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.
KENR6945
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
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
(Alternator Warning Lamp) ................................ 161
Engine Speed Sensor - Remove and Install
(Overspeed Sensor) .......................................... 162
(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 Drive) ................................................ 171
Electric Starting Motor - Remove and Install ..... 173
Index Section
Index ................................................................... 176
KENR6945
KENR6945
5
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
g01816934
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
g01816521
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).
6
KENR6945
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
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
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
g01817257
KENR6945
7
Illustration 6
g01824554
9. Tighten the nuts for clamp (1) to a torque of

47 Nm (35 lb ft). Ensure that the tube assembly is
seated in Position (B).
Illustration 5
g01816521
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
12. Connect hose assembly (3) to zero pressure

regulator (2).

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 Nm (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
component life.
8
KENR6945
NOTICE
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
g01826354
2. Loosen nuts on clamp (2) on zero pressure

regulator (1). Remove nuts and bolts (3) from
bracket (4).
regulator.
3. Remove nuts (5) and remove bracket (4) from the
air charge cooler.
Illustration 9
g01828196
10. Remove spacer (15) and O-ring seal (16) from

the inlet manifold.
11. If necessary, remove studs (17) from the inlet
manifold.
NOTICE
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
KENR6945
9
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
g01828196
Illustration 12
g01826354
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
g01826573
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
g01828134
10
KENR6945
Illustration 14
g01827233
13. Tighten nuts (13) to a torque of 47 Nm (35 lb ft).

14. Tighten the nuts and bolts (10) to a torque of
47 Nm (35 lb ft).
47 Nm (35 lb ft).
47 Nm (35 lb ft). Ensure that tube assembly (18)
is seated in Position (B).
i03401445
Fuel Control Valve - Remove

and Install
(Main Fuel Adjuster)
SMCS Code: 1715-010; 1909-010
Removal Procedure
NOTICE
component life.
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
NOTICE
g01824894
KENR6945
11
g01824915
Illustration 16
Illustration 17
g01824961
Illustration 18
g01824915
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).
Table 2
Required Tools
Tool
Part Number
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.
12
KENR6945
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 Nm (18 lb ft).
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
g01824894
15. Connect gas inlet hose to connection (8) for

zero pressure regulator (2). Tighten hose for the
connection securely.
i03401446
Governor - Remove
(Governor Control Unit)
SMCS Code: 1264-011
Removal Procedure
NOTICE
component life.
Illustration 20
g01824554

carburetor (6).
6. Position the assembly of zero pressure regulator
(2) and fuel control valve (4) onto the support
regulator and the fuel control valve.
KENR6945
13
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
g01860986
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
g01859657
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
g01860994
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).
14
KENR6945
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

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.
KENR6945
Illustration 26
15
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
NOTICE
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 Nm
(35 lb ft).
Tighten nuts and bolts (20) to a torque of
47 Nm (35 lb ft).
b. Install ignition control unit. Refer to Disassembly
and Assembly, Governor Install (Ignition
Control Unit) for the correct procedure.
16
KENR6945
7. Position cover (8) onto the governor control unit.

Install screws (7) and tighten screws securely.
Illustration 28
g01860994
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 Nm (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 Nm (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.
position.
i03535840
Governor - Install
(Ignition Control Unit)
SMCS Code: 1264-012
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
g01860986
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 Nm (80 lb in).
KENR6945
17
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
Tool
Part
Number
484/45
Part Description
Spark plug Socket
Qty
1
NOTICE
component life.
3. Install mounting bracket (13) onto mounting plate

(12). Install nuts (7) and nuts (9). Tighten nuts to a
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 Nm (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).
g01833385
18
KENR6945
Illustration 35
g01834534
Illustration 36
g01834533
g01834533
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.
Table 4
Required Tools
Tool
Part
Number
484/45
Part Description
Spark plug Socket
Qty
1
NOTICE
component life.
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 Nm
(30 lb ft).
KENR6945
19
g01833385
Illustration 37
Illustration 38
g01833385
Illustration 39
g01833389
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
Removal Procedure
Table 5
Required Tools
Tool
Part
Number
484/49
Part Description
Spark plug Socket
Qty
1
NOTICE
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.
20
KENR6945
Table 6
Required Tools
Tool
Part Number
484/49
Part Description
Spark plug Socket
Qty
1
NOTICE
component life.
Illustration 41
g01833389
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
g01833554
3. Tighten multitorch spark plug (5) to a torque of

50 Nm (30 lb ft).
Illustration 42
g01833385
4. Install high tension lead (2) to ignition coil (1).
KENR6945
21
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
Illustration 44
g01817994
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).
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 Nm (35 lb ft).
Note: Support the weight of the assembly of the fuel
control valve and zero pressure regulator.
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.
22
KENR6945
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
21820221
Description
POWERPART
Rubber Grease
Qty
1
Illustration 46
g01819874
KENR6945
23
Illustration 47
g01818715
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
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.
24
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 Nm (18 lb ft).
Illustration 48
g01817994
Illustration 50
g01829773
8. Tighten the nuts on clamps (1) to a torque of

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

carburetor (5). Install carburetor (5) onto
turbocharger adapter (7).
3. Install nuts (8) to carburetor (5) and tighten the
nuts hand tight.
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.
KENR6945
25
i03401454
Air Cleaner - Remove and

Install
SMCS Code: 1051-010-HG
Removal Procedure
NOTICE
component life.
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).
NOTICE
component life.
26
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 Nm (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 Nm (30 lb ft).
SMCS Code: 1052-011
Removal Procedure
NOTICE
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
27
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).

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.
28
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).
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
Table 8
Required Tools
Tool
Part Number
21820221
CV60889
Part Description
Qty
POWERPART
Rubber Grease
POWERPART
Anti-Sieze Compound
NOTICE
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
29
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 Nm (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 Nm
(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 Nm (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 Nm (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 Nm (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 Nm
(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 Nm (80 lb in). Repeat this Step until the V-band
clamps are secure.
30
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.
47 Nm (35 lb ft).
23. Tighten bolts (2) and bolts (3) to a torque of
41 Nm (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
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.

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
31
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.
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.
32
KENR6945
2. If necessary, remove the exhaust temperature

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).
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
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.
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.
Tool
Illustration 70
Qty
1
NOTICE
component life.
6. Position gasket (28) (not shown) onto exhaust

bellow (22).
KENR6945
Illustration 71
33
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 Nm (50 lb ft).
11. Tighten nuts and bolts (23) to a torque of 58 Nm
(43 lb ft).
12. Install the turbocharger. Refer to Disassembly
and Assembly, Turbocharger - Install.
13. If necessary, install the exhaust temperature
Manifold Front and Center Sections

1. Ensure that the gasket surfaces of the exhaust
free from damage. Ensure that the bellows are

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.
(19). Install the nuts and bolts hand tight.
34
KENR6945

(43 lb ft).

(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
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.
(43 lb ft).
blanking plate (12).
14. Install blanking plate (12) to exhaust manifold
(9) and position bracket (15) onto the exhaust
manifold.
g01836237
19. Position heat shield (1) onto the exhaust manifold.

Install nuts (5) and tighten the nuts to a torque of
44 Nm (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
35
i03401459
Exhaust Elbow - Remove and

Install
NOTICE
component life.
SMCS Code: 1061-010-E4
Removal Procedure
1. Ensure that the exhaust elbow is clean and free
from damage.
NOTICE
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.
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).
36
KENR6945
4. Tighten V-band clamps (2) to a torque of 9 Nm

(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 Nm (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
Illustration 80

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
37
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
Illustration 81
g01834896
NOTICE
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
free from damage.
38
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.
(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.
Tighten nuts and bolts (13) to a torque of 47 Nm
(35 lb ft).
KENR6945
39
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.
(35 lb ft).
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 Nm (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
Removal Procedure
Table 10
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
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
40
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.
the remaining valves.
Table 11
Required Tools
Tool
A
Part
Number
Part Description
T6253/243 Valve Spring Compressor
Qty
1
NOTICE
component life.
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
41
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

Engine Oil Line - Remove and

Install
(Engine Oil Rail)
SMCS Code: 1307-010

Removal Procedure
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
NOTICE
component life.
NOTICE
mandates.
Illustration 90
g01453609
4. Use Tooling (A) in order to compress valve spring

(3). Install valve collets (1).
NOTICE
1. Turn gas supply to the OFF position.
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.
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.
42
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.
Table 12
Required Tools
Tool
Part Number
21820121
Part Description
POWERPART
Hydraulic Threadseal
Qty
1
NOTICE
component life.
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
43
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 Nm
(30 lb ft).
8. Tighten bolts (5) for the bracket to a torque of
47 Nm (35 lb ft).
9. Tighten bolts for the bracket to the engine oil rail
10. Connect the ignition wiring harness. Refer to
Disassembly and Assembly , Ignition Wiring
Harness for more information.
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.
44
KENR6945
i03401465
Engine Oil Filter Base Remove

SMCS Code: 1306-011
Removal Procedure
Table 13
Required Tools
Tool
Part Number
Part Description
Strap Wrench
Qty
1
NOTICE
component life.
NOTICE
mandates.
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
45
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.
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
Part Description
Guide Stud
M10 by 75 mm
Qty
2
NOTICE
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.
46
KENR6945

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 Nm (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 Nm (35 lb ft). Tighten the bolts in the
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
47
i03401469
Engine Oil Cooler - Remove

SMCS Code: 1378-011
Removal Procedure
NOTICE
component life.
NOTICE
Illustration 108
g01810005
Illustration 109
g01810434

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).
48
Illustration 110
KENR6945
g01810098
Illustration 112
g01810006

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
49
c. Remove O-ring seal (29) (not shown).

12. Drain the oil from the engine oil cooler into a
suitable container.
NOTICE
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
Start By:
a. Remove the engine oil cooler. Refer to
Disassembly and Assembly, Engine Oil Cooler
- Remove.
NOTICE
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).
50
KENR6945
i03401472
Engine Oil Cooler - Assemble
4. Install bolts (5). Tighten the bolts to a torque of

40 Nm (30 lb ft).
SMCS Code: 1378-016
5. Place a new O-ring seal (3) in position and install

cover (2).
Assembly Procedure

40 Nm (30 lb ft).
NOTICE
7. Pressure test the engine oil cooler for leaks. Refer

to Systems Operation, Testing and Adjusting,
General Information - Cooling System for the
correct procedure.

component life.
End By:
1. Ensure that all parts of the engine oil cooler are
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
Table 15
Required Tools
Tool
Part Number
Part Description
Guide Stud
M10 by 75 mm
Qty
2
NOTICE
Illustration 117
g01811722

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
51
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
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
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
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
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).
47 Nm (35 lb ft).
Illustration 121
g01810839
Illustration 123
g01810842
52
KENR6945
17. Install tube assembly (5) to engine oil cooler (1).

Install bolts (4) and bolts (6) finger tight.
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).

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
KENR6945
53
Tighten bolts (23) to a torque of 47 Nm (35 lb ft).

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
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
Removal Procedure
NOTICE
component life.
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
3. Remove plunger (1).

4. Remove gasket (3).
Table 16

mandates.
Required Tools
Tool
A
Part Number
Part Description
Qty
Bolts
M8 by 50 mm
Nuts M8
54
KENR6945
Note: The plunger must slide freely in the bore.

NOTICE
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).
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
component life.
Illustration 129
g01811853
NOTICE
mandates.
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
55
g01821493
Illustration 133
g01821553
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.

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).

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).
56
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
21820117
Part Description
Qty
POWERPART
Threadlock and Nutlock
Guide Stud
M10 by 75 mm
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 Nm (18 lb ft).
NOTICE
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
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
57
NOTICE
mandates.
NOTICE
Illustration 137
g01821493

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.
10. Tighten bolts (4) and (6) to a torque of 40 Nm
(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
Removal Procedure
NOTICE
component life.
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.
58
KENR6945

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.
NOTICE
Note: Cap all open ports.

component life.
NOTICE
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.
i03401478
Engine Oil Pump - Disassemble

SMCS Code: 1304-015
g01836190
Illustration 140
Table 18
1. The weight of the engine oil pump is approximately

32 kg (71 lb).
Required Tools
Tool
Part Number
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
59
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
Assembly Procedure
Table 19
Required Tools
Tool
Part Number
Part Description
Qty
21820117
POWERPART
Bolts M10 by 200 mm
M10 Nuts
M10 Flat Washers
NOTICE
component life.
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.
60
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 Nm
(18 lb ft).
KENR6945
61
i03401477
Engine Oil Pump - Install

SMCS Code: 1304-012
Table 20
Required Tools
Tool
Part
Number
21820117
Part Description
Qty
POWERPART
NOTICE
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).

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 Nm (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.
62
KENR6945
5. Install nuts (10) to the studs. Tighten nuts (10) to a

16. Turn the gas supply to the ON position.

i03401480
Water Pump - Remove

SMCS Code: 1361-011
Removal Procedure
NOTICE
component life.
NOTICE
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.
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.

mandates.
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
63
i03401482
Water Pump - Disassemble

SMCS Code: 1361-015
Table 21
Required Tools
Tool
Part Number
Part Description
Qty
Circlip Pliers
Start By:
a. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.
Illustration 149
g01841094
NOTICE
component life.
NOTICE
mandates.
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).
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
64
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
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
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
21820117
POWERPART
21820221
POWERPART
Rubber Grease
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 Nm (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.
65
i03401481
Water Pump - Install

SMCS Code: 1361-012
Table 23
Required Tools
Tool
Part Number
Part Description
Guide Stud
M10 by 100 mm
Qty
2
NOTICE
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
66
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).
7. Position a new gasket (6) (not shown) onto water
pump (1). Install elbow connection (4) and install
bolts (3).
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
12. Tighten hose clamps (9) and hose clamp for hose
(2) securely.
NOTICE
component life.
NOTICE
mandates.
KENR6945
67
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).
NOTICE
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
68
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
Removal Procedure
Illustration 158
g01842675
NOTICE
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).

component life.
3. Position thermostat housing (16) onto tube

assembly (9) and rail (6).
NOTICE
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.
(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
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 Nm (35 lb ft).

mandates.
position.
2. Drain the raw water from the raw water cooling
system.
KENR6945
Illustration 159
69
g01866334
Illustration 161
g01866474
8. Disconnect tube assembly (14) from auxiliary

water pump (4) and the engine cylinder block.
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.
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.
70
KENR6945
i03524404
Auxiliary Water Pump Disassemble

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
Table 24
Required Tools
Tooling
Part Number
Description
T6253/121
Pegged Socket
T6253/258
Circlip Pliers
Qty
Start By:
a. Remove the auxiliary water pump. Refer to
Disassembly and Assembly, Auxiliary Water
Pump - Remove.
NOTICE
component life.
Illustration 163
g01867113
5. Remove nuts (7) and remove adapter plate (5)

from auxiliary water pump (1).
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
71
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
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).
72
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).
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

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
T6253/121
Pegged Socket
T6253/258
Circlip Pliers
21820117
POWERPART
Threadlock and
Nutlock
Qty
NOTICE
component life.
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).
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
73
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).
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
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).
74
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.
adapter plate (5).
27. Position adapter plate (5) onto auxiliary water
pump (1). Install nuts (7) and tighten the nuts to a
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 Nm (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 Nm (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 Nm
(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
75
i03524403
Auxiliary Water Pump - Install

SMCS Code: 1371-012

47 Nm (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.
NOTICE
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
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.
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.
76
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.
47 Nm (35 lb ft).
17. Tighten the nut and the bolt for V-band clamp (5)
18. Tighten the nut and the bolt for V-band clamp (7)
NOTICE
mandates.
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

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
component life.
Illustration 178
g01828318
KENR6945
77

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).
Illustration 181
g01828154

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.
78
KENR6945
i03494320
Aftercooler - Disassemble
SMCS Code: 1063-015
NOTICE
component life.
NOTICE
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
4. Remove plate assembly (8) from the inlet
manifold. Remove gasket (7) (not shown).
Illustration 182
g01831015
KENR6945
79
i03496260
Aftercooler - Assemble
SMCS Code: 1063-016
Assembly Procedure
NOTICE
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 Nm
(14 lb ft).
80
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 Nm (14 lb ft). Tighten the nuts
and allen head bolts (16) to a torque of 19 Nm
(14 lb ft).
i03401486
Aftercooler - Install
(Air Charge Cooler)
SMCS Code: 1063-012
NOTICE
Illustration 187
g01832833

component life.
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 Nm (14 lb ft). Tighten the nuts to a torque of
19 Nm (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
81
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.
(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.
(35 lb ft).
Tighten bolts (1) to a torque of 47 Nm (35 lb ft).
13. Tighten the bolts for the clamps on tube
assemblies (3).
82
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
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

of backplate (1). The weight of the backplate is
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:
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
Table 26
Required Tools
Tool
Part Number
Part Description
Guide Studs
M10 by 100 mm
Qty
2

component life.
NOTICE
1. If necessary, remove the auxiliary water pump.

Refer to Disassembly and Assembly, Auxilary
Water Pump - Remove.

component life.
2. Ensure that the engine is adequately supported.
1. Ensure that the gasket surface of the crankcase

and the backplate are clean.
KENR6945
83
i03401782
Flywheel - Remove
SMCS Code: 1156-011
Removal Procedure
Table 27
Required Tools
Tool
Part
Number
T6253/157
Part Description
Qty
Support Studs
Flywheel and Damper
Bolt M12 by 100mm
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

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.
NOTICE
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 Nm
(35 lb ft).

component life.
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
84
KENR6945
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
85
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
T6253/157
Support Studs
Flywheel and Damper
CV60889
Anti-Seize Compound
Part Description
Qty
NOTICE
component life.
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.
86
KENR6945
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
Sensor - (Overspeed Sensor) Remove and
Install.
Illustration 202
g01454201
c. Install the engine speed sensor. Refer to

Sensor - (Engine Speed for Governor Control)
Remove and Install.
i03401784
Crankshaft Rear Seal - Remove

and Install
SMCS Code: 1161-010
Removal Procedure
Table 29
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
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).
NOTICE
b. Position a suitable piece of wood (3) between

bolt (1) and the floor.

component life.
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 Nm
(100 lb ft) in the sequence that is shown in
Illustration 203.
c. Tighten bolts (2) to a torque of 337 Nm
Illustration 203.
NOTICE
mandates.
KENR6945
87
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.
Table 30
Required Tools
Tool
B
Part
Number
Part Description
Qty
T6253/140 Rear Oil Seal Insertion Kit
NOTICE
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.
88
KENR6945
i03401785
Flywheel Housing - Remove

and Install
SMCS Code: 1157-010
Removal Procedure
Table 31
Required Tools
Tool
Part Number
Part Description
Guide Studs
M10 by 100 mm
Qty
2
Start By:
a. Remove the engine speed sensor. Refer to
Sensor - Remove and Install.
b. Remove the overspeed sensor. Refer to
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
component life.
NOTICE
mandates.
Illustration 207
g01848255

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
89
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.
Table 32
Required Tools
Tool
Part Number
Part Description
Qty
Guide Studs
M10 by 100 mm
Loctite 518
NOTICE
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
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).
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).
90
KENR6945
i03538581
Vibration Damper - Remove

and Install
(Damper and Plate)
SMCS Code: 1205-010
Removal Procedure
Table 33
Required Tools
Illustration 210
Tool
Part Number
T6253/209A
T6253/209
g01848260
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
Crankshaft Adapter
Extractor
Nuts and Bolts M12 by

125 mm
High Tensile Bolts

-
Heavy Duty Flat

Washers
NOTICE
component life.
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
Sensor (Overspeed) - Remove and Install.
e. Install the engine speed sensor. Refer to
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
91
Note: Support the weight of vibration damper

assembly on removal of bolts (2).
g01868662
Illustration 213
Illustration 212
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).

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).
g01868674
Illustration 214

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).
Table 34
8. Lay the assembly on a flat surface.
Required Tools
Tool
Part Number
CV60889
Part Description
POWERPART
Anti-Seize Compound
Qty
1
92
KENR6945

damper bolts to the correct torque.
NOTICE
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.

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.
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).
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

Illustration 216.
KENR6945
93
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.

Repeat this Step until a torque of 340 Nm
(250 lb ft) has been achieved.
2. Install Tooling (A). Use a suitable lifting device in

order to support the weight of the assembly.

i03538580
Vibration Damper - Remove

and Install
SMCS Code: 1205-010
Removal Procedure
Table 35
Required Tools
Tool
Part Number
Part Description
Qty
T6253/214
Damper Lifting Tool
T6253/209A
Retaining Plate
T6253/209
Crankshaft Adapter
Extractor
NOTICE
component life.
Illustration 220
g01868014
4. Install Tooling (B) to the nose of the crankshaft.
94
KENR6945
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.
Table 36
Required Tools
Tool
Part Number
T6253/214
CV60889
Qty
Damper Lifting Tool
POWERPART
Anti-Seize Compound
NOTICE
component life.
free from damage.
6. Remove Tooling (C).

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

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
95

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

Illustration 223.
Table 37
Required Tools
Tool
Part Number
Part Description
Qty
T6253/157
Support Studs
Flywheel and Damper
T6253/214
Damper Lifting Tool
T6253/209A
Retaining Plate
T6253/209
Crankshaft Adapter
Extractor
Start By:
a. Remove the V-belts from the fan drive. Refer to
OEM.
NOTICE
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
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).
96
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.
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
97
Table 38
Required Tools
Tool
Part Number
Part Description
Qty
T6253/157
Support Studs
Flywheel and Damper
T6253/214
Damper Lifting Tool
CV60889
POWERPART
Anti-Seize Compound
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.
NOTICE


component life.
7. Remove Tooling (D).

free from damage.
8. Remove Tooling (C).

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
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).
98
KENR6945

Illustration 231
g01867315

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
99
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
Removal Procedure
Illustration 235
g01867214
Table 39
Required Tools

Illustration 235.
c. Tighten bolts (3) to a torque of 340 Nm
Illustration 235.
Tool
Part
Number
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
component life.
NOTICE
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
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.
100
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).
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.
Table 40
Required Tools
Tool
B
Part
Number
Part Description
T6253/141 Front Oil Seal Insertion Kit
Qty
1
NOTICE
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.
End By:
a. Install the damper to the crankshaft. Refer to
KENR6945
101
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
component life.
Illustration 240
g01855214
2. Remove bolts (2).

NOTICE
3. Carefully remove camshaft gear (1) from the

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

mandates.
Illustration 241
g01855753

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.
102
KENR6945
i03401790
Gear Group (Front) - Install

SMCS Code: 1206-012
Table 41
Required Tools
Tool
Part
Number
21825617
Part Description
Qty
Dial Indicator Group
NOTICE
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
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 Nm (35 lb ft).
KENR6945
Illustration 244
103
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.
150 Nm (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.
104
KENR6945
End By:
a. Install the timing case. Refer to Disassembly and
Assembly, Housing (Front) - Install.
b. Install the rocker assemblies. Refer to
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
c. Remove the camshaft speed sensor from timing
case. Refer to Disassembly and Assembly,
Engine Speed Sensor (Camshaft) - Remove and
Install.
NOTICE
component life.
Illustration 248
g01857913

of timing case (3). The timing case weighs
4. Remove bolts (4) from timing case (3).
NOTICE
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.
8. Use a suitable drift to remove the crankshaft front
seal from the timing case.
KENR6945
105
NOTICE
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
B
C
Part Description
Qty
Guide Studs
M10 by 100 mm
T6253/354
Seal Carrier Alignment

Tool
21820117
POWERPART
106
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
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 Nm (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
g01871593
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 Nm (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
107
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
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
Removal Procedure
NOTICE
component life.
NOTICE
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).

mandates.
Illustration 255
g01838075
108
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

b. Remove bolts (17) and remove bracket (18).
c. Remove nuts (20) and remove the assembly of
breather tube (19). Remove O-ring seal (21)
(not shown).
Illustration 258
g01839533
KENR6945
109
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).
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 Nm (35 lb ft).

c. Remove nuts (20) and remove the assembly of
breather tube (19). Remove O-ring seal (21)
(not shown).
NOTICE
component life.
1. If necessary, assemble the crankcase breather.
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 Nm
(35 lb ft).
c. Position bracket (16) onto the engine cylinder
block. Install bolts (15). Tighten bolts to a
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.

bracket is installed.
d. Position bracket (18) onto the engine cylinder
block. Install bolts (17). Tighten bolts to a
bracket is installed.
110
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
Removal Procedure
NOTICE
component life.
NOTICE
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 Nm (35 lb ft).
KENR6945
Illustration 263
111
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 Nm (35 lb ft).
NOTICE
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
Shaft - Remove.
NOTICE
component life.
112
KENR6945
NOTICE
Note: If necessary, carefully tap the rocker box with a

soft faced hammer in order to loosen the rocker box.

mandates.
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.
Cooling System Coolant - Change for the correct
procedure.
Table 43
Required Tools
Tool
Part Number
Part Description
Qty
21820117
POWERPART
NOTICE
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
113
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 Nm (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 Nm (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
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
114
KENR6945
3. Remove bridge piece (4) and bridge piece (5)

from the rocker box.
NOTICE
4. Remove pushrod (6) (not shown) and pushrod (7).

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.

the remaining rocker assemblies.
i03401800
Rocker Arm - Disassemble

SMCS Code: 1123-015
Start By:
a. Remove the rocker assembly. Refer to
Shaft - Remove.
NOTICE
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
115
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
Assembly Procedure
Table 44
Required Tools
Tool
Part Number
Part Description
Qty
Loctite Activator
Loctite 603
NOTICE
Illustration 274
g01865274
3. If necessary, remove nuts (5) and adjusters (6)

from the rocker arms.

component life.
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
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
116
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
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
117
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.
NOTICE
4. Install bridge piece (4) and bridge piece (5).

component life.
5. Equalize the bridge pieces. Refer to Systems

Operation, Testing and Adjusting, Engine Valve
Lash - Adjust.

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 Nm (90 lb ft).
9. Recheck the torque of allen head bolts (6). Tighten
the allen head bolts (6) to a torque of 70 Nm
(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
118
KENR6945
End By:
a. Install the cover to the rocker box. Refer to
Cover - Remove and Install.
i03401802
Cylinder Head - Remove

SMCS Code: 1100-011
Removal Procedure
Table 45
Required Tools
Tool
Part Number
Part Description
T6253/237
Cylinder head Lifting

Tool
Bolts M10 by 70 mm
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
Inlet Manifold - Remove.
NOTICE
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
Cover Base - Remove and Install.

component life.
NOTICE
mandates.
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
119
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.
120
KENR6945
i03403561
Cylinder Head - Install

SMCS Code: 1100-012
Table 46
Required Tools
Tool
Illustration 289
g01865196
Part Number
Part Description
T6253/237
Cylinder head Lifting

Tool
Bolts M10 by 70 mm
POWERPART
Anti-Seize Compound
POWERPART
Rubber Grease
Loctite Copper Sealant
9. Remove O-ring seals (11), (12), (14), (15) and

(16).
CV60889
10. Remove flame ring (13).
21820221
5920
Qty
NOTICE
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
121
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 Nm
(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.
122
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
b. Tighten the cylinder head bolts to a torque of
135 Nm (100 lb ft) in the sequence that is
shown in Illustration 299.
c. Tighten the cylinder head bolts to a torque of
d. Tighten the cylinder head bolts to a torque of
e. Tighten the cylinder head bolts to a torque of
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
123
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
Removal Procedure
NOTICE
Illustration 300
g01865394

component life.
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.
NOTICE
mandates.
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 Nm (35 lb ft).
(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
End By:
a. Install the appropriate sections of the inlet
Inlet Manifold - Install.
b. Install the appropriate sections of the exhaust
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.
124
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
Start By:
a. Remove the cam followers. Refer to Disassembly
and Assembly, Lifter Group - Remove.
NOTICE
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.
used components.
i03401808
Lifter Group - Assemble

(Cam Followers)
SMCS Code: 1209-016
Assembly Procedure
Table 47
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
21820117
POWERPART
NOTICE
component life.
KENR6945
125
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

from damage.
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
NOTICE
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.
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 Nm (50 lb ft).
126
KENR6945
NOTICE
component life.
g01855773
Illustration 306
4. Install new gasket (3) (not shown). Align the cam

follower to the dowels in the crankcase. Install
cam follower (1).
50 Nm (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
Removal Procedure
Table 48
Required Tools
Tool
Part Number
Part Description
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
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
127
g01859034
Illustration 309
5. Remove bolts (4) and remove cover (5).
i03401810
Camshaft - Install
Table 49
6. When camshaft (3) is in the correct position,

remove Tooling (A).
Required Tools
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
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 Nm (35 lb ft).
128
KENR6945
NOTICE
component life.
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 Nm
(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
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.
Table 51
Required Tools
Tool
Part Number
Part Description
T6253/199
Camshaft Bearing
Removal/Fitting Tool
Qty
1
KENR6945
129
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
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
Removal Procedure
NOTICE
component life.
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).
NOTICE
mandates.
130
KENR6945
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
131
Suction Pipe and Strainer

NOTICE
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

Table 52
Required Tools
4. Tighten the nuts on clamp (16) to a torque of

25 Nm (18 lb ft).
Tool
Part
Number
21820221
POWERPART
Rubber Grease
5. Ensure that suction pipe (17) and strainer (18) are

installed correctly in the engine oil pan.
21820518
POWERPART
Gasket and Flange
Sealant
Engine Oil Pan
Guide Studs
M10 by 50 mm
1. Ensure that the gasket surfaces of the engine oil

pan and the crankcase are clean.
21820117
POWERPART
Part Description
Qty
132
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.
47 Nm (35 lb ft).
9. Install the dipstick and tube (13) to engine oil pan
(9). Tighten tube (13) securely.
Illustration 323
g01820033
KENR6945
133
i03401816
Cylinder Liner - Remove

SMCS Code: 1216-011
Removal Procedure
Table 53
Required Tools
Tool
Part Number
SE253
T6253/152
Part Description
Qty
Engine Turning Tool
Liner Extractor
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
component life.
13. Install bolts (7) to engine oil pump (1) hand tight.
NOTICE
14. Apply Tooling (D) to the threads of bolts (5). Install

bolts (5) hand tight.

mandates.
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.

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.
1. Use Tooling (A) in order to rotate the crankshaft.

Rotate the crankshaft until there is sufficient
clearance in order to install Tooling (B).
134
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
Table 54
Required Tools
Tool
Part Number
21820221
Qty
POWERPART
Rubber Grease
Loctite 638
Liner Clamp Kit
Cylinder Head Bolts
Spacers
T6253/200
E
Part Description
NOTICE
component life.
KENR6945
135
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 Nm
(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

Connecting Rods - Install.
136
KENR6945
i03401818
Piston Cooling Jets - Remove

and Install
SMCS Code: 1331-010
Removal Procedure
Table 55
Required Tools
Tool
Part Number
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
NOTICE
2. Remove bolt (3) and remove plate (2).

component life.
3. Rotate cooling jet (1) clockwise by 90 degrees.

Rotate into Position (C). Withdraw the cooling jet
from the crankcase.
NOTICE
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
137
1. lubricate the O-ring seal with clean engine oil.

Install O-ring seal (4).
Table 56
Required Tools
Tool
Part Number
SE253
T9142/21
Part Description
Qty
Engine Turning Tool
Drift
2. Install cooling jet (1) into Position (C). Rotate the

cooling jet counterclockwise by 90 degrees.
NOTICE
component life.
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)
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
138
KENR6945
i03401819
Pistons and Connecting Rods

- Remove
SMCS Code: 1225-011
Removal Procedure
Table 57
Required Tools
Tool
Part Number
SE253
T6253/295
Part Description
Qty
Engine Turning Tool
Suction Cup
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
NOTICE
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
139
i03401821

- Disassemble
SMCS Code: 1225-015
Table 58
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
T6253/258
Circlip Pliers
T6253/256
Piston Ring Pliers
T6253/159
Small End Bush Tool
Part Description
Qty
Start By:
a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, Pistons and
NOTICE
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.
140
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

- Assemble
SMCS Code: 1225-016
Assembly Procedure
Table 59
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
T6253/258
Circlip Pliers
T6253/256
Piston Ring Pliers
T6253/159
Small End Bush Tool
Part Description
Qty
NOTICE
component life.
1. Follow Step 1.a through Step 1.e in order to
inspect the pistons and the connecting rods.
KENR6945
141
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.
142
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
KENR6945
143
i03401820

- 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.
Table 60
Required Tools
Tool
Part
Number
SE253
Part Description
Qty
Engine Turning Tool
T6253/295
Suction Cup
T6253/139
Piston Ring Compression

Tool
SE671K
30 Degree Indicator Socket

Tool
NOTICE
component life.
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.
Illustration 350
Illustration 349
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.
144
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

connecting rod bolts to the correct torque.
a. Tighten connecting rod bolts (4) to a torque of
110 Nm (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
145
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 Nm
(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.
- Remove.
NOTICE
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.
NOTICE
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.
146
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

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

caps.
b. Remove the pistons and connecting rods. Refer

Note: The lower main bearings are plain bearings

that have no oil holes.
c. Remove the engine oil pan. Refer to Disassembly

d. Remove the back plate. Refer to Disassembly and
Assembly, Engine Support (Front) - Remove and
Install.
e. Remove the flywheel housing. Refer to
NOTICE
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.
- 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
147
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

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

c. Remove the engine oil pan. Refer to Disassembly
d. Remove the back plate. Refer to Disassembly and
Install.
148
KENR6945
e. Remove the flywheel housing. Refer to

NOTICE
5. Remove thrust washers (3) from the crankcase.

Note: The crankshaft has two thrust washers. The
main bearing.

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

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
Table 61
Required Tools
Illustration 364
g01855276
Tool
Part
Number
21825617
Part Description
Dial Indicator
Qty
1
KENR6945
149
NOTICE
component life.
1. Inspect the crankshaft for wear and for damage.
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
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
main bearing. Install the thrust washers with the
grooves toward the crankshaft.
g01855273

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
150
KENR6945
c. Tighten main bearing bolts (1) to a torque of

d. Tighten main bearing bolts (1) to a torque of
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
Install.
Sequence for tightening main bearing bolts (1)
b. Install the back plate. Refer to Disassembly and

Install.

main bearing bolts to the correct torque.
c. Install the engine oil pan. Refer to Disassembly

Illustration 370
g01333139
a. Tighten main bearing bolts (1) to a torque of

d. Install the pistons and connecting rods. Refer

b. Tighten main bearing bolts (1) to a torque of

e. Install the piston cooling jets. Refer to Disassembly

and Assembly, Piston Cooling Jets - Remove
and Install.
KENR6945
151
Crankshaft - Install
(Eight Cylinder TRS Engines)

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
21825617
Part Description
Dial Indicator
Qty
1
NOTICE
component life.
1. Inspect the crankshaft for wear and for damage.
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
main bearing. Install the thrust washers with the
grooves toward the crankshaft.
Note: Install the main bearings dry when clearance

correct procedure. Apply clean engine oil on the face
of the main bearings for final assembly.
Illustration 374
Illustration 372
Typical example
g01854055
g01853913
152
KENR6945
b. Tighten main bearing bolts (1) to a torque of

c. Tighten main bearing bolts (1) to a torque of
d. Tighten main bearing bolts (1) to a torque of
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.
threads of main bearing bolts (1) with clean engine
oil. Install the main bearing bolts finger tight.
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

f. Ensure that the crankshaft rotates freely.
Illustration 376
g01854235
Sequence for tightening main bearing bolts (1)

main bearing bolts to the correct torque.
a. Tighten main bearing bolts (1) to a torque of
KENR6945
153
i03401827
Crankshaft Gear - Remove and

Install
SMCS Code: 1204-010-GE
Removal Procedure
Table 63
Required Tools
Tool
Part
Number
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

NOTICE
component life.
Maximum crankshaft end play (service

limit) ................................... 0.55 mm (0.025 inch)
End By:
a. Install the flywheel housing. Refer to Disassembly
Install.
b. Install the back plate. Refer to Disassembly and
Install.
c. Install the engine oil pan. Refer to Disassembly
d. Install the pistons and connecting rods. Refer
e. Install the piston cooling jets . Refer to
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).
NOTICE
component life.
154
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)
Plastic Gauge (Red)

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

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

0.230 to 0.510 mm
(0.009 to 0.020 inch)
Always wear protective gloves when handling

parts that have been heated.
Part Description
NOTICE
component life.
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
155
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
Removal Procedure
NOTICE
component life.
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
3. If necessary, follow Step 1 through Step 5 in order
to remove the remaining knock sensors from the
engine cylinder block.
156
KENR6945
i03401840
NOTICE
component life.
NOTICE
Incorrect installation of the knock sensors may lead to
poor operation of the engine control system. Subsequently lead to engine damage.

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
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
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
157
i03535760
Table 65
Required Tools
Tool
Part
Number
CV60889
Part Description
POWERPART
Anti-Sieze Compound
Qty
1
NOTICE
component life.

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
Removal Procedure
NOTICE
component life.
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).
158
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.
Required Tools
Part Number
21820121
Part Description
POWERPART
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
NOTICE
component life.
5. Tighten nuts (10) to a torque of 9 Nm (80 lb in).

Tighten tube assembly (9) securely.
KENR6945
159
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.
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

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
component life.
NOTICE
mandates.
Table 67
Required Tools
Tool
Part Number
21820121
Part Description
POWERPART
Qty
1
NOTICE
component life.
160
KENR6945
NOTICE
mandates.
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 Nm (22 lb ft).
3. Connect harness assembly (1) to coolant
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.
NOTICE
b. Remove sealing washer (1).

component life.
Table 68
Required Tools
Tool
Part Number
21820121
Part Description
POWERPART
Qty
1
KENR6945
161
i03401842
NOTICE
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).
NOTICE
b. Apply Tooling (A) to the threads of adapter (2).

Install adapter (2) to the engine cylinder block.

component life.
c. Tighten the adapter to a torque of 47 Nm

(35 lb ft).
NOTICE
mandates.
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 Nm (84 lb in).
3. Connect harness assembly (4) to engine oil
Illustration 394
g01860834
1. Disconnect harness assembly (1) from engine oil

2. Remove engine oil pressure switch (2) from
engine oil filter base(3).
162
KENR6945
i03401844
Table 69
Required Tools
Tool
Part Number
21820121
Part Description
Qty
POWERPART
SMCS Code: 1907-010; 5626-010
Removal Procedure
NOTICE
component life.
Illustration 395
Engine Speed Sensor Remove and Install

(Overspeed Sensor)
NOTICE
component life.
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 Nm (84 lb in).
Illustration 396
2. Connect harness assembly (1) to engine oil

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).
Table 70
Required Tools
Tool
Part
Number
SE253
Part Name
Engine cranking device
Qty
1
NOTICE
component life.
KENR6945
163
1. Refer to Operation and Maintenance Manual,

Speed Sensor - Clean/Inspect for the correct
procedure.
i03530361

(Camshaft Timing Sensor)
SMCS Code: 1907-010; 5626-010
Removal Procedure
NOTICE
component life.
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 Nm
(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

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).
164
KENR6945
Table 71
Required Tools
Tool
Part
Number
SE253
Part Name
Qty
NOTICE
component life.
procedure.
Illustration 400
g01861514

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 Nm
(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 Nm (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
165
i03401845
NOTICE

(Engine Speed for Governor
Control)

component life.
procedure.
SMCS Code: 1907-010; 5626-010
Removal Procedure
NOTICE
component life.
Illustration 402
g01859003
2. Install tooling (A) to flywheel housing (2).

one tooth of the flywheel ring gear to the center
position of the tapped hole in flywheel housing (2).
g01859003
Illustration 401

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 Nm
(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
SE253
Part Name
Qty
1
6. Remove tooling (A) from flywheel housing (2).

7. Connect harness assembly (1) to engine speed
sensor (3).
166
KENR6945
i03401846
NOTICE
Boost Pressure Sensor Remove and Install

(Boost Pressure and
Temperature Sensor)

component life.
SMCS Code: 1917-010
Removal Procedure
NOTICE
component life.
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 Nm
(80 lb in).
g01862655
Illustration 403
1. Disconnect harness assembly (5) from boost

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
Required Tools
Part Number
21820221
Part Description
POWERPART
Rubber Grease
SMCS Code: 1408-010
Removal Procedure
NOTICE
Table 73
Tool
Ignition Wiring Harness Remove and Install

(Ignition Wiring Harness Rail)
Qty
1

component life.
KENR6945
167
5. Disconnect the customer connection.

NOTICE
1. Turn the gas supply to the OFF position.
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).
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).
168
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 Nm
(18 lb ft).
NOTICE
component life.
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

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 Nm (18 lb ft).
4. Connect coil lead (3) and connect harness
assembly (1) to the control box.
Illustration 410
g01839674
KENR6945
169
NOTICE
component life.
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.
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.
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.
170
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 Nm (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 Nm (15 lb ft).
Note: Ensure that the pulley is seated against the
shoulder on the shaft of the alternator.
NOTICE
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
171
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 Nm (35 lb ft).
Tighten the nut and bolt (5) to a torque of 47 Nm
(35 lb ft).
4. Position guard (4) and install bolts (6). Tighten the
5. Connect the harness assemblies to the alternator.
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
Removal Procedure
NOTICE
component life.
NOTICE
Illustration 419

mandates.
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
172
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).
NOTICE
component life.
c. Install bolts (10). Tighten the bolts to a torque

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
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 Nm (15 lb ft).
8. Position the drive belt onto pulley (13).
KENR6945
173
i03401865
Electric Starting Motor Remove and Install

SMCS Code: 1453-010
Removal Procedure

Illustration 423
g01871656
9. Position bracket (3) and install bolts (4). Tighten

the bolts to a torque of 47 Nm (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

being worked on.
NOTICE
component life.
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 Nm (35 lb ft).
Illustration 425
g01861654
174
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
b. Position solenoid (12) onto bracket (8). Install
the nuts and bolts (9) and tighten the bolts to a
torque of 9 Nm (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.
NOTICE
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 Nm (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.
position.
175
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
Alternator Drive)................................................. 171
Installation Procedure ...................................... 172
Removal Procedure ......................................... 171
Alternator) .......................................................... 169
Auxiliary Water Pump - Assemble (Gilkes Raw Water
Pump) .................................................................. 72
Auxiliary Water Pump - Disassemble (Gilkes Raw
Water Pump)........................................................ 70
Auxiliary Water Pump - Install (Gilkes Raw Water
Pump) .................................................................. 75
Auxiliary Water Pump - Remove (Gilkes Raw Water
Pump) .................................................................. 68
B
Bearing Clearance - Check ................................. 154
Measurement Procedure ................................. 154
Boost Pressure Sensor - Remove and Install (Boost
Pressure and Temperature Sensor)................... 166
C
Camshaft - Install................................................. 127
Camshaft - Remove............................................. 126
Camshaft Bearings - Install ................................. 128
Camshaft Bearings - Remove ............................. 128
Carburetor - Assemble .......................................... 22
Carburetor - Disassemble...................................... 21
Carburetor - Install................................................. 23
Carburetor - Remove............................................. 21
Coolant Temperature Switch - Remove and
Install ................................................................. 159
Crankcase Breather - Remove and Install........... 107
Crankshaft - Install (Eight Cylinder TRS
Engines)............................................................. 151
Crankshaft - Install (Six Cylinder TRS)................ 148
Crankshaft - Remove (Eight Cylinder TRS
Engines)............................................................. 146
Crankshaft - Remove (Six Cylinder TRS
Engines)............................................................. 147
Crankshaft Front Seal - Remove and Install.......... 99
Crankshaft Gear - Remove and Install ................ 153
Crankshaft Main Bearings - Remove and Install.. 145
Crankshaft Rear Seal - Remove and Install .......... 86
Cylinder Head - Install ......................................... 120
Cylinder Head - Remove ...................................... 118
Removal Procedure .......................................... 118
Cylinder Liner - Install.......................................... 134
Cylinder Liner - Remove...................................... 133
D
Disassembly and Assembly Section........................ 5
E
Electric Starting Motor - Remove and Install ....... 173
Engine Oil Cooler - Assemble ............................... 50
Engine Oil Cooler - Disassemble........................... 49
Engine Oil Cooler - Install...................................... 50
KENR6945
Engine Oil Cooler - Remove.................................. 47

Engine Oil Filter Base - Install ............................... 45
Engine Oil Filter Base - Remove ........................... 44
Engine Oil Line - Remove and Install (Engine Oil
Rail) ..................................................................... 41
Engine Oil Pan - Install ........................................ 131
Engine Oil Pan - Remove .................................... 129
Engine Oil Pressure Switch - Remove and
Install ................................................................. 160
(Alternator Warning Lamp) ................................ 161
Engine Oil Pump - Assemble................................. 59
Engine Oil Pump - Disassemble............................ 58
Engine Oil Pump - Install ....................................... 61
Engine Oil Pump - Remove ................................... 57
Oil Cooler)............................................................ 54
Oil Pressure Regulator) ....................................... 53
Engine Sensors - Remove and Install (Exhaust
Temperature Thermocouple) ............................. 156
Engine Sensors - Remove and Install (High Inlet
Manifold Pressure Shutdown Sensor) ............... 157
Engine Sensors - Remove and Install (Knock
Sensor) .............................................................. 155
(Camshaft Timing Sensor) ................................. 163
Engine Speed Sensor - Remove and Install (Engine
Speed for Governor Control) ............................. 165
(Overspeed Sensor) .......................................... 162
177
Index Section
Engine Support (Front) - Remove and Install

(Backplate)...........................................................
Installation Procedure ........................................
Removal Procedure ...........................................
Exhaust Elbow - Remove and Install.....................
Exhaust Manifold - Remove and Install .................
82
82
82
35
35
35
30
32
30
F
Flywheel - Install.................................................... 85
Flywheel - Remove................................................ 83
Flywheel Housing - Remove and Install ................ 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
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
Gear Group (Front) - Remove ............................. 101
Governor - Install (Governor Control Unit)............. 15
Governor - Install (Ignition Control Unit) ................ 16
Governor - Remove (Governor Control Unit)......... 12
Governor - Remove (Ignition Control Unit) ............ 14
H
Housing (Front) - Install (Timing Case) ...............
Installation Procedure ......................................
Housing (Front) - Remove (Timing Case) ...........
Removal Procedure .........................................
105
105
104
104
178
Index Section
KENR6945
Ignition Wiring Harness - Remove and Install (Ignition

Wiring Harness Rail).......................................... 166
Important Safety Information ................................... 2
Inlet and Exhaust Valves - Remove and Install ..... 39
Inlet Manifold - Install............................................. 37
Inlet Manifold - Remove......................................... 36
Table of Contents..................................................... 3
Turbocharger - Install ............................................ 28
Turbocharger - Remove ........................................ 26
L
Lifter Group - Assemble (Cam Followers) ...........
Assembly Procedure........................................
Lifter Group - Disassemble (Cam Followers) ......
Disassembly Procedure ...................................
Lifter Group - Install (Cam Followers)..................
Lifter Group - Remove (Cam Followers)..............
124
124
124
124
125
125
123
123
P
Piston Cooling Jets - Remove and Install............
Pistons and Connecting Rods - Assemble ..........
Assembly Procedure........................................
Pistons and Connecting Rods - Disassemble .....
Disassembly Procedure ...................................
Pistons and Connecting Rods - Install.................
Pistons and Connecting Rods - Remove.............
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
S
Spark Plugs - Remove and Install .........................
Spark Plugs - Remove and Install (Multitorch) ......
17
18
17
19
20
19
V
Valve Mechanism Cover - Remove and Install
(Rocker Box Cover) ............................................ 110
Valve Mechanism Cover Base - Remove and Install
(Rocker Box)....................................................... 111
Vibration Damper - Remove and Install................. 93
Vibration Damper - Remove and Install (Damper and
Plate) ................................................................... 90
Vibration Damper and Pulley - Remove and Install
(Single Vibration Damper) ................................... 95
W
Water Pump - Assemble........................................ 64
Water Pump - Disassemble................................... 63
Water Pump - Install .............................................. 65
Water Pump - Remove .......................................... 62
Water Temperature Regulator Housing - Remove and
Install (Thermostat Housing)................................ 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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KENR6945

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Aftercooler - Disassemble ..................................... 78

Engine Sensors - Remove and Install (High Inlet

Disassembly and Assembly

Gas Pressure Regulator Remove

3. Loosen hose clamp. Disconnect plastic hose

SMCS Code: 1270-011

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

Note: Support the weight of the zero pressure

8. Remove the assembly of zero pressure regulator

10. If necessary, remove zero pressure regulator (2)

2. Disconnect gas inlet hose from connection (8)

b. Make a temporary mark on tube assembly (11)

c. Make a temporary mark on tube assembly (12)

Gas Pressure Regulator Install

2. If necessary, Install tube assembly (11) and tube

a. Mount tube assembly (12) for fuel control valve

9. Tighten the nuts for clamp (1) to a torque of

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

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

11. Connect harness assembly (5) to fuel control

4. Position the assembly of zero pressure regulator

12. Connect hose assembly (3) to zero pressure

Note: Support the weight of the zero pressure

13. Connect plastic hose assembly (7) and tighten

Fuel Control Actuator Remove and Install

4. Remove the nuts and bolts (10) from tube

2. Loosen nuts on clamp (2) on zero pressure

10. Remove spacer (15) and O-ring seal (16) from

8. Install tube assembly (6) onto air charge cooler

11. Install bracket (4) to the tube assembly. Install

2. If necessary, install studs (17) from the inlet

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

13. Tighten nuts (13) to a torque of 47 Nm (35 lb ft).

Fuel Control Valve - Remove

2. Disconnect gas inlet hose from connection (8) on

10. Mount the assembly of fuel control valve (4) in a

1. Ensure that all components of the fuel control

2. Mount tube assembly (11) for the fuel control valve

7. Install clamp (1) to the assembly of zero pressure

15. Connect gas inlet hose to connection (8) for

5. Position a new gasket (9) (not shown) onto

Accidental engine starting can cause injury or

4. Remove screws (7) from cover (8) for the governor

1. Turn the battery disconnect switch to the OFF

6. Remove nuts (12) and remove bolts (13). Remove

9. If necessary, remove mounting bracket (21) from

1. Turn the battery disconnect switch to the OFF

5. Remove nuts (9) and nuts (7). Remove mounting

1. If necessary, install mounting bracket (21) to the

7. Position cover (8) onto the governor control unit.

2. Install rubber mountings (14) to mounting bracket

8. Connect harness assembly (1), harness assembly

5. Position governor control unit (10) onto the

6. Turn the battery disconnect switch to the ON

Spark Plugs - Remove and

2. Install rubber mounting (8) to mounting bracket

3. Install mounting bracket (13) onto mounting plate

4. Position ignition control unit (5) onto mounting

1. Remove high tension lead (2) from ignition coil (1).