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January 2016
This document has been printed from SPI2. NOT FOR RESALE
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.
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UENR4544 3
Table of Contents
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4 UENR4544
Disassembly and Assembly Section
Disassembly and
Assembly Section
i06513480
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 1 g01429930
NOTICE
Care must be taken to ensure that fluids are con- 3. Disconnect tube assembly (3) from fuel lift pump
tained during performance of inspection, mainte- (5). Cap all open tube assembly and connection.
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain- 4. Disconnect tube assembly (4) from fuel lift pump
ers before opening any compartment or disassem- (5). Cap all open tube assembly and connection.
bling any component containing fluids.
5. Remove nuts (1) and remove fuel lift pump (5)
Dispose of all fluids according to local regulations from the engine oil pump.
and mandates.
6. Remove gasket (2) (not shown).
1. Turn the fuel supply to the “OFF” position. 7. If necessary, remove fuel priming pump (6) from
fuel lift pump (5). Refer to Disassembly and
2. Switch OFF battery charger (if installed) or the Assembly, “Fuel Priming Pump - Remove and
disconnect the mains supply and disconnect the Install” for the correct procedure.
negative lead from the batteries.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 5
Disassembly and Assembly Section
i06541716
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 2 g01429930
NOTICE
2. If necessary, install fuel priming pump (6) to fuel lift Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
pump (5). Refer to Disassembly and Assembly, nance, testing, adjusting and repair of the product.
“Fuel Priming Pump - Remove and Install” for the Be prepared to collect the fluid with suitable contain-
correct procedure. ers before opening any compartment or disassem-
bling any component containing fluids.
3. Position a new gasket (2) (not shown) onto the
engine oil pump. Lubricate the drive for the fuel lift Dispose of all fluids according to local regulations
pump and the seal in the engine oil pump with and mandates.
clean engine oil.
4. Install fuel lift pump (5) on the engine oil pump. 1. Switch OFF battery charger (if installed) or the
Install nuts (1). Tighten the nuts to a torque of disconnect the mains supply and disconnect the
25 N·m (18 lb ft). negative lead from the batteries.
2. Turn the fuel supply to the OFF position.
Note: Ensure that the shaft of the fuel lift pump is
aligned with the drive in the rear of engine oil pump.
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6 UENR4544
Disassembly and Assembly Section
Illustration 3 g06009914
Typical example
Illustration 5 g06009992
Illustration 4 g06009972
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UENR4544 7
Disassembly and Assembly Section
Installation Procedure
Table 1
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 6 g06010119
Front and rear sections of engine oil rail and fuel rail
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8 UENR4544
Disassembly and Assembly Section
Illustration 7 g06010119
Front and rear sections of engine oil rail and fuel rail
b. Install nuts and bolts (24) to bracket (26). 3. Position engine oil rail (1) onto the cylinder heads.
Hand tighten the nuts and bolts. Install bolts (16) hand tight.
4. Connect hose assembly (19) to connection (17).
c. If necessary, repeat Step 2.a through Step 2.b Use a suitable tool to hold the connection and
to install remaining bracket (26) to engine oil tighten tube nut (18) to a torque of 35 N·m
rail (1). (26 lb ft). Ensure that connection(17) is not moved
d. Install a new sealing washer (23) (not shown) as the tube nut (18) is tightened.
and a new sealing washer (25) to connection Note: Ensure that the hose assembly is not
(10) and connection (13). contacting any other engine components.
e. Apply Tooling (A) to the threads of connection
(10) and connection (13).
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UENR4544 9
Disassembly and Assembly Section
Illustration 9 g06009972
Illustration 11 g06010416
Typical example
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Disassembly and Assembly Section
Illustration 13 g06010418
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UENR4544 11
Disassembly and Assembly Section
i06513475
Governor - Remove
(Electronic Control Unit)
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 14 g06030162
Typical example
Illustration 15 g06030160
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12 UENR4544
Disassembly and Assembly Section
6. Remove bracket (7) and governor control unit (1) Note: Note the position of the washer for
from rubber mounts (5). installation purposes.
7. If necessary, follow Step 7 through Step 7.c to
i06513476
remove bracket (10) from the inlet manifold.
Illustration 16 g06030155
c. Remove governor control unit (1) from bracket 2. If necessary, follow Step 2.a through Step 2.d to
(8). Remove washers (16) (not shown). install governor control unit (1) to bracket (7).
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UENR4544 13
Disassembly and Assembly Section
Illustration 19 g06030162
Typical example
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Disassembly and Assembly Section
Illustration 20 g06015805
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UENR4544 15
Disassembly and Assembly Section
Illustration 22 g06016108
Note: Make temporary marks on the lever and the 10. If necessary, follow Step 10.a through Step 10.c
shaft of the governor actuator for installation to remove lever (14) from shaft (15). Do not
purposes. remove the lever unless the lever is damaged,
the oil seal or shaft require replacing.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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16 UENR4544
Disassembly and Assembly Section
Table 2
Required Tools
Illustration 25 g06029222
Illustration 26 g06029181
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UENR4544 17
Disassembly and Assembly Section
Lever.
c. Lubricate a new oil seal (18) with clean engine
oil. Carefully position the oil seal over shaft
(15) and use a suitable tool to install the oil
seal into housing (19). Ensure that the oil seal
is correctly installed into the housing.
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18 UENR4544
Disassembly and Assembly Section
Illustration 28 g06016108
Illustration 30 g06015816
Tube assemblies not shown for clarity
Illustration 29 g06016130
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Disassembly and Assembly Section
Illustration 33 g06029648
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20 UENR4544
Disassembly and Assembly Section
(0.012 inch to 0.020 inch). Loosen the nut and 3. Calibrate the operation of the governor actuator
bolt and repeat Step 1.c to achieve the correct and the governor electronic control unit. Refer to
end play. Operation and Maintenance Manual, “Governor
Actuator - Check” for more information.
d. Remove spacer (20) from between the two
levers of the lever assembly. i06513469
e. After the end play has been set, use a 4 mm Fuel Injection Control Linkage
(0.158 inch) drill to drill through pin (16) hole in
lever (14) and the shaft. - Remove
f. Use a suitable tool to install pin (16)to lever
(14). Support the shaft as the pin is installed.
Removal Procedure
Installation Procedure for Guard Start By:
a. Remove the rocker assemblies. Refer to
Disassembly and Assembly, “Rocker Arm and
Shaft - Remove” for the correct procedure.
b. Remove the cam followers. Refer to
Disassembly and Assembly, “Lifter Group -
Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 34 g06015805
Illustration 35 g06015056
The ZERO FUEL position on the governor actuator
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UENR4544 21
Disassembly and Assembly Section
Illustration 38 g06015071
Illustration 37 g06015064
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22 UENR4544
Disassembly and Assembly Section
2. Disconnect harness assembly (14) from solenoid 10. If necessary, follow Step 10.a through Step 10.d
(13). to disassemble bracket (11).
3. Compress the plunger on stop solenoids (13). Use a. Measure the distance of bolt (23) for
suitable cable straps to secure the plunger in the installation purposes.
compressed position
b. Loosen lock nut (24) and remove bolt (23)
4. Remove bolts (12) from solenoid (13). Remove
from bracket (11).
solenoid from bracket (11).
5. Remove pin (18) from shaft (20). Support the shaft c. Measure the distance of bolt (25) for
as the pin is removed installation purposes.
6. Remove circlip (19) from shaft (20) d. Loosen lock nut (26) and remove bolt (25)
from bracket (11).
7. Remove lever (21) from shaft (20). As the shaft is
removed disconnect spring (17) from pin in the
timing case.
8. Remove spring (17) and washers (16) from shaft
(20). Note the orientation of the spring and also
the number of washers for installation purposes.
9. if necessary, remove nuts and bolts (22) from
bracket (11). Remove the bracket and bracket (15)
(not shown) from the timing case.
Note: Make temporary mark on the suspension plate
to show the position of (15) (not shown) for
installation purposes. Note position of thick washer
on bracket (15) (not shown).
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UENR4544 23
Disassembly and Assembly Section
Illustration 41 g06015170
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24 UENR4544
Disassembly and Assembly Section
Illustration 42 g06015514
2. Remove locking nut (37) and bolt (36) from rod (8).
If necessary, remove rod (8). Repeat Step 2 to
remove the remaining locking nut, and bolt, and
rods.
3. Remove nuts (32) from plate (34).
4. Remove Allen head bolts (33) from plate (34).
Remove the plate from the cylinder block. Remove
O-ring seal (35) (not shown).
5. Repeat Step 3 through Step 4 to remove remaining
plate (34).
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Disassembly and Assembly Section
i06513471
B - LOCTITE 542 1
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26 UENR4544
Disassembly and Assembly Section
Illustration 45 g06015514
Illustration 47 g06015528
Illustration 46 g06030187
3. Carefully install the assembly of fuel injection
control linkage (42) into from the cylinder block.
Push supports (44) for fuel injection control linkage
into the cylinder block. Ensure that the supports
for fuel injection control linkage are correctly
located into the cylinder block.
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UENR4544 27
Disassembly and Assembly Section
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28 UENR4544
Disassembly and Assembly Section
4. If necessary, follow Step 4.a through Step 4.b to 5. if necessary, position bracket (11) onto the timing
assemble bracket (11). case and install nuts and bolts (22). Install bracket
(15) (not shown) to the nut and bolt on the rear of
a. Install bolt (23) to bracket (11). Set the bolt to the suspension plate. Align the bracket to the
measurement taken on the removal temporary marks on the suspension plate.
procedure. Tighten lock nut (24)to a torque of
25 N·m (221 lb in). Note: Ensure that the thick washer is correctly
positioned onto the bracket.
b. Install bolt (25) to bracket (11). Set the bolt to
measurement taken on the removal 6. Tighten the nuts and bolts to a torque of 47 N·m
procedure. Tighten lock nut (26)to a torque of (35 lb ft). Ensure that bracket (15) (not shown)
25 N·m (221 lb in). remains correctly orientated.
7. Install spring (17) and washers (16) to shaft (20).
Ensure that the spring is correctly orientated.
8. Install lever (21) to shaft (20). Connect spring (17)
to pin in the timing case and the lever.
9. Install circlip (19) to shaft (20). Ensure that the
circlip is correctly installed into groove of the shaft.
10. Install pin (18) to shaft (20). Support the shaft as
the pin is installed.
11. Position solenoid (13) onto bracket (11). Install
bolts (12). Tighten the bolts to a torque of 47 N·m
(35 lb ft).
12. Remove the cable strap from solenoid (13).
13. Connect harness assembly (14) to solenoid (13).
14. Install the governor actuator. Refer to
Disassembly and Assembly, “Governor Actuator -
Remove and Install” for the correct procedure.
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UENR4544 29
Disassembly and Assembly Section
Illustration 52 g06015064
Illustration 51 g06015071
Illustration 53 g06015056
The ZERO FUEL position on the governor actuator
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30 UENR4544
Disassembly and Assembly Section
10. Position link (2) onto fuel injector (4) and install
spacer (3).Install Allen head bolt (1) to the link.
11. Tighten locking nut and bolt (5) and Allen head
bolt (1) to a torque of 8 N·m (70 lb in). Ensure that
the fuel injector lever is not strained as the Allen
head bolt is tightened.
12. Calibrate the fuel injector, Refer to Operation and
Maintenance Manual, “Fuel Injector - Inspect/
Adjust” for the correct procedure.
End By:
a. Install the cam followers. Refer to Disassembly
and Assembly, “Lifter Group - Install” for the
correct procedure.
b. Install the rocker assemblies. Refer to
Disassembly and Assembly, “Rocker Arm and
Shaft - Install” for the correct procedure.
i06511856
Illustration 54 g06015060
Fuel Injector - Remove
Removal Procedure
Table 5
Required Tools
Start By:
a. Remove the rocker assembly. Refer to
Disassembly and Assembly, “Rocker Arm and
Shaft - Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 55 g06015641
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UENR4544 31
Disassembly and Assembly Section
Note: Do not allow the unions to turn when the tube 4. Remove Allen head bolt (8) from clamp (9).
assemblies are disconnected from the fuel rail. Allow
the unions to turn will damage the threads in the fuel NOTICE
rail. Use two spanners to loosen the tube assemblies For engines that have cover extensive service
from the connections. hours, removal of the injectors will require Tool-
ing (A) to be used to free the injector from the car-
bon build-up on the fuel injector nozzle. Failure to
break the carbon build-up on the fuel injector
nozzle could result in the fuel injector sleeve be-
coming dislodged from the cylinder head.
Illustration 56 g01439660
Typical example
Illustration 58 g01439664
i06511860
Installation Procedure
Table 6
Required Tools
Illustration 57 g01439666
(continued)
3. Remove Allen head bolt (5) and spacer (7) to
disconnect link (6) from fuel injector (4).
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32 UENR4544
Disassembly and Assembly Section
(Table 6, contd)
GE50028 Vacuum Pump 1
B Tube
GE50030 7.9 mm (0.31 inch) Outside 1
Diameter
Delphi Lockheed Rubber
C - 1
Grease
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 60 g01621582
1. Use Tooling (B) to remove any fuel from the
cylinder. 4. Install clamp (9) to fuel injector (4). Install the fuel
injector and the clamp to the cylinder head as an
Note: Evacuate as much fuel as possible from the assembly.
cylinder before installing the fuel injector.
5. Install Allen head bolt (8) to clamp (9) finger tight.
Rotate injector (4) in a clockwise direction against
the clamp. Ensure that the fuel injector is pushed
firmly downward against the seat in the cylinder
head. Tighten the Allen head bolt to a torque of
95 N·m (70 lb ft).
Illustration 61 g01440088
Illustration 59 g01439664
(X) NO FUEL position
2. Install a new O-ring seal (10) and a new O-ring
seal (11) to fuel injector (4). Lubricate the O-ring 6. Rotate the arm on fuel injector (4)
seals with Tooling (C). Install a new sealing counterclockwise to Position (X). The fuel injector
washer (12) to fuel injector (4). is now in the NO FUEL position.
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UENR4544 33
Disassembly and Assembly Section
Note: If three or more fuel injectors have been a. Install the rocker assembly. Refer to
installed, all the fuel injectors should be calibrated. Disassembly and Assembly, “Rocker Arm and
Shaft - Install” for the correct procedure.
i06513472
Removal Procedure
Table 7
Required Tools
Start By:
a. Remove the cylinder head. Refer to
Illustration 63 g01439660 Disassembly and Assembly, “Cylinder Head -
Typical example Remove” for the correct procedure.
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34 UENR4544
Disassembly and Assembly Section
1. Place the cylinder head in the inverted position on 4. Remove O-ring seal (2) from the cylinder head.
a suitable support. Use Tooling (A) to drill out the
swaging from sleeve (1). i06513473
Note: Take care to avoid drilling into the cylinder Fuel Injector Sleeve - Install
head.
NOTICE
Keep all parts clean from contaminants.
Illustration 65 g06013926
Removing the sleeve from the cylinder head Contaminants may cause rapid wear and shortened
component life.
3. Place the cylinder head in the inverted position.
Insert a suitable brass rod into the injector bore of 1. Ensure that the bore in the cylinder head for the
the cylinder head. Use a hammer and the brass sleeve is clean and free from corrosion.
rod to remove Tooling (B) and sleeve (1) from the
cylinder head.
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UENR4544 35
Disassembly and Assembly Section
Illustration 67 g06013928
Illustration 69 g06013943
Illustration 68 g06013942
Illustration 70 g06013945
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36 UENR4544
Disassembly and Assembly Section
5. Use Tooling (G) to swage the end of sleeve (1) 7. Place the cylinder head in the upright position. Use
sufficiently so that the sleeve is held in position. Tooling (F) to expand top of sleeve (1).
Note: The final forming of the swage is completed
after the sleeve has been expanded.
Illustration 74 g06013946
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UENR4544 37
Disassembly and Assembly Section
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
correct procedure.
i06511714
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 75 g06013951
Illustration 77 g06018870
Illustration 76 g06013954 1. Loosen hose clamp (1) and hose clamp (3) for
hose assembly (2).
9. Use Tooling (J) to check Distance (Z). Use Tooling
(H) to face sleeve (1) so that Distance (Z) is 2. Attach a suitable lifting equipment to air cleaner
122.6 ± 0.166 mm (4.8207 ± 0.004 inch). assembly (8). The weight of the air cleaner is
approximately 15 kg (33 lb).
10. Ensure that sleeve (1) is free from burrs or
damage after the installation procedure has been 3. Remove bolts (4) and remove air cleaner
completed. Failure to ensure that the injector assembly (8) from bracket (5).
sleeve is free from burrs or damage could damage 4. Remove hose assembly (2), hose clamp (1), and
to the injector O-ring seals. hose clamp (3) from turbocharger (6).
5. If necessary, remove air cleaner indicator (7) from
air cleaner assembly (8).
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38 UENR4544
Disassembly and Assembly Section
6. If necessary , follow 1 Step through Step 5 to b. Attach a suitable lifting device to air cleaner
remove the remaining air cleaner assembly. bracket (5). The weight of the air cleaner
bracket is approximately 8 kg (17 lb).
Installation Procedure
Table 9
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 79 g06018892
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UENR4544 39
Disassembly and Assembly Section
Illustration 80 g06018882
Illustration 82 g06018870
Illustration 81 g06018892
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Disassembly and Assembly Section
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UENR4544 41
Disassembly and Assembly Section
Removal Procedure For Outer 4. Sufficiently loosen V-band clamp (15) and position
Turbocharger the V-band clamp away from the outlet of
turbocharger (14).
5. Attach a suitable lifting equipment to support the
turbocharger (14). The weight of the turbocharger
is approximately 35 kg (77 lb).
6. Remove nuts and bolts (17) and remove
turbocharger (14) from the exhaust manifold
assembly.
7. Remove gasket (18) (not shown) and O-ring seal
(16) (not shown).
8. Plug all open ports turbocharger (14) to prevent
the entry of dirt. Plug open port tube assembly (19)
and tube assembly (20).
9. If necessary. remove connection (20a) from the
rear tube assembly. Refer to the section removal
procedure for inner and outer turbocharger
connections Disassembly and Assembly,
Turbocharger - Remove for the correct procedure.
Illustration 85 g06007528
Outer turbocharger
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42 UENR4544
Disassembly and Assembly Section
Removal Procedure For Inner 4. Sufficiently loosen V-band clamp (28) and position
Turbocharger the V-band clamp away from the outlet of
turbocharger (27).
5. Attach a suitable lifting equipment to support the
turbocharger (27). The weight of the turbocharger
is approximately 35 kg (77 lb).
6. Remove nuts and bolts (30) and remove
turbocharger (27) from the exhaust manifold
assembly.
7. Remove gasket (31) (not shown) and O-ring seal
(29) (not shown).
8. Plug all open ports of turbocharger (14) to prevent
the entry of dirt. Plug open port of tube assembly
(19) and tube assembly (20).
9. If necessary. remove connection (33a) from the
rear tube assembly. Refer to the section removal
procedure for inner and outer turbocharger
connections Disassembly and Assembly,
Turbocharger - Remove for the correct procedure.
Illustration 86 g06007532
Outer turbocharger not shown for clarity
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UENR4544 43
Disassembly and Assembly Section
Illustration 88 g06028418
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44 UENR4544
Disassembly and Assembly Section
Illustration 89 g06028701
Illustration 90 g06028754
2. Disconnect hose assembly (20) from oil feed
manifold (41). Remove O-ring seal (39) (not 8. Disconnect hose assembly (32) from oil drain
shown) from the oil feed manifold. manifold (51). Remove O-ring seal (56) from
connection (55).
3. Disconnect hose assembly (33) from oil feed
manifold (41). Remove O-ring seal (40) (not 9. Disconnect hose assembly (19) from oil drain
shown) from the oil feed manifold. manifold (51). Remove O-ring seal (59) from
connection (58).
4. Remove hose assembly (46) from oil feed manifold
(41) and connection (48). Remove O-ring seal (44) 10. If necessary, follow Step 10.a through Step 10.d
(not shown) and O-ring seal (49) (not shown). to remove oil drain manifold (51) from the cylinder
block and remove connection (55) and connection
5. Remove bolts (42) and remove oil feed manifold (58) from the oil drain manifold.
(41) from bracket (45).
6. If necessary, remove bolts (43) (not shown) and a. Remove nuts (53) and remove oil drain
bolts (47) from bracket (45). Support the bracket manifold (51) from the cylinder block. Remove
as the bolts are removed. O-ring seal (52) (not shown).
7. If necessary. remove connection (48) from the b. Position oil drain manifold (51) in suitable
cylinder block. Remove sealing washer (50). support.
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UENR4544 45
Disassembly and Assembly Section
i06511743
Turbocharger - Install
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46 UENR4544
Disassembly and Assembly Section
Illustration 92 g06028701
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UENR4544 47
Disassembly and Assembly Section
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48 UENR4544
Disassembly and Assembly Section
Turbocharger Orientation
Illustration 94 g06020258
c. Apply Tooling (A) to the inner and out section 1. If necessary, follow Step 1.a through Step 1.b to
of seal (36). Install the seal to connection (35). orientate the rotate on the body turbocharger.
Ensure that the seal is not damaged and is
a. Loosen V-band clamp (34) and V-band clamp
installed squarely positioned onto elbow
(35). Ensure that the housings are free to
connection.
rotate on the body of turbocharger (36).
d. Align temporary marks on connection (35) and
Note: Do not allow the housings to come in
rear tube assembly (38). Install the connection
contact with the turbine or the compressor
to rear tube assembly. Ensure that the seal is wheels.
not damaged and the temporary marks remain
correctly aligned. b. If necessary, remove the V-band clamps and
clean the mating surfaces of the turbocharger.
Installation Procedure Lubricate the mating surfaces with Tooling (C)
and install the V-band clamps.
NOTICE
Keep all parts clean from contaminants.
Note: Do not allow the housings to come in
Contaminants may cause rapid wear and shortened contact with the turbine or the compressor
component life. wheels.
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UENR4544 49
Disassembly and Assembly Section
Installation Procedure For Inner 4. Position turbocharger (27) onto the exhaust
Turbocharger manifold assembly. Install a new gasket (31) (not
shown) between the turbocharger and the exhaust
manifold assembly.
5. Apply Tooling (C) to nuts and bolts (30). Install the
nuts and bolts to turbocharger (27) and exhaust
manifold assembly. Tighten the nuts and bolts
hand tight.
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50 UENR4544
Disassembly and Assembly Section
Illustration 97 g06007961
Illustration 98 g06007979
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UENR4544 51
Disassembly and Assembly Section
Installation Procedure For Outer 4. Position turbocharger (14) onto the exhaust
Turbocharger manifold assembly. Install a new gasket (18) (not
shown) between the turbocharger and the exhaust
manifold assembly.
5. Apply Tooling (C) to nuts and bolts (17). Install the
nuts and bolts to turbocharger (14) and exhaust
manifold assembly. Tighten the nuts and bolts
hand tight.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
i06548424
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Disassembly and Assembly Section
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Disassembly and Assembly Section
1. Make temporary marks on hose assembly (12) and 3. Remove bolts (23) from tube assembly (22).
tube assembly (22). Loosen hose clamps (19) for
4. Remove bolts (24) and remove tube assembly
the hose assembly. Remove the hose assembly
(22). Remove gasket (25) (not shown).
from tube assembly (22).
2. Remove nuts (20) from clamp (21). Remove the
clamp from tube assembly (22).
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Disassembly and Assembly Section
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
The turbocharger compressor outlet tube assemblies
can be installed as an assembly or the turbocharger
compressor outlet tube assemblies can be installed
individually. For installed of individually section all or
part of this installed procedure can be used.
1. Ensure all components of the turbocharger
compressor outlet tube assemblies, are free from
wear or damage. If necessary, replace any
component that is worn or damaged.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
Upper Section of the Rear Exhaust 2. If equipped, remove exhaust temperature sensor
Manifold (30) from exhaust manifold (26). Refer to
Disassembly and Assembly, “Engine Sensors -
(Exhaust Temperature Thermocouple) Remove
and Install” for the correct procedure.
3. Remove air cleaner (27). Refer to Disassembly
and Assembly, “Air Cleaner- Remove and Install”
for the correct procedure.
4. Remove turbocharger (28) from exhaust manifold
(26). Refer to Disassembly and Assembly,
“Turbocharger - Remove” for the correct
procedure.
5. Sufficiently loosen V-band clamp (25) to enable the
V-band clamp to be removed.
6. Remove bolts (31) and bolts (32) from exhaust
manifold (26). Remove the exhaust manifold.
7. Remove V-band clamp (25) from the exhaust
bellows.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
Installation Procedure
Table 14
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
Illustration 131 g06010656 3. Tighten V-band clamp (25) hand tight. Ensure that
V-band clamp and exhaust manifold (26) are
correctly located onto the exhaust bellows.
4. Install bolts (31) and bolts (32) to exhaust manifold
(26). Hand tighten the bolts. Ensure that the
exhaust manifold is correctly aligned onto the
exhaust bellows.
5. Tighten bolts (31) and bolts (32) to a torque of
58 N·m (43 lb ft).
6. Tighten V-band clamp (37) to a torque of 9 N·m
(80 lb in).
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
i06511747
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
9. Tighten bolts (1) to a torque of 58 N·m (43 lb ft). 1. Remove the Original Equipment Manufacture
10. Tighten V-band clamp (9) and V-band clamp (5) (OEM) exhaust system (1) from exhaust elbow (5).
to a torque of 9 N·m (80 lb in). 2. If equipped with an exhaust temperature sensor.
Remove exhaust temperature sensor (4) from
a. Lightly tap the V-band clamps with a soft faced exhaust elbow (7). Refer to OEM for the correct
hammer to seat the V-band clamps. Again, procedure.
tighten the V-band clamps to a torque of 9 N·m
(80 lb in). Repeat this Step 10.a until the V- 3. Attach a suitable lifting equipment to support
exhaust elbow (5). The weight of the exhaust
elbow is approximately 35 kg (77 lb).
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
6. Install the remaining V-band clamp (3) and Note: Removal of individual sections of an inlet
remaining V-band clamp (8) onto exhaust bellow manifold without removing the complete manifold is
(2) and exhaust bellow (9). Ensure that both V- possible. If removal of a complete manifold is
band clamps are correctly orientated. necessary, use a suitable lifting device.
7. Attach a suitable lifting equipment to support Front Section of the Inlet Manifolds
exhaust elbow (5). The weight of the exhaust
elbow is approximately 35 kg (77 lb).
8. Use the suitable lifting equipment to install exhaust
elbow (5) onto the bracket.
9. Install V-band clamp (3) and V-band clamp (8) onto
exhaust elbow (5). Hand tighten the V-band
clamps.
10. Apply Tooling (A) to the threads of bolts (6) (not
shown).
11. Install bolts (6) (not shown) and spacers (7) (not
shown) exhaust elbow (5). hand tighten the bolts.
12. Tighten bolts (6) (not shown) to a torque of
58 N·m (43 lb ft).
13. Tighten bolts (10) to a torque of 58 N·m (43 lb ft).
14. Tighten V-band clamp (37) to a torque of 9 N·m
(80 lb in).
i06511740
NOTICE
Illustration 147 g06006487
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened 1. Remove nuts and bolts (3) from connection (6).
component life.
2. Loosen hose clamps (7) and slide the connection
away from inlet manifold (2). Remove gasket (5)
(not shown).
3. Remove nuts and bolts (1).
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Disassembly and Assembly Section
4. Support inlet manifold (2). Remove bolts (8) from Inlet Manifold Center Sections
the inlet manifold.
5. Remove inlet manifold (2) from the cylinder heads.
Remove gaskets (9) (not shown).
6. Remove O-ring seal (4) (not shown) from inlet
manifold (10).
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Disassembly and Assembly Section
2. Remove nuts and bolts (11) nuts and bolts (13), Inlet Manifold Rear Section
and nuts and bolts (15) from inlet manifold (12)
inlet manifold (14), and inlet manifold (10).
3. Remove 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.
4. Support inlet manifold (12) inlet manifold (14) and
remove bolts (20) and bolts (22). Remove the inlet
manifolds from the cylinder heads.
5. Remove O-ring seal (16) (not shown).O-ring seal
(18) (not shown), and O-ring seal (19) (not shown)
from inlet manifold (12) inlet manifold (14).
6. Remove gasket (21) (not shown) and gasket (23)
(not shown).
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Disassembly and Assembly Section
i06511741
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
4. Install new O-ring seal (18) (not shown), and new Front Section of the Inlet Manifolds
O-ring seal (19) (not shown) to inlet manifold (12)
inlet manifold (14).
5. Install inlet manifold (12) onto the cylinder heads.
Install bolts (20) to the inlet manifold finger tight.
Ensure that gaskets (21) (not shown) and O-ring
seal (16) (not shown) remain correctly located.
6. Install inlet manifold (14) onto the cylinder heads.
Install bolts (22) to the inlet manifold finger tight.
Ensure that gaskets (23) (not shown), O-ring seal
(18) (not shown), and O-ring seal (19) (not shown)
remain correctly located.
7. Install nuts and bolts (11) nuts and bolts (13) and
nuts and bolts (15) to the inlet manifolds hand
tight.Do not install the nuts and bolts for
governor (17) bracket to the inlet manifolds.
8. Tighten bolts (20) to a torque of 47 N·m (35 lb ft).
9. Tighten bolts (22) to a torque of 47 N·m (35 lb ft).
10. Tighten nuts and bolts (11) nuts and bolts (13),
and nuts and bolts (15) to a torque of 47 N·m Illustration 156 g06006487
(35 lb ft).
11. Install the bracket for governor (17). Refer to
Disassembly and Assembly, “Governor - Remove”
for the correct procedure.
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Disassembly and Assembly Section
4. Install nuts and bolts (11) to inlet manifolds (2) Note: Do not stamp the heads of the valves.
hand tight. Stamping or punching the heads of the valves could
cause the valves to fracture.
5. Tighten bolts (8) to a torque of 47 N·m (35 lb ft).
6. Tighten nuts and bolts (1) to a torque of 47 N·m
(35 lb ft).
Personal injury can result from being struck by
7. Slide connection (6) towards inlet manifold (2). parts propelled by a released spring force.
Position new gasket (5) (not shown) between the
connection and the inlet manifold. Make sure to wear all necessary protective
equipment.
8. Install nuts and bolts (3) to connection (6) hand
Follow the recommended procedure and use all
tight. Tighten the nuts and bolts to a torque of recommended tooling to release the spring force.
47 N·m (35 lb ft).
9. Tighten hose clamps (7) securely to a torque of
7 N·m (62 lb in). NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
i06511693
Removal Procedure
Table 16
Required Tools
Start By:
a. Remove the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head -
Remove” for the correct procedure.
NOTICE
Inlet, exhaust, valves, and valve seat on the 4008-
30 have a valve seat and valve angle of 20 degree.
For further information contact your Perkins
distributor.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
Installation Procedure
Table 17
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
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Disassembly and Assembly Section
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
correct procedure.
i06511692
Removal Procedure
Table 18
Required Tools
a. Remove the inlet and exhaust valves. Refer to 1. Use Tooling (A) and a suitable press to push valve
Disassembly and Assembly, “Inlet and guides (1) out of the cylinder head.
Exhaust Valves - Remove and Install” for the
correct procedure.
Installation Procedure
NOTICE Table 19
Removal and installation of the valve guide and valve Required Tools
seat must be carried out by personnel with the correct
training. Also special machinery is required. For more Tool Part Number Part Description Qty
information, refer to your authorized Perkins
distributor. B T85002/3 Valve Guide Installation Tool 1
NOTICE NOTICE
Keep all parts clean from contaminants. Removal and installation of the valve guide and valve
seat must be carried out by personnel with the correct
Contaminants may cause rapid wear and shortened training. Also special machinery is required. For more
component life. information, refer to your authorized Perkins
distributor.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
Note: Replacement valve guides are supplied, 6. Check the depths of the valves below the face of
finished to the correct size. the cylinder head. Refer to System Operation,
Testing and Adjusting, “Valve Depth - Inspect” for
3. Use Tooling (B) and a suitable press to install the more information.
valve guide to the cylinder head. Press the valve
guide until Tooling (B) bottoms out on the cylinder End By:
head. a. Install the inlet valves and the exhaust valves.
Refer to this Disassembly and Assembly
Note: The counterbore in Tooling (B) ensures that Manual, “Inlet and Exhaust Valves - Remove
the valve guide is installed to the correct height. and Install” for the correct procedure.
4. Repeat Step 2 and Step 3 to install the remaining i06510362
valve guides.
Engine Oil Filter Base -
Remove
Removal Procedure
Table 20
Required Tools
A - Strap Wrench 1
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates. Illustration 165 g01808193
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Disassembly and Assembly Section
i06510369
Installation Procedure
Table 21
Required Tools
Guide Stud
B - 2
M10 by 75 mm
NOTICE
Illustration 167 g01808338
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
5. Remove bolts (7) from tube assembly (6). component life.
6. Remove O-ring seal (8) (not shown) from tube
assembly (6). 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.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
10. Install bolts to tube clip (5) and clips (3) to tube
assembly (3). Tighten bolts for the tube clips
securely.
11. Install new engine oil filters (1) to engine oil filter
Illustration 172 g01808674
base (2). Refer to Operation and Maintenance
The bolt tightening sequence for the engine oil filter Manual, “Engine Oil and Filter Change” for the
base
correct procedure.
7. Tighten bolts (7) for tube assembly (8) to a torque 12. If the engine oil cooler is equipped with an oil
of 47 N·m (35 lb ft). Tighten the bolts in the pressure switch, connect the harness assembly to
sequence that is shown in Illustration 172 . the oil pressure switch.
8. Tighten bolts (9) for engine oil filter base (2) to a
i06510370
torque of 47 N·m (35 lb ft). Tighten the bolts in the
sequence that is shown in Illustration 172 . Engine Oil Cooler - Remove
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
Illustration 173 g01808194
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
14. Remove bolts (31). Remove bracket (33) from 1. Remove bolts (1) and bolts (5). Remove cover (2)
engine oil cooler (1). Do not remove dowel pins and cover (6) from the engine oil cooler.
(34).
Note: If necessary, tap the covers with a soft faced
Note: Mark the position of the bracket for installation hammer to loosen the covers.
purpose.
2. Remove O-ring seal (3). Remove gasket (4) (not
i06510371 shown).
Disassembly Procedure
Start By:
a. Remove the engine oil cooler. Refer to
Disassembly and Assembly, “Engine Oil
Cooler - Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Illustration 184 g01811722
Contaminants may cause rapid wear and shortened
component life. 3. Carefully tap the rear face of tubestack (8) with a
soft faced hammer to drive the tubestack from the
housing of the engine oil cooler.
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Disassembly and Assembly Section
i06510372
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 185 g01811722
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Disassembly and Assembly Section
End By:
a. Install the engine oil cooler. Refer to
Disassembly and Assembly, “Engine Oil
Cooler - Install” for the correct procedure.
i06510373
Installation Procedure
Table 22
Required Tools
Illustration 188 g01810233
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Disassembly and Assembly Section
5. Install Tooling (A) to the cylinder block. 11. Install Tooling (A) to the cylinder block.
6. Attach a suitable lifting device to engine oil cooler 12. Install a new gasket (14) (not shown) and install
(1). The weight of the engine oil cooler is valve (13).
approximately 45 kg (100 lb).
7. Use a suitable lifting device to position engine oil
cooler (1) onto Tooling (A). Align the engine oil
cooler with the dowel pins in the cylinder block and
install the engine oil cooler to the cylinder block.
8. Install bolts (25) and bolts (26) to engine oil cooler
(1).
9. Remove Tooling (A) from the cylinder block. Install
remaining bolts (25) and bolts (26) to engine oil
cooler (1).
10. Tighten bolts (25) and bolts (26) to a torque of
47 N·m (35 lb ft).
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Disassembly and Assembly Section
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Disassembly and Assembly Section
i06510374
Contaminants may cause rapid wear and shortened 1. Carefully loosen bolts (6). Remove the bolts and
component life. remove plate (5).
Note: The spring force will be released suddenly
NOTICE when the bolts are removed.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- 2. Remove spring seat (2) and spring (4).
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain- 3. Remove plunger (1).
ers before opening any compartment or disassem-
bling any component containing fluids. 4. Remove gasket (3).
Bolts
- 2
A M8 by 50 mm
- Nuts M8 2
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
3. Place spring seat (2), gasket (3) and plate (6) into
position. Use Tooling (A) to hold the plate
temporarily in place. Refer to Illustration 198 .
Using of temporary nuts and bolts to install the
plate to the engine oil pressure regulator.
4. Tighten the nuts on Tooling (A) evenly to compress
spring (4).
5. Remove one nut and bolt from Tooling (A). Install
bolt (6) hand tight. Remove the remaining nut and
bolt from Tooling (A). Install the remaining bolt (6).
6. Tighten bolts (6) to a torque of 25 N·m (18 lb ft).
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Disassembly and Assembly Section
i06510375
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life. Illustration 199 g01821493
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
a. Remove plug (15) from the assembly of valve Illustration 202 g01821553
(13).
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Disassembly and Assembly Section
i06510376
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Disassembly and Assembly Section
3. Disconnect tube nut (1) and tube nut (6) for tube
assembly (2). Remove the tube assembly from
fuel transfer pump (8) and the connection.
4. Disconnect tube nut (7) and tube nut (10) for tube
assembly (9). Remove the tube assembly from
fuel transfer pump (8) and the fuel filter base.
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Disassembly and Assembly Section
Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
i06510378
Disassembly Procedure
Table 25
Required Tools Illustration 209 g06012567
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Disassembly and Assembly Section
3. Use Tooling (A) to pull gear (2) from the shaft of b. Place rear section (9) of engine oil pump (5).
engine oil pump (18). Remove key (21). Ensure that the gasket face of the engine oil
pump is not damaged. Use a suitable tool to
4. Remove key (1) from the shaft of engine oil pump
press the bush from the front section of the
(5).
engine oil pump.
i06510379
Assembly Procedure
Table 26
Required Tools
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Disassembly and Assembly Section
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Disassembly and Assembly Section
NOTICE
The end play of the engine oil pump is controlled by
the gasket. Always assemble a new POWERPART
joint to the engine oil pump. Failure to use a new
POWERPART gasket may result in serious damage
to the engine.
i06510380
Installation Procedure
Table 27
Required Tools
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
i06510381
Illustration 218 g01841094
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
Illustration 219 g01841095
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Disassembly and Assembly Section
i06510392
Disassembly Procedure
Table 28
Required Tools
A - Circlip Pliers 1
Start By:
a. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove” for the
correct procedure. Illustration 220 g01842553
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Disassembly and Assembly Section
i06510393
Assembly Procedure
Table 29
Required Tools
A - Circlip Pliers 1
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Disassembly and Assembly Section
i06510394
Installation Procedure
Table 30
Required Tools Illustration 223 g01841095
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Disassembly and Assembly Section
i06510402
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Disassembly and Assembly Section
Installation Procedure
Table 31
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
b. Align the bolt holes in tube assembly (11) with Removal Procedure
bracket (13). Tighten hose clamps (9) from
hose assembly (10) to a torque of 8 N·m Start By:
(71 lb in). a. Remove the engine oil pump. Refer to
5. Install a new O-ring seal (4) (not shown) to rail (5). Disassembly and Assembly, “Engine Oil Pump
Ensure that the O-ring seal is correctly installed - Remove” for the correct procedure.
into the recess of the rail. b. Remove the timing gears. Refer to
6. Install a new O-ring seal (7) (not shown) to Disassembly and Assembly, “Gear Group
(Front) - Remove” for the correct procedure.
thermostat housing (6). Ensure that the O-ring
seal is correctly installed into the recess of the NOTICE
thermostat housing. Keep all parts clean from contaminants.
7. Install thermostat housing (6) to tube assembly Contaminants may cause rapid wear and shortened
(11) and rail (5). Ensure that the O-ring seals are component life.
not dislodged as the thermostat housing is
installed.
8. Install bolts (3) and nuts (8) to thermostat housing
(6). Hand tighten the bolts and the nuts.
9. Tighten nuts (8) to a torque of 47 N·m (35 lb ft).
Tighten bolts (3) to a torque of 47 N·m (35 lb ft).
10. Connect the harness assembly to coolant
temperature switch (2) (not shown).
11. Connect hose (1) to thermostat housing (6).
Tighten the hose clamps to a torque of 8 N·m
(71 lb in).
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118 UENR4544
Disassembly and Assembly Section
2. Attach a suitable lifting device to the back plate (1). Required Tools
The weight of the back plate is approximately Tool Part Number Part Description Qty
45 kg (100 lb).
Guide Studs
A - 2
3. Remove bolts (2). M10 by 100 mm
4. Use the suitable lifting device and remove back |B - Loctite 638 1
plate (1) from the crankcase.
5. Remove gasket (3) (not shown). NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
c. If necessary, use a suitable tool to remove 3. If necessary, follow Step 3.a through Step 3.d to
bush (5) form housing (4). Ensure that the remove housing (4) from back plate (1).
housing is not damaged as the bush is
removed. a. If necessary, use a suitable tool to install bush
(5) to housing (4). Ensure that the bush is
installed into the housing correctly.
This document has been printed from SPI2. NOT FOR RESALE
UENR4544 119
Disassembly and Assembly Section
i06510412
Flywheel - Remove
Removal Procedure
Table 33
Required Tools
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120 UENR4544
Disassembly and Assembly Section
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UENR4544 121
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
b. Use a hammer and a chisel to split ring gear Note: The chamfered side of the ring gear teeth
(5). Remove the ring gear from the flywheel. must face toward the starting motor when the
flywheel is installed.
i06510417
c. Heat ring gear (5) in an oven to a maximum
Flywheel - Install temperature of 250 °C (482 °F).
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122 UENR4544
Disassembly and Assembly Section
8. Remove Tooling (A) and install the remaining bolts The tightening sequence for the flywheel bolts
(2) hand tight.
9. Follow Step 9.a and Step 9.b to prevent the
flywheel from rotating.
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UENR4544 123
Disassembly and Assembly Section
Illustration 240 .
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” for the correct
procedure.
b. Install the overspeed sensor. Refer to
Disassembly and Assembly, “Engine Speed
Sensor - (Overspeed Sensor) Remove and
Install” for the correct procedure.
c. Install the engine speed sensor. Refer to
Disassembly and Assembly, “Engine Speed
Sensor - (Engine Speed for Governor Control)
Remove and Install” for the correct procedure.
i06510419
Remove and Install 1. Use a 4 mm (1/8 inch) drill to make three equally
spaced holes in crankshaft rear seal (1).
Note: Ensure that debris does not enter the
Removal Procedure crankcase.
Table 35
2. Screw Tooling (A) firmly into one of the holes. Use
Required Tools Tooling (A) to dislodge crankshaft rear seal (1).
When the crankshaft rear seal begins to move,
Tool Part Number Part Description Qty
unscrew Tooling (A). Install Tooling (A) in the next
A 27610311 Slide Hammer Puller 1 hole. Repeat the process using each hole, until the
crankshaft rear seal is removed.
Start By:
Installation Procedure
a. Remove the flywheel. Refer to Disassembly Table 36
and Assembly, “Flywheel - Remove” for the
correct procedure. Required Tools
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124 UENR4544
Disassembly and Assembly Section
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install” for the correct
procedure.
i06510425
Removal Procedure
Table 37
Required Tools
Guide Studs
A - 2
M10 by 100 mm
Illustration 242 g01454208
Start By:
2. Ensure that Tooling (B) is clean, dry, and free from
damage. Install Tooling (B) (oil seal locator) to the a. Remove the engine speed sensor. Refer to
rear of the crankshaft. Disassembly and Assembly, “Engine Speed
Sensor - Remove and Install” for the correct
3. Position a new crankshaft rear seal (1) on Tooling procedure.
(B) (oil seal locator).
b. Remove the overspeed sensor. Refer to
Note: A new crankshaft rear seal is supplied with a Disassembly and Assembly, “Engine Speed
plastic sleeve. The plastic sleeve should be aligned Sensor (Overspeed) - Remove and Install” for
the correct procedure.
with the chamfer on Tooling (B) (oil seal locator).
c. Remove the starting motor. Refer to
4. Push crankshaft rear seal (1) squarely over Tooling Disassembly and Assembly, “Electric Starting
(B) (oil seal locator). The plastic sleeve will be Motor - Remove and Install” for the correct
forced out of the crankshaft rear seal. Discard the procedure.
plastic sleeve. Push the crankshaft rear seal up to
d. Remove the flywheel. Refer to Disassembly
the flywheel housing. and Assembly, “Flywheel - Remove” for the
5. Install Tooling (B) (outer sleeve). Lubricate the face correct procedure.
of the washer with clean engine oil and install the e. Remove the engine oil pan. Refer to
nut. Disassembly and Assembly, “Engine Oil Pan -
Remove” for the correct procedure.
6. Tighten the nut on Tooling (B) until the crankshaft
rear seal is pushed into the bore in the flywheel
NOTICE
housing. Keep all parts clean from contaminants.
7. Remove Tooling (B). Contaminants may cause rapid wear and shortened
component life.
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UENR4544 125
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
2. Use a suitable hoist to lift the rear of the engine. 8. Use a suitable drift to remove the crankshaft rear
The weight of the engine is approximately 3350 kg seal from the flywheel housing.
(7385 lb). Raise the rear of the engine so that
there is a distance of 10 mm (0.4 inch) between
Installation Procedure
Table 38
flywheel housing (1) and the base frame.
Required Tools
Note: Ensure that the engine is supported.
Tool Part Number Part Description Qty
Guide Studs
A - 2
M10 by 100 mm
B - Loctite 518 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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126 UENR4544
Disassembly and Assembly Section
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UENR4544 127
Disassembly and Assembly Section
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install” for the
correct procedure.
b. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install” for the correct
procedure.
c. Install the starting motor. Refer to Disassembly
and Assembly, “Electric Starting Motor -
Remove and Install” for the correct procedure.
d. Install the overspeed sensor. Refer to
Disassembly and Assembly, “Engine Speed
Sensor (Overspeed) - Remove and Install” for
the correct procedure.
e. Install the engine speed sensor. Refer to
Disassembly and Assembly, “Engine Speed
Sensor - Remove and Install” for the correct
procedure.
Illustration 247 g01848260
i06513739
9. Use a suitable hoist to lower the rear of the engine Vibration Damper and Pulley -
onto the base frame. The weight of the engine is
approximately 3350 kg (7385 lb). Remove and Install
10. Install bolts (2) and bolts (3). Tighten the bolts (Twin Vibration Dampers)
securely.
11. Install a new crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear Removal Procedure
Seal - Remove and Install” for the correct Table 39
procedure.
Required Tools
Crankshaft Adapter
D T6253/209 1
Extractor
Start By:
a. Remove the V-belts from the fan drive. Refer to
Disassembly and Assembly, “V-Belts - Remove
and Install” for the correct procedure.
b. Remove the mounting bracket for the governor
actuator. Refer to Disassembly and Assembly,
“Governor Actuator - Remove and Install” for
the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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128 UENR4544
Disassembly and Assembly Section
3. Lubricate two Allen head bolts (2) with clean 7. Install Tooling (B) and a suitable lifting device to
engine oil. Install the Allen head bolts into the support the weight of front damper (5). The weight
jacking holes in pulley (1). Tighten the Allen head of the damper is approximately 95 kg (210 lb).
bolts alternately until the center of the pulley is
8. Use Tooling (B) to remove front damper (5).
released from shaft (3).
9. Remove Tooling (A).
4. Remove pulley (2) from shaft (3). If necessary,
remove the key from the shaft.
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UENR4544 129
Disassembly and Assembly Section
Installation Procedure
Table 40
Required Tools
Loctite C5-A
E - 1
Anti-Seize Compound
Illustration 253 g01582017
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130 UENR4544
Disassembly and Assembly Section
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UENR4544 131
Disassembly and Assembly Section
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132 UENR4544
Disassembly and Assembly Section
End By:
a. Install the governor actuator and the mounting
bracket. Refer to Disassembly and Assembly,
“Governor Actuator - Remove and Install” for
the correct procedure.
b. Install the V-belts to the fan drive. Refer to
Disassembly and Assembly, “V-Belts - Remove
and Install” for the correct procedure.
i06510432
Removal Procedure
Table 41
Required Tools
Illustration 261 g01861573
Tool Part Number Part Description Qty
A 27610311 Slide Hammer Puller 1 1. Use a 4 mm (1/8 inch) drill to make three equally
spaced holes in crankshaft front seal (1).
Start By: Note: Ensure that debris does not enter the
crankcase.
a. Remove the damper from the crankshaft. Refer
to Disassembly and Assembly, “Vibration
2. Screw Tooling (A) firmly into one of the holes. Use
Damper and Pulley - Remove and Install” for
the correct procedure. Tooling (A) to dislodge crankshaft front seal (1).
When the crankshaft front seal begins to move,
NOTICE unscrew Tooling (A). Install Tooling (A) in the next
Keep all parts clean from contaminants. hole. Repeat the process using each hole, until the
crankshaft front seal is removed.
Contaminants may cause rapid wear and shortened
component life.
Installation Procedure
Table 42
NOTICE Required Tools
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Tool Part Number Part Description Qty
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain- B T6253/141 Front Oil Seal Insertion Kit 1
ers before opening any compartment or disassem-
bling any component containing fluids.
NOTICE
Dispose of all fluids according to local regulations Keep all parts clean from contaminants.
and mandates.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 133
Disassembly and Assembly Section
End By:
a. Install the damper to the crankshaft. Refer to
Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install” for
the correct procedure.
i06510434
Removal Procedure
Start By:
a. Remove the rocker assemblies. Refer to
Disassembly and Assembly, “Rocker Arm and
Shaft - Remove” for the correct procedure.
b. Remove the timing case. Refer to Disassembly
and Assembly, “Housing (Front) - Remove” for
Illustration 262 g01861574 the correct procedure.
2. Ensure that Tooling (B) is clean, dry, and free from NOTICE
damage. Install Tooling (B) (oil seal locator) to the Keep all parts clean from contaminants.
nose of the crankshaft.
Contaminants may cause rapid wear and shortened
3. Position a new crankshaft front seal (1) on Tooling component life.
(B) (oil seal locator).
Note: A new crankshaft front seal is supplied with a NOTICE
plastic sleeve. The plastic sleeve should be seated Care must be taken to ensure that fluids are con-
over the chamfer on Tooling (B) (oil seal locator). tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
4. Push crankshaft front seal (1) squarely over Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
Tooling (B) (oil seal locator). The plastic sleeve will bling any component containing fluids.
be forced out of the crankshaft front seal. Push the
crankshaft front seal up to the timing case. Discard Dispose of all fluids according to local regulations
the plastic sleeve. and mandates.
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134 UENR4544
Disassembly and Assembly Section
i06510437
Installation Procedure
Table 43
Required Tools
NOTICE
Keep all parts clean from contaminants.
Illustration 264 g01855214
Contaminants may cause rapid wear and shortened
component life.
2. Remove bolts (2).
3. Carefully remove camshaft gear (1) from the
camshaft.
4. Do not remove dowel (3) from the camshaft unless
the dowel is damaged.
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UENR4544 135
Disassembly and Assembly Section
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136 UENR4544
Disassembly and Assembly Section
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UENR4544 137
Disassembly and Assembly Section
i06510440
Removal Procedure
Start By:
a. Remove the water pumps. Refer to
Disassembly and Assembly, “Water Pump -
Remove” for the correct procedure.
b. Remove the damper from the crankshaft. Refer
to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install” for
the correct procedure.
c. Remove the crankshaft front seal . Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Remove and Install” for the correct
procedure.
NOTICE
Keep all parts clean from contaminants.
Illustration 272 g06018977
Contaminants may cause rapid wear and shortened
component life. 3. Remove stop solenoid (2) and stop lever (1). Refer
to Disassembly and Assembly, Governor Actuator
- Remove and Install for the correct procedure.
NOTICE
Care must be taken to ensure that fluids are con- 4. Attach a suitable lifting device to support the
tained during performance of inspection, mainte-
weight of timing case (4). The timing case weighs
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain- approximately 90 kg (200 lb).
ers before opening any compartment or disassem- 5. Remove bolts (3) and nuts and bolts (7) from
bling any component containing fluids.
timing case (4). Note the position of the bolts and
Dispose of all fluids according to local regulations the nuts and bolts for installation purpose.
and mandates.
6. Use suitable lifting device to remove timing case
(4) from back plate (6). Care should be take not to
1. Remove tube assembly from the water damage the nose of the crankshaft as the timing
temperature regulator and the elbow on the water case is removed.
pump. Refer to Disassembly and Assembly,
“Water Temperature Regulator - Remove and 7. Remove gasket (5) (not shown).
Install” for the correct procedure.
2. If necessary, remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan -
Remove” for the correct procedure.
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138 UENR4544
Disassembly and Assembly Section
8. If necessary, follow Step 8.a through Step 8.c to 9. If necessary, follow Step 9 through Step 9.b to
remove adapter (9) from timing cover (4). remove oil seal (12) and bush (13) from timing
cover (4).
a. Remove nuts and washers (8) from adapter
(9). Remove the adapter from timing cover (4). a. Use a suitable tool and remove oil seal (12)
from timing cover (4). Ensure that the timing
b. Remove gasket (10). cover is not damaged as the oil seal is
removed.
c. If necessary, remove stud (11) from timing
cover (4). b. If necessary, place timing cover (4) on a
suitable press. Use a suitable tool to press out
bush (13) from the timing cover.
i06510443
Installation Procedure
Table 44
Required Tools
(continued)
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UENR4544 139
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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140 UENR4544
Disassembly and Assembly Section
Illustration 277 g06019124 11. Remove Tooling (A) and install remaining bolts
(3).
12. Remove suitable lifting device from timing case
(4).
13. Tighten bolts (4) to a torque of 47 N·m (35 lb ft).
Tighten the nuts and bolts (7) to a torque of
47 N·m (35 lb ft).
Remove excess material from gasket (5) (not
shown). The gasket should be flush with the base
of the timing case.
14. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install” for the
correct procedure.
15. Install stop lever (1) and stop solenoid (2). Refer
to Disassembly and Assembly, Governor Actuator
- Remove and Install for the correct procedure.
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UENR4544 141
Disassembly and Assembly Section
End By:
a. Install the damper to the crankshaft. Refer to
Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install” for
the correct procedure.
b. Install the water pumps. Refer to Disassembly
and Assembly, “Water Pump - Install” for the
correct procedure.
i06510445
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 279 g06019349
Contaminants may cause rapid wear and shortened
16. If necessary, Install Tooling (B) to timing case (4) component life.
to align adapter (9) to the timing case. Tighten nuts
and washers (8) to a torque of 25 N·m (18 lb ft).
NOTICE
17. Install a new crankshaft front oil seal. Refer to Care must be taken to ensure that fluids are con-
Disassembly and Assembly, “Crankshaft Front Oil tained during performance of inspection, mainte-
Seal - Remove and Install” for the correct nance, testing, adjusting and repair of the product.
procedure. Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
18. If necessary, install tube assembly from the water bling any component containing fluids.
temperature regulator and the elbow on the water
Dispose of all fluids according to local regulations
pump. Refer to Disassembly and Assemble, and mandates.
“Water Temperature Regulator - Remove and
Install” for the correct procedure.
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142 UENR4544
Disassembly and Assembly Section
1. Disconnect the Original Equipment Manufacture 4. If necessary, follow Step through Step to
(OEM) hose assembly from the crankcase disassemble crankcase breather (2).
breather (2). Refer to the OEM for the correct
procedure. a. Make temporary marks on crankcase breather
(2) and cover (8) for installation purposes.
2. Loosen hose clamp (4) and hose clamp (6).
Remove hose assembly (5) from crankcase b. Place crankcase breather (2) in a suitable
breather (2) and the timing cover. support.
3. Support crankcase breather (2) and remove bolts c. Remove bolts (7) from the assembly of
(3). Remove the crankcase breather from the crankcase breather (2).
water rail.
d. Remove cover (8) from the assembly of
crankcase breather (2)
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 143
Disassembly and Assembly Section
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144 UENR4544
Disassembly and Assembly Section
6. Connect the Original Equipment Manufacture Note: If necessary, carefully tap the rocker box cover
(OEM) hose assembly to the crankcase breather with a soft faced hammer to loosen the rocker box
(2). Refer to the OEM for the correct procedure. cover.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
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UENR4544 145
Disassembly and Assembly Section
i06510450
Removal Procedure
Start By:
a. Remove the rocker assembly. Refer to
Disassembly and Assembly, “Rocker Arm and
Shaft - Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Illustration 287 g06013358
Contaminants may cause rapid wear and shortened
component life. 2. Loosen tube assembly (3) at both ends. Allow the
oil to drain from the oil rail.
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146 UENR4544
Disassembly and Assembly Section
8. Remove O-ring seal (8). 2. If necessary, follow Step 2.a through Step 2.c to
install stud (9) and stud (10) to cylinder head (11).
9. If necessary, follow Step 9.a through Step 9.b to
remove stud (9) and stud (10) from cylinder head a. Ensure the threads of stud (8) and stud (10)
(11). are clean and dry. Ensure the holes for the
stud in cylinder head (11) are clean and dry.
a. To remove stud (9) and stud (10) from cylinder
head (11) first drain the coolant to a level that b. Apply Tooling (A) to the threads of stud (8) and
is below the cylinder head. Refer to Operation stud (10).
and Maintenance Manual, “Cooling System
Coolant - Change” for the correct procedure. Note: Apply the Tooling to the end of the studs that
have the short thread.
b. Use a suitable stud extractor to stud (9) and
stud (10) from cylinder head (11). c. Install stud (8) and stud (10) to cylinder head
(11). Tighten the studs to a torque of 47 N·m
Installation Procedure (35 lb ft).
Table 45
Note: Ensure that the coolant is filled to the correct
Required Tools level. Refer to Operation and Maintenance Manual,
Tool Part Number Part Description Qty “Cooling System Coolant - Change” for the correct
procedure.
A - Loctite 2701 1
3. Position a new O-ring seal (7) in the recess in
cylinder head (11).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 147
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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148 UENR4544
Disassembly and Assembly Section
i06510457
Disassembly Procedure
Start By:
a. Remove the rocker assembly. Refer to
Disassembly and Assembly, “Rocker Arm and
Shaft - Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 293 g01433401
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UENR4544 149
Disassembly and Assembly Section
3. Remove rocker arm assembly (2) from rocker shaft 7. Inspect pad (7) for wear or damage. If the pad is
(4). worn or damaged, use a suitable press to remove
the pad from bridge piece (7).
4. Remove rocker arm assembly (1) from rocker shaft
(4).
i06510460
Assembly Procedure
Table 46
Required Tools
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150 UENR4544
Disassembly and Assembly Section
e. Use a suitable press to install pad (7) to bridge Illustration 301 g03670959
piece (10).
6. Lubricate the rocker shaft and the rocker arm
Note: Position the bridge piece with the pad
assemblies with clean engine oil.
upward. Allow Tooling (B) to cure for 2 hours
before installing the bridge piece. 7. Install rocker arm assembly (1), rocker arm
assembly (4)
3. Install adjuster (17) to bridge piece (6) and install
nut (18) to the adjuster. 8. Install rocker arm assembly (2) to rocker shaft (4).
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UENR4544 151
Disassembly and Assembly Section
i06510461
Installation Procedure
Table 47
Required Tools
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152 UENR4544
Disassembly and Assembly Section
6. Lubricate pad (5) with petroleum jelly and install Start By:
the pad to rocker assembly (2).
a. Remove the fuel rail. Refer to Disassembly and
7. Position rocker assembly (2) onto the rocker box. Assembly, “Fuel Manifold (Rail) - Remove and
Take care not to misplace pad (5). Install” for the correct procedure.
Note: Ensure that the rocker assembly is aligned b. Remove the appropriate sections of the
with the dowels in the rocker box. Ensure that the exhaust manifold. Refer to Disassembly and
adjustment screws are properly seated in the ends of Assembly, “Exhaust Manifold - Remove and
the pushrods. Install” for the correct procedure.
c. Remove the appropriate sections of the inlet
8. Install nut (1) and nut (3). Evenly tighten the nuts to manifold. Refer to Disassembly and Assembly,
pull the rocker assembly into position. Tighten the “Inlet Manifold - Remove” for the correct
nuts to a torque of 120 N·m (90 lb ft). procedure.
9. Use Tooling (C) to turn nut (1) and nut (3) through NOTICE
an additional 90 degrees. Cylinder heads that are being removed for over-
haul on 4008-30 have a valve seat and valve angle
10. Adjust the engine valve lash. Refer to Systems of 20 degree. For further information contact your
Operation, Testing and Adjusting, “Engine Valve Perkins distributor.
Lash - Adjust” for the correct procedure. Adjust the
fuel injector timing. Refer to Systems Operation,
Testing and Adjusting, “Fuel Injector Adjustment” NOTICE
for the correct procedure. Keep all parts clean from contaminants.
End By: Contaminants may cause rapid wear and shortened
component life.
a. Install the cover to the rocker box. Refer to
Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install” for the
correct procedure. NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
i06511729 nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
Cylinder Head - Remove ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
Removal Procedure
Table 48
1. Drain the coolant from the cooling system into a
Required Tools suitable container. Refer to Operation and
Tool Part Number Part Description Qty Maintenance Manual, “Cooling System Coolant -
Change” for the correct procedure.
T6253/237 Cylinder head Lifting Tool 1
A
- Bolts (M10 by 25 mm) 2
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UENR4544 153
Disassembly and Assembly Section
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154 UENR4544
Disassembly and Assembly Section
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Disassembly and Assembly Section
12. Remove O-ring seal (15), O-ring seal (16), O-ring 2. Install flame ring (17).
seal (18), O-ring seal (19) and O-ring seal (20).
3. Install new O-ring seals (15), (16), (18), (19) and
13. Remove flame ring (17). (20).
i06511730
Note: Use petroleum jelly to hold the O-ring seals in
position.
Cylinder Head - Install
Installation Procedure
Table 49
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 312 g06006341
1. Thoroughly clean the gasket surfaces of the
cylinder head and the crankcase. Ensure that 4. Install a new O-ring seal (14) to recess (13) of
there is no debris in the cylinder bores, the coolant cylinder head (12). Ensure that the O-ring seal is
passages, or the lubricant passages. correctly located into the recess of the cylinder
head.
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Disassembly and Assembly Section
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UENR4544 157
Disassembly and Assembly Section
c. Tighten the cylinder head bolts to a torque of Front section of the coolant rail
270 N·m (200 lb ft) in the sequence that is
14. Follow Step 14.a through Step 14.e to install the
shown in Illustration 317 .
sections of the coolant rail to the cylinder head.
d. Tighten the cylinder head bolts to a torque of
540 N·m (400 lb ft) in the sequence that is a. Install O-ring seal (3) to coolant rail (4). Install
shown in Illustration 317 . gasket (5) to the cylinder head.
e. Tighten the cylinder head bolts to a torque of b. Install coolant rail (4) to the cylinder head.
725 N·m (530 lb ft) in the sequence that is
shown in Illustration 317 . c. Install bolts (1) finger tight. Install nuts and
bolts (2) finger tight.
11. Install the fuel injection control linkage to the
cylinder head. Refer to Disassembly and d. Tighten bolts (1) to a torque of 50 N·m
Assembly, “Valve Mechanism Cover Base - (35 lb ft). Tighten nuts and bolts (2) to a torque
Remove and Install” for the correct procedures. of 50 N·m (35 lb ft).
12. Install the rocker box to the cylinder head. Refer e. Position heat shield (6) to assembly of coolant
to Disassembly and Assembly, “Valve Mechanism rail (4). Install bolts (7) to the heat shield .
Cover Base - Remove and Install” for the correct Tighten the bolts to a torque of 25 N m
procedures. (221 lb in).
13. Install the fuel injector to the cylinder head. Refer
to Disassembly and Assembly, “Fuel Injector -
Install” for the correct procedures.
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158 UENR4544
Disassembly and Assembly Section
NOTICE
Lifter Group - Disassemble
Keep all parts clean from contaminants. (Cam Followers)
Contaminants may cause rapid wear and shortened
component life.
Disassembly Procedure
NOTICE Start By:
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. a. Remove the assembly of the cam followers.
Be prepared to collect the fluid with suitable contain- Refer to Disassembly and Assembly, “Lifter
ers before opening any compartment or disassem- Group - Remove (Cam Followers)” for the
bling any component containing fluids. correct procedure.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
i06511735
Assembly Procedure
Table 50
Required Tools
A - Loctite 242 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 161
Disassembly and Assembly Section
End By:
a. Install the cam followers. Refer to Disassembly
and Assembly, “Lifter Group - Install (Cam
Followers)” for the correct procedure.
i06511737
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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162 UENR4544
Disassembly and Assembly Section
Start By:
a. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
Housing - Remove and Install” for the correct
procedure.
b. Remove the cam followers. Refer to
Disassembly and Assembly, “Lifter Group -
Remove” for the correct procedure.
c. Remove the camshaft gear. Refer to
Disassembly and Assembly, “Gear Group
(Front) - Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
i06511768
Camshaft - Remove
Illustration 325 g01858958
Removal Procedure 1. Remove allen head bolts (1) and thrust plate (2).
Table 51 2. Ensure that Tooling (A) is clean and free from
Required Tools burrs. Install Tooling (A) to the nose of camshaft
Part Description Qty
(3).
Tool Part Number
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Disassembly and Assembly Section
i06511769
Camshaft - Install
Installation Procedure
Table 52
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 326 g06028002
Typical example
1. Ensure that the camshaft is clean and free from
3. Use a long wooden drift to push on Tooling (A). wear or damage. Refer to Specifications,
Carefully push camshaft (3) out of the rear of the “Camshaft” for more information.
engine. Use a suitable sling to support the 2. Inspect the camshaft bearings for wear or damage.
camshaft during the removal procedure. If necessary, replace the camshaft bearings. Refer
4. Lift the camshaft from the engine. The weight of to Disassembly and Assembly, “Camshaft
the camshaft is approximately 70 kg (155 lb). Bearings - Remove” and Disassembly and
Place the camshaft on a suitable support. If Assembly, “Camshaft Bearings - Install” for the
necessary, remove Tooling (A) from the camshaft. correct procedures.
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Disassembly and Assembly Section
i06511770
Removal Procedure
Table 53
Required Tools
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Disassembly and Assembly Section
NOTICE
Camshaft Bearings - Install
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life. Installation Procedure
Table 54
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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166 UENR4544
Disassembly and Assembly Section
i06511724
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
i06511725
A -
Delphi Lockheed Rubber
1 5. Ensure that suction pipe (17) and strainer (18) are
Grease installed correctly in the engine oil pan.
Loctite 518 Gasket and
B - 1
Flange Sealant Engine Oil Pan
Guide Studs
C - 2 1. Ensure that the gasket surfaces of the engine oil
M10 by 50 mm
pan and the crankcase are clean.
Loctite 542 Thread lock and
D - 1
Nut lock
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Disassembly and Assembly Section
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Disassembly and Assembly Section
Start By:
a. Remove the pistons and connecting rods.
Refer to Disassembly and Assembly, “Pistons
and Connecting Rods - Remove” for the
correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are con-
Illustration 343 g06008455 tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
10. Apply Tooling (A) to a new O-ring seal (2), a new Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
O-ring seal (4) and a new O-ring seal (8). bling any component containing fluids.
11. Position a new O-ring seal (2) (not shown) and
Dispose of all fluids according to local regulations
install spacer (3) (not shown) onto engine oil pan. and mandates.
Position a new O-ring seal (4) (not shown) onto
spacer (3) (not shown).
1. Use Tooling (A) to rotate the crankshaft. Rotate the
12. Position a new O-ring seal (2) (not shown) onto crankshaft until there is sufficient clearance to
pipe (7). Install pipe (7) onto engine oil pump (1) install Tooling (B).
and engine oil pan.
13. Install bolts (7) to engine oil pump (1) hand tight.
14. Apply Tooling (D) to the threads of bolts (5).
Install bolts (5) hand tight.
15. Tighten bolts (7) to a torque of 47 N·m (35 lb ft).
16. Tighten bolts (5) to a torque of 41 N·m (30 lb ft).
17. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter- Change” for the correct procedure.
18. Prime the engine oil system. Refer to Operation
and Maintenance Manual, “Before Starting the
Engine” for the correct procedure.
i06511727
Removal Procedure
2. Follow Step 2.a through Step 2.c to assemble
Table 56
Tooling (B) to the cylinder liner.
Required Tools
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Disassembly and Assembly Section
i06511728
Installation Procedure
Table 57
Required Tools
- Spacers 2
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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172 UENR4544
Disassembly and Assembly Section
Dimension (X)
. . . 2.07 mm to 2.20 mm ((0.082 inch to 0.087 inch))
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Disassembly and Assembly Section
End By:
a. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Install” for the correct
procedure.
i06511694
Removal Procedure
Table 58
Required Tools
Start By:
a. Remove the engine oil coolers. Refer to
Disassembly and Assembly, “Engine Oil
Cooler - Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
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174 UENR4544
Disassembly and Assembly Section
Installation Procedure
Table 59
Required Tools
B T9142/21 Drift 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 175
Disassembly and Assembly Section
End By:
a. Install the engine oil coolers. Refer to
Disassembly and Assembly, “Engine Oil
Cooler - Install” for the correct procedure.
b. Install the Aftercooler. Refer to Disassembly
and Assembly, “Aftercooler- Remove and
Install” for the correct procedure.
i06511697
Removal Procedure
Table 60
Required Tools
Illustration 353 g06009640
Tool Part Number Part Description Qty
1. lubricate O-ring seal (4) and O-ring seal (6) with
A SE253 Engine Turning Tool 1
clean engine oil.
B T6253/212 Piston Crown Handle 1
2. Install O-ring seal (4) to piston cooling jet (1).
Install O-ring seal (6) to plug (5)
Start By:
3. Install cooling jet (1) into Position (C). Rotate the
cooling jet counterclockwise by 90 degrees. a. Remove the cylinder heads. Refer to
Disassembly and Assembly, “Cylinder Head -
4. Temporarily install bolt (3) to piston cooling jet (1). Remove” for the correct procedure.
5. Position Tooling (B) onto piston cooling jet (1). b. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling
6. Use Tooling (B) to install the piston cooling jet into Jets - Remove and Install” for the correct
the crankcase. Remove tooling (B) and bolt (3). procedure.
7. Install plug (5) to cooling jet (1). Ensure that the
NOTICE
plug is correctly installed into the piston cooling jet. Keep all parts clean from contaminants.
8. Install plate (2) and install bolt (3). Tighten the bolt Contaminants may cause rapid wear and shortened
to a torque of 47 N·m (35 lb ft). component life.
9. If necessary, repeat Step 1 through Step 8 to
install remaining piston cooling jets (1) into the 1. Use Tooling (A) to rotate the crankshaft to a
crankcase. convenient position.
2. Remove the carbon ridge from the top of the
cylinder liner bore. Remove the carbon from the
piston crown.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
i06511698
Disassembly Procedure
Table 61
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
4. Use Tooling (D) to remove compression ring (7) 7. Inspect small end bush (13) for wear or for
and compression ring (8), and oil control ring (9) damage. Refer to Specifications, “Pistons and
from piston (12). Rings” for more information. If the small end bush
is damaged or worn beyond the specified limits,
Note: Identify the position and the orientation of the use Tooling (E) to remove the small end bush from
compression rings and the oil control ring.
connecting rod (1).
5. Use Tooling (C) to remove circlips (10) from piston
i06511700
(12).
6. Remove piston pin (11) and connecting rod (1) Pistons and Connecting Rods
from piston (12).
- Assemble
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. Assembly Procedure
Table 62
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
i06511701
Installation Procedure
Table 63
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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182 UENR4544
Disassembly and Assembly Section
5. Ensure that the gaps for the piston rings are at 120
degrees away from each other. Position Tooling
(F) onto the piston to compress the piston rings.
Carefully position the piston and the connecting
rod into the cylinder liner bore.
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Disassembly and Assembly Section
NOTICE
Discard all used connecting rod bolts.
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Disassembly and Assembly Section
End By:
a. Install the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling
Jets - Remove and Install” for the correct
procedure.
b. Install the cylinder heads. Refer to
Disassembly and Assembly, “Cylinder Head -
Install” for the correct procedure.
i06511702
Removal Procedure
Start By:
Illustration 372 g06009075 a. Remove the crankshaft and the thrust washers.
Refer to Disassembly and Assembly,
Using feeler gauges to check the side float of the “Crankshaft - Remove” for the correct
connecting rods procedure.
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UENR4544 185
Disassembly and Assembly Section
Note: The lower main bearings are plain bearings 3. Install upper main bearings (1) to the crankcase.
that have no oil holes.
Note: The upper main bearings have a groove and
two oil holes.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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186 UENR4544
Disassembly and Assembly Section
End By:
a. Install the crankshaft and the thrust washers.
Refer to Disassembly and Assembly,
“Crankshaft - Install” for the correct procedure.
i06511703
Crankshaft - Remove
Removal Procedure
Start By:
a. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling
Jets - Remove and Install”.
b. Remove the pistons and connecting rods.
Refer to Disassembly and Assembly, “Pistons
and Connecting Rods - Remove”.
Illustration 378 g01853913
c. Remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan - 2. Rotate the crankshaft so that the center balance
Remove”.
weights are in the horizontal position.
d. Remove the back plate. Refer to Disassembly
3. Remove allen head bolts (3).
and Assembly, “Engine Support (Front) -
Remove and Install”. Note: Check the marking on each bearing cap.
e. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel 4. Remove main bearing bolts (1).
Housing - Remove and Install”. 5. Remove main bearing caps (2).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 187
Disassembly and Assembly Section
i06511704
Typical example
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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188 UENR4544
Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
End By:
a. Install the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
Housing - Remove and Install” for the correct
procedure.
b. Install the back plate. Refer to Disassembly
and Assembly, “Engine Support (Front) -
Remove and Install” for the correct procedure.
c. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Install” for the correct
procedure.
d. Install the piston cooling jets . Refer to
Illustration 388 g01454825
Disassembly and Assembly, “Piston Cooling
Jets - Remove and Install” for the correct
procedure. 1. Make marks in Position (X) on crankshaft gear (2)
and crankshaft (1) in the upward position.
e. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install” for the 2. Use Tooling (A) to pull crankshaft gear (2) from
correct procedure. crankshaft (1).
B - Hot Plate 1
Removal Procedure
Table 65
NOTICE
Keep all parts clean from contaminants.
Required Tools
Contaminants may cause rapid wear and shortened
Tool Part Number Part Description Qty component life.
A - Puller 1
Start By:
a. Remove the timing gears. Refer to
Disassembly and Assembly, “Gear Group
(Front) - Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
Remove and Install 2. Remove engine oil pressure switch (3) from
adapter (2).
3. If necessary, remove adapter (2) from the engine
Removal Procedure cylinder block. Follow Step 3.a through Step 3.b to
remove the adapter from the engine cylinder
NOTICE block.
Keep all parts clean from contaminants.
a. Remove adapter (2) from the engine cylinder
Contaminants may cause rapid wear and shortened block.
component life.
b. Remove sealing washer (1).
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194 UENR4544
Disassembly and Assembly Section
Installation Procedure
Table 69
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
i06511710
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 195
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
1. Disconnect harness assembly (1) from engine oil Temperature Sensor (Exhaust)
pressure switch (2).
- Remove and Install
2. Remove engine oil pressure switch (2) from engine
oil filter base (3). (Exhaust Temperature
Installation Procedure Thermocouples)
Table 70
Required Tools
Removal Procedure
Tool Part Number Part Description Qty
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196 UENR4544
Disassembly and Assembly Section
2. Disconnect harness assembly (4) from the engine 2. If necessary, apply Tooling (A) to threads adaptor
harness assembly. (3). Install the adaptor exhaust elbow (1). Tighten
the adaptor to a torque of 20 N·m (177 lb in).
3. Remove exhaust temperature thermocouple (2)
from exhaust elbow (1). 3. Apply Tooling (A) to threads exhaust temperature
thermocouple (2). Install the exhaust temperature
4. If necessary, remove adaptor (3) exhaust elbow
thermocouple to exhaust elbow (1). Tighten the
(1).
adaptor to a torque of 20 N·m (177 lb in).
Installation Procedure 4. Connect harness assembly (4) to the engine
Table 71 harness assembly.
Required Tools
i06511712
Tool Part Number Part Description Qty
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Disassembly and Assembly Section
Installation Procedure
Table 72
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
procedure.
2. Install Tooling (A) to flywheel housing (2).
3. Use Tooling (A) to rotate the engine. Align one
tooth of the flywheel ring gear (5) to the center
position of the tapped hole in flywheel housing (2).
Refer to Illustration 401 .
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198 UENR4544
Disassembly and Assembly Section
i06511713
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 199
Disassembly and Assembly Section
i06511719
Removal Procedure
Illustration 403 g06011479
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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200 UENR4544
Disassembly and Assembly Section
1. Disconnect the harness assembly from boost 1. Install a new O-ring seal (2) to boost pressure
pressure sensor (1). sensor (1).
2. Use a deep socket to remove boost pressure 2. Use a deep socket to install boost pressure sensor
sensor (1). (1). Tighten the boost pressure sensor to a torque
of 10 N·m (89 lb in).
3. Remove O-ring seal (2) from boost pressure
sensor (1). 3. Connect the harness assembly to boost pressure
sensor (1).
Installation Procedure
i06551747
NOTICE
Keep all parts clean from contaminants. V-Belts - Remove and Install
Contaminants may cause rapid wear and shortened
component life. (Fan Drive Belts)
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 201
Disassembly and Assembly Section
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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202 UENR4544
Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
Installation Procedure
1. Ensure that all components are free from wear or
damage. If necessary, replace any component that
is worn or damaged.
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4544 207
Disassembly and Assembly Section
5. Install bolt (15) and the self-locking nut to Alternator - Remove and Install
alternator (7) and bracket (14).
6. Connect harness assembly (12) to alternator (7).
(Battery Charging Alternator
Tighten the terminal nuts. Refer to Specifications, Drive)
Alternator and Regulator for the correct torque
values.
7. Install alternator belt (11) to alternator (7). Refer to Removal Procedure
Disassembly and Assembly, Alternator Belt -
Remove and Install for the correct procedure. NOTICE
Keep all parts clean from contaminants.
8. After tensioning of the alternator belt, tighten bolt
(13) to a torque of 47 N·m (35 lb ft). Contaminants may cause rapid wear and shortened
component life.
Securely tighten the self-locking nut and bolt (8)
and the self-locking nut and bolt (15).
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208 UENR4544
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
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UENR4544 209
Disassembly and Assembly Section
Installation Procedure
Table 74
Required Tools
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants. f. Lubricate seal (19) and bearing (20) (not
shown) with clean engine oil.
Contaminants may cause rapid wear and shortened
component life. g. Install bearing carrier (15) onto the back plate.
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Disassembly and Assembly Section
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212 UENR4544
Disassembly and Assembly Section
11. Again, tighten grub screws (14) to a torque of 17. Switch ON battery charger (if installed) or the
22 N·m (15 lb ft). connect the mains supply and connect the
negative lead to the batteries.
12. Remove Tooling (B).
13. Install the alternator. Refer to Disassembly and i06511715
Assembly, “Alternator (Battery Charging
Alternator) - Remove and Install” for the correct Electric Starting Motor -
procedure.
Remove and Install
14. 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 - Removal Procedure
Check.” and Disassembly and Assembly,
“Alternator (Battery Charging Alternator Drive) -
Remove and Install” for the correct procedure.
Accidental engine starting can cause injury or
death to personnel working on the equipment.
To avoid accidental engine starting, disconnect
the battery cable from the negative (−) battery ter-
minal. Completely tape all metal surfaces of the
disconnected battery cable end in order to pre-
vent contact with other metal surfaces which
could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop
switch location to inform personnel that the
equipment is being worked on.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI2. NOT FOR RESALE
UENR4544 213
Disassembly and Assembly Section
3. Disconnect harness assembly (3) and harness 7. If necessary, remove the solenoid and the bracket
assembly (5) from electric starting motor (2). from the engine oil pan. Follow Step 1.a through
Step 7.c to remove the solenoid and the bracket
4. Disconnect harness assembly (4) from electric
from the engine oil pan.
starting motor (2).
5. Attach a suitable sling and a lifting device to the a. Disconnect harness assembly (6), harness
upper electric starting motor (2). The weight of the assembly(10) and harness assembly (11) from
electric starting motor is approximately 26 kg solenoid (12).
(57 lb).
b. Remove the nuts and bolts (9) and remove
6. Remove nuts (1). Use the lifting device to remove solenoid (12) from bracket (8).
electric starting motor (2) from the flywheel
housing. c. Remove bolts (7) and remove bracket (8) from
the engine oil pan.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI2. NOT FOR RESALE
214 UENR4544
Disassembly and Assembly Section
1. If necessary, install the solenoid and the bracket to 2. Attach a suitable sling and a lifting device to the
the engine oil pan. Follow Step 1.a through Step 1. lower electric starting motor (2). The weight of the
c to install the solenoid and the bracket to the electric starting motor is approximately 26 kg
engine oil pan. (57 lb).
a. Position bracket (8) onto the engine oil pan. 3. Use the lifting device to install electric starting
Install bolts (7) and tighten the bolts to a motor (2) to the flywheel housing. Install nuts (1).
torque of 47 N·m (35 lb ft). Tighten the nuts to a torque of 85 N·m (60 lb ft).
4. Connect harness assembly (3) and harness
b. Position solenoid (12) onto bracket (8). Install
assembly (5) to electric starting motor (2). Tighten
the nuts and bolts (9) and tighten the bolts to a
nuts for the harness assemblies securely.
torque of 9 N·m (80 lb in).
5. Connect harness assembly (4) to electric starting
c. Connect harness assembly (6), harness motor (2). Tighten nuts for the harness assembly
assembly (10) and harness assembly (11) to securely.
solenoid (12). Tighten nuts for the harness
assemblies securely. 6. Switch ON battery charger (if installed) or the
connect the mains supply and connect the
negative lead to the batteries.
This document has been printed from SPI2. NOT FOR RESALE
UENR4544 215
Index Section
Index
A Installation Procedure .................................... 190
Removal Procedure ....................................... 190
Air Cleaner - Remove and Install ..........................37 Crankshaft Main Bearings - Remove and Install... 184
Installation Procedure ......................................38 Installation Procedure .................................... 185
Removal Procedure .........................................37 Removal Procedure ....................................... 184
Air Lines - Remove and Install (Turbocharger Crankshaft Rear Seal - Remove and Install ......... 123
Compressor Outlet Tube Assemblies) .................53 Installation Procedure .................................... 123
Installation Procedure for Center Section of Tube Removal Procedure ....................................... 123
Assembly ......................................................59 Cylinder Head - Install ....................................... 155
Installation Procedure for Front Section of Tube Installation Procedure .................................... 155
Assembly ......................................................60 Cylinder Head - Remove.................................... 152
Installation Procedure for Rear Section of Tube Removal Procedure ....................................... 152
Assembly ......................................................57 Cylinder Liner - Install ........................................ 171
Removal Procedure for Center Section of Tube Installation Procedure .................................... 171
Assembly ......................................................55 Cylinder Liner - Remove .................................... 170
Removal Procedure for Front Section of Tube Removal Procedure ....................................... 170
Assembly ......................................................53
Removal Procedure for Rear Section of Tube
Assembly ......................................................56 D
Alternator - Remove and Install (Battery
Charging Alternator Drive)................................ 207 Disassembly and Assembly Section .......................4
Installation Procedure .................................... 209
Removal Procedure ....................................... 207
Alternator - Remove and Install (Battery E
Charging Alternator) ........................................ 204 Electric Starting Motor - Remove and Install ........ 212
Installation Procedure .................................... 206 Installation Procedure .................................... 213
Removal Procedure ....................................... 204 Removal Procedure ....................................... 212
Alternator Belt - Remove and Install.................... 203 Engine Oil Cooler - Assemble...............................94
Installation Procedure .................................... 204 Assembly Procedure ........................................94
Removal Procedure ....................................... 203 Engine Oil Cooler - Disassemble ..........................93
Disassembly Procedure ...................................93
Engine Oil Cooler - Install ....................................95
B Installation Procedure ......................................95
Bearing Clearance - Check ................................ 191 Engine Oil Cooler - Remove.................................90
Measurement Procedure ................................ 191 Removal Procedure .........................................90
Boost Pressure Sensor - Remove and Install....... 199 Engine Oil Filter Base - Install ..............................88
Installation Procedure .................................... 200 Installation Procedure ......................................88
Removal Procedure ....................................... 199 Engine Oil Filter Base - Remove...........................86
Removal Procedure .........................................86
Engine Oil Pan - Install ...................................... 168
C Installation Procedure .................................... 168
Engine Oil Pan - Remove................................... 166
Camshaft - Install .............................................. 163 Removal Procedure ....................................... 166
Installation Procedure .................................... 163 Engine Oil Pressure Switch - Remove and
Camshaft - Remove .......................................... 162 Install ............................................................. 193
Removal Procedure ....................................... 162 Installation Procedure .................................... 194
Camshaft Bearings - Install ................................ 165 Removal Procedure ....................................... 193
Installation Procedure .................................... 165 Engine Oil Pressure Switch - Remove and
Camshaft Bearings - Remove ............................ 164 Install (Alternator Warning Lamp)...................... 194
Removal Procedure ....................................... 164 Installation Procedure .................................... 195
Coolant Temperature Switch - Remove and Removal Procedure ....................................... 194
Install ............................................................. 192 Engine Oil Pump - Assemble.............................. 105
Installation Procedure .................................... 192 Assembly Procedure ...................................... 105
Removal Procedure ....................................... 192 Engine Oil Pump - Disassemble ......................... 104
Crankcase Breather - Remove and Install ........... 141 Disassembly Procedure ................................. 104
Installation Procedure .................................... 142 Engine Oil Pump - Install.................................... 107
Removal Procedure ....................................... 141 Installation Procedure .................................... 107
Crankshaft - Install ............................................ 187 Engine Oil Pump - Remove ................................ 102
Installation Procedure .................................... 187 Removal Procedure ....................................... 102
Crankshaft - Remove......................................... 186 Engine Oil Relief Valve - Remove and Install
Removal Procedure ....................................... 186 (Engine Oil Cooler) .......................................... 100
Crankshaft Front Seal - Remove and Install......... 132 Installation Procedure .................................... 101
Installation Procedure .................................... 132 Removal Procedure ....................................... 100
Removal Procedure ....................................... 132
Crankshaft Gear - Remove and Install ................ 190
This document has been printed from SPI2. NOT FOR RESALE
216 UENR4544
Index Section
Engine Oil Relief Valve - Remove and Install Installation Procedure ......................................15
(Engine Oil Pressure Regulator) .........................98 Installation Procedure for Guard........................20
Installation Procedure ......................................98 Removal Procedure .........................................13
Removal Procedure .........................................98
Engine Speed Sensor - Remove and Install
(Engine Speed for Governor Control) ................ 198 H
Installation Procedure .................................... 198 Housing (Front) - Install (Timing Case)................ 138
Removal Procedure ....................................... 198 Installation Procedure .................................... 138
Engine Speed Sensor - Remove and Install Housing (Front) - Remove (Timing Case) ............ 137
(Overspeed Sensor) ........................................ 196 Removal Procedure ....................................... 137
Installation Procedure .................................... 197
Removal Procedure ....................................... 196
Engine Support (Front) - Remove and Install I
(Back plate)..................................................... 117
Installation Procedure .................................... 118 Important Safety Information ..................................2
Removal Procedure ....................................... 117 Inlet and Exhaust Valve Guides - Remove and
Exhaust Elbow - Remove and Install.....................73 Install ...............................................................85
Installation Procedure ......................................74 Installation Procedure ......................................85
Removal Procedure .........................................73 Removal Procedure .........................................85
Exhaust Manifold - Remove and Install .................63 Inlet and Exhaust Valves - Remove and Install.......82
Installation Procedure ......................................67 Installation Procedure ......................................83
Removal Procedure .........................................63 Removal Procedure .........................................82
Inlet Manifold - Install...........................................79
Installation Procedure ......................................79
F Inlet Manifold - Remove .......................................76
Removal Procedure .........................................76
Flywheel - Install ............................................... 121
Installation Procedure .................................... 121
Flywheel - Remove............................................ 119 L
Removal Procedure ....................................... 119
Flywheel Housing - Remove and Install............... 124 Lifter Group - Assemble (Cam Followers)............ 160
Installation Procedure .................................... 125 Assembly Procedure ...................................... 160
Removal Procedure ....................................... 124 Lifter Group - Disassemble (Cam Followers) ....... 158
Fuel Injection Control Linkage - Install...................25 Disassembly Procedure ................................. 158
Installation of the Fuel Injection Control Linkage Lifter Group - Install (Cam Followers).................. 161
from the Crankcase ........................................25 Installation Procedure .................................... 161
Fuel Injection Control Linkage - Remove ...............20 Lifter Group - Remove (Cam Followers) .............. 158
Removal Procedure .........................................20 Removal Procedure ....................................... 158
Fuel Injector - Install ............................................31
Installation Procedure ......................................31
Fuel Injector - Remove ........................................30 P
Removal Procedure .........................................30 Piston Cooling Jets - Remove and Install ............ 173
Fuel Injector Sleeve - Install .................................34 Installation Procedure .................................... 174
Installation Procedure ......................................34 Removal Procedure ....................................... 173
Fuel Injector Sleeve - Remove .............................33 Pistons and Connecting Rods - Assemble........... 178
Removal Procedure .........................................33 Assembly Procedure ...................................... 178
Fuel Manifold (Rail) - Remove and Install Pistons and Connecting Rods - Disassemble ...... 177
(Engine Oil and Fuel Rail) ....................................5 Disassembly Procedure ................................. 177
Installation Procedure ........................................7 Pistons and Connecting Rods - Install................. 181
Removal Procedure ...........................................5 Installation Procedure .................................... 181
Fuel Transfer Pump - Remove and Install (Lift Pistons and Connecting Rods - Remove ............. 175
Pump) ................................................................4 Removal Procedure ....................................... 175
Installation Procedure ........................................4
Removal Procedure ...........................................4
R
G Rocker Arm - Assemble ..................................... 149
Assembly Procedure ...................................... 149
Gear Group (Front) - Install ................................ 134 Rocker Arm - Disassemble................................. 148
Installation Procedure .................................... 134 Disassembly Procedure ................................. 148
Gear Group (Front) - Remove ............................ 133 Rocker Arm and Shaft - Install ............................ 151
Removal Procedure ....................................... 133 Installation Procedure .................................... 151
Governor - Install (Electronic Control Unit) ............12 Rocker Arm and Shaft - Remove ........................ 147
Installation Procedure ......................................12 Removal Procedure ....................................... 147
Governor - Remove (Electronic Control Unit)......... 11
Removal Procedure ......................................... 11
Governor Actuator - Remove and Install................13 T
Adjustment and Set Up Procedure for a New
Governor Actuator Lever.................................19 Table of Contents ..................................................3
This document has been printed from SPI2. NOT FOR RESALE
UENR4544 217
Index Section
V
V-Belts - Remove and Install (Fan Drive Belts)..... 200
Installation Procedure .................................... 201
Removal Procedure ....................................... 200
Valve Mechanism Cover - Remove and Install
(Rocker Box Cover) ......................................... 144
Installation Procedure .................................... 144
Removal Procedure ....................................... 144
Valve Mechanism Cover Base - Remove and
Install (Rocker Box) ......................................... 145
Installation Procedure .................................... 146
Removal Procedure ....................................... 145
Vibration Damper and Pulley - Remove and
Install (Twin Vibration Dampers) ....................... 127
Installation Procedure .................................... 129
Removal Procedure ....................................... 127
W
Water Pump - Assemble .................................... 112
Assembly Procedure ...................................... 112
Water Pump - Disassemble................................ 111
Disassembly Procedure ................................. 111
Water Pump - Install .......................................... 113
Installation Procedure .................................... 113
Water Pump - Remove ...................................... 110
Removal Procedure ....................................... 110
Water Temperature Regulator Housing -
Remove and Install (Thermostat Housing) ......... 114
Installation Procedure .................................... 115
Removal Procedure ....................................... 114
This document has been printed from SPI2. NOT FOR RESALE
©2016 Perkins Engines Company Limited
All Rights Reserved
This document has been printed from SPI2. NOT FOR RESALE