 159 Installation Procedure ...................................... 159 Removal Procedure ......................................... 159 Crankcase Breather - Remove and Install........... 107 Installation Procedure ...................................... 109 Removal Procedure ......................................... 107 Crankshaft - Install (Eight Cylinder TRS Engines)............................................................. 151 Installation Procedure ...................................... 151 Crankshaft - Install (Six Cylinder TRS)................ 148 Installation Procedure ...................................... 148 Crankshaft - Remove (Eight Cylinder TRS Engines)............................................................. 146 Removal Procedure ......................................... 146 Crankshaft - Remove (Six Cylinder TRS Engines)............................................................. 147 Removal Procedure ......................................... 147 Crankshaft Front Seal - Remove and Install.......... 99 Installation Procedure ...................................... 100 Removal Procedure ........................................... 99 Crankshaft Gear - Remove and Install ................ 153 Installation Procedure ...................................... 153 Removal Procedure ......................................... 153 Crankshaft Main Bearings - Remove and Install.. 145 Installation Procedure ...................................... 145 Removal Procedure ......................................... 145 Crankshaft Rear Seal - Remove and Install .......... 86 Installation Procedure ........................................ 87 Removal Procedure ........................................... 86 Cylinder Head - Install ......................................... 120 Installation Procedure ...................................... 120 Cylinder Head - Remove ...................................... 118 Removal Procedure .......................................... 118 Cylinder Liner - Install.......................................... 134 Installation Procedure ...................................... 134 Cylinder Liner - Remove...................................... 133 Removal Procedure ......................................... 133 D Disassembly and Assembly Section........................ 5 E Electric Starting Motor - Remove and Install ....... 173 Installation Procedure ...................................... 174 Removal Procedure ......................................... 173 Engine Oil Cooler - Assemble ............................... 50 Assembly Procedure.......................................... 50 Engine Oil Cooler - Disassemble........................... 49 Disassembly Procedure ..................................... 49 Engine Oil Cooler - Install...................................... 50 Installation Procedure ........................................ 50

KENR6945

Engine Oil Cooler - Remove.................................. 47 Removal Procedure ........................................... 47 Engine Oil Filter Base - Install ............................... 45 Installation Procedure ........................................ 45 Engine Oil Filter Base - Remove ........................... 44 Removal Procedure ........................................... 44 Engine Oil Line - Remove and Install (Engine Oil Rail) ..................................................................... 41 Installation Procedure ........................................ 42 Removal Procedure ........................................... 41 Engine Oil Pan - Install ........................................ 131 Installation Procedure ...................................... 131 Engine Oil Pan - Remove .................................... 129 Removal Procedure ......................................... 129 Engine Oil Pressure Switch - Remove and Install ................................................................. 160 Installation Procedure ...................................... 160 Removal Procedure ......................................... 160 Engine Oil Pressure Switch - Remove and Install (Alternator Warning Lamp) ................................ 161 Installation Procedure ...................................... 162 Removal Procedure ......................................... 161 Engine Oil Pump - Assemble................................. 59 Assembly Procedure.......................................... 59 Engine Oil Pump - Disassemble............................ 58 Disassembly Procedure ..................................... 58 Engine Oil Pump - Install ....................................... 61 Installation Procedure ........................................ 61 Engine Oil Pump - Remove ................................... 57 Removal Procedure ........................................... 57 Engine Oil Relief Valve - Remove and Install (Engine Oil Cooler)............................................................ 54 Installation Procedure ........................................ 56 Removal Procedure ........................................... 54 Engine Oil Relief Valve - Remove and Install (Engine Oil Pressure Regulator) ....................................... 53 Installation Procedure ........................................ 53 Removal Procedure ........................................... 53 Engine Sensors - Remove and Install (Exhaust Temperature Thermocouple) ............................. 156 Installation Procedure ...................................... 157 Removal Procedure ......................................... 156 Engine Sensors - Remove and Install (High Inlet Manifold Pressure Shutdown Sensor) ............... 157 Installation Procedure ...................................... 158 Removal Procedure ......................................... 157 Engine Sensors - Remove and Install (Knock Sensor) .............................................................. 155 Installation Procedure ...................................... 156 Removal Procedure ......................................... 155 Engine Speed Sensor - Remove and Install (Camshaft Timing Sensor) ................................. 163 Installation Procedure ...................................... 164 Removal Procedure ......................................... 163 Engine Speed Sensor - Remove and Install (Engine Speed for Governor Control) ............................. 165 Installation Procedure ...................................... 165 Removal Procedure ......................................... 165 Engine Speed Sensor - Remove and Install (Overspeed Sensor) .......................................... 162 Installation Procedure ...................................... 162 Removal Procedure ......................................... 162

177 Index Section

Engine Support (Front) - Remove and Install (Backplate)........................................................... Installation Procedure ........................................ Removal Procedure ........................................... Exhaust Elbow - Remove and Install..................... Installation Procedure ........................................ Removal Procedure ........................................... Exhaust Manifold - Remove and Install ................. Installation Procedure ........................................ Removal Procedure ...........................................

82 82 82 35 35 35 30 32 30

F Flywheel - Install.................................................... 85 Installation Procedure ........................................ 85 Flywheel - Remove................................................ 83 Removal Procedure ........................................... 83 Flywheel Housing - Remove and Install ................ 88 Installation Procedure ........................................ 89 Removal Procedure ........................................... 88 Fuel Control Actuator - Remove and Install (Throttle Governor)............................................................... 7 Installation Procedure .......................................... 8 Removal Procedure ............................................. 7 Fuel Control Valve - Remove and Install (Main Fuel Adjuster) .............................................................. 10 Installation Procedure ......................................... 11 Removal Procedure ........................................... 10 G Gas Pressure Regulator - Install (Zero Pressure Regulator) .............................................................. 6 Installation Procedure .......................................... 6 Gas Pressure Regulator - Remove (Zero Pressure Regulator) .............................................................. 5 Removal Procedure ............................................. 5 Gear Group (Front) - Install ................................. 102 Installation Procedure ...................................... 102 Gear Group (Front) - Remove ............................. 101 Removal Procedure ......................................... 101 Governor - Install (Governor Control Unit)............. 15 Installation Procedure ........................................ 15 Governor - Install (Ignition Control Unit) ................ 16 Installation Procedure ........................................ 16 Governor - Remove (Governor Control Unit)......... 12 Removal Procedure ........................................... 12 Governor - Remove (Ignition Control Unit) ............ 14 Removal Procedure ........................................... 14 H Housing (Front) - Install (Timing Case) ............... Installation Procedure ...................................... Housing (Front) - Remove (Timing Case) ........... Removal Procedure .........................................

105 105 104 104

178 Index Section

KENR6945

I

T

Ignition Wiring Harness - Remove and Install (Ignition Wiring Harness Rail).......................................... 166 Installation Procedure ...................................... 168 Removal Procedure ......................................... 166 Important Safety Information ................................... 2 Inlet and Exhaust Valves - Remove and Install ..... 39 Installation Procedure ........................................ 40 Removal Procedure ........................................... 39 Inlet Manifold - Install............................................. 37 Installation Procedure ........................................ 37 Inlet Manifold - Remove......................................... 36 Removal Procedure ........................................... 36

Table of Contents..................................................... 3 Turbocharger - Install ............................................ 28 Installation Procedure ........................................ 28 Turbocharger - Remove ........................................ 26 Removal Procedure ........................................... 26

L Lifter Group - Assemble (Cam Followers) ........... Assembly Procedure........................................ Lifter Group - Disassemble (Cam Followers) ...... Disassembly Procedure ................................... Lifter Group - Install (Cam Followers).................. Installation Procedure ...................................... Lifter Group - Remove (Cam Followers).............. Removal Procedure .........................................

124 124 124 124 125 125 123 123

P Piston Cooling Jets - Remove and Install............ Installation Procedure ...................................... Removal Procedure ......................................... Pistons and Connecting Rods - Assemble .......... Assembly Procedure........................................ Pistons and Connecting Rods - Disassemble ..... Disassembly Procedure ................................... Pistons and Connecting Rods - Install................. Installation Procedure ...................................... Pistons and Connecting Rods - Remove............. Removal Procedure .........................................

136 137 136 140 140 139 139 143 143 138 138

R Rocker Arm - Assemble........................................ 115 Assembly Procedure......................................... 115 Rocker Arm - Disassemble................................... 114 Disassembly Procedure .................................... 114 Rocker Arm and Shaft - Install.............................. 117 Installation Procedure ....................................... 117 Rocker Arm and Shaft - Remove.......................... 113 Removal Procedure .......................................... 113 S Spark Plugs - Remove and Install ......................... Installation Procedure ........................................ Removal Procedure ........................................... Spark Plugs - Remove and Install (Multitorch) ...... Installation Procedure ........................................ Removal Procedure ...........................................

17 18 17 19 20 19

V Valve Mechanism Cover - Remove and Install (Rocker Box Cover) ............................................ 110 Installation Procedure ....................................... 111 Removal Procedure .......................................... 110 Valve Mechanism Cover Base - Remove and Install (Rocker Box)....................................................... 111 Installation Procedure ....................................... 112 Removal Procedure .......................................... 111 Vibration Damper - Remove and Install................. 93 Installation Procedure ........................................ 94 Removal Procedure ........................................... 93 Vibration Damper - Remove and Install (Damper and Plate) ................................................................... 90 Installation Procedure ........................................ 91 Removal Procedure ........................................... 90 Vibration Damper and Pulley - Remove and Install (Single Vibration Damper) ................................... 95 Installation Procedure ........................................ 97 Removal Procedure ........................................... 95 W Water Pump - Assemble........................................ 64 Assembly Procedure.......................................... 64 Water Pump - Disassemble................................... 63 Disassembly Procedure ..................................... 63 Water Pump - Install .............................................. 65 Installation Procedure ........................................ 65 Water Pump - Remove .......................................... 62 Removal Procedure ........................................... 62 Water Temperature Regulator Housing - Remove and Install (Thermostat Housing)................................ 66 Installation Procedure ........................................ 67 Removal Procedure ........................................... 66

KENR6945

179 Index Section

©2009 Caterpillar All Rights Reserved

Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Printed in U.S.A.

Disassembly & Assembly 4006-8 TRS_KENR6945-00

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