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1204F ASSY Perkins
1204F ASSY Perkins
November 2014
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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UENR4491 3
Table of Contents
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4 UENR4491
Table of Contents
Front Cover - Remove and Install (Heavy Duty Crankshaft Timing Ring - Remove and Install 232
Front Cover)........................ ........................ 136 Crankshaft Gear - Remove and Install ..... .... 233
Gear Group (Front) - Remove and Install ... .. 137 Crankshaft Gear (Balancer Drive) - Remove and
Gear Group (Front) - Remove and Install (Heavy Install.............................. ............................. 235
Duty Gear Group (Front)).............. .............. 142 Bearing Clearance - Check ............. ............. 236
Idler Gear - Remove ................... .................. 151 Refrigerant Compressor - Remove and
Idler Gear - Install ..................... .................... 153 Install.............................. ............................. 237
Housing (Front) - Remove .............. .............. 156 Nitrogen Oxide Sensor - Remove and Install
Housing (Front) - Remove (Heavy Duty Housing (Nitrogen Oxide Sensor on Engine)...... ...... 240
(Front))............................ ............................ 158 Nitrogen Oxide Sensor - Remove and Install
Housing (Front) - Install ................ ................ 159 (Nitrogen Oxide Sensor Positioned in Original
Housing (Front) - Install (Heavy Duty Housing Equipment Manufacture (OEM) Exhaust Tube
(Front))............................ ............................ 162 Assembly).......................... ......................... 242
Accessory Drive - Remove and Install Atmospheric Pressure Sensor - Remove and
(Accessory Drive SAE "B") ............. ............ 165 Install.............................. ............................. 243
Accessory Drive - Remove and Install Camshaft Position Sensor - Remove and
(Accessory Drive SAE "A") ............. ............ 168 Install.............................. ............................. 244
Crankcase Breather - Remove ........... .......... 170 Crankshaft Position Sensor - Remove and
Crankcase Breather - Install ............. ............ 171 Install.............................. ............................. 245
Valve Mechanism Cover - Remove and Coolant Temperature Sensor - Remove and
Install.............................. ............................. 173 Install.............................. ............................. 246
Rocker Shaft and Pushrod - Remove...... ..... 175 Engine Oil Pressure Sensor - Remove and
Rocker Shaft - Disassemble ............. ............ 177 Install.............................. ............................. 247
Rocker Shaft - Assemble............... ............... 178 Fuel Temperature Sensor - Remove and
Rocker Shaft and Pushrod - Install........ ....... 179 Install.............................. ............................. 248
Cylinder Head - Remove ............... ............... 183 Ammonia Sensor - Remove and Install
Cylinder Head - Install ................. ................. 187 (Ammonia Sensor if Equipped).......... ......... 249
Lifter Group - Remove and Install (Hydraulic Soot Antenna - Remove and Install....... ....... 251
Lifter Group)........................ ........................ 191 Temperature Sensor (Exhaust) - Remove and
Camshaft - Remove and Install .......... .......... 192 Install (Selective Catalytic Reduction (SCR)
Camshaft Gear - Remove and Install ...... ..... 194 Temperature Sensor) ................. ................. 252
Camshaft Bearings - Remove and Install ... .. 199 Temperature Sensor (DPF) - Remove and
Engine Oil Pan - Remove and Install (Aluminum Install.............................. ............................. 253
and Pressed Steel Oil Pans)............ ........... 200 Temperature Sensor (Catalyst Inlet) - Remove
Engine Oil Pan - Remove and Install (Cast Iron and Install.......................... .......................... 254
Oil Pan) ............................ ........................... 204 Temperature Sensor (Cooled Exhaust Gas) -
Balancer - Remove.................... ................... 208 Remove and Install ................... .................. 255
Balancer - Install...................... ..................... 210 Pressure Sensor (Cooled Exhaust Gas) -
Piston Cooling Jets - Remove and Install... .. 212 Remove and Install (Differential Pressure
Pistons and Connecting Rods - Remove... ... 214 Sensor and Inlet Pressure Sensor)....... ...... 256
Pistons and Connecting Rods - Disassemble 215 Boost Pressure Sensor - Remove and Install 260
Pistons and Connecting Rods - Assemble .. . 216 Inlet Manifold Temperature Sensor - Remove
Pistons and Connecting Rods - Install..... ..... 218 and Install.......................... .......................... 260
Connecting Rod Bearings - Remove (Connecting Glow Plugs - Remove and Install......... ......... 261
Rods in Position)..................... .................... 220 Alternator Belt - Remove and Install ....... ...... 263
Connecting Rod Bearings - Install (Connecting Idler Pulley - Remove and Install (Grooved Idler
Rods in Position)..................... .................... 221 Pulley)............................. ............................ 264
Crankshaft Main Bearings - Remove and Install Idler Pulley - Remove and Install (Flat Idler
(Crankshaft in Position) ............... ............... 222 Pulley)............................. ............................ 265
Crankshaft - Remove.................. .................. 227 Belt Tensioner - Remove and Install....... ...... 266
Crankshaft - Install.................... .................... 229 Fan - Remove and Install............... ............... 267
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UENR4491 5
Table of Contents
Index Section
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6 UENR4491
Disassembly and Assembly Section
Removal Procedure
Table 1
Required Tools
Illustration 1 g03734667
NOTICE
Ensure that all adjustments and repairs that are
3. Make a temporary identification mark on plastic
carried out to the fuel system are performed by
authorized personnel that have the correct tube assemblies in order to show the correct
training. position of the tube assemblies.
Before beginning ANY work on the fuel system, 4. Disconnect plastic tube assembly (3) and plastic
refer to Operation and Maintenance Manual, “Gen- tube assembly (6) from fuel priming pump (2).
eral Hazard Information and High Pressure Fuel
Lines” for safety information. 5. Use Tooling (A) in order to plug the plastic tube
assemblies. Use Tooling (A) in order to cap the
Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de- connections for plastic tube assemblies on the fuel
tailed information on the standards of cleanliness priming pump.
that must be observed during ALL work on the
fuel system. 6. Disconnect Original Equipment Manufactures
(OEM) wiring harness assembly (1) from fuel
priming pump (2).
NOTICE
Care must be taken to ensure that fluids are con- 7. Remove bolts (4) from bracket (5).
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be Note: Support the bracket as the bolts are removed.
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling 8. Remove fuel priming pump (3) and bracket (5) as
any component containing fluids. an assembly from the cylinder block.
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UENR4491 7
Disassembly and Assembly Section
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de-
Illustration 2 g03734667 tailed information on the standards of cleanliness
that must be observed during ALL work on the
2. Position fuel priming pump (3) and bracket (5) as fuel system.
an assembly onto the cylinder block.
1. Turn the fuel supply to the OFF position.
3. Install bolt (4) to bracket (5). Tighten the bolt to a
torque of 22 N·m (195 lb in). 2. Turn the battery disconnect switch to the OFF
position.
4. Remove plugs from plastic tube assembly (3) and
plastic tube assembly (5). Remove cap from
connections on fuel priming pump (2).
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8 UENR4491
Disassembly and Assembly Section
Illustration 3 g02596577
Installation Procedure
1. Ensure that all component at free from wear and
damage. If any part of the flow control valve is
worn or damaged, the flow control valve must be
replaced as an assembly. The flow control valve kit
contains the guide pins in order to install the flow
control valve assembly.
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UENR4491 9
Disassembly and Assembly Section
Illustration 6 g02306933
Flow control valve guide pins
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10 UENR4491
Disassembly and Assembly Section
13. Install bolt (4) and bolt (10) (not shown) to bracket
NOTICE
(7). Tighten the bolts to a torque of 9 N·m (80 lb in)
Ensure that all adjustments and repairs that are
. carried out to the fuel system are performed by
14. Connect harness assembly (5) to fuel pressure authorized personnel that have the correct
sensor (6). training.
Before beginning ANY work on the fuel system,
15. Connect harness assembly (9) to flow control refer to Operation and Maintenance Manual, “Gen-
valve (8). eral Hazard Information and High Pressure Fuel
Lines” for safety information.
16. Connect harness assembly (2) to the coolant
temperature sensor. Slide locking tab (1) into the Refer to System Operation, Testing and Adjusting,
locked position. “Cleanliness of Fuel System Components” for de-
tailed information on the standards of cleanliness
17. Install a new cable strap (3). that must be observed during ALL work on the
fuel system.
Note: Ensure that the cable strap meets the Original
Equipment Manufactures (OEM) specification.
NOTICE
18. Replace the filters for primary fuel system. Refer Care must be taken to ensure that fluids are con-
to Operation and Maintenance Manual, “Fuel tained during performance of inspection, mainte-
System Primary (Water Separator) Element - nance, testing, adjusting and repair of the product. Be
Replace” for the correct procedure. prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
19. Replace the filters for secondary fuel system. any component containing fluids.
Refer to Operation and Maintenance Manual, “Fuel Dispose of all fluids according to local regulations and
System Secondary Filter - Replace” for the correct mandates.
procedure.
20. Turn the fuel supply to the ON position. 1. Turn the fuel supply to the OFF position.
21. Turn the battery disconnect switch to the ON 2. Turn the battery disconnect switch to the OFF
position. position.
22. Install the crankcase breather. Refer to 3. Drain the secondary filters. Refer to Operation and
Disassemble and Assemble, “Crankcase Breather Maintenance Manual, “Fuel System Secondary
- Install” for the correct procedure. Filter - Replace” for the correct procedure.
i05981756
Removal Procedure
Table 2
Required Tools
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UENR4491 11
Disassembly and Assembly Section
Illustration 8 g02597024
5. Place a suitable container below the fuel filter base Illustration 9 g02597038
in order to catch any fuel that might be spilled.
9. Remove secondary filters (8) from canisters (9).
6. Disconnect plastic tube assembly (1), plastic tube
Refer to Operation and Maintenance Manual, “Fuel
assembly (2), and plastic tube assembly (5) from
System Secondary Filter - Replace” for the correct
fuel filter base (3).
procedure.
7. Remove plastic tube assembly (1), plastic tube
10. Remove bolts (6) and bolts (7) from fuel filter base
assembly (2), and plastic tube assembly (5) from
(3). Remove the fuel filter base from the mounting
clips (4).
bracket.
8. Use Tooling (A) in order to plug the plastic tube Note: Do not disassemble the fuel filter base.
assemblies with new plugs. Use Tooling (A) in
order to cap the ports in the fuel filter base with
new caps.
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12 UENR4491
Disassembly and Assembly Section
11. If necessary, follow Step 11.a. through Step 11.c. 1. If necessary, follow Step 1.a. through Step 1.d. in
in order to remove the bracket for secondary fuel order to install the bracket for secondary fuel filter.
filter.
a. Position fuel filter bracket (10) onto the NRS
a. Cut cable strap (10) and cable strap (11) from induction mixer assembly.
harness assembly (12).
b. Install bolts (11), bolts (12) and bolt (16) to fuel
b. Remove bolts (11), bolts (12), and bolt (16) filter bracket (10).
from fuel filter bracket (10).
c. Tighten bolts (11), bolts (12) and bolt (16) to a
Note: Note position of different length bolts. torque of 22 N·m (195 lb in).
c. Remove fuel filter bracket (10) from the NRS d. Install new cable strap (10) and cable strap
induction mixer assembly. (11) to harness assembly (12).
Installation Procedure Note: Ensure that the cable straps meet the
Original Equipment Manufactures (OEM)
NOTICE specification.
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de-
tailed information on the standards of cleanliness
that must be observed during ALL work on the
fuel system.
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UENR4491 13
Disassembly and Assembly Section
Illustration 13 g02597024
Illustration 12 g02597038
NOTICE
Ensure that the plastic tube assemblies are installed
2. Ensure that fuel filter base (3) is clean and free in the original positions. Failure to connect the plastic
from damage. If necessary, replace the complete tube assemblies to the correct ports will allow contam-
fuel filter base and filter assembly. ination to enter the fuel system. Serious damage to
the engine will result if contaminated fuel enters the
3. Position fuel filter base (3) on the mounting fuel system.
bracket. Install bolts (6) and bolts (7). Tighten the
bolts to a torque of 44 N·m (32 lb ft).
6. Connect plastic tube assembly (1), plastic tube
4. If necessary, install new fuel filters (8) to canisters assembly (2), and plastic tube assembly (5) to fuel
(9). Refer to Operation and Maintenance Manual, filter base (3).
“Fuel System Secondary Filter - Replace” for the
correct procedure. 7. Install plastic tube assembly (1), plastic tube
assembly (2), and plastic tube assembly (5) to
clips (4).
i05981755
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14 UENR4491
Disassembly and Assembly Section
Removal Procedure
Table 3
Required Tools
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to System Operation, Testing and Adjusting, Illustration 14 g02526916
“Cleanliness of Fuel System Components” for de-
tailed information on the standards of cleanliness 3. Make temporary identification marks on plastic
that must be observed during ALL work on the
fuel system. tube assemblies in order to show the correct
position of the tube assemblies.
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UENR4491 15
Disassembly and Assembly Section
Illustration 16 g02599177
Installation Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de-
tailed information on the standards of cleanliness
that must be observed during ALL work on the
fuel system.
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16 UENR4491
Disassembly and Assembly Section
NOTICE
Ensure that the wiring harness assembly is correctly
routed and the cable straps are not over tightened.
Over tightening of the cable straps will damage the
wiring harness and the convoluting.
Illustration 18 g02526918
Illustration 17 g02599177
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UENR4491 17
Disassembly and Assembly Section
i05981923
Removal Procedure
Table 4
Required Tools
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Illustration 19 g02526916
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
5. Remove the plugs from the plastic tube eral Hazard Information and High Pressure Fuel
assemblies. Remove the caps from the ports in the Lines” for safety information.
fuel filter base.
Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de-
NOTICE tailed information on the standards of cleanliness
Ensure that the plastic tube assemblies are installed that must be observed during ALL work on the
in the original positions. Failure to connect the plastic fuel system.
tube assemblies to the correct ports will allow contam-
ination to enter the fuel system. Allowing contamina- 1. Turn the battery disconnect switch to the OFF
tion to enter the fuel system will cause serious position.
damage to the engine.
2. Turn the fuel supply to the OFF position.
6. Connect plastic tube assembly (1), plastic tube
assembly (2), and plastic tube assembly (5) to the
fuel filter base.
7. Install plastic tube assembly (1), plastic tube
assembly (2), and plastic tube assembly (5) to
clips (4).
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18 UENR4491
Disassembly and Assembly Section
3. Make temporary identification marks on plastic 8. If necessary, follow Step 8.a. through Step 8.d. in
tube assemblies in order to show the correct order to disassembly the assembly of primary fuel
position of the plastic tube assemblies. filter (1).
4. Place a suitable container below the fuel filter base a. Remove connection (7) and remove O-ring
in order to catch any fuel that might be spilled. seal (8). Use Tooling (A) in order to plug the
primary fuel filter (1) with new plug. Use
5. Disconnect plastic tube assembly (3) and plastic Tooling (A) in order to cap connection (7) with
tube assembly (4) from the assembly of primary new caps.
fuel filter (1). Use Tooling (A) in order to plug the
plastic tube assemblies with new plugs. Use b. Remove connection (10) and remove O-ring
Tooling (A) in order to cap the ports in the primary seal (9). Use Tooling (A) in order to plug the
fuel filter with new caps. primary fuel filter (1) with new plug. Use
Tooling (A) in order to cap connection (10) with
6. Disconnect the Original Equipment Manufactures new caps.
(OEM) harness assembly from the connection on
harness assembly (5) for water in fuel sensor (6). c. Remove water in fuel sensor (6) and remove
O-ring seal (12).
7. Remove bolts (2) and remove the assembly of
primary fuel filter (1) from the mounting bracket. d. Remove the filter element from fuel filter
canister (11). Refer to Operation and
Maintenance Manual, “Fuel System Primary
Filter (Water Separator) Element - Replace” for
the correct procedure.
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UENR4491 19
Disassembly and Assembly Section
Installation Procedure
d. Remove caps from connection (10). Install a
NOTICE new O-ring seal (9) to connection (10).
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by e. Remove cap from primary fuel filter (1). Install
authorized personnel that have the correct connection (10) to primary fuel filter (1).
training. Tighten the connection to a torque of 20 N·m
(177 lb in).
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel f. Install a new O-ring seal (12) to water in fuel
Lines” for safety information. sensor (6). Install water in fuel sensor (6) to
primary fuel filter (1). Tighten water in fuel
Refer to System Operation, Testing and Adjusting, sensor (6) hand tight.
“Cleanliness of Fuel System Components” for de-
tailed information on the standards of cleanliness
that must be observed during ALL work on the
fuel system.
Illustration 23 g02524979
c. Remove cap from primary fuel filter (1). Install 6. Connect plastic tube assembly (3) and plastic tube
connection (7) to primary fuel filter (1). Tighten assembly (4) to primary fuel filter (1).
the connection to a torque of 20 N·m
(177 lb in).
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20 UENR4491
Disassembly and Assembly Section
i05981763
Illustration 24 g02484242
Removal Procedure
Table 5
Required Tools
Start By:
a. Remove the fuel injection lines. Refer to Illustration 25 g02484286
Disassembly and Assembly, “Fuel Injection Lines -
Remove” for the correct procedure. 1. Thoroughly clean the area around fuel manifold (1).
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UENR4491 21
Disassembly and Assembly Section
Installation Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de-
tailed information on the standards of cleanliness
that must be observed during ALL work on the Illustration 26 g02484242
fuel system.
Illustration 27 g02484286
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22 UENR4491
Disassembly and Assembly Section
NOTICE
10. Connect harness assembly (4) to fuel pressure Ensure that all adjustments and repairs that are
sensor (5). carried out to the fuel system are performed by
authorized personnel that have the correct
11. Remove the air from the fuel system. Refer to training.
Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure. Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
i05981758
Lines” for safety information.
Fuel Injection Lines - Remove Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de-
tailed information on the standards of cleanliness
that must be observed during ALL work on the
Removal Procedure fuel system.
Start By:
a. Remove crankcase breather canister and plastic NOTICE
tube assemblies. Refer to Disassembly and Care must be taken to ensure that fluids are con-
Assembly, “Crankcase Breather - Remove” for the tained during performance of inspection, mainte-
correct procedure. nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
b. Remove secondary fuel filter assembly. Refer to before opening any compartment or disassembling
Disassembly and Assembly, “Fuel Filter Base any component containing fluids.
(Single Secondary Fuel Filter) - Remove and
Install” for the correct procedure. Dispose of all fluids according to local regulations and
mandates.
c. Remove water separator and fuel filter (Primary).
Refer to Disassembly and Assembly, “Water
Separator and Fuel Filter (Primary) - Remove and Note: Put identification marks on all hoses on all
Install” for the correct procedure. hose assemblies and on wires and all tube
assemblies for installation purposes. Plug all hose
d. Remove the Inlet Air Control (NRS Induction Mixer).
Refer to Disassembly and Assembly, “Inlet Air assemblies and tube assemblies. Plugging and
Control (NRS Induction Mixer) - Remove” for the capping hose assemblies and tube assemblies will
correct procedure. help to prevent fluid loss and helps to keep
contaminants from entering the system.
Table 6
Required Tools 1. Turn the fuel supply to the OFF position.
Tool Part Number Part Description Qty
2. Turn the battery disconnect switch to the OFF
A T410437 Capping Kit 1 position.
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UENR4491 23
Disassembly and Assembly Section
12. Use Tooling (A) in order to plug the open port for
the electronic unit injector.
Illustration 28 g02481081
Illustration 30 g02625818
5. Disconnect fuel injection line (1) and fuel injection 18. Position bracket (18) and the harness assembly
line (4) from the electronic unit injector. away from the fuel injection pump.
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24 UENR4491
Disassembly and Assembly Section
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de-
tailed information on the standards of cleanliness
that must be observed during ALL work on the
fuel system.
i05981757
Illustration 32 g02481080
Installation Procedure
Table 7 1. Remove plugs from fuel manifold (5) and fuel
Required Tools injection pump (23).
Tool Part Number Part Description Qty
2. Remove the caps from new fuel injection line (24).
B 27610294 Injector Pipe Nut Tool 1
3. Position fuel injection line (24) onto fuel injection
C T400030 Wrench 1 pump (23) and fuel manifold (5). Loosely install
nuts for the fuel injection line onto the fuel manifold
and the fuel injection pump.
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UENR4491 25
Disassembly and Assembly Section
Illustration 34 g02481216
Illustration 33 g02625818
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Disassembly and Assembly Section
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UENR4491 27
Disassembly and Assembly Section
Illustration 38 g02619657
1. Remove clip (7) and clip (12) from tube assembly 9. Remove bolts (14) and bolts (23) from tube
(3) and tube assembly (6). assembly (15).
2. Remove banjo bolt (2) from tube assembly (3). 10. Remove tube assembly (15) from exhaust cooler
Remove sealing washers (1) (not shown). (25) and the cylinder head.
3. Remove banjo bolt (9) from tube assembly (6). 11. Remove gaskets (16) (not shown) and gasket (24)
Remove sealing washers (13) (not shown). (not shown) from tube assembly (15).
4. Remove tube assembly (6). 12. Prior to and during removal of bolts (17) and bolts
(29) apply releasing fluid to the bolts. Remove
5. remove bolt (8) from clip for tube assembly (6). bolts (17) and bolts (29) from tube assembly (19).
6. Remove bolts (5) and bolts (11) from tube 13. Remove tube assembly (19) from exhaust cooler
assembly (6). (25) and the exhaust manifold.
7. Remove tube assembly (6) from the turbo charger 14. Remove gaskets (18) (not shown) and gasket
and the cylinder block. (28) (not shown) from tube assembly (19).
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28 UENR4491
Disassembly and Assembly Section
Illustration 40 g02619660
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UENR4491 29
Disassembly and Assembly Section
Illustration 41 g02619660
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30 UENR4491
Disassembly and Assembly Section
i05981737
Removal Procedure
Start By:
a. Remove the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Remove (Side
Mounted Turbocharger)” for the correct procedure.
Illustration 43 g02619657
20. Install new bolts (17) and new bolts (29) to tube
assembly (19).
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UENR4491 31
Disassembly and Assembly Section
Illustration 44 g02619576
2. Remove bolts (1) and bolts (10) from tube 11. Cut cable straps (21) for wiring harness assembly
assembly (2). (17). Ensure that all the cable straps are removed
from all harness assemblies.
3. Remove tube assembly (2) from exhaust cooler
(12) and the cylinder head. 12. Slide locking tab (18) into the unlocked position.
Disconnect wiring harness assembly (17) from
4. Remove gaskets (3) (not shown) and gasket (11) engine wiring harness assembly (19).
(not shown) from tube assembly (2).
13. Remove bolts (20) from tube assembly (23).
5. Prior to and during removal of bolts (4) and bolts
(16) apply releasing fluid to the bolts. Remove 14. Remove bolt (24) from clamp on tube assembly
bolts (4) and bolts (16) from tube assembly (6). (23).
6. Remove tube assembly (6) from exhaust cooler 15. Remove bolts (25) from tube assembly (23).
(12) and the exhaust manifold.
16. Remove tube assembly (23). Remove gasket (26)
7. Remove gaskets (5) (not shown) and gasket (15) (not shown) and gasket (22) (not shown) from tube
(not shown) from tube assembly (6). assembly (23).
8. Remove bolts (8) and bolts (14) from tube
assembly (7).
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32 UENR4491
Disassembly and Assembly Section
17. Remove bolt (27) and bolts (28) from exhaust 3. Position exhaust cooler (12) onto the cylinder
cooler (12). block. Install bolt (27) and bolts (28) to exhaust
cooler (12). Hand tighten bolt (27) and bolts (28).
Note: The exhaust cooler should be supported as the
bolts are removed. Note: The exhaust cooler should be supported as the
bolts are installed.
18. Remove exhaust cooler (12) from the cylinder
block. 4. Tighten bolt (27) and bolts (28) to a torque of
22 N·m (195 lb in).
Installation Procedure
NOTICE
Ensure that the wiring harness assembly is correctly
routed and the cable straps are not over tightened.
Over tightening of the cable straps will damage the
wiring harness and the convoluting.
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UENR4491 33
Disassembly and Assembly Section
Illustration 49 g02619576
20. Install new bolts (4) and new bolts (16) to tube
assembly (6).
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34 UENR4491
Disassembly and Assembly Section
i05981736
Removal Procedure
Start By: Illustration 50 g02477077
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UENR4491 35
Disassembly and Assembly Section
Illustration 52 g02477067
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36 UENR4491
Disassembly and Assembly Section
Illustration 53 g02477067
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UENR4491 37
Disassembly and Assembly Section
i05981790
20. Install new bolts (4) and new bolts (16) to tube
assembly (6).
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38 UENR4491
Disassembly and Assembly Section
Illustration 56 g02503476
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UENR4491 39
Disassembly and Assembly Section
i05981789
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Ensure that the wiring harness assembly is correctly
routed and the cable straps are not over tightened.
Over tightening of the cable straps will damage the
wiring harness convoluting.
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40 UENR4491
Disassembly and Assembly Section
Illustration 60 g02509196
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UENR4491 41
Disassembly and Assembly Section
Illustration 63 g02614076
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42 UENR4491
Disassembly and Assembly Section
Start By:
25. Connect wiring harness assembly (3) to wiring
harness assembly (1) for the wastegate solenoid. a. Remove crankcase breather canister and plastic
tube assemblies. Refer to Disassembly and
Slide locking tab (2) into the locked position. Assembly, “Crankcase Breather - Remove” for the
correct procedure.
26. Connect harness assembly (7) to NRS valve (9).
Slide locking tab (8) into the locked position. Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
27. Install new cable straps to the engine wiring
harness. Ensure that the engine wiring harness is
correctly routed and that all cable straps are
correctly positioned. Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
Note: Ensure that the cable straps meet OEM spray may cause a fire hazard. Failure to follow
specifications. these inspection, maintenance and service in-
structions may cause personal injury or death.
28. If necessary, install secondary fuel filter base and
bracket. Refer to Disassembly and Assembly,
“Fuel Filter Base - Remove and Install” for the NOTICE
correct procedure. Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
29. If necessary, install water separator and fuel filter authorized personnel that have the correct
(Primary). Refer to Disassembly and Assembly, training.
“Water Separator and Fuel Filter (Primary) -
Remove and Install” for the correct procedure. Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
30. If the Clean Emissions Module (CEM) assembly is eral Hazard Information and High Pressure Fuel
mounted on the valve mechanism cover, Lines” for safety information.
installation of the DPF assembly will be necessary Refer to System Operation, Testing and Adjusting,
after the NRS induction mixer has been installed. “Cleanliness of Fuel System Components” for de-
Refer to Disassembly and Assembly, “Clean tailed information on the standards of cleanliness
Emissions Module - Remove and Install” for the that must be observed during ALL work on the
correct procedure. fuel system.
Fuel Injection Pump - Remove 2. Turn the battery disconnect switch to the OFF
position.
Removal Procedure
Table 8
Required Tools
27610291 Housing 1
A(2)
27610289 Engine Turning Tool 1
Timing Pin
27610286 1
(Crankshaft)
B
27610287 Adapter 1
Timing Pin
C T400015 1
(Fuel Injection Pump)
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Disassembly and Assembly Section
12. Disconnected harness assembly (15) from the 19. Remove nuts (19) and bolts (22) from fuel
engine oil pressure sensor. Refer to Disassembly injection pump (13). Note position of the different
and Assembly, “Engine Oil Pressure Sensor - length bolts.
Remove and Install” for the correct procedure.
Note: The fuel injection pump should be supported by
13. Remove bolt (4) and bolt (9) (not shown) from hand as the bolts are removed.
bracket (5). Remove the bracket and position away
from the fuel injection pump.
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Disassembly and Assembly Section
i05981759
Installation Procedure
Table 9
Required Tools
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Disassembly and Assembly Section
Illustration 68 g02482036
15. Install a new cable strap (3) to harness assembly 25. Turn the fuel supply to the ON position.
(1).
26. Turn the battery disconnect switch to the ON
Note: Ensure that the new cable strap meets Original position.
Equipment Manufactures (OEM) specifications.
27. Install crankcase breather canister and plastic
16. Connected harness assembly (7) to the pressure tube assemblies. Refer to Disassembly and
sensor in the fuel manifold. Assembly, “Crankcase Breather - Install” for the
correct procedure.
17. Connected harness assembly (16) to the flow
control valve. 28. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
18. Connected harness assembly (14) to the fuel
- Prime” for the correct procedure.
temperature sensor. Refer to Disassembly and
Assembly, “Fuel Temperature Sensor - Remove
and Install” for the correct procedure.
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46 UENR4491
Disassembly and Assembly Section
i05981762
Removal Procedure
Table 10
Required Tools
i05981761
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4491 47
Disassembly and Assembly Section
Removal Procedure
Table 11
Required Tools
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft -
Remove” for the correct procedure.
b. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection Lines -
Remove” for the correct procedure.
Illustration 71 g02483636 Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
2. Position a new O-ring seal (5) onto fuel injection
pump (7).
3. Position adapter plate (4) onto fuel injection pump Contact with high pressure fuel may cause fluid
(7). penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
4. Install new bolts (9) and washer (8). Tighten the these inspection, maintenance and service in-
bolts to a torque of 22 N·m (195 lb in). structions may cause personal injury or death.
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Disassembly and Assembly Section
NOTICE
Use a deep socket in order to remove the electrical
connections from the electronic unit injectors. Use of
incorrect tooling will result in damage to the electronic
unit injectors.
Illustration 73 g01971773
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UENR4491 49
Disassembly and Assembly Section
Illustration 74 g01971775
Illustration 76 g02047333
13. Use Tooling (B) to pry beneath clamp (10) and c. Disconnect harness assembly (16) from
free electronic unit injector (8) from the cylinder harness assembly (6).
head.
d. Remove bolt (15) for harness assembly (6).
Note: Always handle electronic unit injectors with
care. e. Withdraw harness assembly (6) from cylinder
head (17).
14. Use a suitable tool in order to remove sealing
washer (12) from electronic unit injector (8). f. Remove O-ring seal (14) from harness
Ensure that the sealing washer is removed from assembly (6).
the cylinder head.
g. If necessary, repeat Step 18.a. through Step
Note: Ensure that the nozzle for the electronic unit 18.f. in order to remove the remaining harness
injector is not damaged in any way on removal of the assemblies from the cylinder head.
sealing washer.
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Disassembly and Assembly Section
i05980736
Installation Procedure
Table 12
Required Tools
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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Use a deep socket in order to remove the electrical
connections from the electronic unit injectors. Use of
incorrect tooling will result in damage to the electronic
unit injectors.
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Disassembly and Assembly Section
3. If necessary, follow Step 3.a. through Step 3.e. in 5. On installing an original electronic unit injector,
order to install harness assemblies (6) to cylinder install a new O-ring seal (11).
head (17).
Note: Do not lubricate the O-ring seal.
a. Install a new O-ring seal (14) to harness
assembly (6). 6. Use a suitable tool in order to install a new sealing
washer (12) to electronic unit injector (8).
Note: Do not lubricate the O-ring seal.
Note: Ensure that the nozzle for the electronic unit
b. Install harness assembly (6) to cylinder head injector is not damaged in any way on installation of
(17). the new sealing washer.
c. Install a new bolt (15) to harness assembly (6). 7. Ensure that O-ring seal (12) and sealing washer
Tighten the bolt to a torque of 5.5 N·m (12) on a new electronic unit injector are not
(49 lb in). damaged and in place.
d. Install new assemblies of the cable strap (13) Note: Do not lubricate the O-ring seal.
to harness assembly (6). 8. Ensure that the seat for the electronic unit injector
Note: Ensure that the cable straps meet the in the cylinder head is clean and free from
Original Equipment Manufactures (OEM) damage. Ensure that the sealing washer has been
specification. Ensure that the assemblies of the removed from the cylinder head.
cable strap are correctly installed into the cylinder
head.
e. Connect harness assembly (16) to harness
assembly (6).
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Disassembly and Assembly Section
Illustration 80 g01971773
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Disassembly and Assembly Section
Removal Procedure
Start By:
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 containers
Illustration 82 g02475251
before opening any compartment or disassembling
any component containing fluids.
19. Remove cap from tube assembly (1). Install a
new O-ring seal (3) (not shown) to tube assembly Dispose of all fluids according to local regulations and
(1). mandates.
i05981907
Turbocharger - Remove
(Second Stage Turbocharger)
Illustration 83 g02529457
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54 UENR4491
Disassembly and Assembly Section
Note: If the V-band clamp (2) and V-band clamp (7) 10. Remove gasket (10) (not shown).
remain tight on the flanges, apply releasing fluid on
the V-band clamps in order to assist removal. Lightly 11. Remove bolts (15) and bolts (19) from tube
tap the bolts on the V-band clamps with a soft faced assembly (17).
hammer in order to assist removal. Do not use a
prybar in order to remove V-band clamps. 12. Remove tube assembly (17) from turbocharger
(8).
3. Remove the elbow from turbocharger (3) and
turbocharger (8). 13. Remove gasket (13) (not shown) and gasket (20)
(not shown).
4. Remove V-band clamp (4) from air duct (5) and
loosen hose clamps (9). Remove hose assembly
(6) and air duct (5) from the outlet of turbocharger
(8) and turbocharger (3).
Illustration 85 g02529479
5. Disconnect hose assembly (12) from the 16. If necessary, remove studs (22) from turbocharger
connection on turbocharger (8). Plug the (8).
connection on the turbocharger. Cap the hose
17. If necessary, follow Step 17.a. through Step 17.b.
assembly.
in order to remove bracket (23) from cylinder block
6. Remove bolts (11) from tube assembly (14). (24).
7. remove bolt (21) from clamp for tube assembly a. Remove bolts (25).
(14). Note: Support the bracket as the bolts are
removed.
8. Remove banjo bolt (16). Remove sealing washers
(18) (not shown). b. Remove bracket (23) from cylinder block (24).
9. Remove tube assembly (14) from turbocharger (8).
Plug the tube assembly. Plug the turbocharger and
the cylinder block.
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Disassembly and Assembly Section
Illustration 86 g02526997
2. Slide hose clamp along hose assembly (5). 7. Remove banjo bolt (13) from hose assembly (14).
Disconnect hose assembly (5) from the wastegate
8. Remove sealing washers (12) (not shown).
actuator.
3. Loosen the allen head bolt on V-band clamp (2) 9. Disconnect hose assembly (14) from the
and loosen the allen head bolt on V-band clamp (9) connection on turbocharger (10). Plug and cap the
from elbow (1). Remove the V-band clamps from turbocharger. Plug and cap the hose assembly.
the elbow. 10. Remove hose assembly (14).
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56 UENR4491
Disassembly and Assembly Section
11. Remove bolt (18) from the clip for tube assembly
(17). Removal Procedure
12. Remove bolts (16) and bolts (20) from tube Start By:
assembly (17).
a. Remove the exhaust elbow from the turbocharger.
Refer to Disassembly and Assembly, “Exhaust
13. Remove tube assembly (17) from turbocharger Elbow - Remove and Install” for the correct
(3) and the cylinder block. procedure.
14. Remove gasket (15) (not shown) and gasket (19) NOTICE
(not shown) from tube assembly (17). Keep all parts clean from contaminants.
Note: Plug the oil drain tube assembly for the Contaminants may cause rapid wear and shortened
turbocharger. Plug the port on the turbocharger and component life.
the cylinder block.
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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Illustration 88 g02526999
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Disassembly and Assembly Section
Illustration 91 g02570158
9. Remove gasket (19) (not shown). e. Remove bolts (26) and remove tube assembly
(14).
10. Remove gasket (16) (not shown) from tube
assembly (14). f. Remove gasket (27) (not shown).
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Disassembly and Assembly Section
Contaminants may cause rapid wear and shortened 6. Remove bolts (11) and bolts (13). Remove tube
component life. assembly (12) from the turbocharger.
Illustration 93 g03735741
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Disassembly and Assembly Section
i05981910
Turbocharger - Install
(Side Mounted Turbochargers)
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 95 g03735741
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Disassembly and Assembly Section
Illustration 97 g03735744
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Disassembly and Assembly Section
End By:
a. Install the exhaust elbow to the turbocharger. Refer
to Disassembly and Assembly, “Exhaust Elbow -
Remove and Install” for the correct procedure.
i05984597
Turbocharger - Install
(Second Stage Turbocharger)
Installation Procedure
Table 13
Required Tools
A - Anti-Seize Compound 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 98 g02529479
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62 UENR4491
Disassembly and Assembly Section
11. Remove the plug from oil inlet port (27). Lubricate
the turbocharger bearings with clean engine oil
through the oil inlet port. Rotate the wheel of the
compressor several times in order to lubricate the
bearings.
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UENR4491 63
Disassembly and Assembly Section
End By:
a. Install the exhaust elbow to the second stage
turbocharger. Refer to Disassembly and Assembly,
“Exhaust Elbow - Remove and Install” for the
correct procedure.
i05981902
Turbocharger - Install
(First Stage Turbocharger)
Installation Procedure
Table 14
Required Tools
A - Anti-Seize Compound 1
NOTICE
21. Use Tooling (A) to lubricate the allen head bolt for Keep all parts clean from contaminants.
V-band clamp (4). Position V-band clamp (4) onto
air duct (5). Contaminants may cause rapid wear and shortened
component life.
22. Position hose assembly (6) and air duct (5) onto
the outlet of turbocharger (8) and turbocharger (3).
Tighten the allen head volt V-band clamp to a
torque of 12 N·m (106 lb in).
25. Use Tooling (A) to lubricate the allen head bolt for
V-band clamp (2). Position V-band clamp (2) onto
elbow (1).
26. Use Tooling (A) to lubricate the allen head bolt for
V-band clamp (7). Position V-band clamp (7) onto
turbocharger (8).
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Disassembly and Assembly Section
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Disassembly and Assembly Section
15. Install bolt (18) to the clip for tube assembly (17).
17. Remove the plug from oil inlet port (28). Lubricate
the turbocharger bearings with clean engine oil
through the oil inlet port. Rotate the wheel of the
compressor several times in order to lubricate the
bearings.
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Disassembly and Assembly Section
i05981917
Turbocharger - Install
(Top Mounted Turbocharger )
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
24. Use Tooling (A) to lubricate the allen head bolt for
V-band clamp (6). Position V-band clamp (6) onto
air duct (7).
25. Position hose assembly (11) and air duct (7) onto
the outlet of turbocharger (10) and turbocharger
(3). Tighten the allen head bolt for V-band clamp to
a torque of 12 N·m (106 lb in).
28. Use Tooling (A) to lubricate the allen head bolt for
V-band clamp (2). Position V-band clamp (2) onto
elbow (1).
29. Use Tooling (A) to lubricate the allen head bolt for Illustration 108 g03735219
V-band clamp (9). Position V-band clamp (9) onto
turbocharger (10). 1. Ensure that turbocharger (15) is clean and free
from damage. Inspect the turbocharger for wear.
30. Position elbow (1) onto turbocharger (3) and Refer to System Operation, Testing and Adjusting,
turbocharger (10). “Turbocharger Inspect” for more information. If the
turbocharger is worn, the complete turbocharger
31. Tighten the allen head bolt for V-band clamp (2)
must be replaced.
and the allen head bolt for V-band clamp (7) finger
tight. Ensure that the V-band clamps are seated 2. Test wastegate actuator (28) for correct operation.
correctly onto the turbochargers. Refer to System Operation, Testing and Adjusting,
“Turbocharger Inspect” for more information. If the
32. Tighten the allen head bolt for V-band clamp (2)
wastegate actuator is damaged or the wastegate
and the allen head bolt for V-band clamp (9) to a
actuator does not operate within the specified
torque of 12 N·m (106 lb in).
limits, the complete turbocharger must be
33. Connect hose assembly (5) to the wastegate replaced.
actuator. Slide hose clamp along hose assembly
(5) ensure that hose clamp is correctly positioned.
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UENR4491 67
Disassembly and Assembly Section
b. Position a new gasket (27) (not shown) onto 4. Clean the gasket surfaces of the exhaust manifold
tube assembly (14). (20). If necessary, install studs (17) (not shown) to
the turbocharger (15). Tighten the studs to a torque
c. Position tube assembly (14) onto cylinder of 18 N·m (13 lb ft).
block. Install bolts (26) finger tight.
5. Position a new gasket (16) (not shown) onto tube
d. Install bolt (21) and spacer (22) (not shown) assembly (14).
finger tight.
6. Position a new gasket (16) (not shown) onto
e. Tighten bolts (26) to a torque of 22 N·m exhaust manifold (20).
(195 lb in).
7. Position turbocharger (15) on exhaust manifold
Tighten bolt (21) to a torque of 18 N·m (20).
(159 lb in).
Note: Do not use the actuator rod to lift the
f. Position a new sealing washer (24) (not turbocharger.
shown) onto banjo bolt (23). Install banjo bolt
(23) to tube assembly (8) and install remaining 8. Install nuts (18). Tighten the nuts to a torque of
new sealing washer (24) (not shown) onto 44 N·m (32 lb ft).
banjo bolt (23).
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Disassembly and Assembly Section
14. Install clip (9) from tube assembly (8) and tube
assembly (14).
Illustration 111 g02568360 18. Tighten bolt (3) and bolt (11) to a torque of 22 N·m
Typical example (195 lb in).
i05981920
Removal Procedure
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UENR4491 69
Disassembly and Assembly Section
1. If the Diesel Particulate Filter (DPF) assembly is 12. Remove allen head bolts (15) from wastegate
mounted on the valve mechanism cover, removal solenoid (3). Remove bracket (4).
of the DPF assembly will be necessary in order to
access the wastegate solenoid. Refer to 13. Remove wastegate solenoid (3) from inlet
Disassembly and Assembly, “Diesel Particulate connection (12).
Filter - Remove” for the correct procedure.
14. Plug inlet connection (12) and cap wastegate
2. Loosen hose clamps and remove hose assembly solenoid (3) with new plugs and caps.
from connection (12).
Installation Procedure
3. Remove plastic tube assembly (2) from the valve Table 15
mechanism cover and the crankcase breather Required Tools
canister.
Tool Part Number Part Description Qty
4. Slide locking tab (13) into the unlocked position.
Delphi Lockheed Rubber
Disconnect harness assembly (5) from the harness A - 1
Grease
assembly for wastegate solenoid (3).
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Disassembly and Assembly Section
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Disassembly and Assembly Section
22. If the Clean Emissions Module (CEM) assembly 3. Loosen allen head bolt on V-band clamp (6).
was mounted on the valve mechanism cover,
installation of the DPF assembly will be necessary Note: If the V-band clamp (6) remain tight on the
flanges, apply releasing fluid on the V-band clamps in
after the installation of the wastegate solenoid.
order to assist removal. Lightly tap the bolts on the V-
Refer to Disassembly and Assembly, “Clean band clamps with a soft faced hammer in order to
Emissions Module - Remove and Install” for the assist removal. Do not use a prybar in order to
correct procedure. remove V-band clamps.
Removal Procedure
Start By:
a. Remove the flexible exhaust pipe from the exhaust
back pressure valve. Refer to Disassembly and
Assembly, “Flexible Exhaust Pipe - Remove and
Install” for the correct procedure.
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Disassembly and Assembly Section
Installation Procedure
Table 16
Required Tools
A - Anti-Seize Compound 1
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Disassembly and Assembly Section
6. Ensure that V-band clamp (6) is seated onto 1. Ensure that the purge process for the DEF
exhaust back pressure valve (5) and exhaust system is completed before turning the battery
elbow (7). Tighten the allen head bolt for the V- disconnect switch to the OFF position. Refer to
band clamp hand tight. the Operation and Maintenance Manual,
“Battery Disconnect Switch” for further
7. Tighten the allen head bolt for V-band clamp (6) to information.
a torque of 12 N·m (106 lb in).
i05980446
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Disassembly and Assembly Section
8. Remove the Original Equipment Manufacture 2. Attach a suitable lifting device to the assembly of
(OEM) exhaust tube assembly (7) from Clean CEM (12).
Emissions Module (CEM) (12). Refer to the OEM
for the correct procedure. 3. Use the suitable lifting device to install CEM (12) to
the bracket. Install bolts (10) and bolts (11) to CEM
9. Disconnect the harness assembly from exhaust (12). Tighten the bolts to a torque of 44 N·m
temperature sensor (8). (32 lb ft).
10. Attach a suitable lifting device to the assembly of 4. Remove the suitable lifting device from CEM (12).
CEM (12).
5. Connect the harness assembly to exhaust
11. Remove bolts (10) and bolts (11) from CEM (12). temperature sensor (8).
Use the suitable lifting device to remove the CEM
from the bracket. 6. Install the Original Equipment Manufacture (OEM)
exhaust tube assembly (7) to Clean Emissions
Installation Procedure Module CEM (12). Refer to the OEM for the correct
procedure.
1. Ensure that all components are clean and free from
wear and damage. If necessary, replace the CEM
as an assembly. The assembly of the CEM will be
supplied with mounting brackets. The orientation
of the CEM to the brackets will be preset. The
clamps retaining the CEM to the bracket should
not be loosened or removed.
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UENR4491 75
Disassembly and Assembly Section
NOTICE
Ensure that all adjustments and repairs that are
carried out to the Diesel Emission Fluid (DEF)
system are performed by authorized personnel
that have the correct training.
Before beginning ANY work on the DEF system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard” for safety information.
NOTICE
Care must be taken to ensure that Diesel Emission
Fluid (DEF) for the system are contained during per-
formance of inspection, maintenance, testing, adjust-
ing, and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component con-
taining fluids.
Dispose of all fluids according to local regulations and
mandates.
Illustration 125 g03726978
7. Install flexible exhaust pipe (1). Refer to 1. Ensure that the purge process for the DEF
Disassembly and Assembly, “Flexible Exhaust system is completed before turning the battery
Pipe - Remove and Install” for the correct disconnect switch to the OFF position. Refer to
procedure. the Operation and Maintenance Manual,
“Battery Disconnect Switch” for further
8. Connect the harness assembly to exhaust information.
temperature sensor (2).
10. Remove the caps from DEF injector (3) and diesel
emission fluid line (5) and diesel emission fluid line
(6). Connect the diesel emission fluid lines to the
DEF injector. Refer to Disassembly and Assembly,
“Diesel Exhaust Fluid Lines - Remove and Install”
for the correct procedure.
i05980648
Removal Procedure
Table 18
Required Tools
B - De-ionized Water 1
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Disassembly and Assembly Section
2. Ensure that the area around Manifold (DEF 5. Disconnect the Original Equipment Manufacture
Heater) (7), Diesel Exhaust Fluid (DEF) pump (OEM) harness assemblies from harness
(4), Diesel Exhaust Fluid injector (14) and assembly (1), harness assembly (8), and harness
Diesel Exhaust Fluid (DEF) line (3) and Diesel assembly (9) for the Diesel Exhaust Fluid (DEF)
Exhaust Fluid (DEF) line (6) is clean and free lines.
dirt and debris. If necessary, use Tooling (B)
and a suitable tool to clean the area around the 6. Make temporary marks on cable straps for
DEF component. installation purposes. Cut cable straps (2) and
cable straps (5). Ensure that all cable straps are
3. Refer to the Original Equipment Manufacture removed.
(OEM) for the correct location of the Manifold (DEF
7. Disconnect diesel exhaust fluid line (6) and diesel
Heater) (7), Diesel Exhaust Fluid (DEF) pump (4),
exhaust fluid line (3) from manifold DEF heater (7).
and Diesel Exhaust Fluid injector (14). Refer to the
OEM for the correct routing of the diesel exhaust 8. Use Tooling (A) to cap manifold DEF heater (7).
fluid lines. Use Tooling (A) to plug diesel exhaust fluid line (6)
4. Ensure that the area around manifold DEF heater and diesel exhaust fluid line (3).
(7), DEF pump (4), and DEF injector (14) are clean 9. Disconnect diesel exhaust fluid line (10) and diesel
and free dirt and debris. If necessary, clean the exhaust fluid line (11) from DEF pump (4).
area around the manifold DEF heater, DEF pump,
and DEF injector. 10. Use Tooling (A) to cap DEF pump (4). Use Tooling
(A) to plug diesel exhaust fluid line (10) and diesel
exhaust fluid line (11).
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Disassembly and Assembly Section
Installation Procedure
Table 19
Required Tools
B - De-ionized Water 1
2. Remove caps manifold DEF heater (7) and plug 3. Connect DEF line (6) and DEF line (3) to manifold
from DEF line (6) and DEF line (3). DEF heater (7).
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Disassembly and Assembly Section
g. Use Tooling (B) to clean any DEF fluid from the 1. Refer to the Original Equipment Manufacture
end of the DEF supply line. (OEM) for the location of the DEF pump.
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Disassembly and Assembly Section
2. Ensure that the purge process for the DEF Installation Procedure
system is completed before turning the battery Table 21
disconnect switch to the OFF position. Refer to Required Tools
the Operation and Maintenance Manual,
“Battery Disconnect Switch” for further Tool Part Number Part Description Qty
information. B - De-ionized Water 1
4. Disconnect harness assembly (3) from Original 2. If necessary, install a new DEF filter (2) (not
Equipment Manufacture (OEM) harness assembly shown). Refer to Operation and Maintenance
(4). Manual, “Diesel Exhaust Fluid Filter - Clean/
Replace” for the correct procedure.
5. Make temporary marks on DEF lines for installation
purposes. Remove the DEF line from connection 3. Install DEF pump (1) and install bolts (7) to diesel
(5) and the DEF line from connection (6) from DEF exhaust fluid pump. Support the weight of the DEF
fluid pump(1). Refer to Disassembly and pump as the bolts are installed. Tighten the bolts to
Assembly, “Diesel Exhaust Fluid Lines - Remove a torque of 16 N·m (142 lb in).
and Install” for the correct procedure.
4. Remove plugs from the DEF lines. Remove the
6. Use Tooling (A) to plug the DEF lines. Tooling (A) caps from connection (5) and connection (6).
to cap connection (5) and connection (6).
5. Install the DEF line to connection (5) and the DEF
7. Remove bolts (7) from DEF pump (1). Support the line to connection (6). Refer to Disassembly and
weight of the DEF pump as the bolts are removed. Assembly, “Diesel Exhaust Fluid Lines - Remove
Remove the DEF pump. and Install” for the correct procedure.
8. If necessary, remove DEF filter (2) (not shown). Note: Ensure that the DEF lines are connected into
Refer to Operation and Maintenance Manual, the correct positions.
“Diesel Exhaust Fluid Filter - Clean/Replace” for
the correct procedure. 6. Connect harness assembly (3) to OEM harness
assembly (4).
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Disassembly and Assembly Section
b. Disconnect DEF line (8) from DEF injector (9). DEF Injector and Mounting -
Remove and Install
c. Use Tooling (A) to cap DEF injector (9) and
DEF line (8).
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Disassembly and Assembly Section
Dispose of all fluids according to local regulations and 6. Remove the DEF line from connection (9) on DEF
mandates. injector (2). Refer to Disassembly and Assembly,
“Diesel Exhaust Fluid Lines - Remove and Install”
1. Ensure that the purge process for the DEF for the correct procedure.
system is completed before turning the battery
7. Use Tooling (A) to cap connection (9) on DEF
disconnect switch to the OFF position. Refer to
injector (2) and the DEF line.
the Operation and Maintenance Manual,
“Battery Disconnect Switch” for further 8. Make temporary marks on DEF injector (2) and
information. Clean Emissions Module (CEM) (6) for installation
purposes.
Installation Procedure
Table 23
Required Tools
B - De-ionized Water 1
1. Ensure that the DEF injector and the CEM are free
from wear or damage. Replace any component
that is worn or damaged.
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Disassembly and Assembly Section
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i05980669
Removal Procedure
Table 24
Required Tools
B - De-ionized Water 1
NOTICE
Ensure that all adjustments and repairs that are
carried out to the Diesel Emission Fluid (DEF)
system are performed by authorized personnel
Illustration 134 g03736268 that have the correct training.
9. Tighten allen head bolt (1) for V-band clamp (8) to a Before beginning ANY work on the DEF system,
torque of 4 N·m (35 lb in). Ensure that the clamp refer to Operation and Maintenance Manual, “Gen-
eral Hazard” for safety information.
remains in Position (X).
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Disassembly and Assembly Section
9. Remove bolt (4) and bolt (12) for strap (2) and
strap (10). Remove the straps from diesel exhaust
fluid tank (1).
Installation Procedure
1. Ensure that all components are free from wear or
damage. Replace any component that is worn or
damaged.
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Disassembly and Assembly Section
i05981795
Removal Procedure
Table 25
Required Tools
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
4. If necessary, follow Step 4.a. through Step 4.b. in 5. Install a new O-ring seal (8) to manifold DEF heater
order to install filter (12) to manifold DEF heater (7).
(7).
6. Install manifold DEF heater (7) to DEF tank (10).
a. Install filter (12) to manifold DEF heater (7). Ensure that the manifold DEF heater is correctly
Ensure that the filter is correctly positioned seated into DEF tank.
onto the manifold DEF heater.
7. Install ring (2) to manifold DEF heater (7). Ensure
b. Install Torx screw to filter (12). Use Tooling that the ring is correctly orientated and correctly
(A) and Tooling (B) to tighten the Torx screw seated onto the manifold DEF heater.
to a torque of 1.24 N·m (11 lb in).
8. Install Torx screws (1) to ring (2). Use Tooling (A)
and Tooling (C) to tighten Torx screws to a torque
of 2.8 N·m (25 lb in).
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Disassembly and Assembly Section
i05981816
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Disassembly and Assembly Section
NOTICE
The bellows must be supported at all times when the
bellows are not installed in the application. Failure to
support the bellows adequately could result in the fail-
ure of the bellows. Do not use power tools in order to
disassemble or assemble any part of the flexible ex-
haust system.
The alignment of the bellows is important. Incorrect
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the uniformity of the spacing between the
convolutions on the bellows.
Inspect the bellows for damage prior to installation. If
there is any damage to the convolutions, discard the
bellows. If there is any difficulty in installation after the
repair, discard the bellows.
Illustration 144 g03727977
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Disassembly and Assembly Section
Drill Bit
Disassembly Procedure for the B -
6.5 mm (0.256 inch) Ø
1
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Disassembly and Assembly Section
NOTICE
Use the correct personal protective equipment when
removing the clamp.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
NOTICE
Failure to reinstall the bellows into the original position Removal Procedure
will result in a failure of the bellows and possible emis-
sions failure. Start By:
i05981742
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Disassembly and Assembly Section
Installation Procedure
Table 28
Required Tools
Illustration 155 g02477643 1. Ensure that the exhaust manifold is clean and free
from damage. If necessary, replace the exhaust
8. Loosen bolts (12) in reverse numerical order. Refer manifold. Clean the gasket surface of the cylinder
to Illustration 154 . head.
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Disassembly and Assembly Section
2. Position a new exhaust manifold gasket (14) (not 5. Install bolts (12) and spacers (11) hand tight.
shown) onto the cylinder head. Install Tooling (A) in Ensure that the different length spacer is installed
Positions (X) and Tooling (B) in Positions (Y). into the correct position.
Refer to Illustration 156 .
6. Remove Tooling (A) and Tooling (B). Install
Note: Ensure that the exhaust manifold gasket is remaining bolts (12) and spacers (11) hand tight.
correctly oriented.
7. Tighten bolts (12) to a torque of 44 N·m (32 lb ft).
3. Align exhaust manifold (13) with Tooling (A) and Tighten the bolts in the sequence that is shown in
Tooling (B). Install the exhaust manifold to the Illustration 155 .
cylinder head.
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Disassembly and Assembly Section
i05981741
Removal Procedure
Start By:
a. Remove the turbocharger for top mounted
turbocharged engine. Refer to Disassembly and
Assembly, “Turbocharger (Top Mounted
Turbocharger) - Remove” for the correct procedure.
b. Remove the turbocharger for side mounted
turbocharged engine. Refer to Disassembly and
Assembly, “Turbocharger (Side Mounted
Illustration 158 g02477639
Turbocharger) - Remove” for the correct procedure.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
Installation Procedure
Table 29
Required Tools
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Disassembly and Assembly Section
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Disassembly and Assembly Section
16. Install a new O-ring seal (15) (not shown) and a Exhaust Elbow - Remove and
new seal (16) (not shown) to the dipstick tube
assembly. Loosely install nut (14) for dipstick tube Install
assembly (4).
17. Install bolt (5) and bolt (13) to dipstick tube Removal Procedure
assembly (4).
Installation Procedure
Table 30
Required Tools
A - Anti-Seize Compound 1
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Disassembly and Assembly Section
i05981739
Removal Procedure
4. Position exhaust elbow (2) onto turbocharger (5). Illustration 167 g02476645
Install V-band clamp (4) onto exhaust elbow (2) Typical example
and hand tighten the allen head bolt on the V-band
clamp. 1. If necessary, remove exhaust back pressure valve
(1) from exhaust elbow (2). Refer to Disassembly
Note: Support the weight of the exhaust elbow as the
and Assembly, “Exhaust Back Pressure Valve -
V-band clamp is installed.
Remove and Install” for the correct procedure.
5. Install the spacers and bolts (3) hand tight. Ensure
2. Remove nuts (4) from turbocharger (6).
that exhaust elbow (2) is correctly positioned onto
turbocharger (5) and is correctly aligned. 3. Make temporary marks on exhaust elbow (2) and
turbocharger (6) to show correct orientation.
6. Tighten the allen head bolt for V-band clamp (4) to
Remove exhaust elbow (2) from turbocharger (6).
a torque of 12 N·m (106 lb in).
4. Remove gasket (5) (not shown) from turbocharger
7. Tighten bolts (3) to a torque of 44 N·m (32 lb ft).
(6).
8. If necessary, install exhaust back pressure valve
5. If necessary, remove studs (3) from turbocharger
(1) to exhaust elbow (2). Refer to Disassembly and
(6).
Assembly, “Exhaust Back Pressure Valve -
Remove and Install” for the correct procedure. Installation Procedure
Table 31
Required Tools
A - Anti-Seize Compound 1
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i05981818
Removal Procedure
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Disassembly and Assembly Section
4. If necessary, follow Step 4.a. through Step 4.e. in 2. If necessary, follow Step 2.a. through Step 2.e. in
order to disassemble bracket assembly (2). order to assemble bracket assembly (2).
a. Remove nuts (7) and remove washers (8). a. If necessary, install studs (14) from rear
bracket (15) and front bracket (16). Tighten the
b. Remove mounts (9) from upper bracket (10). studs to a torque of 25 N·m (221 lb in).
c. Remove upper bracket (10) from rear bracket b. Install mounts (13), sleeves (12), and flanges
(15) and front bracket (16). (11) onto studs (14) of rear bracket (15) and
front bracket (16). Ensure that the flanges are
d. Remove flanges (11), sleeves (12), and
correctly seated onto the mounts and the
mounts (13).
sleeves into the mounts.
e. If necessary, remove studs (14) from rear c. Install upper bracket (10) to rear bracket (15)
bracket (15) and front bracket (16). and front bracket (16). Ensure that the
brackets are correctly orientated.
5. When bracket assembly (2), is removed from valve
mechanism cover (4). Replacement of the valve d. Install mounts (9) to upper bracket (10).
mechanism cover gasket is recommended. Refer
to Disassembly and Assembly, “Valve Mechanism e. Install washers (8) and nuts (7) hand tight
Cover - Remove and Install” for the correct
procedure.
Installation Procedure
1. Ensure that all components are clean and free from
wear and damage. If necessary, replace any
components that are worn or damaged.
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Disassembly and Assembly Section
27610291 Housing 1
B(2)
27610289 Engine Turning Tool 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Illustration 172 g03729120 Contaminants may cause rapid wear and shortened
component life.
3. Install bracket assembly (2) onto valve mechanism
cover (4). Note: The following procedure should be adopted in
order to remove the valve springs when the cylinder
4. Install bolt (1) and nuts (3) to bracket assembly (2). head is installed to the engine. Refer to Disassembly
Support the bracket assembly as the bolt and the and Assembly, “Inlet and Exhaust Valves - Remove
nuts are installed. and Install” for the procedure to remove the valve
springs from a cylinder head that has been removed
5. Tighten bolt (1) and nuts (3) to a torque of 22 N·m from the engine.
(195 lb in).
Note: Ensure that the appropriate piston is at top
6. If necessary, tighten the nuts for the mountings on dead center before the valve spring is removed.
bracket assembly (2) to a torque of 78 N·m Failure to ensure that the piston is at top dead center
(58 lb ft). Refer to Illustration 171 . may allow the valve to drop into the cylinder bore.
Inlet and Exhaust Valve Follow the recommended procedure and use all
recommended tooling to release the spring force.
Springs - Remove and Install
NOTICE
Plug the apertures for the push rods in the cylinder
Removal Procedure head in order to prevent the entry of loose parts into
Table 32 the engine.
Required Tools
(continued)
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Disassembly and Assembly Section
b. Use a deep socket to remove connections (1) a. Install Tooling (A) in position on the cylinder
from electronic unit injectors (2). head in order to compress a valve spring (10)
for the appropriate piston.
c. Cut cable straps (4) and remove the remaining
sections of the cable straps from the cylinder b. Use Tooling (A) in order to compress valve
head. spring (10) and open the valve slightly.
d. Disconnect plug (6) from harness assembly Note: Do not compress the spring so that valve
(3). spring retainer (9) touches valve stem seal (11).
e. Remove bolt (5) from harness assembly (3). c. Use Tooling (B) in order to rotate the
crankshaft carefully, until the piston touches
f. Withdraw harness assembly (3) from the the valve.
cylinder head.
Note: Do not use excessive force to turn the
g. Remove O-ring seal (7) from harness crankshaft. The use of force can result in bent
assembly (3). valve stems.
h. Repeat Step 1.a. through Step 1.g. in order to d. Continue to rotate the crankshaft and
remove the remaining harness assemblies. gradually release the pressure on Tooling
(A) until the piston is at the top dead center
position. The valve is now held in a position
that allows the valve spring to be safely
removed.
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Disassembly and Assembly Section
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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 rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and Personal injury can result from being struck by
Pushrod - Install” for the correct procedure. parts propelled by a released spring force.
Make sure to wear all necessary protective
i05981792 equipment.
Inlet and Exhaust Valves - Follow the recommended procedure and use all
recommended tooling to release the spring force.
Remove and Install
Removal Procedure
Table 34
Required Tools
A 27610235 Adapter 1
27610295 Head 1
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove” for the
correct procedure.
NOTICE
Keep all parts clean from contaminants.
Illustration 177 g02511756
Contaminants may cause rapid wear and shortened
component life. 4. Install Tooling (A) in position on the cylinder head in
order to compress appropriate valve spring (3).
1. Clean the bottom mating surface of the cylinder
head. Check the depth of the valves below the
face of the cylinder head before the valve springs NOTICE
Ensure that the valve spring is compressed squarely
are removed. Refer to Specifications, “Cylinder
or damage to the valve stem may occur.
Head Valves” for the correct dimensions.
2. Place a temporary identification mark on the heads 5. Apply sufficient pressure to Tooling (A) in order to
of the valves in order to identify the correct remove valve keepers (1).
position.
Note: Do not compress the spring so that valve
Note: Inlet valves have a recess in the center of the spring retainer (2) touches valve stem seal (4).
head.
6. Slowly release pressure on Tooling (A).
3. Use a suitable lifting device to position the cylinder
head with the valve springs upward. The weight of
the cylinder head is approximately 65 kg (143 lb).
Note: Ensure that the cylinder head is kept on a
clean, soft surface in order to prevent damage to the
machined face.
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Disassembly and Assembly Section
7. Place a temporary identification mark on valve c. Inspect the valve guides for wear and for
spring (3) in order to identify the correct position. damage. Refer to Specifications, “Cylinder
Head Valves” and System Operation, Testing
8. Remove valve spring retainer (2). Remove valve and Adjusting, “Valve Guide - Inspect” for
spring (3). further information.
9. Repeat Step 4 through Step 8 for the remaining d. Inspect the valves for wear and for damage.
valves. Refer to Specifications, “Cylinder Head
Valves” for further information.
10. Remove Tooling (A).
e. Inspect valve springs (3) for damage and for
11. Remove valve stem seals (4). the correct length. Refer to Specifications,
“Cylinder Head Valves” for further information.
12. Use a suitable lifting device in order to carefully
turn over the cylinder head.
Installation Procedure
Table 35
Required Tools
A 27610235 Adapter 1
27610295 Head 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
2. Lubricate the stems of valves (5) with clean engine 6. Install Tooling (A) in the appropriate position on the
oil. Install valves (5) in the appropriate positions in cylinder head in order to compress valve spring
the cylinder head. Check the depth of the valves (3).
below the face of the cylinder head. Refer to
System Operation, Testing and Adjusting, “Valve
Depth - Inspect” for more information. NOTICE
Ensure that the valve spring is compressed squarely
3. Use a suitable lifting device in order to carefully or damage to the valve stem may occur.
turn over the cylinder head. The weight of the
cylinder head is approximately 65 kg (143 lb). 7. Apply sufficient pressure to Tooling (A) in order to
install valve keepers (1).
Note: Ensure that all of the valves remain in place.
Note: Do not compress the spring so that valve
4. Install new valve stem seals (4) onto each of the spring retainer (2) touches valve stem seal (4).
valve guides.
5. Install valve spring (3) onto the cylinder head. The valve spring keepers can be thrown from the
Position valve spring retainer (2) on valve spring valve when the valve spring compressor is re-
leased. Ensure that the valve spring keepers are
(3).
properly installed on the valve stem. To help pre-
vent personal injury, keep away from the front of
the valve spring keepers and valve springs during
the installation of the valves.
Personal injury can result from being struck by
8. Carefully release the pressure on Tooling (A).
parts propelled by a released spring force.
Make sure to wear all necessary protective 9. Repeat Step 5 through Step 8 for the remaining
equipment. valves.
Follow the recommended procedure and use all 10. Remove Tooling (A) from the cylinder head.
recommended tooling to release the spring force.
End By:
a. Install the cylinder head. Refer to Disassembly and
Assembly, “Cylinder Head - Install” for the correct
procedure.
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Disassembly and Assembly Section
i05980781 2. Use Tooling (A) to remove engine oil filter (5). Refer
to Operation and Maintenance Manual, “Engine Oil
Engine Oil Filter Base - and Filter - Change” for the correct procedure.
Remove and Install 3. Remove bolts (3).
A - Strap Wrench 1
Installation Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened
Contaminants may cause rapid wear and shortened component life.
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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Place a suitable container below engine oil filter 5. Tighten bolts (3) to a torque of 22 N·m (195 lb in).
base (5) in order to catch any oil that might be
spilled.
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Disassembly and Assembly Section
6. Install a new engine oil filter (5) and check the level
of the engine lubricating oil. Refer to Operation and
Maintenance Manual, “Engine Oil Level - Check”
for the correct procedure.
i05980772
Removal Procedure
Start By:
a. Remove the Electronic Control Module (ECM).
Refer to Disassembly and Assembly, “Electronic
Control Module - Remove” for the correct
procedure.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by Illustration 183 g03701812
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de-
tailed information on the standards of cleanliness
that must be observed during ALL work on the
fuel system.
NOTICE
Keep all parts clean from contaminants.
Illustration 184 g02475493
Contaminants may cause rapid wear and shortened
component life.
2. Remove spacer (1) (not shown) from the cylinder
block.
NOTICE 3. Remove bolt (2) from the assembly of engine oil
Care must be taken to ensure that fluids are con-
cooler (3).
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be Note: Support the engine oil cooler as the bolts are
prepared to collect the fluid with suitable containers removed.
before opening any compartment or disassembling
any component containing fluids. 4. Remove the assembly of engine oil cooler (3) from
the cylinder block.
Dispose of all fluids according to local regulations and
mandates. 5. Remove gasket (4) from engine oil cooler (3).
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Disassembly and Assembly Section
Engine Oil Cooler - Install Note: The holes in the gasket have serrations that
hold the bolts captive.
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Disassembly and Assembly Section
i05981734
Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove” for the Illustration 189 g02476517
correct procedure.
1. Remove bolts (2). Remove suction pipe (1) from
NOTICE engine oil pump (4).
Keep all parts clean from contaminants.
2. Remove gasket (3).
Contaminants may cause rapid wear and shortened
component life. 3. Remove bolts (5) and remove the assembly of
engine oil pump (4) from the cylinder block.
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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
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116 UENR4491
Disassembly and Assembly Section
i05981733
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 191 g02476518
Contaminants may cause rapid wear and shortened
component life. 2. If necessary, follow Step 2.a. through Step 2.f. in
order to assembly engine oil pump (4).
NOTICE a. Lubricate the internal components for the
If any part of the engine oil pump is worn or damaged, assembly of engine oil pump (4) with clean
the complete assembly of the engine oil pump must
engine oil.
be replaced.
b. Install outer rotor (7) to the housing of engine
1. Ensure that all components of the engine oil pump oil pump (4).
are clean and free from wear and damage. Refer
to System Operation, Testing and Adjusting, c. Install front cover assembly (8) to the housing
“Engine Oil Pump - Inspect” for more information. of the engine oil pump (4).
Replace the complete assembly of the engine oil d. Install bolts (9) to front cover assembly (8).
pump if any of the components are worn or Tighten the bolts finger tight.
damaged.
e. Tighten bolts (9) to a torque of 24 N·m
(212 lb in).
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Disassembly and Assembly Section
i05981922
Removal Procedure
Start By:
a. Remove the fan and the fan pulley. Refer to
Disassembly and Assembly, “Fan - Remove and
Install” 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 192 g02476517 tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
3. Position the assembly of engine oil pump (4) onto prepared to collect the fluid with suitable containers
the cylinder block. before opening any compartment or disassembling
any component containing fluids.
Note: Ensure that the dowels in the housing of the
engine oil pump are aligned with the holes in the Dispose of all fluids according to local regulations and
cylinder block. mandates.
6. Position a new gasket (3) onto suction pipe (1). 2. Loosen the hose clamps and remove the hose
Install the assembly of suction pipe (1) onto the from the water pump inlet.
assembly of engine oil pump (4).
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118 UENR4491
Disassembly and Assembly Section
Installation Procedure
Table 37
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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UENR4491 119
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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
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120 UENR4491
Disassembly and Assembly Section
i05981925
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
Illustration 198 g01985813 prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
3. Clean the gasket surface of housing (3). any component containing fluids.
Dispose of all fluids according to local regulations and
4. Install Tooling (A) in Position (X). mandates.
5. Use Tooling (A) in order to align new gasket (2) to
housing (3). Install the gasket onto the housing. 1. Drain the coolant from the cooling system to a level
below the water temperature regulator, into a
6. Align water pump (1) to Tooling (A). Install the suitable container for storage or for disposal. Refer
water pump to housing (1). to Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct draining
Note: Ensure that the gear of the water pump and the
gear of the fuel injection pump mesh. procedure.
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Disassembly and Assembly Section
3. Remove bolts (2) from water temperature regulator Note: Ensure the correct orientation of the water
housing (1). temperature regulator housing.
4. Remove water temperature regulator housing (1) 4. Install bolts (2). Tighten the bolts to a torque of
from the cylinder head. 22 N·m (195 lb in).
Note: Note the orientation of the water temperature 5. Connect the upper radiator hose and tighten the
regulator housing. hose clamps.
Installation Procedure 6. Fill the cooling system to the correct level. Refer to
Operation and Maintenance Manual, “Cooling
NOTICE System Coolant - Check” and Operation and
Keep all parts clean from contaminants. Maintenance Manual, “Cooling System Coolant -
Change” for the correct filling procedure.
Contaminants may cause rapid wear and shortened
component life.
i05981749
Start By:
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - 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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122 UENR4491
Disassembly and Assembly Section
i05981748
Flywheel - Install
Installation Procedure
Table 39
Illustration 201 g01336668 Required Tools
Typical example
Tool Part Number Part Description Qty
1. Remove bolts from Position (X) on flywheel (1). Guide Studs
A - 2
1/2 inch - UNF by 4 inch
2. Install Tooling (A) in Position (X) on flywheel (1).
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Disassembly and Assembly Section
2. Inspect the crankshaft rear seal for leaks. If there Crankshaft Rear Seal - Remove
are any oil leaks, replace the crankshaft rear seal.
Refer to Disassembly and Assembly, “Crankshaft
Rear Seal - Remove” for the correct procedure.
Removal Procedure
Table 40
Required Tools
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - 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 204 g01336668 tained during performance of inspection, mainte-
Typical example nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
3. Install a suitable lifting device on flywheel (1). The before opening any compartment or disassembling
flywheel can weigh 71 kg (156 lb). any component containing fluids.
4. Install Tooling (A) in Position (X) on the crankshaft. Dispose of all fluids according to local regulations and
mandates.
5. Use the lifting device to position flywheel (1) onto
Tooling (A).
Note: The crankshaft rear seal and the housing are
6. If necessary, install pilot bearing (3) and bolts (2) to manufactured as a one-piece assembly. The
assembly is not serviceable. If the crankshaft rear
flywheel (1).
seal is removed, the assembly must be replaced.
7. Install bolts (4) to flywheel (1).
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Disassembly and Assembly Section
i05980590
Installation Procedure
Table 41
Required Tools
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Disassembly and Assembly Section
Guide Stud
A - M10 by 100 mm 2
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - 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
Guide Studs
A - 2
M10 by 100 mm
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
2. Ensure that the bolts are clean and free from oil
or grease. Ensure that all threaded holes in the
cylinder block are clean and free from oil or
grease.
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128 UENR4491
Disassembly and Assembly Section
Required Tools
Guide Studs
A - 2
M10 by 100 mm
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove” for the correct
procedure.
NOTICE
Illustration 215 g01984554 Keep all parts clean from contaminants.
Identification of the bolt Grade.
Contaminants may cause rapid wear and shortened
13. When 8.8 Graded bolts are installed, follow Step component life.
13.a. through Step 13.b..
i05981751
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UENR4491 129
Disassembly and Assembly Section
2. Install Tooling (A) into Position (X) on flywheel 7. If necessary, remove dowels (4) from the cylinder
housing (1). block.
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
i05982959
NOTICE
Keep all parts clean from contaminants.
Crankshaft Pulley - Remove
Contaminants may cause rapid wear and shortened
and Install component life.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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132 UENR4491
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
i05980464
Removal Procedure
Table 49
Required Tools
A - Combination Puller 1
Start By:
a. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft Front
Pulley- Remove and Install” for the correct
procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 226 g02445197
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134 UENR4491
Disassembly and Assembly Section
1. Install the legs of Tooling (A) behind crankshaft 2. Assemble Tooling (B).
front seal (2). Install a suitable spacer between
Tooling (A) and the crankshaft. 3. Correctly position a new crankshaft front seal (2) to
front cover (1).
2. Use Tooling (A) in order to pull crankshaft front seal
(2) out of front cover (1). Note: If the crankshaft front seal is supplied with a
sleeve, remove the sleeve from the crankshaft front
Note: Do not damage the edge of the front cover for seal before installation.
the crankshaft front seal.
4. Use Tooling (B) to install crankshaft front seal (2) to
Installation Procedure front cover (1). Ensure that the front face of the
crankshaft front seal is installed to a depth of
Table 50
6.5 ± 0.2 mm (0.256 ± 0.008 inch).
Required Tools
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Disassembly and Assembly Section
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136 UENR4491
Disassembly and Assembly Section
10. Remove Tooling (B) from the front cover. 3. Remove front cover (1) from front housing (5).
End By: 4. Remove gasket (2).
a. Install the crankshaft pulley. Refer to Disassembly
and Assembly, “Crankshaft Pulley - Remove and Installation Procedure
Install” for the correct procedure. Table 52
Required Tools
b. If the engine has a fan, install the fan. Refer to
Disassembly and Assembly, “Fan - Remove and Tool Part Number Part Description Qty
Install” for the correct procedure.
Guide Studs
A - M8 by 70 mm 2
i05981753
Install
(Heavy Duty Front Cover)
Removal Procedure
Start By:
a. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft Pulley -
Remove and Install” for the correct procedure.
b. If the engine has a fan, remove the fan. Refer to
Disassembly and Assembly, “Fan - Remove and
Install” for the correct procedure.
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UENR4491 137
Disassembly and Assembly Section
7. Install bolts (3) and bolts (4) finger tight. Ensure Start By:
that the bolts of different length are installed in the
correct positions. a. Remove the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install” for
the correct procedure.
8. Use Tooling (B) to align the front cover assembly.
b. Remove the valve mechanism cover. Refer to
9. Remove Tooling (A) and install the remaining bolts. Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install” for the correct
10. Tighten bolts (3) and bolts (4) to a torque of procedure.
22 N·m (195 lb in).
NOTICE
11. Remove Tooling (B). Keep all parts clean from contaminants.
12. Install a new front seal to the front cover. Refer to Contaminants may cause rapid wear and shortened
Disassembly and Assembly, “Crankshaft Front component life.
Seal - Remove and Install” for the correct
procedure.
NOTICE
End By: Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
a. Install the crankshaft pulley. Refer to Disassembly nance, testing, adjusting and repair of the product. Be
and Assembly, “Crankshaft Pulley - Remove and prepared to collect the fluid with suitable containers
Install” for the correct procedure.
before opening any compartment or disassembling
b. If the engine has a fan, install the fan. Refer to any component containing fluids.
Disassembly and Assembly, “Fan - Remove and
Install” for the correct procedure. Dispose of all fluids according to local regulations and
mandates.
i05981767
Note: Care must be taken in order to ensure that the
Gear Group (Front) - Remove fuel injection pump timing is not lost during the
and Install removal of the front gear group. Carefully follow the
procedure in order to remove the gear group.
Removal Procedure
Table 53
Required Tools
27610291 Housing 1
A
27610289 Engine Turning Tool 1
Timing Pin
C T400015 1
(Fuel Injection Pump)
Timing Pin
27610286 1
(Crankshaft)
D
27610287 Adapter 1
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138 UENR4491
Disassembly and Assembly Section
5. Use Tooling (E) in order to loosen threaded inserts 9. Use Tooling (C) in order to lock the fuel injection
(4) on all rocker arms (3). Unscrew threaded pump gear in the correct position. Refer to
inserts (4) on all rocker arms (3) until all valves are Disassembly and Assembly, “Fuel Injection Pump -
fully closed. Remove” for the correct procedure.
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
10. Mark gear (5), gear (6), gear (7) and gear (8) in
order to show alignment. Refer to Illustration 236 .
Note: Identification will ensure that the gears can be
installed in the original alignment.
Table 54
2. If necessary, install Tooling (D) into Hole (W) in the
Required Tools
cylinder block. Use Tooling (D) in order to lock the
Tool Part Number Part Description Qty crankshaft in the correct position. Refer to System
Operation, Testing and Adjusting, “Finding Top
27610291 Housing 1
A Center Position for No.1 Piston” for the correct
27610289 Engine Turning Tool 1 procedure.
Timing Pin
B 27610212 1 Note: Do not use excessive force to install Tooling
(Camshaft)
(D). Do not use Tooling (D) to hold the crankshaft
Timing Pin during repairs.
C T400015 1
(Fuel Injection Pump)
3. Ensure that all of the components of the front gear
Timing Pin
27610286 1 group are clean and free from wear and damage. If
(Crankshaft)
D necessary, replace any components that are worn
27610287 Adapter 1 or damaged.
E 27610307 T40 Torx Socket 1
21825617 Dial Indicator 1
F
- Magnetic Base and Stand 1
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Disassembly and Assembly Section
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Disassembly and Assembly Section
8. Ensure that the fuel injection pump is locked in the 12. Use Tooling (F) in order to measure the backlash
correct position. Refer to Disassembly and for gear (5), gear (6), gear (7) and gear (8). Refer
Assembly, “Fuel Injection Pump - Install” for the to Specifications, “Gear Group (Front)” for further
correct procedure. information.
9. Remove Tooling (B) and Tooling (C). 13. Lubricate each gear with clean lubricating engine
oil.
10. When bolt (10) is a 8.8 Grade. Tighten bolt (10)
for camshaft gear (5) to a torque of 95 N·m 14. If necessary, use Tooling (A) in order to rotate the
(70 lb ft). crankshaft so that number one piston is at top
dead center on the compression stroke. Refer to
When bolt (10) is a 10.9 Grade. Tighten bolt (10) System Operation, Testing and Adjusting, “Finding
for camshaft gear (5) to a torque of 120 N·m Top Center Position for No.1 Piston” for the correct
(89 lb ft). procedure. If necessary, use Tooling (D) in order to
11. Use Tooling (F) in order to check the end play of lock the crankshaft so that number one piston is at
the camshaft gear. Refer to Specifications, top dead center on the compression stroke.
“Camshaft” for more information. 15. Remove Tooling (D).
NOTICE
Failure to ensure that the crankshaft is positioned at
the safe position will result in interference between
the pistons and the valves. Interference between the
pistons and the valves will result in damage to the
engine.
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142 UENR4491
Disassembly and Assembly Section
17. Use Tooling (E) in order to tighten threaded 19. Install a new O-ring seal (1) to plug (2). Install the
inserts (4) on all rocker arms (3). Tighten the plug into Hole (W) in the cylinder block. Tighten
threaded inserts to a torque of 30 N·m (265 lb in). plug (2) to a torque of 21 N·m (186 lb in).
Removal Procedure
Table 55
Required Tools
27610291 Housing 1
A
27610289 Engine Turning Tool 1
Timing Pin
B 27610212 1
(Camshaft)
Timing Pin
C T400015 1
(Fuel Injection Pump)
(continued)
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Disassembly and Assembly Section
(Table 55, contd) Note: Do not use excessive force to install Tooling
Timing Pin (D). Do not use Tooling (D) to hold the crankshaft
27610286 1 during repairs.
(Crankshaft)
D
27610287 Adapter 1
Start By:
a. Remove the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install” for
the correct procedure.
b. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install” 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 246 g02486477
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be 5. Remove plug (1) from the cylinder block. Remove
prepared to collect the fluid with suitable containers O-ring seal (2) from the plug.
before opening any compartment or disassembling
any component containing fluids. 6. Use Tooling (A) in order to rotate the crankshaft so
that number one piston is at top dead center on the
Dispose of all fluids according to local regulations and
mandates. compression stroke. Refer to System Operation,
Testing and Adjusting, “Finding Top Center
Position for No.1 Piston” for the correct procedure.
Note: Care must be taken in order to ensure that the Install Tooling (D) through Hole (W) in order to lock
fuel injection pump timing is not lost during the the crankshaft so that number one piston is at top
removal of the front gear group. Carefully follow the dead center on the compression stroke.
procedure in order to remove the gear group.
7. Remove Tooling (D).
1. If the air compressor is equipped with a hydraulic
pump, remove the hydraulic pump. Refer to 8. Use Tooling (A) in order to rotate the crankshaft in
Original Equipment Manufactures (OEM) for the a clockwise direction and position the crankshaft at
correct procedure. the safe position. Refer to System Operation,
Testing and Adjusting, “Position the Valve
2. If the engine is equipped with an air compressor, Mechanism Before Maintenance Procedures” for
remove the air compressor. Refer to Disassembly the correct procedure.
and Assembly, “Air Compressor - Remove” for the
correct procedure.
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144 UENR4491
Disassembly and Assembly Section
9. Use Tooling (E) in order to loosen threaded inserts 11. Install Tooling (B) through Hole (X) in camshaft
(4) on all rocker arms (3). Unscrew threaded gear (5) into the front housing. Use Tooling (B) in
inserts (4) on all rocker arms (3) until all valves are order to lock the camshaft in the correct position.
fully closed. Refer to System Operation, Testing and Adjusting,
“Finding Top Center Position for No.1 Piston” for
Note: Ensure that ALL threaded inserts are fully the correct procedure.
unscrewed.
12. Use Tooling (C) in order to lock the fuel injection
10. Use Tooling (A) in order to rotate the crankshaft
pump gear in the correct position. Refer to
so that number one piston is at top dead center on
Disassembly and Assembly, “Fuel Injection Pump -
the compression stroke. Refer to System
Remove” for the correct procedure.
Operation, Testing and Adjusting, “Finding Top
Center Position for No.1 Piston” for the correct
procedure. Install Tooling (D) through Hole (W) in
order to lock the crankshaft so that number one
piston is at top dead center on the compression
stroke. Refer to Illustration 262 .
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Disassembly and Assembly Section
17. Mark gear (5), gear (15), gear (16) and gear (17)
in order to show alignment. Refer to Illustration 251
.
16. If necessary, follow Step 16.a. through Step 16.b. 18. Remove camshaft gear (6). Refer to Disassembly
in order to disassemble gear assembly (10). and Assembly, “Camshaft Gear - Remove and
Install” for the correct procedure.
a. Remove circlip (12) from gear assembly (10).
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146 UENR4491
Disassembly and Assembly Section
23. Remove idler gear (25) and idler gear hub (24)
from front housing (11).
Installation Procedure
Table 56
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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148 UENR4491
Disassembly and Assembly Section
18. Use Tool (H) in order to check the end play of the
camshaft gear. Refer to Specifications, “Camshaft”
for more information.
19. Use Tool (H) in order to check the end play of the
idler gears. Refer to Specifications, “Gear Group
(Front)” and refer to Disassembly and Assembly,
“Idler Gear - Remove and Install” for further
information.
Illustration 257 g03706903
20. Use Tooling (H) in order to measure the backlash
12. Install camshaft gear (5). Ensure that the for gear (5), gear (15), gear (16) and gear (17).
camshaft gear and the idler gear timing marks are Refer to Specifications, “Gear Group (Front)” for
correctly aligned. further information.
13. Install Tooling (B) through Hole (X) in camshaft
gear (6) into the front housing.
14. Loosely install bolt (27) and washer (26) for the
camshaft gear. Refer to Disassembly and
Assembly, “Camshaft Gear - Remove and Install”
for the correct procedure.
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UENR4491 149
Disassembly and Assembly Section
21. If necessary, follow Step 21.a. through Step 21.c. 22. Install gear assembly (10) to front housing (11).
in order to assemble gear assembly (10). Ensure that the shaft of gear assembly (10) is
correctly aligned with the bearing in front housing
a. Apply a small continuous bead of Tooling (G) (11).
to inner Surface (Z) of bearing (13). Place the
inner race of bearing (13) onto a suitable 23. Install circlip (9) to front housing (11).
support. Press the shaft of gear (14) into
bearing (13) until the shoulder of the gear is Note: Ensure that the circlip is correctly located in the
front housing.
against the bearing. Remove any excess
bearing mount compound. 24. Ensure that there is tactile backlash between the
b. Install circlip (12) to gear assembly (10). camshaft gear and the accessory drive gear.
NOTICE
Failure to ensure that the crankshaft is positioned at
the safe position will result in interference between
the pistons and the valves. Interference between the
pistons and the valves will result in damage to the
engine.
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150 UENR4491
Disassembly and Assembly Section
31. Install a new O-ring seal (1) to plug (2). Install the
plug into Hole (W) in the cylinder block. Tighten
plug (2) to a torque of 21 N·m (186 lb in).
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Disassembly and Assembly Section
i05981781
Removal Procedure
Table 57
Required Tools
27610291 Housing 1
(1) A
27610289 Engine Turning Tool 1
Timing Pin
B T400015 1
(Fuel Injection Pump)
Timing Pin
C 27610212 1
(Camshaft)
Timing Pin
27610286 1
(Crankshaft)
D
Illustration 263 g02485936
27610287 Adapter 1
Start By:
a. Remove the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install” for
the correct procedure.
b. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install” for the correct
procedure.
Note: Care must be taken in order to ensure that the
fuel injection pump timing is not lost during the
removal of the fuel pump gear. Carefully follow the
procedure in order to remove the fuel pump gear.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life. Illustration 264 g01994553
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152 UENR4491
Disassembly and Assembly Section
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Disassembly and Assembly Section
i05981780
Installation Procedure
Table 58
Required Tools
27610291 Housing 1
(1) A
27610289 Engine Turning Tool 1
Timing Pin
B T400015 1
(Fuel Injection Pump)
Timing Pin
C 27610212 1
(Camshaft)
Timing Pin
27610286 1
(Crankshaft)
D
Illustration 268 g02491276
27610287 Adapter 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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154 UENR4491
Disassembly and Assembly Section
6. Clean hub (9) and inspect the hub for wear and
damage. Refer to Specifications, “Gear Group
(Front)” for more information. If necessary, replace
the hub.
7. Lubricate hub (9) with clean engine oil. Install hub
(9) into the recess in the front housing. Ensure that
oil Hole (Z) is to the top of the hub.
8. Install idler gear (4) onto hub (9). Ensure that the
timing marks are toward the front of the idler gear.
11. Lubricate plate (8) with clean engine oil. Align the
holes in plate (8) with the holes in hub (9). Install
the plate in the original orientation.
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Disassembly and Assembly Section
14. Use Tooling (F) in order to check the end play for
the idler gear. Refer to Specifications, “Gear Group
(Front)” for more information.
NOTICE 20. Ensure that the guides for the pushrods are
Failure to ensure that the crankshaft is set in the safe correctly positioned on the threaded inserts (5).
position will result in interference between the pistons Use Tooling (E) in order to tighten threaded inserts
and the valves. Interference between the pistons and (5) on all rocker arms (6). Tighten the threaded
the valves will result in damage to the engine. inserts to a torque of 30 N·m (265 lb in).
Note: When the threaded insert is tightened, the
19. Use Tooling (A) in order to rotate the crankshaft in threaded insert must be seated correctly into the cup
a clockwise direction and position the crankshaft at for the pushrod.
the safe position. Refer to System Operation,
Testing and Adjusting, “Position the Valve 21. The engine should not be operated for a period 45
Mechanism Before Maintenance Procedures” for minutes after the threaded inserts on all the rocker
the correct procedure. arms have been tightened. This period will allow
the force of the valve springs to purge off
excessive engine oil from the hydraulic lifters.
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Disassembly and Assembly Section
i05981778
Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install” for the
correct procedure.
b. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft Pulley -
Remove and Install” for the correct procedure.
c. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove” for the
correct procedure.
d. If the engine has an accessory drive, remove the
accessory drive. Refer to Disassembly and
Illustration 274 g02485936 Assembly, “Accessory Drive - Remove and Install”
for the correct procedure.
22. Position a new O-ring seal (2) onto plug (1). Install
the plug to the cylinder block and tighten the plug e. Remove the water pump. Refer to Disassembly
to a torque of 21 N·m (186 lb in). and Assembly, “Water Pump - Remove” for the
correct procedure.
End By:
f. Remove the timing gears. Refer to Disassembly
a. Install the front cover. Refer to Disassembly and and Assembly, “Gear Group (Front) - Remove and
Assembly, “Front Cover - Remove and Install” for Install” for the correct procedure.
the correct procedure.
g. Remove the fuel injection pump. Refer to
b. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Fuel Injection Pump -
Disassembly and Assembly, “Valve Mechanism Remove” for the correct procedure.
Cover - Remove and Install” 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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
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Disassembly and Assembly Section
1. Slide locking tab (1) (not shown) into the unlocked 6. Remove bolts (10), bolts (11) and bolts (12) from
position. front housing (7).
2. Disconnect harness assembly (2) from coolant Note: The bolts are three different lengths. Note the
temperature sensor (3). positions of the different bolts.
3. Cut cable strap (4) and remove harness assembly 7. Remove front housing (7) from the cylinder block.
(2) from bypass tube (5).
8. Remove gasket (13).
4. Remove bolts (6) that secure bypass tube (5) to
front housing (7).
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i05981774
Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install” for the
correct procedure.
b. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft Pulley -
Remove” for the correct procedure.
c. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove” for the
correct procedure.
d. If the engine has an accessory drive, remove the Illustration 278 g02490356
accessory drive. Refer to Disassembly and
Assembly, “Accessory Drive - Remove and Install” 1. Slide locking tab (1) (not shown) into the unlocked
for the correct procedure. position.
e. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove” for the 2. Disconnect harness assembly (2) from coolant
correct procedure. temperature sensor (3).
f. Remove the timing gears. Refer to Disassembly 3. Cut cable strap (4) and remove harness assembly
and Assembly, “Gear Group (Front) - Remove and (2) from bypass tube (5).
Install” for the correct procedure.
4. Remove bolts (6) that secure bypass tube (5) to
g. Remove the fuel injection pump. Refer to
Disassembly and Assembly, “Fuel Injection Pump - front housing (7).
Remove” for the correct procedure.
5. Remove bypass tube (5) from the cylinder head.
NOTICE Remove O-ring seal (8) and O-ring seal (9) from
Keep all parts clean from contaminants. bypass tube (5).
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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
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Disassembly and Assembly Section
6. Remove bolts (11), bolts (12) and bolts (13) from 10. Remove thrust washer (15) from cylinder block
front housing (7). (16).
7. Remove front housing (7) from the cylinder block. Housing (Front) - Install
8. Remove gasket (14).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Ensure that the wiring harness assembly is correctly
routed and the cable straps are not over tightened.
Over tightening of the cable straps will damage the
wiring harness and the convoluting.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
9. Install bolts (12) to front housing (7) finger tight. 14. Install a new O-ring seal (8) and a new O-ring seal
(9) to bypass tube (5). Use Tooling (D) in order to
10. Remove Tooling (B). lubricate the O-ring seals.
11. Loosely install bolts (10) and bolts (11). Refer to 15. Install bypass tube (5) to the cylinder head. Install
Illustration 283 for the correct position of the bolts. bolts (6). Tighten the bolts to a torque of 9 N·m
(80 lb in).
12. Tighten bolts (10), bolts (11) and bolts (12) in the
sequence that is shown in Illustration 284 to a 16. Connect harness assembly (2) to coolant
torque of 28 N·m (248 lb in). temperature sensor (3).
13. Remove Tooling (C) from the cylinder block. 17. Slide locking tab (1) (not shown) into the locked
position.
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End By:
NOTICE
a. Install the fuel injection pump. Refer to Keep all parts clean from contaminants.
Disassembly and Assembly, “Fuel Injection Pump -
Install” for the correct procedure. Contaminants may cause rapid wear and shortened
component life.
b. Install the timing gears. Refer to Disassembly and
Assembly, “Gear Group (Front) - Install” for the
correct procedure. NOTICE
Ensure that the wiring harness assembly is correctly
c. If the engine has an accessory drive, install the routed and the cable straps are not over tightened.
accessory drive. Refer to Disassembly and Over tightening of the cable straps will damage the
Assembly, “Accessory Drive - Remove and Install”
for the correct procedure. wiring harness and the convoluting.
d. Install the engine oil pan plate. Refer to 1. Ensure that the front housing is clean and free from
Disassembly and Assembly, “Engine Oil Pan Plate
- Remove” for the correct procedure. damage. If necessary, replace the front housing.
e. Install the crankshaft pulley. Refer to Disassembly If necessary, install blanking plugs to a new front
and Assembly, “Crankshaft Pulley - Install” for the housing. Use Tooling (A) in order to seal all D-
correct procedure. plugs.
f. Install the water pump. Refer to Disassembly and 2. Clean all the gasket surfaces of the cylinder block.
Assembly, “Water Pump - Install” for the correct
procedure.
g. Install the fan. Refer to Disassembly and Assembly,
“Fan - Remove and Install” for the correct
procedure.
h. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Fill” for the correct procedure.
i05981771
Installation Procedure
Table 60
Required Tools
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Disassembly and Assembly Section
18. Slide locking tab (1) (not shown) into the locked
position.
13. Tighten bolts (11), bolts (12) and bolts (13) in the
sequence that is shown in Illustration 290 to a
torque of 28 N·m (248 lb in).
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End By:
NOTICE
a. Install the fuel injection pump. Refer to Care must be taken to ensure that fluids are con-
Disassembly and Assembly, “Fuel Injection Pump - tained during performance of inspection, mainte-
Install” for the correct procedure. nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
b. Install the timing gears. Refer to Disassembly and before opening any compartment or disassembling
Assembly, “Gear Group (Front) - Install” for the any component containing fluids.
correct procedure.
Dispose of all fluids according to local regulations and
c. If the engine has an accessory drive, install the mandates.
accessory drive. Refer to Disassembly and
Assembly, “Accessory Drive - Remove and Install”
for the correct procedure. 1. If necessary, remove the OEM driven equipment
from the auxiliary drive.
d. Install the engine oil pan . Refer to Disassembly
and Assembly, “Engine Oil Pan - Install” for the
correct procedure.
e. Install the crankshaft pulley. Refer to Disassembly
and Assembly, “Crankshaft Pulley - Install” for the
correct procedure.
f. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install” for the correct
procedure.
g. Install the fan. Refer to Disassembly and Assembly,
“Fan - Remove and Install” for the correct
procedure.
h. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Fill” for the correct procedure.
i05980405
Removal Procedure
Table 61
Required Tools
- Bearing Puller 1
- Puller 1
A
- Crossblock 1
- Puller Leg 2
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 62
Required Tools
Illustration 293 g02418257
Tool Part Number Part Description Qty
2. If OEM driven equipment has not been installed to Loctite 603 Retaining
B - -
the auxiliary drive, remove bolts (1). Remove cover Compound
plate (2) and remove gasket (3) (not shown). Loctite 242 Thread Lock
C - 1
Compound
3. Remove allen head screws (4) from accessory
drive housing (5). Remove allen head screw (6)
from accessory drive housing (5). NOTICE
Keep all parts clean from contaminants.
4. Remove accessory drive housing (5) from the front
housing. Contaminants may cause rapid wear and shortened
component life.
5. Remove gasket (7) from accessory drive housing
(5).
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i05980404
Removal Procedure
Table 63
Illustration 298 g02418257
Required Tools
5. Apply Tooling (C) to allen head screws (4) and Tool Part Number Part Description Qty
allen head screw (6). Install allen head screws (4)
and allen head screw (6) to accessory drive - Bearing Puller 1
housing (5). - Puller 1
A
6. Tighten allen head screws (4) to a torque of 22 N·m - Crossblock 1
(195 lb in). - Puller Leg 2
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Disassembly and Assembly Section
NOTICE
Installation Procedure
Care must be taken to ensure that fluids are con- Table 64
tained during performance of inspection, mainte- Required Tools
nance, testing, adjusting and repair of the product. Be
Tool Part Number Part Description Qty
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling Loctite 603 Retaining
any component containing fluids. B - -
Compound
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
3. If necessary, follow Step 3.a. through Step 3.c. in 1. If necessary, follow Step 1.a. through Step 1.e. in
order to disassemble the accessory drive. order to assemble the accessory drive.
a. Remove circlip (8) from accessory drive a. Inspect the condition of the teeth and the
housing (2). splines of gear (5) for wear and damage.
Inspect bearing (7), bearing (4), and circlip (8).
b. Place accessory drive housing (2) onto a Inspect the front housing for wear and
suitable support. Press the assembly of gear damage. Replace any components that are
(5) and bearing (7) and bearing (4) out of worn or damaged.
accessory drive housing (2). Use Tooling (A) in
order to remove bearing (7) and bearing (4) b. Apply a small continuous bead of Tooling (B)
from gear (5). to inner Surface (Y) of bearing (4). Place the
gear shaft on a suitable support. Press on the
c. Remove gasket (1) from accessory drive inner race of bearing (4) until bearing (4) is
housing (2). against the shoulder of gear (5). Remove any
excess compound.
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Disassembly and Assembly Section
i05980459
c. Apply a small continuous bead of Tooling (B)
to inner Surface (Z) of bearing (7). Place the Crankcase Breather - Remove
inner race of bearing (7) onto a suitable
support. Press the shaft of gear (5) into
bearing (7) until the shoulder of the gear is Removal Procedure
against the bearing. Remove any excess
compound. NOTICE
When disconnecting and connecting the plastic tube
d. Apply a small continuous bead of Tooling (B)
assemblies for the crankcase breather system, the
to the outer Surface (X) of bearing (7) and plastic tube assemblies should not be twisted. Twist-
bearing (4). Place accessory drive housing (2) ing of the plastic tube assemblies will result in the
on a suitable support. Press the assembly of seals being damaged. Damaged to seals will result in
the gear into the accessory drive housing. leakage.
Ensure that bearing (4) is against the front face
of the recess in accessory drive housing (2).
Remove any excess compound. NOTICE
Keep all parts clean from contaminants.
e. Install circlip (8) into the groove in accessory
drive housing (2). Ensure that circlip (8) is Contaminants may cause rapid wear and shortened
correctly positioned in the groove. component life.
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i05980456
Installation Procedure
Illustration 304 g02439738
NOTICE
When disconnecting and connecting the plastic tube
7. If necessary, follow Step 7.a. through Step 7.b. in assemblies for the crankcase breather system, the
order to remove valve (9) from the cylinder block. plastic tube assemblies should not be twisted. Twist-
ing of the plastic tube assemblies will result in the
a. Remove bolt (11) from valve (9). seals being damaged. Damaged to seals will result in
leakage.
b. Remove valve (9) from the cylinder block.
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NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
i05981919
5. Connect plastic tube assembly (7) to breather
canister (3) and valve (9) in the cylinder block. Valve Mechanism Cover
6. Connect harness assembly (8) to the fuel -Remove and Install
temperature sensor.
Removal Procedure
Start By:
a. If the Clean Emission Module (CEM) is mounted on
the valve mechanism cover. Removal of the CEM
will be necessary in order to access the valve
mechanism cover. Refer to Disassembly and
Assembly, “Support and Mounting (CEM) -
Remove and Install” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Remove bolts (1) and bolts (4) from bracket (2) and
bracket (3). Position brackets and harness
assembly away from valve mechanism cover (7).
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Disassembly and Assembly Section
Installation Procedure Note: Ensure that the gasket is fully seated into the
groove of the valve mechanism cover.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
i05981813
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Disassembly and Assembly Section
Start By:
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install” for the correct
procedure.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
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
1. Make an identification mark on each rocker arm 8. If necessary, follow Step 8.a. through Step 8.b. in
assembly in order to show the location. order to remove threaded inserts (1) from the
rocker arms.
Note: The components must be reinstalled in the
original location. Do not interchange components. a. Make a temporary identification mark on each
threaded inserts (1) in order to show the
location.
i05981807
Assembly 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
Note: The rocker arm assembly for the inlet valve is 27610291 Housing 1
longer than the rocker arm assembly for the exhaust A(2)
27610289 Engine Turning Tool 1
valve. Used components should be installed in the
original location. B - T40 Torx Socket 1
C - E10 Torx Socket 1
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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
NOTICE
Damage to the engine will occur if all threaded inserts
are not fully unscrewed.
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Disassembly and Assembly Section
Removal Procedure
Table 67
Required Tools
Start By:
a. If necessary, remove the secondary fuel filter and
the fuel filter base. Refer to Disassembly and
Assembly, “Fuel Filter Base - Remove and Install”
for the correct procedure.
b. If necessary, remove the water separator and fuel
filter (Primary). Refer to Disassembly and
Assembly, “Fuel Water Separator and Fuel Filter
(Primary) - Remove and Install” for the correct
procedure.
c. Remove the exhaust manifold. Refer to
Disassembly and Assembly, “Exhaust Manifold - Illustration 330 g02452914
Remove and Install” for the correct procedure.
d. Remove the fuel manifold. Refer to Disassembly 2. Disconnect the upper radiator hose from water
and Assembly, “Fuel Manifold (Rail) - Remove and temperature regulator housing (1) on the cylinder
Install” for the correct procedure. head.
e. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove” for the correct procedure.
f. Remove the glow plugs. Refer to Disassembly and
Assembly, “Glow Plugs - 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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Disassembly and Assembly Section
3. Follow Step 3.a. through Step 3.b. in order to 6. Disconnect plastic tube assembly (8) and plastic
disconnect harness assembly (7) from boost tube assembly (11) from tube assembly (15). Use
pressure sensor (5). Tooling (A) in order to plug the plastic tube
assemblies and to cap the tube assembly.
a. Slide the locking tab into unlocked position (4).
7. Disconnect hose assembly (13) from connection
b. Disconnect harness assembly (7) from boost on tube assembly (15). Remove O-ring seal (14)
pressure sensor (5). (not shown). Use Tooling (A) in order to plug the
hose assembly and to cap the tube assembly.
4. Follow Step 4.a. through Step 4.b. in order to
disconnect harness assembly (6) from inlet air 8. Use a suitable tool in Position (X) in order to hold
temperature sensor (3). tube assembly (15) as nut (12) is loosened.
Remove bolt (16) from tube assembly (15).
a. Slide the locking tab into unlocked position (2).
9. Remove tube assembly (15) from the bracket and
b. Disconnect harness assembly (6) from inlet air
the cylinder head. Use Tooling (A) in order to plug
temperature sensor (3).
the cylinder head and to cap the tube assembly.
5. Remove all cable straps that secure harness
10. Remove O-ring seal (15) from tube assembly
assembly to the cylinder head. The harness
(17).
assembly should be positioned away from the
cylinder head in order to avoid causing an
obstruction during the removal of the cylinder
head.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
NOTICE
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.
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Disassembly and Assembly Section
i05980636
Installation Procedure
Table 68
Required Tools
Guide Studs
A - 2
M16 by 115mm
NOTICE
Keep all parts clean from contaminants.
Illustration 338 g02460199
Contaminants may cause rapid wear and shortened
component life. 3. Inspect dowels (35) for damage. If necessary,
replace the dowels in the cylinder block.
NOTICE 4. Install Tooling (A) to the cylinder block.
Ensure that the wiring harness assembly is correctly
routed and the cable straps are not over tightened. 5. Align cylinder head gasket (36) with dowels (35).
Over tightening of the cable straps will damage the Install cylinder head gasket (36) onto the cylinder
wiring harness convoluting. block.
1. Thoroughly clean the gasket surfaces of the 6. Use a suitable lifting device to lift cylinder head.
cylinder head and the cylinder block. Do not The weight of the cylinder head is approximately
damage the gasket surfaces of the cylinder head 66 kg (146 lb).
of the cylinder block. Ensure that no debris enters Note: A spreader bar must be used in order to
the cylinder bores, the coolant passages, or the distribute the weight of the cylinder head during the
lubricant passages. lifting operation.
2. Inspect the gasket surface of the cylinder head for 7. Use Tooling (A) to align the cylinder head with the
distortion. Refer to Specifications, “Cylinder Head” cylinder block. Install the cylinder head to the
for more information. If the gasket surface of the cylinder block.
cylinder head is distorted beyond maximum
permitted limits, replace the cylinder head. Note: Ensure that the cylinder head is correctly
positioned on dowels (35).
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Disassembly and Assembly Section
22. Loosely install bolt (16) to tube assembly (15). 30. Position the harness assembly onto the cylinder
Loosely tighten nut (12) on connection for tube head. Use new cable straps in order to secure the
assembly (15). harness assembly to the cylinder head. Ensure
that cable straps meet the OEM specification.
23. Tighten bolt (16) to a torque of 22 N·m (195 lb in). Ensure that the harness assembly is not strained.
24. Use a suitable tool in order to hold tube assembly Note: Ensure that the harness assembly is clear of
(15) in Position (X). Tighten nut (12) to a torque of other engine components.
28 N·m (248 lb in).
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Disassembly and Assembly Section
i05981794
Removal Procedure
Table 69
Illustration 347 g02008013
Required Tools
Tool Part Number Part Description Qty 1. If the crankshaft is installed, use Tooling (A) to
27610291 Housing 1
rotate the crankshaft in order to gain access to
(1) A appropriate lifters (1).
27610289 Engine Turning Tool 1
2. Use Tooling (B) in order to remove lifters (1).
B - Telescoping Magnet 1
(1) This Tool is used in the aperture for the electric starting motor. Note: Place a temporary identification mark on each
lifter in order to identify the correct location.
Installation Procedure
Table 70
Required Tools
27610291 Housing 1
(1) A
27610289 Engine Turning Tool 1
B - Telescoping Magnet 1
(1) This Tool is used in the aperture for the electric starting motor.
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192 UENR4491
Disassembly and Assembly Section
Note: Either Tooling (A) can be used. Use the Tooling End By:
that is most suitable.
a. Install the camshaft. Refer to Disassembly and
NOTICE Assembly, “Camshaft - Remove and Install” for the
correct procedure.
Keep all parts clean from contaminants.
b. If the engine is equipped with a balancer, install the
Contaminants may cause rapid wear and shortened balancer. Refer to Disassembly and Assembly,
component life.
“Balancer - Install” for the correct procedure.
c. If the engine is not equipped with a balancer, install
NOTICE the engine oil pump. Refer to Disassembly and
It is strongly recommended that all lifters should be re- Assembly, “Engine Oil Pump - Install” for the
placed when a new camshaft is installed. correct procedure.
i05980433
1. Clean the lifters. Follow Step 1.a. through Step 1.c.
in order to inspect the lifters. Replace any worn Camshaft - Remove and Install
lifters or damaged lifters.
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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.
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed. Illustration 351 g02009035
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194 UENR4491
Disassembly and Assembly Section
27610291 Housing 1
A(2)
27610289 Engine Turning Tool 1
Timing Pin
D T400015 1
(Fuel Injection Pump)
Timing Pin
27610286 1
(Crankshaft)
E
27610287 Adapter 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
Start By:
a. Remove the valve mechanism cover. Refer to
Illustration 352 g02009034
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install” for the correct
procedure.
7. Lubricate the thrust washer with clean engine oil.
Align Slot (X) in thrust washer (1) with dowel (2) in b. Remove the front cover. Refer to Disassembly and
the cylinder block. Install thrust washer (1) into the Assembly, “Front Cover - Remove and Install” for
recess in the cylinder block. the correct procedure.
Note: The thrust washer can have one or two Slots Note: Either Tooling (A) can be used. Use the Tooling
(X). that is most suitable.
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Disassembly and Assembly Section
Illustration 353 g02437697 5. Use Tooling (D) in order to lock the fuel injection
pump gear in the correct position. Refer to
2. Remove plug (1) from the cylinder block. Remove Disassembly and Assembly, “Fuel Injection Pump -
O-ring seal (2) from the plug. Remove” for the correct procedure.
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196 UENR4491
Disassembly and Assembly Section
6. Use Tooling (B) in order to loosen threaded inserts 8. Remove Tooling (C). Remove bolt (10) and washer
(4) on all rocker arms (5). Unscrew threaded (9) from camshaft gear (3).
inserts (4) on all rocker arms (5) until all valves are
fully closed. 9. Remove camshaft gear (3) from the camshaft.
Note: If the camshaft gear is a tight fit on the nose of
the camshaft, use a prybar in order to remove the
camshaft gear.
Installation Procedure
Table 72
Required Tools
27610291 Housing 1
A(2)
27610289 Engine Turning Tool 1
Timing Pin
D T400015 1
(Fuel Injection Pump)
Illustration 356 g02437701
Alignment of timing marks Timing Pin
27610286 1
(Crankshaft)
E
7. Mark gear (3), gear (6), gear (7), and gear (8) in 27610287 Adapter 1
order to show alignment. Refer to Illustration 356 .
21825617 Dial Indicator 1
Note: Identification will ensure that the gears can be F
- Magnetic Base and Stand 1
installed in the original alignment.
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Ensure that the key is squarely seated. 5. Align the keyway in camshaft gear (3) with the key
in the camshaft. Install camshaft gear onto the
camshaft. Ensure that the timing marks on gear
(3), gear (6), gear (7) and gear (8) are in alignment
and that the mesh of the gears is correct. Refer to
Illustration 360 .
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198 UENR4491
Disassembly and Assembly Section
NOTICE
Failure to ensure that the crankshaft is set in the safe
position will result in interference between the pistons
and the valves. Interference between the pistons and
the valves will result in damage to the engine.
NOTICE
Damage to the engine will occur if all threaded inserts
are not fully unscrewed.
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Disassembly and Assembly Section
i05980435
Removal Procedure
Table 73
Required Tools
Start By:
a. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove” for the correct procedure.
Illustration 363 g02009115
b. If the engine is not equipped with a balancer,
14. Ensure that the pushrods are correctly positioned remove the engine oil pump. Refer to Disassembly
on the threaded inserts (4). Use Tooling (B) in and Assembly, “Engine Oil Pump - Remove” for
order to tighten threaded inserts (4) on all rocker the correct procedure.
arms (5). Tighten the threaded inserts to a torque c. Remove the camshaft. Refer to Disassembly and
of 30 N·m (266 lb in). Assembly, “Camshaft - Remove and Install” for the
correct procedure.
Note: When the threaded insert is tightened, the
threaded insert must be correctly seated into the cup NOTICE
for the pushrod. Keep all parts clean from contaminants.
15. The engine should not be operated for a period 30 Contaminants may cause rapid wear and shortened
minutes after the threaded inserts on all the rocker component life.
arms have been tightened. This period will allow
the force of the valve springs to purge off
excessive engine oil from the hydraulic lifters.
End By:
a. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install” for
the correct procedure.
b. Install the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install” for the correct
procedure.
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Disassembly and Assembly Section
1. Inspect camshaft bearing (1). Refer to 2. Lubricate the bearing housing in the cylinder block
Specifications, “Camshaft Bearings” for more with clean engine oil.
information.
3. Accurately align large oil Hole (X) in camshaft
2. If camshaft bearing (1) is worn or damaged, use bearing (1) with the oil hole in the cylinder block.
Tooling (A) in order to remove the camshaft
bearing from the cylinder block. Note: The Groove (Y) in the camshaft bearing must
be to the top of the cylinder block.
Note: Remove the camshaft bearing from the front of
the cylinder block. 4. Use Tooling (A) in order to install camshaft bearing
(1) into the cylinder block. Install the camshaft
Installation Procedure bearing so that the front edge of the bearing is
Table 74 flush with the face of the recess in the cylinder
Required Tools block.
Tool Part Number Part Description Qty Note: Ensure that the oil holes are correctly aligned.
If the oil is not correctly aligned, the camshaft bearing
- Camshaft Bearing Tool Group 1 should be removed.
A
- Ratchet Wrench 1 End By:
a. Install the camshaft. Refer to Disassembly and
NOTICE Assembly, “Camshaft - Remove and Install” for the
Keep all parts clean from contaminants. correct procedure.
Contaminants may cause rapid wear and shortened b. If the engine was equipped with a balancer, install
component life. the balancer. Refer to Disassembly and Assembly,
“Balancer - Install” for the correct procedure. If the
engine was not equipped with a balancer, install
1. Clean the bearing housing in the cylinder block. the engine oil pump. Refer to Disassembly and
Ensure that the oil hole in the bearing housing is Assembly, “Engine Oil Pump - Install” for the
free from debris. correct procedure.
i05981731
Contaminants may cause rapid wear and shortened b. Loosen nut (4) and remove tube assembly (1).
component life.
Note: Identify the position and orientation of the
tube assembly.
NOTICE
Care must be taken to ensure that fluids are con- c. Remove O-ring seal (5) and seal (6) from tube
tained during performance of inspection, mainte- assembly (1).
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers 4. Disconnect the Original Equipment Manufacture
before opening any compartment or disassembling (OEM) wiring harness assembly from wiring
any component containing fluids. harness assembly (11) for oil level switch (10).
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Disassembly and Assembly Section
Installation Procedure
Table 75
Required Tools
B - Loctite 5900 1
C - Loctite 243 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Illustration 370 g02476000
component life.
NOTICE
Ensure that the wiring harness assembly is correctly
routed and the cable straps are not over tightened.
Over tightening of the cable straps will damage the
wiring harness and the convoluting.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
10. Tighten bolts (14) and bolts (15) to a torque of 12. If necessary, follow Step 12.a. through Step 12.f.
22 N·m (16 lb ft). Refer to Specifications, “Engine in order to install the assembly of the dipstick tube.
Oil Pan” for the correct tightening sequence.
a. Install a new O-ring seal (5) and a new seal (6)
to tube assembly (1).
15. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for correct procedure.
i05981730
Removal Procedure
Illustration 375 g02476004
Table 76
11. Install a new O-ring seal (9) (not shown) to drain Required Tools
plug (8). Install the drain plug to engine oil pan (7). Tool Part Number Part Description Qty
Tighten the oil drain plug to a torque of 34 N·m
A - Strap Wrench 1
(25 lb ft).
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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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
5. Remove nuts (9) and bolts (10) from engine oil pan
(11).
Note: The bolts are different lengths. Note the
position of the different bolts.
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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
8. Align the rear face of engine oil pan (11) to the rear
face of cylinder block (13) on both sides. Use
Tooling (C) and a feeler gauge in order to check
the alignment between the engine oil pan and the
cylinder block. The maximum step that is allowed
between the cylinder block and the sump is
0.1 mm (0.004 inch).
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Disassembly and Assembly Section
i05980425
Balancer - Remove
Removal Procedure
Table 78
Required Tools
Timing Pin
27610286 1
(Crankshaft)
B
27610287 Adapter 1
Timing Pin
C 27610225 1
Illustration 383 g02475578 (Balancer)
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
10. If necessary, install a new O-ring seal (4) (not
shown) to drain plug (5). Install drain plug (3) to the
engine oil pan. Tighten the drain plug to a torque of Start By:
34 N·m (25 lb ft). a. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
11. Follow Step 11.a. through Step11.c. in order to Install” for the correct procedure.
install the assembly of the dipstick tube.
Note: Either Tooling (A) can be used. Use the Tooling
a. Install a new O-ring seal (7) and a new seal (8) that is most suitable.
to tube assembly (2).
Note: In order to remove the balancer, the engine
b. Apply Tooling (B) to the nut of dipstick tube (2). must be removed from the machine. The engine
Install the tube assembly to the engine oil pan. should be mounted in a suitable stand and placed in
the inverted position.
Note: Ensure the correct orientation of the tube
assembly. NOTICE
Keep all parts clean from contaminants.
c. Tighten the nut to a torque of 18 N·m (13 lb ft).
Install the dipstick . Contaminants may cause rapid wear and shortened
component life.
12. If necessary, install breather hose (1) to the clip.
13. Install a new oil filter (5). After the engine has NOTICE
been installed, ensure that the engine oil pan is Care must be taken to ensure that fluids are con-
filled with lubricating oil to the correct level. Refer tained during performance of inspection, mainte-
to Operation and Maintenance Manual, “Engine Oil nance, testing, adjusting and repair of the product. Be
and Filter - Change” for correct procedure. prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
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Disassembly and Assembly Section
2. Remove plug (1) from the cylinder block. Remove 8. Install Tooling (C) into balancer (6). Ensure that
O-ring seal (2) from the plug. Tooling (C) is engaged into the hole in drive shaft
(8).
3. Install Tooling (B) through Hole (X) in the cylinder
block. Use Tooling (B) in order to lock the 9. Attach a suitable lifting device to balancer (6).
crankshaft in the correct position. Support the weight of the balancer. The balancer
weighs approximately 23 kg (51 lb).
5. Remove suction pipe (4) from balancer (6). Illustration 387 g02435366
6. Remover gasket (5). 11. Do not remove dowel (9) and dowel (10) from the
balancer (6) unless the dowels are damaged.
7. Remove bolts (7) from balancer (6).
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i05980423
Balancer - Install
Installation Procedure
Table 79
Required Tools
Timing Pin
C 27610225 1
(Balancer)
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Disassembly and Assembly Section
7. Use the lifting device to align balancer (6) with 11. Tighten the bolts to a torque of 54 N·m (40 lb ft).
Tooling (G). Install the balancer to the cylinder Tighten the bolts in the sequence that is shown in
block. Ensure that dowel (9) and dowel (10) are Illustration 393 .
aligned with the holes in the cylinder block. Ensure
12. Position a new gasket (5) onto balancer (6).
that gear (11) and the crankshaft gear mesh.
Remove the lifting device. 13. Position suction pipe (2) onto balancer (6).
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Removal Procedure
Table 80
Required Tools
27610291 Housing 1
A(2)
27610289 Engine Turning Tool 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
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Disassembly and Assembly Section
Note: Either Tooling (A) can be used. Use the Tooling NOTICE
that is most suitable. Keep all parts clean from contaminants.
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Disassembly and Assembly Section
End By:
a. If the engine is equipped with a balancer, install the
balancer. Refer to Disassembly and Assembly,
“Balancer - Install” for the correct procedure.
b. If the engine is not equipped with a balancer, install
the engine oil pump. Refer to Disassembly and
Assembly, “Engine Oil Pump - Install” for the
correct procedure.
i05981804
Removal Procedure
Table 82
Required Tools
Illustration 398 g02511838
Tool Part Number Part Description Qty
27610291 Housing 1
A(2)
27610289 Engine Turning Tool 1
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove” for the
correct procedure.
b. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling Jets -
Remove and Install” for the correct procedure.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
Illustration 399 g02511840
NOTICE
Keep all parts clean from contaminants. 3. The connecting rod and the connecting rod cap
Contaminants may cause rapid wear and shortened should have an etched Number (X) on the side.
component life. The number on the connecting rod and the
connecting rod cap must match. Ensure that
connecting rod (3) and connecting rod cap (2) are
1. Use Tooling (A) to rotate the crankshaft until the marked for the correct location. If necessary, make
crank pin is at the bottom center position. a temporary mark on the connecting rod and the
2. Use Tooling (B) to remove the carbon ridge from connecting rod cap in order to identify the cylinder
the top inside surface of the cylinder bore. number.
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Disassembly and Assembly Section
i05981802
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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Disassembly and Assembly Section
i05981800
Assembly Procedure
Table 84
Required Tools
5. Place the piston on a suitable surface with the a. Position the spring for oil control ring (3) into
crown upward. Use Tooling (B) in order to remove the oil ring groove in piston (4). The central
compression rings (1) and (2), and oil control ring wire must be located inside the end of the
(3) from piston (4). spring.
NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins
distributor.
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UENR4491 217
Disassembly and Assembly Section
NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins
distributor.
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Disassembly and Assembly Section
End By:
a. Install the pistons and the connecting rods. Refer
to Disassembly and Assembly, “Piston and
Connecting Rods - Install” for the correct
procedure.
i05981803
Note: Ensure that the circlips are seated in the Contaminants may cause rapid wear and shortened
grooves in the piston. component life.
10. Install lower bearing shell (10) into connecting rod 1. If the connecting rod caps were temporarily
cap (11). Ensure that the bearing is centralized in installed, remove the connecting rod caps. If
the connecting rod. Refer to 405 . necessary, thoroughly clean all of the components.
11. Repeat Step 2 through Step 10 for the remaining 2. Apply clean engine oil to the cylinder bore, to the
piston and connecting rod assemblies. piston rings, to the outer surface of the piston and
Note: Fracture split connecting rods should not be left to the bearing shells for the connecting rod.
without the connecting rod caps installed. After the
Note: Install the bearing shells for the connecting
assembly procedure for the piston and connecting
rods dry when clearance checks are performed.
rod is completed, carry out the installation procedure
Refer to Disassembly and Assembly, “Bearing
as soon as possible. Refer to Disassembly and
Clearance - Check” for the correct procedure. Apply
Assembly, “Piston and Connecting Rods - Install” for
clean engine oil to the bearing shells for the
the correct procedure.
connecting rods during final assembly.
Note: Ensure that the piston and the connecting rod
assembly are installed in the correct cylinder.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
Removal Procedure
Table 86
Required Tools
27610291 Housing 1
A(2)
27610289 Engine Turning Tool 1
Start By:
a. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove” for the correct procedure.
b. If the engine is not equipped with a balancer, Illustration 408 g02437998
remove the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Remove” for
the correct procedure.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Discard all used Connecting Rod fasteners.
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Disassembly and Assembly Section
i05980448
Table 87
2. Install upper bearing shell (5) into connecting rod
Required Tools (3). Ensure that the locating tab for the upper
Tool Part Number Part Description Qty bearing shell is correctly seated in the slot in the
connecting rod.
A(1) T400011 Crankshaft Turning Tool 1
Note: The ends of the upper bearing shell must be
27610291 Housing 1
A(2) centered in the connecting rod. The ends of the upper
27610289 Engine Turning Tool 1 bearing shell must be equally positioned in relation to
the mating faces of the connecting rod.
B - E12 Torx Socket 1
C 21825607 Degree Wheel 1 3. Lubricate upper bearing shell (5) with clean engine
(1)
oil.
The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
4. Use Tooling (A) to rotate the crankshaft until the
crankshaft pin is at the bottom dead center
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable. position.
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222 UENR4491
Disassembly and Assembly Section
Note: Do not allow the connecting rod to contact the Note: If all connecting rod bearings require
piston cooling jet. replacement, the procedure can be carried out on two
cylinders at the same time. The procedure can be
6. Clean connecting rod cap (2). Install lower bearing carried out on the following pairs of cylinders. 1 with 4
shell (4) into connecting rod cap (2). Ensure that and 2 with 3. Ensure that both pairs of the
the locating tab for the lower bearing shell is connecting rod bearings are installed before
correctly seated in the slot in the connecting rod changing from one pair of cylinders to another
cap. pair of cylinders. Refer to Disassembly and
Assembly, “Connecting Rod Bearings - Install” for the
7. Lubricate the pin of the crankshaft and lubricate correct procedure.
lower bearing shell (4) with clean engine oil.
13. If the glow plugs were removed, install the glow
plugs. Ref to Disassembly and Assembly, “Glow
Plugs - Remove and Install” for the correct
procedure.
End By:
a. If the engine is equipped with a balancer, install the
balancer. Refer to Disassembly and Assembly,
“Balancer - Install” for the correct procedure.
b. If the engine is not equipped with a balancer, install
the engine oil pump. Refer to Disassembly and
Assembly, “Engine Oil Pump - Install” for the
correct procedure.
i05980471
Removal Procedure
8. Install connecting rod cap (2) to connecting rod (3).
Table 88
Note: Ensure that etched Number (X) on connecting Required Tools
rod cap (2) matches etched Number (X) on
connecting rod (3). Ensure the correct orientation of Tool Part Number Part Description Qty
the connecting rod cap. The locating tab for the upper A(1) T400011 Crankshaft Turning Tool 1
bearing shell and the lower bearing shell should be
on the same side. 27610291 Housing 1
A(2)
27610289 Engine Turning Tool 1
Note: Do not reuse the old connecting rod bolts in
B - 5mm Allen Socket 1
order to secure the connecting rod cap.
(1) The Crankshaft Turning Tool is used on the front pulley.
9. Install new bolts (1) to the connecting rod. Use (2) This Tool is used in the aperture for the electric starting motor.
Tooling (B) tighten the bolts evenly to a torque of
40 N·m (30 lb ft).
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Disassembly and Assembly Section
Start By:
a. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove” for the correct procedure.
b. If the engine is not equipped with a balancer,
remove the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Remove” for
the correct procedure.
c. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
Seal - Remove” for the correct procedure.
NOTICE
This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in
position.
The removal procedure and the installation procedure Illustration 413 g02447416
must be completed for each pair of main bearing
shells before the next pair of main bearing shells are
removed. 3. Remove bolts (3) and main bearing cap (4) from
the cylinder block.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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224 UENR4491
Disassembly and Assembly Section
Installation Procedure
Table 89
Required Tools
E - Straight Edge 1
NOTICE
This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in
position.
The removal procedure and the installation procedure
must be completed for each pair of main bearing
Illustration 415 g02447419
shells before the next pair of main bearing shells are
removed.
5. For number No. 3 main bearing, remove two thrust
washers (7) from the cylinder block. In order to
NOTICE
remove thrust washers (7), use Tooling (A) to Keep all parts clean from contaminants.
rotate the crankshaft in the correct direction. If
necessary, push the crankshaft toward the front of Contaminants may cause rapid wear and shortened
the engine or push the crankshaft toward the rear component life.
of the engine while you rotate the crankshaft, in
order to aid removal. 1. Ensure that the main bearing shells are clean and
free from wear and damage. If necessary, replace
Note: The thrust washers have a locating tab at one
end. the main bearing shells.
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Disassembly and Assembly Section
3. Lubricate the crankshaft journal and upper main 5. Install lower main bearing shell (3) into main
bearing shell (8) with clean engine oil. Slide upper bearing cap (2). Ensure that the locating tab for the
main bearing shell (8) into position between the lower main bearing shell is correctly seated into
crankshaft journal and the cylinder block. Ensure the slot in the bearing cap. Ensure that the dowel
that the locating tab for the upper main bearing (6) is correctly located.
shell is correctly seated in the slot in the cylinder
block. Note: The lower main bearing shell is a plain bearing
that has no oil holes.
Note: The upper main bearing shell has a groove and
two oil holes.
Illustration 418 g02447419 6. Lubricate the crankshaft journal and the lower main
bearing shell with clean engine oil. Install main
4. For number No. 3 main bearing, ensure that two bearing cap (4) to the cylinder block.
thrust washers (7) are clean and free from wear
and damage. If necessary, replace the thrust Note: Ensure the correct orientation of the main
bearing cap. The locating tab for the upper and the
washers. Lubricate thrust washers (7) with clean
lower bearing should be on the same side of the
engine oil. Slide thrust washers (4) into position engine.
between the crankshaft and the cylinder block.
Ensure that the locating tab is correctly seated in 7. Lubricate the threads of bolts (3) with clean engine
the cylinder block. oil. Lubricate the underside of the heads of bolts
(3) with clean engine oil.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
i05980463
Crankshaft - Remove
Removal Procedure
Table 90
Required Tools
A - Lifting Slings 2
Start By:
a. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove” for the correct procedure.
b. If the engine is not equipped with a balancer,
Illustration 424 g02441836
remove the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Remove” for
the correct procedure. 3. Use Tooling (B) in order to remove allen head
screws (1). Remove bridge piece (2).
c. Remove the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Remove” for the 4. Ensure that the main bearing caps are marked for
correct procedure. the location and orientation.
d. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
Seal - Remove” for the correct procedure.
e. Remove the rocker shaft and pushrods. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove” for the correct procedure.
f. If necessary, remove the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head -
Remove” for the correct procedure.
g. If necessary, 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.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
Note: The upper main bearing shells have a groove 5. Clean the main bearing shells and the thrust
and two oil holes. washers. Inspect the main bearing shells and the
thrust washers for wear and damage. If necessary,
10. Remove thrust washers (7).
replace the main bearing shells and the thrust
11. If necessary, remove the crankshaft timing ring. washers.
Refer to Disassembly and Assembly, “Crankshaft Note: If the main bearing shells are replaced, check
Timing Ring - Remove and Install” for the correct whether oversize main bearing shells were previously
procedure. installed. If the thrust washers are replaced, check
whether oversize thrust washers were previously
12. If necessary, remove the crankshaft gear. Refer to installed.
Disassembly and Assembly, “Crankshaft Gear -
Remove and Install” for the correct procedure.
i05980460
Crankshaft - Install
Installation Procedure
Table 91
Required Tools
A - Lifting Slings 2
E - Straight Edge 1
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Disassembly and Assembly Section
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Disassembly and Assembly Section
14. Lubricate the threads of bolts (3) with clean 18. Check the crankshaft end play. Push the
engine oil. Lubricate the underside of the heads of crankshaft toward the front of the engine. Install
bolts (3) with clean engine oil. Tooling (C) to the cylinder block and the rear face
of the crankshaft. Push the crankshaft toward the
15. Install bolts (3) to main bearing caps (4). Evenly rear of the engine. Use Tooling (C) and Tooling (D)
tighten the bolts in order to pull the caps into to measure the crankshaft end play. The
position. Ensure that the caps are correctly seated. permissible crankshaft end play is 0.10 mm
(0.004 inch) to 0.41 mm (0.016 inch).
Note: Do not tap the main bearing caps into position
as the bearing shells may be dislodged.
19. If the crankshaft has been replaced or the
16. Tighten bolts (3) to a torque of 245 N·m (181 lb ft) crankshaft has been reconditioned, inspect the
. height of the piston above the cylinder block. Refer
to System Operation, Testing and Adjusting,
17. Rotate the crankshaft in order to ensure that there “Piston Height - Inspect” for more information.
is no binding.
20. If the crankshaft has not been replaced or the
crankshaft has not been reconditioned, install the
connecting rod bearings. Refer to Disassembly
and Assembly, “Connecting Rod Bearings - Install”
for the correct procedure.
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232 UENR4491
Disassembly and Assembly Section
End By:
a. If necessary, install the pistons and connecting
rods. Refer to Disassembly and Assembly,
“Pistons and Connecting Rods - Install” for the
correct procedure.
b. If necessary, install the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head -
Install” for the correct procedure.
c. Install the rockershaft and pushrods. Refer to
Disassembly and Assembly, “Rocker shaft and
Push Rods - Install” for the correct procedure.
d. Install the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
Illustration 435 g03747104 Seal - Install” for the correct procedure.
21. Follow Steps 21.a. through Step 21.d. in order to e. Install the front housing. Refer to Disassembly and
install the bridge piece. Assembly, “Housing (Front) - Install” for the correct
procedure.
a. Ensure that the cylinder block and the bridge f. If the engine is equipped with a balancer, remove
piece are clean, dry, and free from old sealant. the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove” for the correct procedure.
b. Install bridge piece (2) and allen head screws
(1). Tighten the allen head screws finger tight. g. If the engine is not equipped with a balancer,
remove the engine oil pump. Refer to Disassembly
c. Use Tooling (E) in order to align the rear face and Assembly, “Engine Oil Pump - Remove” for
of the bridge piece with the rear face of the the correct procedure.
cylinder block.
i05982982
d. Use Tooling (B) in order to tighten the allen
head screws to a torque of 16 N·m (142 lb in). Crankshaft Timing Ring
22. Install the crankshaft rear seal. Refer to -Remove and Install
Disassembly and Assembly, “Crankshaft Rear
Seal - Install” for the correct procedure.
Removal Procedure
Start By:
a. Remove the crankshaft. Refer to Disassembly and
Assembly, “Crankshaft - 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
1. Support crankshaft (3) on a suitable stand. 2. Support crankshaft (3) on a suitable stand.
2. Remove allen head screws (1) from crankshaft 3. If dowel (2) was removed, install a new dowel to
timing ring (5). Do not reuse the allen head screws. crankshaft (3).
3. Carefully remove crankshaft timing ring (5) from 4. Position a new crankshaft timing ring (5) on the
crankshaft (3). Do not reuse the crankshaft timing crankshaft with the teeth toward the crankshaft
ring. web. Align the hole in crankshaft timing ring (5)
with dowel (2) in the crankshaft. Carefully install
Note: Ensure that seal surface (4) of the crankshaft is crankshaft timing ring (5) to crankshaft (3).
not damaged when the crankshaft timing ring is
removed. Note: Ensure that seal surface (4) on the crankshaft
is not damaged when the crankshaft timing ring is
Note: Do not remove dowel (2) from crankshaft (3) installed.
unless the dowel is damaged.
5. Install new allen head screws (1). Tighten the allen
Installation Procedure head screws to a torque of 15 N·m (133 lb in).
i05980470
1. Ensure that the flange for the crankshaft timing ring
on the crankshaft is clean and free from damage. Crankshaft Gear - Remove and
Install
Removal Procedure
Table 92
Required Tools
(continued)
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Disassembly and Assembly Section
- Screw 1
A
- Crossblock 1
- Puller Leg 2
Start By:
a. Remove the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Remove” for the
correct procedure.
b. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove” for the correct procedure.
c. If the engine is not equipped with a balancer,
remove the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Remove” for
the correct procedure.
Illustration 439 g02445757
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Installation Procedure
Table 93
Required Tools
B - Hot Plate 1
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Disassembly and Assembly Section
End By:
NOTICE
Keep all parts clean from contaminants. a. Install the front housing. Refer to Disassembly and
Assembly, “Housing (Front) - Install” for the correct
Contaminants may cause rapid wear and shortened procedure.
component life.
b. If the engine is equipped with a balancer, install the
balancer. Refer to Disassembly and Assembly,
1. Ensure that all components are clean and free from “Balancer - Install” for the correct procedure.
wear and damage. If necessary, replace any
components that are worn or damaged. c. If the engine is not equipped with a balancer, install
the engine oil pump. Refer to Disassembly and
Assembly, “Engine Oil Pump - Install” for the
correct procedure.
i05980468
Removal Procedure
Start By:
a. Remove the crankshaft. Refer to Disassembly and
Assembly, “Crankshaft - Remove” for the correct
procedure.
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Disassembly and Assembly Section
Measurement Procedure
Table 95
Required Tools
Plastigauge (Green)
- 0.025 to 0.076 mm 1
(0.001 to 0.003 inch)
Plastigauge (Red)
- 0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
A
Plastigauge (Blue)
- 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
Plastigauge (Yellow)
- 0.230 to 0.510 mm 1
(0.009 to 0.020 inch)
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Illustration 443 g02649080
component life.
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UENR4491 237
Disassembly and Assembly Section
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
• Ensure that the bearing locking tabs are properly Typical Example
seated in the tab grooves.
4. Remove all of Tooling (A) before you install the
• The crankshaft must be free of oil at the contact bearing cap.
points of Tooling (A).
Note: When Tooling (A) is used, the readings can
1. Put a piece of Tooling (A) on the crown of the sometimes be unclear. For example, all parts of
bearing that is in the cap. Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are within
Note: Do not allow Tooling (A) to extend over the the specification range. Refer to Specifications
edge of the bearing. Manual, “Connecting Rod Bearing Journal” and
Specifications Manual, “Main Bearing Journal” for the
2. Use the correct torque-turn specifications in order correct clearances.
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing i05981806
when the cap is installed.
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Disassembly and Assembly Section
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Disassembly and Assembly Section
Installation Procedure
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Disassembly and Assembly Section
i05981797
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Disassembly and Assembly Section
Installation Procedure
Table 96
Required Tools
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Disassembly and Assembly Section
7. Install new cable straps (1) to the harness Illustration 457 g03732053
assembly. Ensure that the cable straps are Typical example
installed into the original position.
3. Cut cable straps (3) from harness assembly (4).
Note: Ensure that the cable straps meet OEM Note the position of all cable straps for installation
specifications. purposes.
8. Turn the battery disconnect switch to the ON Note: Ensure that the harness assembly is not
position. damaged as the cable straps are cut.
1. Ensure that the nitrogen oxide sensor is not b. Remove bolts (7) nitrogen oxide sensor ECM
dropped or knocked. If the nitrogen oxide (5). Remove the nitrogen oxide sensor ECM
sensor, has been dropped or knocked the from bracket (8). Refer to OEM for further
nitrogen oxide sensor must be replaced as an information.
assembly.
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Disassembly and Assembly Section
Installation Procedure
Table 97 b. Install bolts (7) to the nitrogen oxide sensor
Required Tools
ECM. Support the nitrogen oxide sensor ECM
as the bolts are installed. Tighten the bolts to a
Tool Part Number Part Description Qty torque of 10 N·m (89 lb in).
Bostik Pure Nickel
A -
Anti-Seize Compound
1 c. Connect OEM harness assembly (6) to the
nitrogen oxide sensor ECM (5).
B - 22 mm Crows Foot 1
4. New nitrogen oxide sensor (2) are pre-lubricated.
1. Ensure that the nitrogen oxide sensor is free from When installing an existing nitrogen oxide sensor
wear or damage. Replace the nitrogen oxide (2), lightly lubricate the thread of the nitrogen oxide
sensor as an assembly if worn or damaged. sensor with Tooling (A).
2. Check the threads of the mounting point for 5. Remove the probe of nitrogen oxide sensor (2)
nitrogen oxide sensor in the OEM tube assembly from the plastic bag. Install the nitrogen oxide
for wear or damage. Replace the OEM tube sensor to OEM exhaust tube assembly (1). Ensure
assembly if the mounting point is worn or damage. that harness assembly (4) is not damaged as the
Refer to the OEM for the correct procedure. nitrogen oxide sensor is installed.
i05980420
Removal Procedure
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Disassembly and Assembly Section
i05980443
Removal Procedure
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 containers
before opening any compartment or disassembling
any component containing fluids.
Illustration 459 g02433676 Dispose of all fluids according to local regulations and
mandates.
1. Slide locking tab (2) into the unlocked position.
Disconnect harness assembly (1).
NOTICE
2. Remove atmospheric pressure sensor (3) from the Keep all parts clean from contaminants.
bracket.
Contaminants may cause rapid wear and shortened
Installation Procedure 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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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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
i05980454
Installation 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
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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
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Disassembly and Assembly Section
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to System Operation, Testing and Adjusting,
“Cleanliness of Fuel System Components” for de-
Illustration 468 g02476247 tailed information on the standards of cleanliness
that must be observed during ALL work on the
1. Install a new O-ring seal (4) onto engine oil fuel system.
pressure sensor (3).
Removal Procedure
Table 98
Required Tools
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Disassembly and Assembly Section
3. Disconnect harness assembly (3) from fuel 2. Install a new O-ring seal (1) (not shown) on the fuel
temperature sensor (2). temperature sensor (2).
4. Use a deep socket in order to remove fuel 3. Remove the plug from the fuel injection pump.
temperature sensor (2) from the fuel injection
pump. 4. Install fuel temperature sensor (2) to the fuel
injection pump. Use a deep socket to tighten the
5. Use Tooling (A) to plug the open port of the fuel fuel temperature sensor to a torque of 22 N·m
injection pump. (195 lb in).
6. Remove O-ring seal (1) (not shown) from fuel 5. Connect harness assembly (3) to fuel temperature
temperature sensor (2). sensor (2).
Removal Procedure
1. Ensure that the ammonia sensor is not dropped
or knocked. If the ammonia sensor, has been
dropped or knocked the ammonia sensor must
be replaced as an assembly.
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Disassembly and Assembly Section
Installation Procedure
Table 99
Required Tools
B - 22 mm Crows Foot 1
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Disassembly and Assembly Section
i05981817
Removal Procedure
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Disassembly and Assembly Section
Installation Procedure
Table 100
Required Tools
B - 19 mm Crows Foot 1
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Disassembly and Assembly Section
1. Disconnect the harness assembly from harness 2. Lightly lubricate the thread of SCR temperature
assembly (1) for Selective Catalytic Reduction sensor (2) with Tooling (A). Install the SCR
(SCR) temperature sensor (2). temperature sensor to CEM (1).
2. Remove the SCR temperature sensor (2) from 3. Torque SCR temperature sensor (2) to a torque of
Clean Emissions Module (CEM) (1). 45 N·m (33 lb ft).
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Disassembly and Assembly Section
1. Disconnect the harness assembly from harness 2. Lightly lubricate the thread of DPF temperature
assembly (3) for temperature sensor (2). sensor (2) with Tooling (A). Install the DPF
temperature sensor to DPF (1).
2. Remove the Diesel Particulate Filter (DPF)
temperature sensor (2) from DPF (1). 3. Torque DPF temperature sensors (2) to a torque of
45 N·m (33 lb ft).
Installation Procedure
Table 102 4. Connect the harness assembly to harness
assembly (3) for DPF temperature sensor (2).
Required Tools
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Disassembly and Assembly Section
1. Disconnect the harness assembly from harness 2. Lightly lubricate the thread of temperature sensor
assembly (3) from temperature sensor (2). (2) with Tooling (A). Install the temperature sensor
to CEM (1). Tighten the soot antenna to a torque of
2. Remove temperature sensor (2) from the assembly 45 N·m (33 lb ft).
of the Clean Emissions Module (CEM) (1).
3. Connect the harness assembly to harness
Installation Procedure assembly (3) from temperature sensor (2).
Table 103
Required Tools i05981823
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256 UENR4491
Disassembly and Assembly Section
1. Slide locking tab (2) (not shown) into the unlocked 2. Lightly lubricate the thread of temperature sensor
position. Disconnect harness assembly (1) from (6) with Tooling (A). Install temperature sensor (6)
harness assembly (4) for the temperature sensor. to tube assembly (7) for the NRS Induction mixer.
2. Cut cable straps (5) and cable strap (3). 3. Torque temperature sensors (6) to a torque of
24 N·m (212 lb in).
3. Remove temperature sensor (6) from tube
assembly (7) for the NRS Induction mixer. 4. Connect harness assembly (1) to harness
assembly (4) for the temperature sensor. Slide
Installation Procedure locking tab (2) (not shown) into the locked position.
Table 104
5. Install new cable straps (5) and a new cable strap
Required Tools
(3) to harness assembly (4).
Tool Part Number Part Description Qty
Note: Ensure that cable straps meet the Original
Bostik Pure Nickel Equipment Manufactures (OEM) specification.
A - 1
Anti-Seize Compound
i05981805
NOTICE
Ensure that the wiring harness assembly is correctly Pressure Sensor (Cooled
routed and the cable straps are not over tightened.
Over tightening of the cable straps will damage the
Exhaust Gas) - Remove and
wiring harness and the convoluting. Install
(Differential Pressure Sensor and
1. Ensure that all components are clean and free from
wear and damage. If necessary, replace any Inlet Pressure Sensor)
components that are worn or damaged.
Removal Procedure
1. Turn the battery disconnect switch to the OFF
position.
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UENR4491 257
Disassembly and Assembly Section
2. Disconnect harness assembly (1) from inlet 8. If necessary, follow Step 8.a. through Step 8.c. in
pressure sensor (2). order to remove the manifold (3) and the hose
assemblies from NRS Induction mixer.
3. Use a deep socket in order to remove inlet
pressure sensor (2) from manifold (3). a. Use a suitable tool to remove clamp (11) and
clamp (14) from hose assembly (12) and hose
4. Remove O-ring seal (4) from inlet pressure sensor assembly (15). Disconnect the hose
(2). assemblies from manifold (3).
5. Cut cable strap (9) from harness assembly (8). b. Remove Torx screws (10) from manifold (3).
Remove the manifold from NRS Induction
6. Disconnect harness assembly (8) from differential mixer (17).
pressure sensor (7).
c. Use a suitable tool to remove clamp (13) (not
7. Remove bolts (5) from differential pressure sensor shown) and clamp (16) from hose assembly
(7). Remove the differential pressure sensor from (12) and hose assembly (15). Remove the
manifold (3). Remove O-ring seals (6) (not shown). hose assemblies from NRS Induction mixer
(17).
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Disassembly and Assembly Section
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Disassembly and Assembly Section
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Disassembly and Assembly Section
11. Install a new cable strap (9) to harness assembly Installation Procedure
(8).
NOTICE
Note: Ensure that the cable strap meets the Original Keep all parts clean from contaminants.
Equipment Manufacturer (OEM) specification.
Contaminants may cause rapid wear and shortened
12. Turn the battery disconnect switch to the ON component life.
position.
i05980428
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
i05981793
Illustration 491 g02437637
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Disassembly and Assembly Section
1. Slide locking tab (2) into the unlocked position. 1. Install the new O-ring seal (4) to inlet manifold
temperature sensor (3).
2. Disconnect harness assembly (1) from inlet
manifold temperature sensor (3). Note: Do not lubricate the O-ring seal.
Note: The inlet manifold temperature sensor has a 2. Use a deep socket to install inlet manifold
two-wire plug. temperature sensor (3) to the cylinder head.
Tighten the inlet manifold temperature sensor to a
3. Use a deep socket to remove inlet manifold torque of 20 N·m (177 lb in).
temperature sensor (3) from the cylinder head.
3. Connect harness assembly (1) to inlet manifold
4. Remove O-ring seal (4) from the inlet manifold temperature sensor (3).
temperature sensor (3).
4. Slide locking tab (2) into the locked position.
Installation Procedure
i05981770
NOTICE
Keep all parts clean from contaminants.
Glow Plugs - Remove and
Contaminants may cause rapid wear and shortened
component life. Install
Removal Procedure
Start By:
a. Remove the inlet air control (NRS Induction Mixer).
Refer to Disassembly and Assembly, “Inlet Air
Control (NRS Induction Mixer) - 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
Installation Procedure
Table 105
Required Tools
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
4. Remove nuts (2) that secure bus bar (1) to the glow
plugs.
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Disassembly and Assembly Section
Locking Pin
A - 1
Ø 8mm by 85mm
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Disassembly and Assembly Section
i05981788
Removal Procedure
Start By:
a. Remove the alternator belt. Refer to Disassembly
and Assembly, “Alternator Belt - Remove and
Install” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Illustration 500 g02433716
Typical example Contaminants may cause rapid wear and shortened
component life.
1. If necessary, follow Step 1.a. through Step 1.c. in
order to position the tensioner correctly.
4. Install a 1/2" square drive tool into Hole (X) in 1. Remove bolt (2).
tensioner (2). From the front of the engine, turn the
tool in a clockwise direction. Remove Tooling (A) 2. Remove grooved idler pulley (4) from bracket (3).
from Hole (Y).
Installation Procedure
5. Release the pressure on the 1/2" square drive tool
until the alternator belt is tensioned. Remove the 1/ NOTICE
2" square drive tool from Hole (X). Keep all parts clean from contaminants.
Note: The tensioner should be at the nominal Contaminants may cause rapid wear and shortened
position. component life.
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UENR4491 265
Disassembly and Assembly Section
1. Position grooved idler pulley (1) onto bracket (3). 2. Remove bolt (2).
Loosely tighten bolt (2).
3. Remove flat idler pulley (1) from bracket (3).
2. Tighten bolt (2) to a torque of 44 N·m (32 lb ft).
Installation Procedure
End By:
a. Install the alternator belt. Refer to Disassembly and NOTICE
Assembly, “Alternator Belt - Remove and Install” Keep all parts clean from contaminants.
for the correct procedure.
Contaminants may cause rapid wear and shortened
component life.
i05981782
Removal 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
i05980426
Removal Procedure
1. If the engine has guards, remove the guards. Refer
to the Original Equipment Manufactures (OEM) for
Illustration 506 g02437596
the correct procedure.
3. Loosen bolt (3) sufficiently in order to remove 2. Tighten bolt (3) to a torque of 45 N·m (33 lb ft).
tensioner (2) from mounting bracket (1).
3. Install the alternator belt. Refer to Disassembly and
4. Remove tensioner (2) from mounting bracket (1). Assembly, “Alternator Belt - Remove and Install.”
for the correct procedure.
Installation Procedure
4. If the engine has guards, install the guards. Refer
to the OEM for the correct procedure.
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Disassembly and Assembly Section
i05981744
Removal Procedure
Start By:
a. Remove the alternator belt. Refer to Disassembly
and Assembly, “Alternator Belt - Remove and
Install” for the correct procedure.
2. Remove fan (2). Note: Ensure that the fan is correctly oriented.
Note: Note the orientation of the fan. 7. Inspect the condition of locking nuts (1). If
necessary, replace the locking nuts. Install locking
3. Remove fan adapter (3).
nuts (1). Tighten locking nuts (1) to a torque of
4. Remove fan pulley (4). 22 N·m (195 lb in).
End By:
5. If necessary, remove studs (5) from fan drive (6).
a. Install the Alternator Belt. Refer to Disassembly
Installation Procedure and Assembly, “Alternator Belt - Remove and
Install” for the correct procedure.
1. Ensure that all the components are free from wear
and damage. If necessary, replace any
components that are worn or damaged.
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Disassembly and Assembly Section
i05981745
Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install” for the
correct procedure.
1. Check the fan drive for wear and damage. If the fan
drive is worn or damaged, replace the fan drive.
Removal Procedure
Table 108
Required Tools
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Disassembly and Assembly Section
7. Cut cable strap (2) and cable strap (6) from plastic
tube assembly (1).
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Disassembly and Assembly Section
10. Disconnected harness assembly (4) from the 16. Use a suitable tool in Position (X) in order to hold
engine oil pressure sensor. Refer to Disassembly tube assembly (12) as nut (15) is loosened.
and Assembly, “Engine Oil Pressure Sensor - Remove bolt (13) from tube assembly (12).
Remove and Install” for the correct procedure.
17. Remove tube assembly (12) from the bracket and
11. Disconnect the harness assembly from crankshaft the cylinder head.
position sensor (5) (not shown). Refer to
Disassembly and Assembly, “Crankshaft Position 18. Remove O-ring seal (18) (not shown) from tube
Sensor - Remove and Install” for the correct assembly (12).
procedure.
19. Use Tooling (A) in order to plug the cylinder head
12. Cut cable straps (7) from harness assembly for and to cap the tube assembly.
camshaft position sensor (8) (not shown).
Disconnect the harness assembly from camshaft
position sensor (9) (not shown). Refer to
Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install” for the correct
procedure.
22. Loosen the allen head bolt (22) that secures ECM
plug (20) for engine harness assembly (26) to
ECM (28).
Illustration 515 g03738863 23. Position engine harness assembly (26) away from
Typical example the ECM.
14. Disconnect plastic tube assembly (11) and plastic 24. Remove bolt (25) from Original Equipment
tube assembly (14) from tube assembly (12). Use Manufacture (OEM) plug (21).
Tooling (A) in order to plug the plastic tube
25. Loosen the allen head bolt (23) that secures OEM
assemblies and to cap the tube assembly.
plug (21) for the OEM harness assembly (27) to
15. Use a suitable tool in Position (X) in order to hold ECM (28).
and disconnect hose assembly (16) from
26. Position OEM harness assembly (27) away from
connection on tube assembly (13). Remove O-ring
the ECM.
seal (17) (not shown). Use Tooling (A) in order to
plug the hose assembly and to cap the tube
assembly.
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28. Place a suitable container below the ECM (28) in 37. If necessary, follow Step 37.a. through Step 37.d.
order to catch any fuel that might be spilled. in order to disassemble ECM (28).
29. Disconnect plastic tube assembly (37) and plastic a. Remove isolation mount (45), isolation mount
tube assembly (36). Drain the fuel from ECM (28). (47), and limit sleeves (46).
30. Use Tooling (A) in order to plug plastic tube b. If necessary, remove connection (41) and
assembly (37) and plastic tube assembly (36). connection (44) from ECM (28).
31. Use Tooling (A) in order to cap connections on the c. If necessary, remove O-ring seal (42) and O-
ECM for plastic tube assemblies. ring seal (43) from the connections.
32. Remove plastic tube assembly (33) and plastic d. Use Tooling (A) in order to plug ECM (28). Use
tube assembly (34) from clips (35). Tooling (A) in order to cap the connection (41)
and connection (44).
33. Disconnect the plastic tube assembly from valve
(31) Use Tooling (A) in order to cap connection on
valve (31) and the plastic tube assembly.
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38. If necessary, remove spacers (48) from cylinder 4. If necessary, install spacers (48) to cylinder block
block (49). (49). Tighten the spacers to a torque of 44 N·m
(32 lb ft).
i05980701
Installation Procedure
NOTICE
Ensure that the wiring harness assembly is correctly
routed and the cable straps are not over tightened.
Over tightening of the cable straps will damage the
wiring harness and the convoluting.
3. Ensure that the electronic control module is clean a. Remove caps from connection (41). Install
and free from damage. If necessary, replace the new O-ring seal (42) to the connection.
electronic control module.
b. Remove caps from connection (44). Install a
new O-ring seal (43) to the connection.
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Illustration 522 g03738900 15. Position the OEM harness assembly (27) onto
Typical example ECM (28).
6. Position bracket (32) onto ECM (28). Ensure that 16. Tighten the allen head bolt (23) that secures OEM
the bracket is correctly orientated. plug (21) for the OEM harness assembly (27) to
ECM (28). Ensure that the OEM wiring harness is
7. Position bracket (32) and ECM (28) onto the correctly routed.
cylinder block. Support the weight of the ECM as
Note: Care must be taken in order to avoid damage
the bolts are installed.
to the connector pins during installation of the
Note: Ensure that the fuel injection line is not harness assembly.
damaged during the installation of the bracket.
17. Install bolt (25) to OEM plug (21). Hand tighten
8. Install bolts (38) and washer (39) (not shown) to the bolt.
bracket (32) and to ECM (28). Ensure that earth
18. Tighten allen head bolt (23) to a torque of 6 N·m
strap (40) is correctly positioned between the bolts
(53 lb in).
and the washers. Hand tighten the bolts.
Tighten bolt (25) to a torque of 6.5 N·m (59 lb in).
9. Tighten bolts (38) to a torque of 22 N·m (195 lb in).
19. Position engine harness assembly (26) onto ECM
10. Install spacer (30) and bolt (29) to valve (31). (28). Ensure that the engine wiring harness is
Tighten the bolt to a torque of 9 N·m (80 lb in). correctly routed.
11. Remove caps connection on valve (31) and the 20. Tighten the allen head bolt (22) that secures ECM
plastic tube assembly. Connect the plastic tube plug (20) for engine harness assembly (26) to
assembly to valve (31) ECM (28).
12. Install plastic tube assembly (33) and plastic tube Note: Care must be taken in order to avoid damage
assembly (34) to clips (35). to the connector pins during installation of the
harness assembly.
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21. Install bolt (24) to ECM plug (20). Hand tighten 30. Remove the plug from hose assembly (16) and
the bolt. remove the cap from tube assembly (12).
22. Tighten allen head bolt (22) to a torque of 6 N·m 31. Install a new O-ring seal (17) (not shown). Ensure
(53 lb in). that the O-ring seal is correctly seated into the
recess of the tube assembly.
Tighten bolt (24) to a torque of 6.5 N·m (59 lb in).
32. Connect hose assembly (16) from connection on
23. Install new cable straps (19) to engine harness
tube assembly (13) hand tight.
assembly.
Note: Ensure that the cable straps meet OEM 33. Use the suitable tool to hold tube assembly (12) in
specifications. Position (X). Tighten the nut for hose assembly to
a torque of 43 N·m (32 lb ft).
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41. Install new cable strap (2) and cable strap (6) to
plastic tube assembly (1).
37. Connect the harness assembly from crankshaft Tool Part Number Part Description Qty
position sensor (5) (not shown). Refer to - 1/2 Inch Drive T50 Torx Bit 1
Disassembly and Assembly, “Crankshaft Position A(1) 1/2 Inch Drive x 8 mm Hex
Sensor - Remove and Install” for the correct -
Drive
1
procedure.
(1) Either tool may be necessary in order to remove the alternator
pulley.
38. Connected harness assembly (4) to the engine oil
pressure sensor. Refer to Disassembly and Start By:
Assembly, “Engine Oil Pressure Sensor - Remove
and Install” for the correct procedure. a. Remove the alternator belt. Refer to Disassembly
and Assembly, “Alternator Belt - Remove and
39. Connected harness assembly (3) to the fuel Install” for the correct procedure.
temperature sensor. Refer to Disassembly and
Assembly, “Fuel Temperature Sensor- Remove 1. Turn the battery disconnect switch to the OFF
and Install” for the correct procedure. position.
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Disassembly and Assembly Section
7. If necessary, follow Step 7.a. through Step 7.d. in a. If necessary, remove belt tensioner (21) from
order to remove alternator bracket (12) from the heavy-duty alternator bracket (18). Refer to
cylinder block. Disassembly and Assembly, “Belt Tensioner -
Remove and Install” for the correct procedure.
a. If necessary, remove belt tensioner (14) from
alternator bracket (12). Refer to Disassembly b. If necessary, remove idler pulley (20) from
and Assembly, “Belt Tensioner - Remove and heavy-duty alternator bracket (18). Refer to
Install” for the correct procedure. Disassembly and Assembly, “Idler Pulley (Flat)
- Remove and Install” for the correct
b. Remove bolts (13) from alternator bracket (12). procedure.
c. Remove alternator bracket (12) from the c. Remove bolts (18). Note the position of
cylinder block. spacers (19) in the heavy-duty alternator
bracket (18).
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i05980409
Alternator - Install
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Installation Procedure
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a. Ensure that bracket (12) is clean and free from d. Position a cranked ring spanner onto nut (9)
wear and damage. If necessary, replace the and use a suitable tool in order to prevent the
bracket. cranked ring spanner from turning. Use
Tooling (A) in order to turn the shaft of the
b. Ensure that dowels (15) are free from wear alternator in a counterclockwise direction.
and damage. If necessary, replace the dowels. Tighten the nut to the correct torque. Refer to
c. Position bracket (12) onto the cylinder block. Specifications, “Alternator” for the correct
Ensure that the dowels (15) are correctly torque.
located into the cylinder block.
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i05980683
Removal Procedure
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i05980406
4. Support electric starting motor (3). Remove nuts A(1) T400011 Crankshaft Turning Tool 1
(2). 27610291 Shaft Housing 1
A(2)
5. Remove electric starting motor (3) from flywheel 27610289 Engine Turning Tool 1
housing (1).
Timing Pin
27610286 1
(Crankshaft)
6. If necessary, remove studs (5) from flywheel B
housing (1). 27610287 Adapter 1
C - Combination Puller 1
Installation Procedure
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
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 containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Illustration 543 g02646292
Typical example
NOTICE
Keep all parts clean from contaminants.
1. If necessary, install studs (5) into flywheel housing
(1). Contaminants may cause rapid wear and shortened
component life.
Tighten M10 studs to a torque of 18 N·m
(159 lb in).
Note: Put identification marks on all hoses, on all
2. Position electric starting motor (3) onto the studs in hose assemblies and on all tube assemblies for
flywheel housing (1). installation purposes. Plugging all hose assemblies
and tube assemblies. Plugging all hose assemblies
3. Install nuts (2). and tube assemblies helps to prevent fluid loss.
Plugging helps to keep contaminants from entering
Tighten M10 nuts to a torque of 44 N·m (33 lb ft).
the system.
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Installation Procedure
Table 112
Required Tools
Illustration 547 g02429598 Part Description Qty
Tool Part Number
15. Remove O-ring seal (23) from adapter (24). A(1) T400011 Crankshaft Turning Tool 1
b. Use Tooling (C) in order to remove gear (22) Delphi Lockheed Rubber
E - 1
from the crankshaft of air compressor (6). Grease
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
17. If necessary, follow Step 17 through Step 17.c. in
order to remove adapter (24) from air compressor
(6). Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
a. Remove bolts (19) from adapter (24).
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Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants. a. Ensure that the crankshaft of air compressor
(6) is clean and dry. Ensure that gear (22) is
Contaminants may cause rapid wear and shortened clean and free from damage.
component life.
b. Install gear (22) and a new spring washer (21)
to the crankshaft of the air compressor.
NOTICE
Care must be taken to ensure that fluids are con- c. Apply Tooling (D) to the threads of the
tained during performance of inspection, mainte- crankshaft. Install nut (20) to the crankshaft of
nance, testing, adjusting and repair of the product. Be air compressor (6).
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling d. Use a suitable tool in order to prevent the
any component containing fluids. crankshaft of the compressor from rotating.
Tighten nut (20) to a torque of 120 N·m
Dispose of all fluids according to local regulations and
mandates. (89 lb ft).
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4. Ensure that Tooling (B) is installed in Hole (X) in the 6. Rotate the crankshaft of the air compressor until
cylinder block. Use Tooling (B) in order to lock the timing Mark (Z) is aligned with center Line (Y) of
crankshaft in the correct position. the cylinder of the air compressor.
Note: Do not use excessive force to install Tooling 7. If necessary, install studs (15) from the front
(B). Do not use Tooling (B) to hold the crankshaft housing. Tighten the studs to a torque 25 N·m
during repairs. (221 lb in).
5. If necessary, install hose assembly (27) to the 8. Align air compressor (6) with studs (15). Install the
connection on the cylinder block. Align hose air compressor to the front housing. If necessary,
assembly with the temporary marks. Tighten nut rotate the crankshaft of the air compressor in order
(26) to a torque of 9 N·m (80 lb in). to allow the gears to align.
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Timing Pin
27610286 1
(Crankshaft)
B
27610287 Adapter 1
C - Combination Puller 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
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 containers
before opening any compartment or disassembling
any component containing fluids.
Illustration 556 g02429600 Dispose of all fluids according to local regulations and
mandates.
20. Remove Tooling (B) from Hole (X) in the cylinder
block.
NOTICE
21. Install a new O-ring seal (1) to plug (2). Install the Keep all parts clean from contaminants.
plug to the cylinder block. Refer to Illustration 556 .
Tighten the plug to a torque of 21 N·m (186 lb in). Contaminants may cause rapid wear and shortened
component life.
22. If the engine is equipped with a hydraulic pump on
the rear of the air compressor, install the hydraulic
Note: Put identification marks on all hoses, on all
pump. Refer to the OEM for the correct procedure.
hose assemblies and on all tube assemblies for
23. Fill the cooling system with coolant to the correct installation purposes. Plugging all hose assemblies
and tube assemblies. Plugging all hose assemblies
level. Refer to Operation and Maintenance
and tube assemblies helps to prevent fluid loss and
Manual, “Refill Capacities” and Operation and plugging helps to keep contaminants from entering
Maintenance Manual, “Cooling System Coolant the system.
Level - Check” for the correct procedures.
i05980408
Air Compressor - Remove and Do not disconnect the air lines until the air pres-
sure in the system is at zero. If hose is discon-
Install nected under pressure it can cause personal
(Twin Cylinder Air Compressor) injury.
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NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
a. Use a suitable tool in order to prevent the Dispose of all fluids according to local regulations and
mandates.
crankshaft of the compressor from rotating.
Remove nut (22) and remove spring washer
(23) (not shown).
Installation Procedure
Table 114
Required Tools
(continued)
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16. Connect the air line to port (5) (not shown) and
the air line to port (7) in the air compressor. Refer
to the OEM for the correct procedure.
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Disassembly and Assembly Section
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Index Section
Index
A Boost Pressure Sensor - Remove and Install
..................................................................... 260
Accessory Drive - Remove and Install
Installation Procedure ................................ 260
(Accessory Drive SAE "A") .......................... 168
Removal Procedure ................................... 260
Installation Procedure ................................ 169
Removal Procedure ................................... 168
Accessory Drive - Remove and Install C
(Accessory Drive SAE "B") .......................... 165
Installation Procedure ................................ 166 Camshaft - Remove and Install ..................... 192
Removal Procedure ................................... 165 Installation Procedure ................................ 193
Air Compressor - Remove and Install Removal Procedure ................................... 192
(Single Cylinder Air Compressor) ................ 282 Camshaft Bearings - Remove and Install ...... 199
Installation Procedure ................................ 284 Installation Procedure ................................ 200
Removal Procedure ................................... 282 Removal Procedure ................................... 199
Air Compressor - Remove and Install (Twin Camshaft Gear - Remove and Install ............ 194
Cylinder Air Compressor) ............................ 288 Installation Procedure ................................ 196
Installation Procedure ................................ 291 Removal Procedure ................................... 194
Removal Procedure ................................... 288 Camshaft Position Sensor - Remove and
Alternator - Install........................................... 278 Install............................................................ 244
Installation Procedure ................................ 279 Installation Procedure ................................ 245
Installation Procedure for the Heavy-Duty Removal Procedure ................................... 244
Alternator Bracket .................................... 278 Clean Emissions Module - Remove and
Alternator - Remove....................................... 275 Install.............................................................. 73
Removal Procedure ................................... 275 Installation Procedure .................................. 74
Removal Procedure for Heavy Duty Alternator Removal Procedure ..................................... 73
Bracket ..................................................... 277 Connecting Rod Bearings - Install
Alternator Belt - Remove and Install .............. 263 (Connecting Rods in Position) ..................... 221
Installation Procedure ................................ 263 Installation Procedure ................................ 221
Removal Procedure ................................... 263 Connecting Rod Bearings - Remove
Ammonia Sensor - Remove and Install (Connecting Rods in Position) ..................... 220
(Ammonia Sensor if Equipped).................... 249 Removal Procedure ................................... 220
Installation Procedure ................................ 250 Coolant Temperature Sensor - Remove and
Removal Procedure ................................... 249 Install............................................................ 246
Atmospheric Pressure Sensor - Remove Installation Procedure ................................ 246
and Install..................................................... 243 Removal Procedure ................................... 246
Installation Procedure ................................ 244 Crankcase Breather - Install .......................... 171
Removal Procedure ................................... 243 Installation Procedure ................................ 171
Crankcase Breather - Remove ...................... 170
Removal Procedure ................................... 170
B Crankshaft - Install......................................... 229
Installation Procedure ................................ 229
Balancer - Install............................................ 210
Crankshaft - Remove..................................... 227
Installation Procedure ................................ 210
Removal Procedure ................................... 227
Balancer - Remove........................................ 208
Crankshaft Front Seal - Remove and Install.. 132
Removal Procedure ................................... 208
Installation Procedure ................................ 132
Bearing Clearance - Check ........................... 236
Removal Procedure ................................... 132
Measurement Procedure ........................... 236
Crankshaft Front Seal - Remove and Install
Belt Tensioner - Remove and Install.............. 266
(Crankshaft Front Seal for Heavy Duty
Installation Procedure ................................ 266
Front Cover)................................................. 133
Removal Procedure ................................... 266
Installation Procedure ................................ 134
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Index Section
Exhaust Elbow - Remove and Install............. 101 Front Cover - Remove and Install.................. 134
Installation Procedure ................................ 101 Installation Procedure ................................ 135
Removal Procedure ................................... 101 Removal Procedure ................................... 134
Exhaust Elbow - Remove and Install (Top Front Cover - Remove and Install (Heavy
Mounted and Side Mounted Turbocharger Duty Front Cover) ........................................ 136
Exhaust Elbow)............................................ 102 Installation Procedure ................................ 136
Installation Procedure ................................ 102 Removal Procedure ................................... 136
Removal Procedure ................................... 102 Fuel Filter Base - Remove and Install
Exhaust Manifold - Remove and Install (Single Secondary Fuel Filter) ....................... 13
(Single Turbocharger Exhaust Manifold) ....... 97 Installation Procedure .................................. 15
Installation Procedure .................................. 99 Removal Procedure ..................................... 14
Removal Procedure ..................................... 97 Fuel Filter Base - Remove and Install (Twin
Exhaust Manifold - Remove and Install Secondary Fuel Filter) ................................... 10
(Twin Turbochargers Exhaust manifold)........ 94 Installation Procedure .................................. 12
Installation Procedure .................................. 95 Removal Procedure ..................................... 10
Removal Procedure ..................................... 94 Fuel Injection Lines - Install ............................. 24
Installation Procedure .................................. 24
Fuel Injection Lines - Remove ......................... 22
F Removal Procedure ..................................... 22
Fan - Remove and Install............................... 267 Fuel Injection Pump - Install ............................ 44
Installation Procedure ................................ 267 Installation Procedure .................................. 44
Removal Procedure ................................... 267 Fuel Injection Pump - Remove ........................ 42
Fan Drive - Remove and Install ..................... 268 Removal Procedure ..................................... 42
Installation Procedure ................................ 268 Fuel Injection Pump Gear - Install ................... 46
Removal Procedure ................................... 268 Installation Procedure .................................. 46
Flexible Exhaust Pipe - Remove and Install .... 90 Fuel Injection Pump Gear - Remove ............... 46
Assembly Procedure for the Flexible Exhaust Removal Procedure ..................................... 46
Pipe Assembly ........................................... 91 Fuel Manifold (Rail) - Remove and Install........ 20
Disassembly Procedure for the Flexible Installation Procedure .................................. 21
Exhaust Pipe Assembly ............................. 91 Removal Procedure ..................................... 20
Installation Procedure for the Flexible Exhaust Fuel Priming Pump - Remove and Install
Pipe as an Assembly.................................. 93 (Electric Fuel Lift Pump (EFLP)) ...................... 6
Removal Procedure for the Flexible Exhaust Installation Procedure .................................... 7
Pipe as an Assembly.................................. 90 Removal Procedure ....................................... 6
Flow Control Valve - Remove and Install........... 7 Fuel Temperature Sensor - Remove and
Installation Procedure .................................... 8 Install............................................................ 248
Removal Procedure ....................................... 7 Installation Procedure ................................ 249
Flywheel - Install............................................ 122 Removal Procedure ................................... 248
Installation Procedure ................................ 122
Flywheel - Remove........................................ 121
Removal Procedure ................................... 121
G
Flywheel Housing - Remove and Install Gear Group (Front) - Remove and Install ...... 137
(Standard Housing)...................................... 128 Installation Procedure ................................ 139
Installation Procedure (Standard Housing) Removal Procedure ................................... 137
................................................................. 129 Gear Group (Front) - Remove and Install
Removal Procedure ................................... 128 (Heavy Duty Gear Group (Front)) ................ 142
Flywheel Housing - Remove and Install Installation Procedure ................................ 146
(Wet Back End Housing) ............................. 125 Removal Procedure ................................... 142
Installation Procedure (Wet Back End Glow Plugs - Remove and Install................... 261
Housing)................................................... 127 Installation Procedure ................................ 262
Removal Procedure ................................... 125 Removal Procedure ................................... 261
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Index Section
Rocker Shaft and Pushrod - Install................ 179 Turbocharger - Remove (First Stage
Installation Procedure ................................ 179 Turbocharger) ................................................ 55
Rocker Shaft and Pushrod - Remove............ 175 Removal Procedure ..................................... 55
Removal Procedure ................................... 175 Turbocharger - Remove (Second Stage
Turbocharger) ................................................ 53
Removal Procedure ..................................... 53
S Turbocharger - Remove (Side Mounted
Solenoid Valve (DEF Heater Coolant) - Turbochargers) .............................................. 57
Remove and Install ........................................ 89 Removal Procedure ..................................... 58
Installation Procedure .................................. 89 Turbocharger - Remove (Top Mounted
Removal Procedure ..................................... 89 Turbocharger ) ............................................... 56
Soot Antenna - Remove and Install............... 251 Removal Procedure ..................................... 56
Installation Procedure ................................ 252
Removal Procedure ................................... 251
Support and Mounting (CEM) - Remove
V
and Install..................................................... 103 Valve Mechanism Cover - Remove and
Installation Procedure ................................ 104 Install............................................................ 173
Removal Procedure ................................... 103 Installation Procedure ................................ 174
Removal Procedure ................................... 173
T
Table of Contents............................................... 3
W
Temperature Sensor (Catalyst Inlet) - Wastegate Solenoid - Remove and Install....... 68
Remove and Install ...................................... 254 Installation Procedure .................................. 69
Installation Procedure ................................ 255 Removal Procedure ..................................... 68
Removal Procedure ................................... 254 Water Pump - Install .......................................118
Temperature Sensor (Cooled Exhaust Gas) Installation Procedure .................................118
- Remove and Install.................................... 255 Water Pump - Remove ...................................117
Installation Procedure ................................ 256 Removal Procedure ....................................117
Removal Procedure ................................... 255 Water Separator and Fuel Filter (Primary) -
Temperature Sensor (DPF) - Remove and Remove and Install ........................................ 17
Install............................................................ 253 Installation Procedure .................................. 19
Installation Procedure ................................ 254 Removal Procedure ..................................... 17
Removal Procedure ................................... 253 Water Temperature Regulator - Remove
Temperature Sensor (Exhaust) - Remove and Install..................................................... 120
and Install (Selective Catalytic Reduction Installation Procedure ................................ 121
(SCR) Temperature Sensor) ........................ 252 Removal Procedure ................................... 120
Installation Procedure ................................ 253
Removal Procedure ................................... 252
Turbocharger - Install (First Stage
Turbocharger) ................................................ 63
Installation Procedure .................................. 63
Turbocharger - Install (Second Stage
Turbocharger) ................................................ 61
Installation Procedure .................................. 61
Turbocharger - Install (Side Mounted
Turbochargers) .............................................. 59
Installation Procedure .................................. 59
Turbocharger - Install (Top Mounted
Turbocharger ) ............................................... 66
Installation Procedure .................................. 66
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©2014 Perkins Engines Company Limited
All Rights Reserved
This document has been printed from SPI2. NOT FOR RESALE