UENR4546-02

UENR4546-02 (en-us)
July 2017
Disassembly and Assembly

404A-22SG1 Gas Industrial Engine
EX (Engine)
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.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
UENR4546-02 3
Table of Contents
Table of Contents Bearing Clearance - Check ..................................89

Camshaft Position Sensor - Remove and Install
(Camshaft Speed/Timing Sensor) .......................90
Disassembly and Assembly Section Crankshaft Position Sensor - Remove and Install
(Crankshaft Speed/Timing Sensor) .....................92
Air Cleaner - Remove and Install ............................4 Coolant Temperature Switch - Remove and Install .93
Ignition Coil - Remove and Install ...........................6 Engine Oil Pressure Switch - Remove and Install ..94
Exhaust Manifold - Remove and Install ..................7 Oxygen Sensor - Remove and Install ....................95
Inlet and Exhaust Valve Springs - Remove and Inlet Manifold Temperature and Pressure Sensor -
Install ...............................................................10 Remove and Install ............................................96
Inlet and Exhaust Valves - Remove and Install.......12 V-Belts - Remove and Install ................................97
Engine Oil Line - Remove and Install ....................15 Fan - Remove and Install ....................................99
Engine Oil Relief Valve - Remove and Install .........17 Electronic Control Module - Remove and Install.....99
Engine Oil Pump - Remove (Removal of Engine Oil Alternator - Remove and Install ......................... 101
Pump and Idler Hub with the Engine Removed from Electric Starting Motor - Remove and Install ....... 103
the Application) .................................................19 Spark Plug - Remove and Install......................... 104
Engine Oil Pump - Install (Installation of Engine Oil Fuel Ratio Control - Remove and Install (Throttle
Pump and Idler Hub with the Engine Removed from Control Valve) ................................................. 105
the Application) .................................................21 Fuel Ratio Control - Remove and Install (Trim Control
Engine Oil Pump - Remove and Install (Removal of Valve) ............................................................. 107
Engine Oil Pump and Idler Hub with the Engine Fuel Ratio Control - Remove and Install (Mixing
Installed in the Application).................................24 Chamber) ....................................................... 108
Water Pump - Remove and Install ........................28
Water Temperature Regulator Housing - Remove and Index Section
Install ...............................................................31
Water Temperature Regulator - Remove and Index................................................................ 110
Install ...............................................................32
Flywheel - Remove..............................................34
Flywheel - Install .................................................35
Crankshaft Rear Seal - Remove and Install ...........37
Crankshaft Wear Sleeve (Rear) - Remove and
Install ...............................................................38
Flywheel Housing - Remove and Install ................40
Crankshaft Pulley - Remove and Install ................42
Crankshaft Front Seal - Remove and Install...........44
Housing (Front) - Remove....................................45
Housing (Front) - Install .......................................46
Crankcase Breather - Remove and Install ............48
Valve Mechanism Cover - Remove and Install .......50
Rocker Shaft and Pushrod - Remove ....................55
Rocker Shaft - Disassemble ................................55
Rocker Shaft - Assemble ....................................56
Rocker Shaft and Pushrod - Install........................57
Cylinder Head - Remove......................................58
Cylinder Head - Install .........................................60
Lifter Group - Remove and Install .........................66
Camshaft - Remove ............................................67
Camshaft - Disassemble......................................68
Camshaft - Assemble ..........................................69
Camshaft - Install ................................................69
Camshaft Bearings - Remove and Install ..............71
Engine Oil Pan - Remove and Install ....................74
Pistons and Connecting Rods - Remove ...............75
Pistons and Connecting Rods - Disassemble ........76
Pistons and Connecting Rods - Assemble.............78
Pistons and Connecting Rods - Install...................80
Connecting Rod Bearings - Remove (Connecting
rods in position) .................................................81
Connecting Rod Bearings - Install (Connecting rods
in position) ........................................................82
Crankshaft Main Bearings - Remove.....................83
Crankshaft Main Bearings - Install ........................85
Crankshaft - Remove...........................................87
Crankshaft - Install ..............................................88
4 UENR4546-02
Disassembly and Assembly Section
Disassembly and
Assembly Section
i06595272
Air Cleaner - Remove and

Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 1 g06038783
1. Loosen hose clamp (1) and hose clamp (3).

Remove hose assembly (2) from the assembly of
air cleaner (4) and the fuel ratio control inlet.
2. Remove nuts and bolts (5) from the assembly of
air cleaner (4). Remove the assembly of air
cleaner from bracket (6).
3. If necessary, remove bolts (7) and remove bracket
(6). Support the bracket as the bolts are removed.
UENR4546-02 5
Installation Procedure
NOTICE
component life.
1. Ensure all components of the assembly of the air

cleaner and bracket are from wear or damage.
Replace any component that is worn or damaged.
2. If necessary, install bracket (6) onto the engine.

Install bolts (7) to the bracket. Support the bracket
as the bolts are installed. Tighten the bolt to a
torque of 22 N·m (195 lb in).
3. Install the assembly of air cleaner (4) onto bracket
(6). Install nuts and bolts (5) to the assembly of the
air cleaner. Tighten the nuts and bolts to a torque
of 22 N·m (195 lb in).
4. Install hose assembly (2) to the assembly of air
cleaner (4) and the fuel ratio control inlet. Ensure
that hose clamp (1) and hose clamp (3) are
correctly orientated.
6 UENR4546-02
5. Tighten hose clamp (1) and hose clamp (3) to a

6. If necessary, replace air cleaner element for the
assembly air cleaner (4). Refer to Operation and
Maintenance Manual, Engine Air Cleaner Element
- Replace for the correct procedure.
i06590650
Ignition Coil - Remove and

Install
Removal Procedure
The ignition system may cause an electrical

shock hazard, which may cause personal injury
or death. Avoid contacting the ignition system
components and the ignition system wiring dur-
ing operation.
NOTICE
component life.
1. Turn the battery disconnect switch to the OFF

position.
2. Disconnect harness assembly (3) from ignition coil

(1).
3. Remove bolt (2) from ignition coil (1). Remove the
ignition coil from the bracket.
4. Remove sleeve (4) from ignition coil (1).
5. Remove O-ring seal (5) from sleeve (4)
6. If necessary, follow Step 2 through Step 5 to
remove remaining ignition coil (1) from the
bracket.
UENR4546-02 7
Installation Procedure 5. Connect harness assembly (3) to ignition coil (1).

1. Ensure that all components of the ignition coil are 6. If necessary, follow Step 2 through Step 5 to install
free from wear or damage. If any component is remaining ignition coil (1) to the bracket.
worn or damaged replace the component.
7. Turn the battery disconnect switch to the ON
position.
i06505946
Exhaust Manifold - Remove

and Install
Removal Procedure
NOTICE
component life.
1. Disconnect the Original Equipment Manufacture

(OEM) exhaust system from the adaptor on the
exhaust manifold. Refer to the OEM for the correct
Illustration 7 g06037856 procedure.
2. Remove nuts (1) from the Allen head bolts.

2. Install a new O-ring seal (5) to sleeve (4). Install
the sleeve to ignition coil (1). 3. Remove bolts (3) from bracket (2). Remove the
bracket.
3. Install ignition coil (1) to the bracket. Install bolt (2)
hand tight. Ensure that the ignition coil is correctly
seated onto the bracket.
4. Tighten bolt (2) to a torque of 10 N·m (89 lb in).
8 UENR4546-02
8. Remove exhaust manifold (11) from the cylinder

head.
9. Remove nuts (5) and bolts (6).
10. Remove exhaust manifold (4) from cylinder head
(1). Note the orientation of the exhaust manifold
for installation.
11. Remove gasket (3) from cylinder head (1).
Tightening sequence
4. Cut cable strap (5) and disconnect harness Illustration 13 g06035114

assembly (4).
12. If necessary, remove studs (14) from exhaust
5. Remove nuts (10) and remove adapter (9) from manifold (11).
exhaust manifold (11). Remove gasket (6) (not
shown). 13. If necessary, remove studs (15) from the cylinder
head.
6. Loosen nuts (8) and bolts (13) in reverse numerical
sequence. Refer to Illustration 17 . Identify bolts of Installation Procedure
different lengths so that the bolts can be installed
in the correct positions. NOTICE
Note: Loosen the bolts and the nuts in reverse
numerical sequence will help to prevent distortion of Contaminants may cause rapid wear and shortened
the exhaust manifold. component life.
7. Remove heat shield (7) from exhaust manifold

(11).
UENR4546-02 9
1. Ensure that the gasket surfaces of the cylinder

head and the exhaust manifold are clean and free
from damage. Ensure that all components of the
exhaust manifold are free from wear or damage.
Replace any component that is worn or damaged.
2. If necessary, install studs (14) to exhaust manifold Tightening sequence

(11). Tighten the studs to a torque of 11 N·m
(97 lb in). 4. Install a new gasket (3) onto cylinder head (1).
Ensure that the gasket is correctly orientated.
3. If necessary, install studs (15) to the cylinder head.
Tighten the studs to a torque of 11 N·m (97 lb in). 5. Install exhaust manifold (4) onto cylinder head (1).
Ensure the correct orientation of the exhaust
manifold.
6. Install heat shield (7) to exhaust manifold (11).
Install nuts (5) to the exhaust manifold.
7. Install bolts (6) to exhaust manifold (11). Ensure
that the different lengths bolts are installed into the
correct positions.
8. Tighten nuts (8) and bolts (13) in numerical
sequence to a torque of 26 N·m (230 lb in). Refer
to Illustration 17 .
9. Install a new gasket (6) (not shown).
10 UENR4546-02
10. Install adapter (9) to exhaust manifold (11). 16. Connect the OEM exhaust system to the adaptor
Ensure that the adapter is correctly orientated. on the exhaust manifold. Refer to the OEM for the
Install nuts (10) to the adapter. Tighten the nuts to correct procedure.
a torque of 26 N·m (230 lb in).
i06505947
11. Connect harness assembly (4) and install a new
cable strap (5). Inlet and Exhaust Valve
Note: Ensure that the cable straps meet Original Springs - Remove and Install
Equipment Manufacture (OEM) specifications.
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
21825739 Valve Spring Compressor 1
A 276102295 Head 1
27610235 Adapter 1
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove” for the correct procedure.
Personal injury can result from being struck by

Illustration 18 g06035072 parts propelled by a released spring force.
12. Install bracket (2) and install bolts (3). Make sure to wear all necessary protective
equipment.
13. Install nuts (1) to the Allen head bolts.
Follow the recommended procedure and use all
14. Tighten bolts (3) to a torque of 6 N·m (53 lb in). recommended tooling to release the spring force.
15. Tighten Allen head bolts and nuts (1) to a torque
of 25 N·m (221 lb in).
NOTICE
component life.
NOTICE
Install suitable plugs to the inlet ports of the cylinder
head in order to prevent the entry of loose parts into
the engine.
NOTICE
Plug the apertures for the push rods in the cylinder
the engine.
UENR4546-02 11
Note: For four cylinder engines, if all valve springs spring to be safely removed.
require replacement the procedure can be carried out
on two cylinders at the same time. The procedure NOTICE
can be carried out on the following pairs of cylinders. Ensure that the valve spring is compressed squarely
1 with 4 and 2 with 3. Ensure that all the valve or damage to the valve stem may occur.
springs are installed before changing from one pair of
cylinders to another pair of cylinders.
2. Use tool (A) to compress valve spring (3). Remove
Note: Ensure that the appropriate piston is at the top valve keepers (1).
center position before the valve spring is removed.
Failure to ensure that the piston is at the top center Note: For four cylinder engines, if all valve springs
position may allow the valve to drop into the cylinder require replacement the procedure can be carried out
bore. on two cylinders at the same time. The procedure
can be carried out on the following pairs of cylinders.
1 with 4 and 2 with 3. Ensure that all the valve
springs are installed before changing from one pair of
cylinders to another pair of cylinders.
Note: Ensure that the appropriate piston is at the top

center position before the valve spring is removed.
Failure to ensure that the piston is at the top center
position may allow the valve to drop into the cylinder
bore.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
3. Apply sufficient pressure to Tooling (A) to allow

removal of the valve keepers (1). Remove the
valve keepers.
Note: Do not compress the spring so that the valve
spring retainer (2) touches the valve stem seal.
Illustration 19 g06035166 4. Slowly release the pressure on Tooling (A).

5. Remove valve spring retainer (2) and remove
1. Follow Steps 1.a through 1.d to position the valve spring (3).
appropriate piston at top center.
6. Remove Tooling (A).
a. Install Tooling (A) in position on the cylinder
head to compress a valve spring for the Installation Procedure
appropriate piston. Table 2
Required Tools
b. Use Tooling (A) to compress valve spring (3)
and open the valve slightly. Tool Part Number Part Description Qty
Note: Do not compress the spring so that the valve 21825739 Valve Spring Compressor 1
spring retainer (2) touches the valve stem seal. A 276102295 Head 1
27610235 Adapter 1
c. Carefully rotate the crankshaft until the piston
touches the valve.
Note: Do not use excessive force to turn the NOTICE
crankshaft. The use of force can result in bent Keep all parts clean from contaminants.
valve stems. Contaminants may cause rapid wear and shortened
component life.
d. Continue to rotate the crankshaft and gradually
release the pressure on Tooling (A) until the
piston is at the top center position. The valve is
now held in a position that allows the valve
12 UENR4546-02
3. Install Tooling (A) in the appropriate position on the

NOTICE
Do not turn the crankshaft while the valve springs are cylinder head to compress the valve spring.
removed. 4. Apply sufficient pressure to Tooling (A) to install
valve keepers (1). Install the valve spring keepers.
NOTICE Note: Do not compress the spring so that valve
Plug the apertures for the push rods in the cylinder spring retainer (2) touches the valve stem seal.
the engine.
5. Carefully release the pressure on Tooling (A).
Note: Ensure that the valve keepers are correctly
NOTICE seated.
Install suitable plugs to the inlet ports of the cylinder
the engine.
The valve spring keepers can be thrown from the
1. Inspect the valve springs for the correct length. valve when the valve spring compressor is re-
Refer to Specifications, “Cylinder Head Valves” for leased. Ensure that the valve spring keepers are
the correct procedure. 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 dur-
ing the installation of the valves.
6. Remove Tooling (A). Ensure that all the valves are

secured in place by a valve spring and valve
keepers. Rotate the crankshaft through about 45
degrees to clear the piston from the valve. Lightly
strike the top of the valve with a soft hammer to
ensure that the valve keepers are properly
installed.
End By:
a. Install the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install” for the correct procedure.
i06505948
Inlet and Exhaust Valves -

Remove and Install
2. Install valve spring (3) onto the cylinder head.

Position valve spring retainer (2) onto valve spring Removal Procedure
(3). Table 3
Required Tools

Improper assembly of parts that are spring A - Valve Spring Compressor 1
loaded can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
UENR4546-02 13
Start By:
a. Remove the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head -
Remove” for the correct procedure.
NOTICE
component life.
1. Clean the bottom face of the cylinder head. Check

the depth of the valves below the face of the
cylinder head before the valve springs are
removed. Refer to Specifications, “Cylinder Head
Valves” for the correct dimensions.
2. Place a temporary identification mark on the heads
of the valves to identify the correct position.
Note: Do not stamp the heads of the valves.

Stamping or punching the heads of the valves could Illustration 21 g06035193
cause the valves to fracture.

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
recommended tooling to release the spring force.
NOTICE
Ensure that the valve spring is compressed squarely
3. Use Tooling (A) to compress the appropriate valve

spring (3). Remove valve keepers (1).
Note: Do not compress the valve spring so that valve

spring retainer (2) touches valve stem seal (4).

5. Remove valve spring retainer (2). Remove valve
spring (3).
6. Remove valve (5).
7. Remove valve stem seal (4).
14 UENR4546-02
8. Repeat Step 3 through Step 7 for the remaining

valves.
Table 4
Required Tools
A - Valve Spring Compressor 1
B 21825623 Valve Stem Seal Installer 1
NOTICE
component life.
Note: The installation procedure is identical for the

two cylinder, the three cylinder and the four cylinder
engines. The Illustrations show a four cylinder Illustration 23 g06035228
engine.
2. Use Tooling (B) to install new valve stem seals (4)
1. Clean all components of the cylinder head onto each of the valve guides.
assembly. Ensure that all ports, all coolant
passages, and all lubrication passages in the Note: The outer face of the valve guides must be
cylinder head are free from debris. Follow Step 1.a clean and dry before installing the valve stem seals.
through Step 1.e to inspect the components of the
cylinder head assembly. Replace any components
that are worn or damaged.
a. Inspect the cylinder head for wear and for

damage. Refer to Systems Operation, Testing
and Adjusting, “Cylinder Head Inspect”.
b. Inspect the valve seats for wear and for

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

Refer to Specifications, “Cylinder Head Valves”. Illustration 24 g06035200
3. Lubricate the stem of valve (5) with clean engine

oil. Install valve (5) in the appropriate position in
the cylinder head. Check the depth of the valve
below the face of the cylinder head. Refer to
Systems Operation, Testing and Adjusting, “Valve
Depth - Inspect” for more information.
UENR4546-02 15
4. Install valve spring (3) to the cylinder head. 7. Repeat Step 4 through Step 6 for the remaining
Position valve spring retainer (2) onto valve spring valves.
(3).
8. Place the cylinder head on a suitable support.
Ensure that the heads of the valves are not
obstructed. Gently strike the top of the valves with
a soft hammer to ensure that valve keepers (1) are
parts propelled by a released spring force. properly installed.
End By:
equipment. a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
Follow the recommended procedure and use all correct procedure.
i06505954
NOTICE
Ensure that the valve spring is compressed squarely Engine Oil Line - Remove and
Install
Removal Procedure
NOTICE
component life.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
5. Use Tooling (A) to compress valve spring (3).

Install valve keepers (1).
Note: Do not compress the spring so that valve

spring retainer (2) touches valve stem seal (4).
The valve spring keepers can be thrown from the

valve when the valve spring compressor is re-
leased. Ensure that the valve spring keepers are
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 dur-
ing the installation of the valves.
16 UENR4546-02
3. Remove adaptor (4) and remove sealing washers

(3) (not shown).
4. Remove banjo bolt (7) and remove sealing
washers (6).
5. Remove oil line (8) from the engine.
NOTICE
component life.
1. If necessary, remove engine oil pressure switch

(5). Refer to Disassembly and Assembly, Engine
Oil Pressure Switch -Remove and Install for the
correct procedure.
2. Loosen nut (1) that attaches clip (2) on oil line (8).
UENR4546-02 17
4. Install a new sealing washer (3) (not shown) to

adaptor (4). Install the adaptor to oil line (8) and
install the remaining new sealing washer (3) (not
shown).
5. Install adaptor (4) hand tight.
6. Tighten banjo bolt (7) to a torque of 12 N·m
(106 lb in). Ensure that the oil line is not strained
as the banjo bolt is tightened.
7. Tighten adaptor (4) to a torque of 12 N·m
(106 lb in). Ensure that the oil line is not strained
as the adaptor is tightened.
8. Tighten nut (1) to a torque of 15 N·m (133 lb in).
Ensure that the oil line is not strained as the nut is
tightened.
9. If necessary, install engine oil pressure switch (5).
Refer to Disassembly and Assembly, Engine Oil
Pressure Switch -Remove and Install for the
correct procedure.
i06507043
Engine Oil Relief Valve -

Remove and Install
Removal Procedure
NOTICE
component life.
NOTICE
and mandates.
1. Place oil line (8) on the engine. Ensure that clip (2)
on the oil line is located below nut (1).
2. Install a new sealing washer (6) to banjo bolt (7).
Install the banjo bolt to oil line (8) and install the
remaining new sealing washer (6).
3. Install banjo bolt (7) hand tight.
18 UENR4546-02
Illustration 30 g06035579 Illustration 31 g06035579
1. Remove engine oil relief valve (2) from the cylinder 1. Install a new O-ring seal (1) to engine oil relief
block. valve (2).
2. Remove O-ring seal (1) from engine oil relief valve 2. Lubricate engine oil relief valve (2) with clean
(2). engine oil.
NOTICE
component life.
UENR4546-02 19
3. Install engine oil relief valve (2) into the cylinder Removal of Engine Oil Pump
block. Tighten the engine oil relief valve to a
torque of 64 N·m (47 lb ft).
i06505958
Engine Oil Pump - Remove

(Removal of Engine Oil Pump
and Idler Hub with the Engine
Removed from the Application)
Removal Procedure
Start By:
a. Remove the front housing Refer to
Disassembly and Assembly, “Housing (Front) -
NOTICE
Care must be taken to ensure that fluids are con- Illustration 32 g06039910
bling any component containing fluids. Personal injury can result from being struck by
and mandates. Make sure to wear all necessary protective
equipment.
NOTICE recommended tooling to release the spring force.
Contaminants may cause rapid wear and shortened 1. Remove C-clip (9) that retains idler gear (2) on
component life. idler hub (7).
2. Remove the following items from idler hub (7) :
NOTICE
If the front housing is not installed, do not turn • Collar (8)
the crankshaft. Damage to the engine may occur.
• Spring (6)
Note: This removal procedure of the engine oil • Shims (5)

pump and idler hub is for engine that has been
removed from the application. • Oil pump cover (4)
3. Remove idler gear (2) from idler hub (7).

4. Remove inner rotor (3) from idler hub (2).
5. Remove thrust washer (1) from idler hub (7).
20 UENR4546-02
Removal of Idler Hub
6. To remove the assembly of oil strainer (13), follow

Step 6.a through Step 6.d
a. Remove the engine oil pan. Refer to

Disassembly and Assembly, “Engine Oil Pan -
Remove and Install” for the correct procedure.
b. Remove bolts (12) from the bracket for oil
strainer (13). Remove oil strainer (13) from the
1. Remove camshaft (14). Refer to Disassembly and
cylinder block.
Assembly, “Camshaft - Remove” for the correct
c. Remove suction pipe (12) from the cylinder procedure.
block. 2. Remove bolts (17) from plate (14). Remove the
plate from the cylinder block.
d. Remove O-ring seal (10) from oil suction pipe
(12). 3. Remove gasket (15) (not shown).
4. Remove crankshaft (18). Refer to Disassembly
and Assembly, “Crankshaft - Remove” for the
correct procedure.
UENR4546-02 21
NOTICE
If the front housing is not installed, do not turn
Note: This installation procedure of the engine oil

pump and idler hub is for engine that has been
removed from the application.
Installation for Idler Hub
5. Use a hammer and use a suitable drift to remove

idler hub (7) from the cylinder block. Align the drift
to the rear face of the hub and drive the hub from
the cylinder block outward.
i06505959
Engine Oil Pump - Install

(Installation of Engine Oil Pump Illustration 36 g06039972
and Idler Hub with the Engine 1. Install the pin of Tooling (A) into the cylinder block.
Removed from the Application) 2. Install idler hub (7) into the guide plate of Tooling
(A). Align the guide plate of Tooling (A) with pin of
Tooling (A).
Installation Procedure 3. Use a hammer to strike the guide plate of Tooling
Table 5 (A). Drive idler hub (7) into the cylinder block until
Required Tools the guide plate contacts the front of the cylinder
block.
4. Remove both parts of Tooling (A).
A 27610327 Alignment Tool 1
B - Multipurpose Grease 1
21825617 Dial Indicator 1

C
- Magnetic Base and Stand 1
NOTICE
component life.
22 UENR4546-02
Installation for Engine Oil Pump
5. Install crankshaft (19). Refer to Disassembly and

Assembly, “Crankshaft - Install” for the correct
procedure.
6. Position a new gasket (15) (not shown) onto the
cylinder block. Align plate (16) with the dowels in
the cylinder block and install the plate. Install bolts
(17).Tighten the bolts to a torque of 10 N·m
(89 lb in).
7. Install camshaft (14). Refer to Disassembly and
Assembly, “Camshaft - Install” for the correct
procedure.
1. Install thrust washer (1). Lubricate the thrust

washer with clean engine oil.
Improper assembly of parts that are spring

equipment.
UENR4546-02 23
2. Apply Tooling (B) to the faces of inner rotor (3) and

to the vanes of idler gear (2).
3. Align timing Marks (X) on idler gear (2) with the
respective timing marks on crankshaft gear (19)
and camshaft gear (14). Install idler gear (2) onto
idler hub (7).
4. Install inner rotor (3) to idler gear (2).
Personal injury can result from the release of the

spring force.
The drive shaft, the piston, and the drive gear are
under spring force.
Use a press to slowly release the spring force be-
fore the components are removed.
5. Install the following items to idler hub (7) :
• Oil pump cover (4)
• Shim (5)
• Spring (6)
• Collar (8) Illustration 40 g06040450
Refer to Illustration 38 .
7. Use Tooling (C) to measure the end play of the
6. Install C-clip (9) on idler hub (7). engine oil pump. Refer to Specifications, “Engine
Oil Pump” for the correct information.
8. To install the assembly of oil strainer (13), follow

Steps 8.a through 8.c.
24 UENR4546-02
a. Install a new O-ring seal (10) on oil suction pipe

NOTICE
(11). If the front housing is not installed, do not turn
b. Install oil suction pipe (11) in the cylinder block.
c. Install oil strainer (13) to the cylinder block and Note: This removal procedure of the engine oil
install bolts (12). Tighten the bolts to a torque of pump and idler hub is with engine installed in the
11 N·m (97 lb in). application.
End By:
Removal of Engine Oil Pump
a. Install the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Install” for
the correct procedure.
i06601219
Engine Oil Pump - Remove

and Install
(Removal of Engine Oil Pump
and Idler Hub with the Engine
Installed in the Application)
Removal Procedure
Table 6
Required Tools
A T418753 Oil Pump Hub Puller 1 Illustration 42 g06039910
B 27610311 Slide Hammer Puller 1
Start By:
a. Remove the camshaft. Refer to Disassembly parts propelled by a released spring force.
and Assembly, “Camshaft - Remove” for the
correct procedure. Make sure to wear all necessary protective
equipment.
NOTICE Follow the recommended procedure and use all
Care must be taken to ensure that fluids are con- recommended tooling to release the spring force.
Be prepared to collect the fluid with suitable contain- 1. Remove C-clip (9) that retains idler gear (2) on
ers before opening any compartment or disassem- idler hub (7).
2. Remove the following items from idler hub (7) :
and mandates. • Collar (8)
• Spring (6)
NOTICE
Keep all parts clean from contaminants. • Shims (5)
Contaminants may cause rapid wear and shortened • Oil pump cover (4)
component life.
3. Remove idler gear (2) from idler hub (7).
4. Remove inner rotor (3) from idler hub (2).
UENR4546-02 25
5. Remove thrust washer (1) from idler hub (7).
Removal of Idler Hub
4. Install Tooling (A) to idler hub (7).Install Tooling (B)

to Tooling (A).
5. Use Tooling (A) to remove idler hub (7) from the
cylinder block. Remove Tooling (A) and Tooling (B)
from the idler hub. Discard the idler hub.
Table 7
Required Tools
1. Remove camshaft (10). Refer to Disassembly and Tool Part Number Part Description Qty
Assembly, “Camshaft - Remove” for the correct
C 27610327 Alignment Tool 1
procedure.
D - Multipurpose Grease 1
2. Remove bolts (13) from plate (12). Remove the
plate from the cylinder block. 21825617 Dial Indicator 1
E
3. Remove gasket (11) (not shown). - Magnetic Base and Stand 1
NOTICE
component life.
26 UENR4546-02
Installation for Idler Hub
1. Install the pin of Tooling (C) into the cylinder block.

2. Install idler hub (7) into the guide plate of Tooling
(C). Align the guide plate of Tooling (C) with pin of
Tooling (C).
5. Position a new gasket (11) (not shown) onto the
3. Use a hammer to strike the guide plate of Tooling cylinder block. Align plate (12) with the dowels in
(C). Drive idler hub (7) into the cylinder block until the cylinder block and install the plate. Install bolts
the guide plate contacts the front of the cylinder (13). Tighten the bolts to a torque of 10 N·m
block. (89 lb in).
4. Remove both parts of Tooling (C). 6. Install camshaft (10). Refer to Disassembly and
procedure.
UENR4546-02 27
Installation for Engine Oil Pump 2. Apply Tooling (B) to the faces of inner rotor (3) and
to the vanes of idler gear (2).
3. Align timing Marks (X) on idler gear (2) with the
respective timing marks on crankshaft gear (19)
and camshaft gear (14). Install idler gear (2) onto
idler hub (7).
4. Install inner rotor (3) to idler gear (2).
Personal injury can result from the release of the

spring force.
The drive shaft, the piston, and the drive gear are
under spring force.
Use a press to slowly release the spring force be-
fore the components are removed.
5. Install the following items to idler hub (7) :
• Oil pump cover (4)

• Shim (5)
• Spring (6)
• Collar (8)
6. Install C-clip (9) on idler hub (7).
1. Install thrust washer (1). Lubricate the thrust

washer with clean engine oil.
Improper assembly of parts that are spring

equipment.
28 UENR4546-02
End By:
a. Install the camshaft. Refer to Disassembly and
procedure.
i07082410
Water Pump - Remove and

Install
Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install” for the
correct procedure.
b. If necessary, remove the alternator. Refer to
Disassembly and Assembly, “Alternator -
NOTICE
Illustration 49 g06045435 component life.
7. Use Tooling (E) to measure the end play of the

engine oil pump. Refer to Specifications, “Engine NOTICE
Oil Pump” for the correct information. tained during performance of inspection, mainte-
and mandates.
1. Drain the coolant from the cooling system into a

suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Drain” for more information.
UENR4546-02 29
NOTICE
component life.
1. Ensure that the gasket surfaces of the water pump

and the cylinder block are clean and free from
damage.
Typical example
2. Loosen hose clamp (10) and disconnect hose (11)

from water pump (3).
Correct orientation of the water pump to block gasket
from water pump (3).
4. Loosen hose clamps (4) and disconnect hose (5)
from water pump (3) and the thermostat housing
5. Remove bolt (13) for alternator bracket (7).
Position the alternator bracket away from water
pump (3).
Note: The alternator bracket on some engines is

secured by two bolts.
6. Remove bolts (8) and nut (9) from water pump (1).
Remove the water pump from the cylinder block.
Note: If necessary, gently tap the water pump with a

soft faced hammer to loosen the water pump.
7. Remove gasket (12) (not shown).
Table 8
Required Tools Illustration 52 g06218256
Tool Part Number Part Description Qty Typical example

A - Loctite 242 1
30 UENR4546-02
2. Ensure that the bolt holes in Position (W) and stud

(14) are clean and free from oil and coolant.
3. Install a new gasket (12) (not shown) over stud
(14). Ensure that the gasket is correctly oriented.
Water pump bolts and nut tightening sequence
4. Apply Tooling (A) to the first two threads of bolts

(8) and nut (9).
5. Install water pump (3).
6. Install bolts (8) and nut (9) hand tight. Ensure that
gasket (12) (not shown) is correctly positioned.
7. Tighten bolts (8) and nut (9) to a torque of 5 N·m
(44 lb in) in the sequence shown in Illustration 54 .
Illustration 53 g06215571 8. Tighten bolts (8) and nut (9) to a torque of 10 N·m
Typical example (89 lb in) in the sequence shown in Illustration 54 .
9. Connect hose (1) to water pump (3). Securely
tighten hose clamp (2).
12. Position alternator bracket (7) onto water pump
(3). Loosely install bolt (13) to the alternator
bracket.
Note: The alternator bracket on some engines is
secured by two bolts.
13. Fill the cooling system with coolant. Refer to

System Coolant - Fill” for the correct procedure.
UENR4546-02 31
End By:
a. If necessary, install the alternator. Refer to
Disassembly and Assembly, “Alternator -
b. Install the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install” for the
correct procedure.
i06505962
Water Temperature Regulator

Housing - Remove and Install
Removal Procedure
NOTICE
component life.
NOTICE
ers before opening any compartment or disassem- 2. Loosen hose clamp (1) and disconnect hose (2)
bling any component containing fluids. from water temperature regulator housing (9).
Dispose of all fluids according to local regulations 3. Loosen hose clamps (5) and disconnect hose (6)
and mandates. from water temperature regulator housing (9) and
the water pump.
1. Drain the coolant from the cooling system into a 4. Cut cable strap (3) from clip (4) and harness
suitable container for storage or disposal. Refer to assemblies.
System Coolant - Drain” for more information. 5. Disconnect harness assembly (12) from coolant
temperature switch (11).
6. Remove bolts (10) and nuts (8) from water
temperature regulator housing (9).
7. Remove water temperature regulator housing (9)
from the cylinder head.
9. If necessary, remove coolant temperature switch
(11) from water temperature regulator (9). Refer to
Disassembly and Assembly, “Coolant Temperature
Switch - Remove and Install” for the correct
procedure.
10. If necessary, remove the water temperature
regulator. Refer to Disassembly and Assembly,
“Water Temperature Regulator - Remove and
Install” for the correct procedure.
32 UENR4546-02
Installation Procedure 6. Connect hose (6) to water temperature regulator

housing (9) and the water pump. Tighten hose
NOTICE clamps (5) to a torquer of 8 N·m (71 lb in).
7. Connect hose (2) to water temperature regulator
Contaminants may cause rapid wear and shortened housing (9). Tighten hose clamp (1) to a torquer of
component life. 8 N·m (71 lb in).
8. Connect harness assembly (12) to coolant
1. Ensure that the gasket surfaces of the cylinder
head and the water temperature regulator housing
are clean and free from damage. 9. Install a new cable strap (3) to clip (4) and harness
assemblies.
2. If necessary, install the water temperature
regulator. Refer to Disassembly and Assembly, Note: Ensure that the cable straps meet Original
“Water Temperature Regulator - Remove and Equipment Manufacture (OEM) specifications.
10. Fill the cooling system with coolant. Refer to
System Coolant - Fill” for the correct procedure.
i06507052
Water Temperature Regulator -

Remove and Install
Removal Procedure
NOTICE
component life.
NOTICE
Illustration 56 g06036030 and mandates.
3. If necessary, install coolant temperature switch

(11) from water temperature regulator (9). Refer to
Disassembly and Assembly, “Coolant Temperature
Switch - Remove and Install” for the correct
procedure.
4. Install a new gasket (7) (not shown) to the cylinder
head. Install water temperature regulator housing
(9) to the cylinder head.
5. Install bolts (10) and nuts (8). Tighten the bolts and
the nut to a torque of 10 N·m (89 lb in).
UENR4546-02 33
NOTICE
component life.
1. Inspect the water temperature regulator for wear,

damage, and correct operation. Refer to Systems
Operation, Testing and Adjusting, “Water
Temperature Regulator - Test” for more
information. If necessary, replace the water
temperature regulator.
2. Ensure that the gasket surfaces of the outlet
connection and the water temperature regulator
housing are clean and free from damage.

from outlet connection (3) of water temperature
regulator (8).
3. Remove bolts (4) from outlet connection (3).
Identify the orientation of the outlet connection for
installation.
4. Remove bracket (5). Note position and orientation
of the bracket.
5. Remove water temperature regulator (7) from of
water temperature regulator housing (8).
6. Remove gasket (6).
34 UENR4546-02
7. Tighten bolts (4) to a torque of 14 N·m (124 lb in).

Ensure that bracket (5) remaining in the correct
position.
8. Connect hose (2) to outlet connection (3) of water
temperature regulator (8). Tighten hose clamp (1)
to a torque of 8 N·m (71 lb in).
9. Fill the cooling system with coolant to the correct
level. Refer to Operation and Maintenance
Manual, “Cooling System Coolant -Fill” for more
information.
i06505963
Flywheel - Remove
Removal Procedure
Table 9
Illustration 59 g06036114 Part Description
A - Lifting Sling 1
B - Lifting Bracket 1
Guide Stud (M10 x 1.25 mm

C - 2
by 80 mm)
Start By:
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install” for the correct
procedure.
NOTICE
component life.
3. Install water temperature regulator (7) to water

temperature regulator housing (8).
4. Install a new gasket (3).
5. Install outlet connection (3) to water temperature
regulator housing (8). Ensure the correct
orientation of the outlet connection.
6. Position bracket (5) and install bolts (4) to outlet
connection (3). Ensure that the bracket is installed
into the original position.
UENR4546-02 35
6. Inspect ring gear (4) and flywheel (2) for wear or

damage. If the ring gear or the flywheel is worn or
damaged, use new parts for replacement.
7. To remove ring gear (4) from flywheel (2), place
the flywheel on a suitable support. Use a hammer
1. Remove crankshaft speed sensor (1) from the and a punch (5) to remove the ring gear from the
flywheel housing. Refer to Disassembly and flywheel.
Assembly, Crankshaft speed/timing sensor -
Remove and Install for the correct procedure. i06505964
2. Remove two bolts (3) in Position (X) on flywheel Flywheel - Install

(2). Install Tooling (C).
3. Install Tooling (A) and Tooling (B) to flywheel (2).
Attach a suitable lifting device to the flywheel. The
weight of the flywheel is approximately 42 kg
(93 lb). Table 10
Part Description
4. Remove the remaining bolts (3) and remove
flywheel (2). Tool Part Number Part Description Qty
5. Inspect dowel (4) in the crankshaft. Do not remove A - Lifting Sling 1

the dowel unless the dowel is damaged. B - Lifting Bracket 1
Guide Stud (M10 x 1.25 mm

C - 2
by 80 mm)
NOTICE
component life.
36 UENR4546-02
Always wear protective gloves when handling

parts that have been heated.
1. If the ring gear was removed, follow Step 1.a

through Step 1.c to install ring gear (4) to flywheel 2. Thoroughly clean the flywheel housing. Inspect the
(2). crankshaft rear seal for leaks. If there are any oil
leaks from crankshaft rear seal, replace the
a. Identify the orientation of the new ring gear to crankshaft rear seal. Refer to Disassembly and
install the ring gear correctly onto the flywheel. Assembly, “Crankshaft Rear Seal - Remove and
Note: The chamfered side of Gear Teeth (Y) must
face toward the starting motor when the flywheel is 3. Inspect dowel (4) in the crankshaft. Replace the
installed. The chamfered ensures the correct dowel if the dowel is damaged or worn. Do not
engagement of the starting motor. remove the dowel unless the dowel is worn or
damaged.
b. Heat ring gear (3) in an oven to a maximum
4. Install Tooling (C) to Positions (X) in the
temperature of 150°C (302°F) prior to
crankshaft.
installation.
5. Install Tooling (A) and Tooling (B) to flywheel (2).
Note: Do not use a torch to heat the ring gear. Attach a suitable lifting device to the flywheel. The
weight of the flywheel is approximately 42 kg
c. Ensure the orientation of ring gear (4) is correct (93 lb).
and quickly install the ring gear onto flywheel
(2). 6. Position flywheel (2) onto Tooling (C). Align the
flywheel with dowel (4) in the crankshaft.
7. Install bolts (3) finger tight.
8. Remove Tooling (C) and install the two remaining
bolts (3).
9. Use a suitable tool to prevent flywheel (2) from
rotating. Tighten bolts (3) to a torque of 74 N·m
(54 lb ft).
UENR4546-02 37
10. Remove Tooling (A), Tooling (B) and the lifting

device from flywheel (2).
11. Install crankshaft speed sensor (1) from the
flywheel housing. Refer to Disassembly and
Assembly, Crankshaft speed/timing sensor -
Remove and Install for the correct procedure.
End By:
a. Install the electric starting motor. Refer to
procedure.
i06505965
Crankshaft Rear Seal -

Remove and Install
Removal Procedure Illustration 65 g06036787
Start By: 1. Remove bolts (4) and remove back plate (3) from
cylinder block (6).
a. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel 2. Remove crankshaft rear seal (2) from cylinder
Housing - Remove and Install” for the correct block (6).
procedure.
3. Inspect dowel (1) and dowel (5). Do not remove
NOTICE the dowels unless the dowels are damaged.
component life. Table 11
Required Tools

NOTICE
Care must be taken to ensure that fluids are con- A - Loctite 5900 1
ers before opening any compartment or disassem- NOTICE
bling any component containing fluids. Keep all parts clean from contaminants.
Dispose of all fluids according to local regulations Contaminants may cause rapid wear and shortened
and mandates. component life.
38 UENR4546-02
3. Ensure that crankshaft flange (7) is clean and free

from damage. For a damaged or worn seal
surface of a crankshaft flange, installation of a
wear sleeve can be carries out. Refer to
Disassembly and Assembly, “Crankshaft Wear
Sleeve (Rear) - Remove and Install” for more
information.
4. Apply a continuous bead of Tooling (A) around
Plug (W).
5. Apply a continuous bead of Tooling (A) to Recess
(X) in cylinder block (6) for crankshaft rear seal (2).
6. Apply clean lubricating oil to the flange of
crankshaft (7) around the running surface of
crankshaft rear seal (2).
7. Align a new crankshaft rear seal (2) with the flange
of crankshaft (7). Carefully install the crankshaft
rear seal onto the crankshaft flange.
8. Align back plate (3) with dowel (1) and dowel (5).
Install the back plate to cylinder block (6).
9. Install bolts (4). Tighten the bolts to a torque of
25 N·m (221 lb in).
End By:
a. Install the flywheel housing . Refer to
Disassembly and Assembly, “Flywheel
Housing - Remove and Install” for the correct
procedure.
i06505966
Crankshaft Wear Sleeve (Rear)

- Remove and Install
Removal Procedure
Start By:
a. Remove the crankshaft rear seal. Refer to
Illustration 67 g06036838 Disassembly and Assembly, “Crankshaft Rear
Seal - Remove and Install” for the correct
1. Ensure the mating surface of cylinder block (6) and procedure.
back plate (3) are clean and free from damage.
NOTICE
Inspect dowel (1) and dowel (5). If the dowels are Keep all parts clean from contaminants.
damaged, use new parts for replacement.
2. Ensure that Recess (X) in cylinder block (6) for component life.
crankshaft rear seal (2) is clean and free from
damage.
Note: Wear sleeves are used to reclaim worn seal
surfaces or damaged seal surfaces. Wear sleeves
are not original equipment.
UENR4546-02 39

Sectional view of the crankshaft and of the wear Sectional view of the wear sleeve
sleeve
2. Apply a small continuous bead of Tooling (A) to the
1. Use a sharp tool to score a deep line across inner surface of crankshaft wear sleeve (1) at
crankshaft wear sleeve (1). Position X. Apply the bead of Tooling (A) 5.00 mm
(0.2 inch) from the flange end of the crankshaft
Note: Take care to avoid damaging the
crankshaft. wear sleeve.
2. Insert a thin blade between crankshaft wear sleeve

(1) and crankshaft (2) below the scored line. The
crankshaft wear sleeve will separate along the
line.
3. Remove crankshaft wear sleeve (1) from
crankshaft (2).
Table 12
Required Tools
A - Loctite 509 1
NOTICE
component life.
1. Ensure that the palm of the crankshaft is

thoroughly clean and dry. Remove any areas of
raised damage.
40 UENR4546-02
3. Align crankshaft wear sleeve (1) with crankshaft

(2). Position installation tool (3) that is provided
with the crankshaft wear sleeve over the
crankshaft. Use a hammer to drive the crankshaft
wear sleeve onto the crankshaft. Ensure that
Dimension (W) is 7.5 mm (0.295 inch).
Note: Dimension (W) is the distance from the edge of

the crankshaft wear sleeve from the rear face of the
crankshaft.
4. Remove installation tool (3).

5. If necessary, cut flange (X) of wear sleeve (1) and
use long nose pliers to tear the flange along the
tear off Groove (Y).
6. Ensure that crankshaft wear sleeve (1) has no
rough edges.
End By:
a. Install a new crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
Seal - Remove and Install” for the correct
procedure.
i06505969
Flywheel Housing - Remove
Sectional view of the crankshaft, the wear sleeve, and Install
and the installation tool
Removal Procedure
Start By:
a. Remove the electric starting motor. Refer to
procedure.
b. Remove the flywheel. Refer to Disassembly
and Assembly, “Flywheel - Remove” for the
correct procedure.
NOTICE
component life.
Sectional view of the crankshaft and of the wear
sleeve showing tear off groove (Y)
UENR4546-02 41
1. Install a suitable lifting device to flywheel housing

(2). The weight of the flywheel housing is
approximately 30 kg (66 lb).
2. Remove bolts (1), bolts (3), and nut and bolts (4)
from flywheel housing (2).
3. Use the lifting device to remove flywheel housing
(2) from the engine.
NOTICE
component life.
42 UENR4546-02
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install” for the correct
procedure.
b. Install the electric starting motor. Refer to
procedure.
i06505970
Crankshaft Pulley - Remove

and Install
Removal Procedure
Start By:
a. Remove the V-belt. Refer to Disassembly and
1. Ensure the mating surface of flywheel housing (2) Assembly, “V Belts - Remove and Install” for
and back plate (8) are clean and free from
Table 13
damage. Inspect the crankshaft rear seal (6) for
leaks. If necessary, replace the crankshaft rear Required Tools
seal. Refer to Disassembly and Assembly, Tool Part Number Part Number Qty
“Crankshaft Rear Seal - Remove and Install” for
the correct procedure. Inspect dowel (5) and 21825619 Puller 1
A
dowel (7) for damage. If the dowels are damaged, - Bolt 3
use new parts for replacement.
2. Use a suitable lifting device to align flywheel
housing (2) to dowel (5) and dowel (7). install the
flywheel housing. The weight of the flywheel
housing is approximately 30 kg (66 lb).
3. Install bolts (1), bolts (3), and nut and bolts (4) to
flywheel housing (2).
4. Tighten bolts and nut (4) and bolts (3) to a torque
of 50 N·m (37 lb ft).
Tighten bolts (1) to a torque of 75 N·m (55 lb ft).
5. Remove the lifting device from flywheel housing
(2).
UENR4546-02 43
1. Ensure that the following components are clean
and free from damage: the taper of the crankshaft,
the key, and the bore of the crankshaft pulley.
Replace any components that are damaged.
Ensure that the taper of the crankshaft and the
bore of the crankshaft pulley are clean and dry
before assembly.
2. Install key (1) to crankshaft (4). Ensure that the key

is correctly seated into the crankshaft.
3. Install crankshaft pulley (2) to crankshaft (4).
Ensure that the crankshaft pulley is correctly
seated onto the key and the crankshaft.
4. Lubricate nut (3) with clean engine oil and install
the nut. Tighten the nut to a torque of 304 N·m
(224 lb ft).
1. Loosen nut (3). Do not remove the nut.

2. Install Tooling (A) to crankshaft pulley (2). Use
Tooling (A) to remove crankshaft pulley (2) from
crankshaft (4). Remove Tooling (A).
3. Remove nut (3).
4. Remove pulley (2) from crankshaft (4).
5. Remove key (1) from crankshaft (4).
44 UENR4546-02
End By: 1. Use Tooling (B) and a drill to make three holes in
crankshaft front seal (2).
a. Install the V-belt to the engine. Refer to
Disassembly and Assembly, “V Belts - Remove
NOTICE
and Install” for the correct procedure. Ensure that the main lip is used in order to remove
the crankshaft front seal. Do not damage the edge of
i06505971 the housing for the crankshaft front seal.
Crankshaft Front Seal -

Note: Do not damage the crankshaft during the
Remove and Install removal process of the crankshaft front seal.
2. Use Tooling (A) to remove crankshaft front seal

(2). Alternate the position of Tooling (A) from one
Removal Procedure hole to another hole. Using alternative position will
Table 14 allow you to remove the crankshaft front seal
Required Tools evenly from front housing (1).
Tool Part Number Part Description Qty Alternative Removal Procedure

A 27610311 Slide Hammer Puller 1 Start By:
B - Drill Bit 4 mm (0.158 inch) 1 a. Remove the front housing. Refer to
Start By: Remove” for the correct procedure.
a. Remove the crankshaft pulley. Refer to NOTICE

Disassembly and Assembly, “Crankshaft Keep all parts clean from contaminants.
Pulley - Remove and Install” for the correct
procedure. Contaminants may cause rapid wear and shortened
component life.
NOTICE
Note: The alternative removal procedure can be
Contaminants may cause rapid wear and shortened used to remove the crankshaft front seal. This
component life. procedure may be used if the front housing has
been removed from the engine.
1. Use a suitable mandrel and a press to remove the

crankshaft front seal from the front cover. Ensure
that the front cover is supported to prevent
damage to the cover as the crankshaft front seal is
being removed.
Alternative Installation Procedure

1. The alternative installation procedure can be
used to install the crankshaft front seal. This
procedure may be used if the front housing
has been removed from the engine.
2. Ensure that the front cover is free from wear or
damage. Ensure that the bore for the crankshaft
front seal is free from wear or damage. Replace
any component the are not free from wear or
damage.
3. Place the front cover on a suitable support to
prevent damage to the cover as the oil seal is
Illustration 78 g06046106 being installed. Use a suitable mandrel and a
Typical example press the crankshaft front seal into the front cover.
UENR4546-02 45
Installation Procedure End By:
NOTICE a. Install the crankshaft pulley. Refer to

Keep all parts clean from contaminants. Disassembly and Assembly, “Crankshaft
Contaminants may cause rapid wear and shortened procedure.
component life.
i06505972
Housing (Front) - Remove
Removal Procedure
Start By:
a. Remove the secondary speed sensor. Refer to
Disassembly and Assembly, “Secondary
Speed Sensor- Remove and Install” for the
correct procedure.
b. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft
procedure.
NOTICE
component life.
Typical example
NOTICE
1. Ensure that crankshaft front seal (2) bore in front Care must be taken to ensure that fluids are con-
housing (1) and the nose of the crankshaft are tained during performance of inspection, mainte-
clean and free from damage. nance, testing, adjusting and repair of the product.
2. Lubricate the lip of a new crankshaft front seal (2) ers before opening any compartment or disassem-
with clean engine oil. bling any component containing fluids.
3. Position crankshaft front seal (2) in the bore of Dispose of all fluids according to local regulations
front housing (1). and mandates.
NOTICE
Ensure that the lip of the crankshaft front seal that is
spring loaded is facing toward the inside of the front
housing and that it is square with the bore of the
housing for the crankshaft front seal.
4. Use a suitable tool to install crankshaft front seal

(2) to front housing (1).
46 UENR4546-02
5. Remove crankshaft front seal (5) from housing (2).

Refer to Disassembly and Assembly, “Crankshaft
Front Seal - Remove and Install” for the correct
procedure.
i06505975
Housing (Front) - Install
Table 15
Required Tools
A(1) 21825621 Seal Protector 1

(1) 404S-22 Gas
NOTICE
component life.
Illustration 80 g06032660 NOTICE

With the housing removed from the engine, the
crankshaft should not be turned. Turning the
1. Remove bolts (5) and remove plate (4). crankshaft will result in damaged to the engine
2. Remove nuts (3), bolts (1), and bolts (7). oil pump and the gear group.
NOTICE
After housing (2) has been removed from the en-
gine, the crankshaft should not be turned. Turn-
ing the crankshaft will result in damaged to the
engine oil pump and the gear group.
3. Remove housing (2).

UENR4546-02 47
1. Ensure that gasket surface of housing (2) and

plate (12) are clean and free from damage.
2. Ensure the nose of crankshaft (9) is clean and free
from damage. Install Tooling (A) onto the nose of
the crankshaft.
3. Install a new crankshaft front seal (5) to housing
(2). Refer to Disassembly and Assembly,
“Crankshaft Front Seal - Remove and Install” for
4. Position a new gasket (8) (not shown) onto plate
(12). Ensure that the gasket is correctly orientated
and is correctly positioned onto the plate.
5. Align pin (13) with Hole (X) in oil pump cover (10).
Ensure that the oil pump cover is concentric to
idler gear assembly (11).
6. Align front housing (2) to the dowels in plate (12)
and install front the housing onto the plate.
7. Install nuts (3), bolts (1), and bolts (7) to housing
(2). Tighten the nuts and the bolts hand tight.
Note: Ensure that the housing is correctly seated
onto the plate (12) and the dowels.
8. Tighten nuts (3), bolts (1), and bolts (7) to a torque

of 10 N·m (89 lb in).
9. Remove Tooling (A) from the nose of the
crankshaft.
48 UENR4546-02
10. Position plate (4) onto the rear of plate (12) and
install bolts (5). Tighten the bolts to a torque of
44 N·m (32 lb ft).
End By:
a. Install the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft
procedure.
b. Install the secondary speed sensor. Refer to
Disassembly and Assembly, “Secondary
Speed Sensor- Remove and Install” for the
correct procedure.
i06505976
Crankcase Breather - Remove

and Install
Removal Procedure
1. Remove bolt (4) from clip (3) and clip (5).
NOTICE 2. Loosen hose clamp (1) and disconnect hose
assembly (2) from valve mechanism cover (6).
component life.
NOTICE
and mandates.
3. If necessary, follow Step 3.a through Step 3.d to

disassemble valve mechanism cover (6).
UENR4546-02 49
a. Remove valve mechanism cover (6). Refer to

Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install for the correct
procedure.
b. Remove bolts (7) from the assembly of breather

adaptor (8).
c. Remove breather adaptor (8) from valve

mechanism cover (6). Remove gasket (9).
d. Remove screws (12). Remove baffle plate (11)

and gauze (10) from valve mechanism cover
(6).
Table 16
Required Tools
A 27610296 Torque Wrench 1
NOTICE
component life.
2. If necessary, follow Step 2.a through Step 2.c to

NOTICE
Make sure that the components of the breather as- assemble valve mechanism cover (6).
sembly are installed correctly. Engine damage may
occur if the breather assembly is not working a. Install gauze (10) into valve mechanism cover
properly. (6) and position baffle plate (11) into the valve
mechanism cover. Install screws (12) and use
Tooling (A) to a torque of 1.5 N·m (13 lb in).
1. Ensure that all components of the valve
mechanism cover are free from damage, wear, or b. Install a new gasket (9) onto valve mechanism
restriction. Replace any component that is cover (6). Position breather adaptor (8) onto the
damage, wear, or restricted. valve mechanism cover. Install bolts (7) and
tighten the bolts to a torque of 3 N·m (27 lb in).
c. Install valve mechanism cover (6). Refer to

Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install for the correct
procedure.
50 UENR4546-02
NOTICE
and mandates.

position.
3. Ensure hose assembly (2) is free from restriction.

Replace the hose assembly if the hose assembly
is restricted.
4. Connect hose assembly (2) to valve mechanism
cover (6). Ensure that the hose assembly is
correctly routed and installed.
5. Install bolt (4) to clip (3) and clip (5). Ensure that
the clips are correctly positioned.
6. Tighten hose clamp (1) to a torque of 8 N·m
(71 lb in).
7. Tighten bolt (4) to a torque of 10 N·m (88 lb in).
Ensure that clip (3) and clip (5) are not strained as
the bolt is tightened.
i06505977
Valve Mechanism Cover -

Remove and Install
Removal Procedure
NOTICE
component life.
UENR4546-02 51
5. Disconnect harness assembly (18) for the inlet

manifold temperature and the air pressure sensor.
6. Disconnect harness assembly (21) from the
coolant temperature sensor.
7. Make temporary marks on harness assembly (19)
and harness assembly (21) for installation
purposes. Disconnect the harness assemblies
from the throttle controller and the mixer controller.
8. Disconnect harness assemblies (11) from ignition
coils (12). Remove bolts (13) and remove the
ignition coils from bracket (10).
9. Remove bolts (9) for earth straps (9a) and remove
the earth straps.
10. Position harness assembly (19) away from the
valve mechanism cover.
11. Remove bolt (2) and the spacer from bracket
(10).
12. Remove bolts (4) from bracket (10).
13. Remove bolts (6) from bracket (5). Remove nut
(7) and remove the bracket.
14. Remove bracket (10) from the valve mechanism
cover.
2. Cut cable strap (1), cable strap (3), and cable strap
(8).
Note: Note position of the cable strap for installation

purposes.
3. Cut cable strap (14), cable strap (16), and cable

strap (17).
Note: Note position of the cable strap for installation
purposes.
4. Disconnect harness assembly (15) for the oxygen

sensor.
52 UENR4546-02
19. Remove nuts (33) and washers (32) (not shown)

from valve mechanism cover (36).
Illustration 90 g06033248 20. Remove bolts (34) from valve mechanism cover
(36).
Note: Loosen the bolts evenly to avoid distortion of

the valve mechanism cover.
21. Remove valve mechanism cover (36) from base

(37). Remove O-ring seal (35) (not shown) from
valve mechanism cover (36).
NOTICE
component life.
1. Ensure that all components of the valve

mechanism cover are free from wear or damage.
Replace any component that is worn or damage.
15. Loosen hose clamp (23). Remove bolt (26) from

clip (25) and clip (27). Disconnect hose assembly
(24) from the valve mechanism cover.
Note: Note position and orientation of the clips for

installation purposes.
16. Loosen bolts (30) for bracket (31). sufficiently

loosen the bolt to allow the valve mechanism
cover to be removed.
17. Remove Allen head bolts (29) from the inlet
elbow.
UENR4546-02 53
7. Ensure that the gasket surfacers of the inlet elbow

and the valve mechanism cover are clean and free
from damage. Position a new gasket (26) (not
shown) between the inlet elbow and the valve
mechanism cover. Install Allen head bolts (29)
hand tight.
8. Hand tighten bolts (30) for bracket (31). Ensure
that the inlet elbow is not stained as the bolts are
hand tighten.
9. Tighten bolts (34) to a torque of 10 N·m (89 lb in).
Tighten nuts (33) to a torque of 14 N·m (124 lb in).
Note: Torque the bolts and nuts evenly.

10. Tighten Allen head bolts (29) to a torque of
10 N·m (89 lb in).
Tighten bolts (30) to a torque of 25 N·m
(221 lb in).
2. Ensure the recess in valve mechanism cover (36)

is free from oil.
3. Install a new O-ring seal (35) (not shown) to valve Illustration 95 g06033248
mechanism cover (36). Ensure that the O-ring seal

is correctly installed into the recess into the valve 11. Connect hose assembly (24) to the valve
mechanism cover. mechanism cover. Tighten hose clamp (23) to a
4. Install valve mechanism cover (36) to base (37).
Ensure that the O-ring seal is not damaged or 12. Position clip (25) onto clip (27) and install bolt
dislodged as the valve mechanism cover is (25) to the clips. Ensure that clip (25) is correctly
installed. orientated.
5. Loosely install bolts (34) to valve mechanism cover 13. Tighten bolt (26) to a torque of 10 N·m (89 lb in).
(36).
6. Install new washers (32) (not shown) to the studs.
Loosely install nuts (33) to valve mechanism cover
(36).
54 UENR4546-02
18. Hand tighten bolts (9). Hand tighten bolts (4), bolt
(2), and bolts (6). Ensure that bracket is correctly
position.
19. Tighten bolts (9) to a torque of 44 N·m (32 lb ft).
Ensure that earth straps (9a) are not strained as
the bolts are tightened.
20. Tighten bolts (4), bolt (2), and bolts (6) to a torque
of 10 N·m (89 lb in).
21. Tighten nut to a torque of 44 N·m (32 lb ft).
Ensure that the rubber mount is not strained as the
nut is tightened.
22. Connect harness assembly (15) to the oxygen
sensor.
23. Connect harness assembly (18) to the inlet
manifold temperature and the air pressure sensor.
24. Connect harness assembly (21) to the coolant
temperature sensor.
25. Connect harness assembly (19) the mixer
controller. Connect harness assembly (21) to the
throttle controller. Ensure that the harness
assemblies are connected to the correct
controllers.
26. Install new cable strap (1), cable strap (3), and
cable strap (8).
Note: Ensure that the cable straps meet the Original
Equipment Manufacture (OEM) specification.
27. Install new cable strap (14), cable strap (16), and
cable strap (17).
Note: Ensure that the cable straps meet the Original

Equipment Manufacture (OEM) specification.
28. Install ignition coils (12) into bracket (10). Ensure

that the ignition coils are correctly orientated.
Install bolts (13) hand tight. Tighten the bolts to a
29. Connect harness assemblies (11) to ignition coils
(12).
14. Position bracket (10) onto the valve mechanism
cover. Loosely install bolts (4) to the bracket.
15. Install bracket (5) and loosely install nut (7).
Loosely install bolts (6) to the bracket.
16. Install the spacer between bracket (10) and
loosely install bolt (2).
17. Install harness assembly (19). Ensure that the
harness assembly is correctly routed. Loosely
install bolts (9) to earth straps (9a). Ensure that the
earth straps are correctly positioned and oriented.
UENR4546-02 55
30. Turn the battery disconnect switch to the ON 4. Place temporary identification marks on caps (4)
position. and pushrods (6).
i06505978
Note: Identification will ensure that the pushrods and
the caps can be reinstalled in the original positions.
Do not interchange the positions of used pushrods or
Rocker Shaft and Pushrod - caps.
Remove
5. Remove pushrods (6) from the cylinder head.
Remove caps (4) from the valve stems.
Removal Procedure
Start By:
a. Remove the engine oil line. Refer to
Disassembly and Assembly, “Engine Oil Line -
b. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install” for the
correct procedure.
NOTICE
component life.
6. Remove O-ring seal (8) from rocker shaft

assembly (5).
i06505979
Rocker Shaft - Disassemble
Disassembly Procedure
Start By:
a. Remove the rocker shaft and the pushrods.
Refer to Disassembly and Assembly, “Rocker
Shaft and Pushrod - Remove” for the correct
procedure.
NOTICE
1. Loosen nuts (3) and loosen adjustment screws (2) Keep all parts clean from contaminants.
on all rocker arms. Loosen the adjustment screws
to remove the strain off the rocker arms. Contaminants may cause rapid wear and shortened
component life.
2. Remove nuts (1) and bolts (7) from rocker shaft
assembly (5).
1. Make a temporary identification mark on each
3. Remove rocker shaft assembly (5) from the rocker arm assembly to show the location.
cylinder head.
56 UENR4546-02
Note: Used components must be reinstalled in the 5. Remove adjustment screws (1) and nuts (2) from
original location. Do not interchange components. rocker arms (3).
i06505980
Rocker Shaft - Assemble
Assembly Procedure

equipment.
NOTICE
component life.
1. Ensure that all components are clean and free

from wear or damage. Refer to Specifications,
“Rocker Shaft” for more information. If necessary,
replace any components that are worn or
damaged.
2. To remove rocker shaft (6), install a suitable bolt

into the end of the rocker shaft. Use the bolt to pull
the rocker shaft from base (8).

equipment.
3. Remove rocker arms (3), washers (5), and springs

(4).
4. Remove O-ring seal (7) from rocker shaft (6).
UENR4546-02 57
• Rocker arm (3)
7. Repeat Steps 5 and 6 to install the remaining

components.
8. Ensure that rocker shaft (6) is fully engaged into
base (8). Check that Recesses (X) on the rocker
shaft are aligned with Holes (Y) in the base.
End By:
a. Install the rocker shaft and the pushrods. Refer
to Disassembly and Assembly, “Rocker Shaft
and Pushrod - Install” for the correct
procedure.
i06505981
Rocker Shaft and Pushrod -

Install
NOTICE
component life.

from wear or damage. Refer to Specifications,
“Rocker Shaft” for more information. Replace any
components that are worn or damaged.
2. Lubricate adjustment screw (1) with clean engine

oil. Install adjustment screw (1) and nut (2) to
rocker arm (3). Repeat the process for the
remaining rocker arms.
3. Install a new O-ring seal (7) onto rocker shaft (6).
Lubricate the rocker shaft with clean engine oil.
4. Position the end of rocker shaft (6) into the bore in
base (8). Align Recesses (X) on the rocker shaft
with Holes (Y) in the base.
5. Gradually insert rocker shaft (6) into the base (8).
Install rocker arm (3).
6. Continue to insert rocker shaft (6) and install the
following components to the rocker shaft:
• Rocker arm (3)
• Washer (5)
• Spring (4)
• Washer (5)
58 UENR4546-02
Note: If the pushrods have been used, ensure that

the pushrods are installed in original positions.
5. Lubricate the top of the valve stems with clean

engine oil. Install caps (4) to the valve stems.
Note: If the caps have been used, ensure that the

caps are installed in original positions.
6. Install rocker shaft assembly (5) to the cylinder

head. Ensure that the ends of adjustment screws
(2) are correctly seated in ends of the pushrods.
7. Install nuts (1). Use a deep socket to tighten the
nuts evenly. Begin at the center of the rocker shaft
and work outward. Tighten the nuts to a torque of
33 N·m (292 lb in).
8. Install bolts (7) and tighten to a torque of 10 N·m
(88 lb in).
9. Adjust the valve lash. Refer to Systems Operation,
Testing and Adjusting, “Engine Valve Lash -
Inspect/Adjust” for the correct procedure.
2. Ensure the recess in rocker shaft assembly (5) is Tighten nuts (3) to a torque of 14 N·m (124 lb in).
clean and free from oil or damage. Hold adjustment screws (2) as the nuts are
tightened.
3. Install a new O-ring seal (8) to the base of rocker
shaft assembly (5). Ensure that the O-ring seal is End By:
correctly seated into the recess of the base of
a. Install the valve mechanism cover. Refer to
rocker shaft assembly. Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install” for the
correct procedure.
b. Install the engine oil line. Refer to Disassembly
and Assembly, “Engine Oil Line- Remove and
i07103469
Cylinder Head - Remove
NOTICE
One of two types of cylinder head bolts can be in-
stalled. Type One bolts can be reused if the bolts are
serviceable. Refer to Illustration 104 . Type Two bolts
must be discarded and new bolts installed. Refer to Il-
lustration 105 .
4. Apply clean engine lubricating oil to both ends of

pushrods (2). Install the pushrods to the engine
with the cup upward. Ensure that the pushrods are
installed correctly in the socket of the valve lifters.
UENR4546-02 59
Removal Procedure
Start By:
a. Remove the exhaust manifold. Refer to
Disassembly and Assembly, “Exhaust
Manifold - Remove and Install” for the correct
procedure.
b. Remove the fuel filter base. Refer to
Disassembly and Assembly, “Fuel filter Base -
c. Remove the fuel injectors. Refer to
Disassembly and Assembly, “Fuel Injector -
d. Remove the glow plugs. Refer to Disassembly
and Assembly, “Glow Plugs- Remove and
e. Remove the rocker shaft and the pushrods.
Refer to Disassembly and Assembly, “Rocker
Shaft and Pushrod - Remove” for the correct
procedure.
Type One cylinder head bolts f. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove and
NOTICE
component life.
NOTICE
and mandates.

suitable container for storage or for disposal. Refer
Illustration 105 g06220283 to Operation and Maintenance Manual, “Cooling
Type Two cylinder head bolts System Coolant - Drain” for the correct draining
procedure.
60 UENR4546-02
Note: Do not use a lever to separate the cylinder

head from the cylinder block. Take care not to
damage the machined surfaces of the cylinder head
during the removal procedure. Avoid contamination
of the cylinder bores with coolant or with debris.
NOTICE
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.
5. Remove the cylinder head gasket.
Note: The old gasket for the cylinder head should be

retained for identification. Gaskets of different
thickness are available. Refer to Specifications,
“Cylinder Head” for further information.

Typical example

Typical example
6. Note the position of dowels (3) in the cylinder

block. Do not remove the dowels unless the
dowels are damaged.

7. If necessary, remove the water temperature
regulator from the cylinder head. Refer to
The cylinder head tightening sequence
Disassembly and Assembly, “Water Temperature
2. Gradually loosen bolts (1) in reverse numerical Regulator - Remove and Install” for the correct
order. This order will prevent distortion of the procedure.
cylinder head.
i07103470
Loosen the cylinder head bolts in the reverse
order to the sequence that is shown in Illustration Cylinder Head - Install
107 .
3. Remove bolts (1) from cylinder head (2).
Note: Type Two bolts must be discarded NOTICE
One of two types of cylinder head bolts can be in-
4. Attach a suitable lifting device to cylinder head (2). stalled. Type One bolts can be reused if the bolts are
The weight of the cylinder head is approximately serviceable. Refer to Illustration 109 . Type Two bolts
30 kg (66 lb). Carefully lift the cylinder head off the must be discarded and new bolts installed. Refer to Il-
lustration 110 .
cylinder block.
UENR4546-02 61
Table 17
Required Tools
A - Guide Bolt (M11 by 100 mm) 2
B - Straight Edge 1
1. Thoroughly clean the gasket surfaces of the

cylinder head and the cylinder block. Do not
damage the gasket surfaces of the cylinder head
or the cylinder block. Ensure that no debris enters
the cylinder bores, the coolant passages, or the
lubricant passages.
2. Inspect the gasket surface of the cylinder head for
distortion. Refer to Specifications, “Cylinder Head”
for more information. If the mating surface of the
cylinder head is distorted beyond maximum
permitted limits, replace the cylinder head.
Type One cylinder head bolts

Typical example

Type Two cylinder head bolts
Installation Procedure for Type One

Cylinder Head Bolts
NOTICE
component life. Typical example
62 UENR4546-02

Typical example Inspection of Type One cylinder head bolts
3. Inspect dowels (3) for damage. If necessary, 10. Clean Type One bolts (1). Follow Step 10.a
replace the dowels in the cylinder block. through 10.b to inspect the Type One bolts.
4. Install Tooling (A) to the cylinder block. Refer to a. Check the length of Type One bolts (1).
Illustration 111 .
b. Use Tooling (B) to check the threads of bolts (1).
5. Ensure that the new cylinder head gasket (4) is the
Refer to Illustration 114 . If any Type One bolts
same thickness as the cylinder head gasket that
show visual reduction in the diameter of the
was previously removed. The thickness of the
thread over Length (Y), replace the bolts with
cylinder head gasket is indicated by the number
a new set of Type Two bolts. If Type One
that is shown at Position (X). Refer to
bolts are replaced with a new set of Type
Specifications, “Cylinder Head” for more
Two bolts, refer to the installation procedure
information.
for Type Two bolts.
6. Align cylinder head gasket (4) with Tooling (A) and
11. Install bolts (1) to cylinder head (2).
with dowels (3). Install the cylinder head gasket
onto the cylinder block.
7. Use a suitable lifting device to lift the cylinder
head. The weight of the cylinder head is
8. Use Tooling (A) to align cylinder head (2) with the
cylinder block. Install the cylinder head to the
cylinder block.
Note: Ensure that the cylinder head is correctly
positioned onto dowels (3).

The tightening sequence
UENR4546-02 63
12. Tighten the bolts to a torque of 101 N·m (75 lb ft).

Use the numerical sequence that is shown in
Illustration 115 .
regulator to the cylinder head. Refer to
Regulator- Remove and Install”.
End By:
a. Install the water pump. Refer to Disassembly
and Assembly, “Water Pump - Install”.
b. Install the rocker shaft and the pushrods. Refer
and Pushrod - Install”. Illustration 116 g01317467
c. Install the glow plugs. Refer to Disassembly Typical example

and Assembly, “Glow Plugs - Remove and
Install”.
d. Install the fuel injectors. Refer to Disassembly
and Assembly, “Fuel Injector - Install”.
e. Install the fuel filter base. Refer to Disassembly
and Assembly, “Fuel filter Base - Remove and
Install”.
f. Install the exhaust manifold. Refer to
Manifold - Remove and Install”.
Installation Procedure for Type Two

Cylinder Head Bolts
NOTICE Illustration 117 g01317471
Keep all parts clean from contaminants. Typical example
component life.
Table 18
Required Tools
A - Guide Bolt (M11 by 100 mm) 2
B 21825607 Angle Gauge 1
1. Thoroughly clean the gasket surfaces of the

cylinder head and the cylinder block. Do not
damage the gasket surfaces of the cylinder head
or the cylinder block. Ensure that no debris enters
the cylinder bores, the coolant passages, or the
lubricant passages.
2. Inspect the gasket surface of the cylinder head for
distortion. Refer to Specifications, “Cylinder Head”
for more information. If the mating surface of the
cylinder head is distorted beyond maximum Illustration 118 g06221686
permitted limits, replace the cylinder head. Typical example
64 UENR4546-02
3. Inspect dowels (3) for damage. If necessary,

replace the dowels in the cylinder block.
4. Install Tooling (A) to the cylinder block. Refer to
Illustration 116 .
5. Ensure that the new cylinder head gasket (4) is the
same thickness as the cylinder head gasket that
was previously removed. The thickness of the
cylinder head gasket is indicated by the number
that is shown at Position (X). Refer to
Specifications, “Cylinder Head” for more
information.
6. Align cylinder head gasket (4) with Tooling (A) and
with dowels (3). Install the cylinder head gasket
onto the cylinder block.
7. Use a suitable lifting device to lift the cylinder
head. The weight of the cylinder head is
8. Use Tooling (A) to align cylinder head (2) with the
cylinder block. Install the cylinder head to the
cylinder block.
Note: Ensure that the cylinder head is correctly
positioned onto dowels (3).

10. Install new bolts (1) to cylinder head (2).
UENR4546-02 65

The tightening sequence
11. Tighten the bolts to a torque of 50 N·m (37 lb ft).

Use the numerical sequence that is shown in
Illustration 119 . Use Tooling (B) to turn the bolts a
further 150 degrees in the numerical sequence as
shown in Illustration 119 .
regulator to the cylinder head. Refer to
Regulator- Remove and Install”.
66 UENR4546-02
End By:
a. Install the water pump. Refer to Disassembly
and Assembly, “Water Pump - Install”.
b. Install the rocker shaft and the pushrods. Refer
and Pushrod - Install”.
c. Install the glow plugs. Refer to Disassembly
and Assembly, “Glow Plugs - Remove and
Install”.
d. Install the fuel injectors. Refer to Disassembly
and Assembly, “Fuel Injector - Install”.
e. Install the fuel filter base. Refer to Disassembly
and Assembly, “Fuel filter Base - Remove and
Install”.
f. Install the exhaust manifold. Refer to
Manifold - Remove and Install”.
i06505984 Illustration 120 g06034502
Lifter Group - Remove and 1. Use Tooling (A) to remove lifter (1) from the
Install cylinder block.
Note: Make a temporary identification mark on each
lifter to identify the correct location.
Removal Procedure 2. Repeat Step 1 for remaining lifters (1).
Table 19
Required Tools
Tool Part Number Part Description Qty NOTICE
A - Telescopic Magnet 1
component life.
Start By:
Disassembly and Assembly, “Cylinder Head - NOTICE
Remove” for the correct procedure. It is strongly recommended that all lifters should be
replaced when a new camshaft is installed.
NOTICE
component life.
NOTICE
and mandates.
UENR4546-02 67
End By:
a. Install the cylinder head. Refer to Disassembly
correct procedure.
i06506000
Camshaft - Remove
Removal Procedure
Start By:
a. Remove the lifters. Refer to Disassembly and
Assembly, “Lifter Group - Remove and Install”
for the correct procedure.
b. Remove the front housing. Refer to
1. Clean lifters (1). Follow Steps 1.a through 1.c to NOTICE

inspect the lifters. Replace lifters that are worn or
damaged. Contaminants may cause rapid wear and shortened
component life.
a. Inspect the seat of the pushrod in the lifter for
visual wear or damage. Ensure that oil holes in
the lifter are not restricted. NOTICE
b. Inspect the shank of the lifter for wear or tained during performance of inspection, mainte-
damage. Refer to Specifications, “Lifter Group” nance, testing, adjusting and repair of the product.
for more information. ers before opening any compartment or disassem-
c. Inspect the face of the lifter that runs on the bling any component containing fluids.
camshaft for visual wear or damage. Dispose of all fluids according to local regulations
2. Lubricate lifters (1) with clean engine oil. and mandates.
3. Install lifters (1) into the cylinder block.
Note: The lifters should be free to rotate. If the lifters

have been used, ensure that the lifters are installed in
the original positions.
68 UENR4546-02
4. Rotate the crankshaft until Timing Marks (X) are

aligned on the following gears:
Note: Carefully rotate the crankshaft to align the
timing marks.
• Crankshaft gear (3)
• Camshaft gear (7)
• Idler gear (5)
5. Carefully remove camshaft assembly (3) from

cylinder block (8). Ensure that the lobes of the
camshaft and the camshaft bearings are not
damaged.
i06506006
Camshaft - Disassemble
Disassembly Procedure
Table 20
Required Tools

A - Combination Puller 1
Start By:
a. Remove the camshaft assembly. Refer to
Disassembly and Assembly, “Camshaft -
NOTICE
component life.
1. Remove slider (3) from camshaft gear (4).

2. Rotate camshaft gear (3) to align the access hole
in the camshaft gear with bolts (2) (not shown).
Remove the bolts from camshaft retainer plate (1).
3. Remove camshaft retainer plate (5).
UENR4546-02 69
1. Use Tooling (A) to remove gear (5) from camshaft 2. Install spacer (3) to camshaft (1).
(1).
3. Lubricate the nose of camshaft (1) with clean
Note: The gear should be positioned on a suitable engine oil. Use a suitable press to install bearing
support to prevent damage during the disassembly. (3) to the camshaft.
2. Use Tooling (A) to remove bearing (4) from Note: Ensure that the bearing is installed in the
camshaft (1). correct orientation. The camshaft bearing should be
pressed squarely onto the camshaft or damage to the
Note: Identify the orientation of the bearing for bearing may occur. Do not press on the outer race of
installation. the bearing.
3. Remove spacer (3) and key (2) from camshaft (1). 4. Install key (2) to camshaft (1). Ensure that the key
is correctly seated into the key recess in the
i06506008 camshaft.
Camshaft - Assemble 5. Align gear (5) with key (2). Use a suitable press to
install the gear to the nose of camshaft (1). Ensure
that the gear is located correctly against the
shoulder on the camshaft.
Assembly Procedure Note: The gear should be positioned on a suitable
support to prevent damage during the disassembly.
NOTICE
Keep all parts clean from contaminants. End By:
Contaminants may cause rapid wear and shortened a. Install the camshaft assembly. Refer to
component life. Disassembly and Assembly, “Camshaft -
1. Ensure that all components of the camshaft
i06506009
assembly are clean and free from wear or
damage. Replace any component that is worn or Camshaft - Install
damaged.
NOTICE
component life.
70 UENR4546-02
1. Ensure that the assembly of the camshaft is clean

and free from damage. Replace any component
that is worn or damaged.
2. Lubricate the bearings of the camshaft with clean
engine oil.
3. Carefully install camshaft assembly (3) into

cylinder block (8). Ensure that Timing Marks (X)
are aligned on the following gears:
• Crankshaft gear (7)
• Camshaft gear (3)
UENR4546-02 71
• Idler gear (5)

NOTICE
Note: Do not damage the lobes of the camshaft or tained during performance of inspection, mainte-
the camshaft bearings. nance, testing, adjusting and repair of the product.
4. Place camshaft retainer plate (1) into position. ers before opening any compartment or disassem-
Align the holes in the retainer plate with the holes bling any component containing fluids.
in the cylinder block.
5. Rotate camshaft gear (3) align the access hole in and mandates.
the camshaft gear with the hole for bolts (2) (not
shown). Install the bolts.
6. Tighten bolts (2) (not shown) to a torque of ().
End By:
a. Install the lifters. Refer to Disassembly and
Assembly, “Lifter Group- Remove and Install”.
b. Install the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Install”.
i06602140
Camshaft Bearings - Remove

and Install
Removal Procedure
Table 21
Required Tools
- Camshaft Bearing Tool Group 1

A
- Ratchet Wrench 1
Start By:
a. Remove the camshaft. Refer to Disassembly
and Assembly, “Camshaft - Remove” for the
correct procedure.
b. Remove the flywheel housing and back plate.
Refer to Disassembly and Assembly,
“Flywheel Housing - Remove and Install” for
NOTICE
component life.
72 UENR4546-02
1. Use a suitable tool to remove plug (1) from the 1. Ensure that all the camshaft bearings are free from
cylinder block. Ensure that the surface of the wear or damage. If any camshaft bearing is worn
recess is not damaged as the plug is removed. or damaged replace the component.
2. Use Tooling (A) to remove rear ball bearing (2)
from the cylinder block.
Note: Take note of the installation depth of the rear

ball bearing into the cylinder block for installation
purposes.
3. Use Tooling (A) to remove needle bearing (3) and

needle bearing (4) from the cylinder block.
Note: Take note of the installation depth of the

needle bearing into the cylinder block for installation
purposes.
Table 22
Required Tools
- Camshaft Bearing Tool Group 1

A
- Ratchet Wrench 1
B - Loctite 638 1
NOTICE
component life.
UENR4546-02 73

Installation position of camshaft bearings
Position (A) 244 mm (9.628 inch)
Position (B) 140 mm (5.512 inch)
Position (C) 8 mm (0.315 inch)
2. Use Tooling (A) to install rear ball bearing (2) into

the cylinder block. Refer to Illustration 130 for the
correct position.
3. Use Tooling (A) to install needle bearing (3) and
needle bearing (4) to the cylinder block. Refer to
Illustration 130 for the correct positions.
74 UENR4546-02
NOTICE
and mandates.

Loctite 638 sealant position
4. Ensure the recess in the cylinder block for plug (1)

is clean and free sealant and damage.
5. Apply a bead of Tooling (B) to the recess in the
cylinder block for plug (1). Position the plug into
the cylinder block and use a suitable tool to
depress the center of the plug. Clean away any
excess sealant from the plug and the cylinder
block. Illustration 132 g06034512
End By: 1. Remove drain plug (4) from engine oil pan (2).
a. Install the camshaft. Refer to Disassembly and Drain the engine oil into a suitable container for
Assembly, “Camshaft - Install” for the correct storage or disposal. Refer to Operation and
procedure. Maintenance Manual, “Oil Filter Change” for the
correct procedure.
b. Install the flywheel housing and back plate.
Refer to Disassembly and Assembly, 2. Remove sealing washer (3) from drain plugs (5).
“Flywheel Housing - Remove and Install” for
the correct procedure. 3. Remove bolts (5) from engine oil pan (2).
4. Remove engine oil pan (2) from the engine.
i06506010
5. Remove gasket (1).
Engine Oil Pan - Remove and
Install
NOTICE
Removal Procedure Contaminants may cause rapid wear and shortened

component life.
NOTICE
Keep all parts clean from contaminants. 1. Ensure that the engine oil pan is clean and free
Contaminants may cause rapid wear and shortened from damage. Clean the gasket surfaces of the
component life. cylinder block the engine oil pan.
UENR4546-02 75
Start By:
Disassembly and Assembly, “Cylinder Head -
b. Remove the suction pipe. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Remove” for the correct procedure.
NOTICE
component life.
1. Position the piston that is being removed in the

bottom center position.
2. Use Tooling (A) r to remove the carbon from the
inner surface of the cylinder bore.
2. Position a new gasket (1) onto engine oil pan (2).

3. Position engine oil pan (2) onto the engine cylinder
block.
(97 lb in).
5. Install a new sealing washer (3) onto drain plug
(5).
6. Install drain plug (5) to oil pan (2). Tighten the drain
plugs to a torque of 34 N·m (25 lb ft).
7. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
Filter Change” for the correct procedure.
i06506011
Pistons and Connecting Rods

- Remove
Removal Procedure
Table 23
Required Tools
A 27610274 Ridge Reamer 1
76 UENR4546-02
5. Carefully push piston (5) and the connecting rod

assembly out of the cylinder bore. Lift the piston
out of the top of the cylinder block.
Note: Make an identification mark underneath the
piston on the pin boss to identify the position on the
piston for installation. Always mark the front pin boss.
6. Keep connecting rod bearings (3) with the

respective connecting rod (4) and cap (2).
7. Repeat Steps 1 through 6 to remove the remaining
pistons and connecting rods.
i06506012

- Disassemble
Illustration 134 g06034516 Disassembly Procedure

Table 24
Required Tools
A - Retaining Ring Pliers 1
B - Ring Expander 1
Start By:
a. Remove the pistons and connecting rods.
Refer to Disassembly and Assembly, “Pistons
and Connecting Rods - Remove” for the
correct procedure.
Illustration 135 g06034517 NOTICE

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
1. Make a temporary mark on the components of the
connecting rod (4) and connecting rod cap (2) are
piston and connecting rod assembly. Making a
marked for the correct location. If necessary, make
temporary marks will ensure that the components
a temporary mark on the connecting rod and the
of each piston and connecting rod assembly can
connecting rod cap to identify the cylinder number.
be reinstalled in the original cylinder. Mark the
Note: Do not stamp the connecting rod assembly. front of the piston and the front of the connecting
rod. Do not interchange components.
4. Remove nuts (1) and remove connecting rod cap
(2) from connecting rod (4).
Note: Use tape or rubber tubing on the threads of the
connecting rod bolts to protect the crankshaft
journals. The sharp edges of the connecting rod bolts
could damage the crankshaft journals.
UENR4546-02 77
2. Place the piston and connecting rod assembly on a

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

crown upward. Use Tooling (B) to remove
compression rings (5) and (6), and oil control ring
(7) from piston (2).
Note: Identify the orientation of the piston rings for

installation.
78 UENR4546-02
7. Inspect the connecting rod for wear or damage. If

necessary, replace the connecting rod or replace
the bush for the piston pin.
i06506017

- Assemble
Assembly Procedure
Table 25
Required Tools
A - Retaining Ring Pliers 1
B - Ring Expander 1
NOTICE
component life.
5. Remove nuts (11) and connecting rod cap (10) from wear or damage. If necessary, replace any
from connecting rod (1). components that are worn or damaged.
6. Remove the lower half of connecting rod bearing
(9) from connecting rod cap (10). Remove the
upper half of connecting rod bearing (8) from
connecting rod (1). Keep the bearing shells
together.
NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Caterpillar
dealer.
2. Follow Step 2.a through Step 2.e to install the

piston rings to the piston.
UENR4546-02 79
a. Position the spring for oil control ring (7) into the
oil ring groove in the piston. The central wire
must be located inside the end of the spring.
b. Use Tooling (B) to install oil control ring (7) over

the spring. Illustration 142 g06034533
Note: Ensure that the central wire is 180 degrees

3. Lubricate the bush in connecting rod (1) and
from the ring gap.
lubricate the bore for the piston pin in piston (2)
with clean engine oil.
c. Use Tooling (B) to install intermediate
compression ring (6) into the second groove in 4. Place the piston on a suitable surface with the
the piston. The letter “T” and the Chamfer (Y) on crown downward. Install connecting rod (1) and
the inner face of the ring must be upward. piston pin (3) to piston (2). The name Perkins
inside the piston must align with the stamped
d. Use Tooling (B) to install top compression ring number on the connecting rod. Ensure the correct
(5) into the top groove in the piston. The letter orientation of the connecting rod in the piston.
“T” must be upward.
Note: If the piston pin cannot be installed by hand,
e. Position the piston ring gaps at 120 degrees heat the piston to a temperature of 45 ± 5 °C
away from each other. (113 ± 9 °F). Do not use a torch to heat the piston.
5. Use Tooling (A) to install retaining rings (4) to the

piston pin bore in piston (2).
Note: Ensure that the retaining rings are seated in

the grooves in the piston.
80 UENR4546-02
NOTICE
component life.
1. If the connecting rod caps were temporarily

installed, remove the connecting rod caps. If
necessary, thoroughly clean all the components.
2. Apply clean engine oil to the cylinder bore, to the
piston rings, to the outer surface of the piston and
to the connecting rod bearings.
Note: Install the connecting rod bearings dry when
clearance checks are performed. Refer to
Disassembly and Assembly, “Bearing Clearance -
Check”. Apply clean engine oil to the connecting rod
bearings during final assembly.
3. Rotate the crankshaft until the crankshaft pin is at

the bottom center position. Lubricate the
crankshaft pin with clean engine oil.
6. Install the upper half of connecting rod bearing (8)

to connecting rod (1).
7. Install the lower half of connecting rod bearing (9)
to connecting rod cap (10).
End By:
a. Install the pistons and the connecting rods.
Refer to Disassembly and Assembly, “Piston
and Connecting Rods - Install” for the correct
procedure.
i06506018

- Install
Table 26
Required Tools
A 21825491 Piston Ring Compressor 1
UENR4546-02 81
6. Install connecting rod cap (2) onto connecting rod

(4). Ensure that number (X) on the connecting rod
cap matches Number (X) on the connecting rod.
Install nuts (1).
7. Tighten nuts (1) to a torque of 52 N·m (38 lb ft).
8. Repeat Steps 1 through 6 for the remaining pistons
and connecting rods.
9. Ensure that the installed connecting rod assembly
has tactile side play. Carefully rotate the
crankshaft to ensure that there is no binding.
End By:
a. Install the suction pipe. Refer to Disassembly
and Assembly, “Engine Oil Pump - Install” for
b. Install the cylinder head. Refer to Disassembly
correct procedure.
i06506019
Connecting Rod Bearings -

Remove
(Connecting rods in position)
Removal Procedure
Start By:
a. Remove the suction pipe. Refer to Disassembly
and Assembly, “Engine Oil Pump - Remove”
for the correct procedure.
NOTICE
4. Ensure that the gaps for the piston rings are at 120
degrees away from each other. Install Tooling (A) Contaminants may cause rapid wear and shortened
onto piston (5). Use tape or rubber tubing on the component life.
connecting rod bolts to protect the crankshaft
journals. Note: If all connecting rod bearings require
replacement on a four cylinder engine, the procedure
Note: Ensure that Tooling (A) is installed correctly can be carried out on two cylinders at the same time.
and that the piston can easily slide from the tool. The procedure can be carried out on the following
Ensure that the piston and the connecting rod pairs of cylinders 1 with 4 and 2 with 3. Ensure that
assembly are installed in the correct cylinder. Align both pairs of the connecting rod bearings are
Number (X) on the side of the connecting rod to the installed before changing from one pair of
right side of the cylinder block. The right-hand side is cylinders to another pair of cylinders.. Refer to
determined from the flywheel end of the engine. Disassembly and Assembly, “Connecting Rod
Bearings - Install” for the correct procedure.
5. Carefully push the piston and the connecting rod
assembly into the cylinder bore and onto the
crankshaft pin.
Note: Do not damage the finished surface of the

crankshaft pin.
82 UENR4546-02
Note: Use tape or rubber tubing on connecting rod

bolts (2) to protect the crankshaft journals. The sharp
edges of the connecting rod bolts could damage the
crankshaft journals.
i06506021
Connecting Rod Bearings -

Install
(Connecting rods in position)
NOTICE
component life.
1. Inspect the pins of the crankshaft for damage. If

the crankshaft is damaged, replace the crankshaft
or recondition the crankshaft. Refer to
Disassembly and Assembly, “Crankshaft -
Remove” and Disassembly and Assembly,
Illustration 146 g06035146 “Crankshaft - Install” for the correct procedure.
Typical example Ensure that the connecting rod bearings are clean
and free from wear or damage. If necessary,
Note: The connecting rod and the connecting rod replace the connecting rod bearings.
cap should have matching numbers at Position (X). If
necessary, make a temporary mark on connecting
rod (1) and on connecting rod cap (5).
1. Rotate the crankshaft until the piston is at the

bottom center position. Remove nuts (6) and
remove connecting rod cap (5) from connecting
rod (1).
2. Remove lower connecting rod bearing (4) from
connecting rod cap (5).
3. Carefully push connecting rod (1) into the cylinder
bore. Remove upper connecting rod bearing (3)
from the connecting rod.
UENR4546-02 83
7. Install connecting rod cap (5).

8. Install nuts (4) tighten nuts to a torque of 52 N·m
(38 lb ft).
9. Ensure that the installed connecting rod assembly
has tactile side play. Carefully rotate the
crankshaft to ensure that there is no binding.
Note: If all connecting rod bearings require

replacement on a four cylinder engine, the procedure
can be carried out on two cylinders at the same time.
The procedure can be carried out on the following
pairs of cylinders 1 with 4 and 2 with 3. Ensure that
both pairs of the connecting rod bearings are
installed before changing from one pair of
cylinders to another pair of cylinders. Refer to
Disassembly and Assembly, “Connecting Rod
Bearings - Remove” for more information.
End By:
a. Install the suction pipe. Refer to Disassembly
and Assembly, “Engine Oil Pump - Install” for
i06506032
Crankshaft Main Bearings -

Remove
Typical example
2. Clean the bearing surface of connecting rod (1)

and connecting rod cap (5). Ensure that Number Removal Procedure
(X) on connecting rod cap (5) aligns with Number
(X) on connecting rod (1). Start By:
3. Install upper connecting rod bearing (3) to a. Remove the crankshaft assembly. Refer to
connecting rod (1). Lubricate the bearing surface Disassembly and Assembly, “Crankshaft -
of the connecting rod bearing with clean engine
oil.
NOTICE
4. Carefully pull connecting rod (1) against the Keep all parts clean from contaminants.
crankshaft pin. Contaminants may cause rapid wear and shortened
component life.
Note: Use tape or rubber tubing on connecting rod
bolts (2) to protect the crankshaft journals. The sharp
edges of the connecting rod bolts could damage the 1. Ensure that the bearing caps are marked for
crankshaft journals. orientation and the correct position.
5. Clean the connecting rod cap. Install lower
connecting rod bearing (4) to connecting rod cap
(5).
6. Lubricate the pin of the crankshaft and lubricate
lower connecting rod bearing (3) with clean engine
oil.
NOTICE
When the connecting rod caps are installed, ensure
that the identification marks are aligned.
84 UENR4546-02

Rear main bearings and thrust washers
7. Remove bolts (7) from upper main bearing cap (2).

8. Remove upper main bearing cap (8) from lower
main bearing cap (15).
9. Remove thrust washer (9), thrust washers(12), and
2. Remove bolts (1) from upper main bearing cap (2). thrust washers(13). Note position and orientation
of the thrust washers.
3. Remove upper main bearing cap (2) from lower
main bearing cap (3). 10. Remove main bearing (10) and main bearing (11)
from the main bearing caps. Keep the main
4. Remove main bearing (4) and main bearing (5)
bearings with the respective bearing caps.
from upper main bearing cap (2) and lower main
bearing cap (3). Keep the main bearings with the 11. Do not remove dowels (14) from the main bearing
respective bearing caps. cap.
5. Do not remove dowels (6) from the main bearing Removal Procedure for Crankshaft
cap.
Main Bearing (Front)
6. Repeat Step 2 through Step 5 to remove remaining
Table 27
main bearing (4) and main bearing (5).
Tool Part Number Parts Description Qty
A 27610275 Driver 1
UENR4546-02 85

Front main bearing
1. Use Tooling (A) to remove crankshaft bearing (16)

from the cylinder block.
i06506034
Crankshaft Main Bearings -

Install
Installation Procedure Main bearings one to three

1. Clean the crankshaft and inspect the crankshaft for 3. Inspect dowels (6) in the main bearing cap. If
wear or damage. Refer to Specifications, necessary, replace dowels if the dowels are
“Crankshaft” for more information. damaged.
2. Clean the main bearings and the main bearing 4. Install upper main bearing (4) to upper main
caps. Clean the thrust washers. Inspect all bearing cap (2). Ensure that the locating tab for
components for wear or damage. the main bearing is seated in the slot in the main
bearing cap.
Note: The lower bearing is a plain bearing that has
oil holes.
5. Install lower main bearing (5) to lower main

bearing cap (3). Ensure that the locating tab for
the main bearing is seated in the slot in the main
bearing cap.
Note: The lower bearing is a plain bearing that has

oil holes.
6. Lubricate main bearing (4) and main bearing(5)

with clean engine oil.
86 UENR4546-02
7. Position the upper half of main bearing cap (2) in 12. Install lower main bearing (11) to lower main
position on the crankshaft. Position the lower half bearing cap (15). Ensure that the locating tab for
of main bearing cap (3) in position on the the main bearing is seated in the slot in the main
crankshaft. Ensure the correct location and bearing cap.
orientation of the bearing caps. The locating tabs
for the upper and the lower bearings should be on Note: The lower bearing is a plain bearing that has
oil holes.
the same side of the engine. Ensure that dowels
(6) are in the correct position. Ensuring that the 13. Lubricate main bearing (10) and main bearing
dowels are correctly aligned will ensure that the (11) with clean engine oil.
two halves of the main bearing caps are aligned.
14. Position thrust washer (9) onto main bearing cap
8. Install bolts (1). Tighten the bolts to a torque of (8). Ensure that the thrust washer is correctly
52 N·m (38 lb ft). Ensure that the main bearing orientated and oil grooves are facing the
assembly is free to rotate without binding. crankshaft.
9. Repeat Step 1 through Step 8 to install remaining 15. Position thrust washer(12), and thrust washers
main bearing (4) and main bearing (5). (13) onto bearing cap (15). Ensure that the thrust
washer is correctly orientated and oil grooves are
facing the crankshaft.
16. Position the upper half of main bearing cap (8) in
position on the crankshaft. Position the lower half
of main bearing cap (15) in position on the
crankshaft. Ensure the correct location and
orientation of the bearing caps. The locating tabs
for the upper and the lower bearings should be on
the same side of the engine. Ensure that dowels
(14) are in the correct position. Ensuring that the
dowels are correctly aligned will ensure that the
two halves of the main bearing caps are aligned.
Ensure that the thrust washers are not dislodged
as the main bearing caps are installed.
17. Install bolts (7). Tighten the bolts to a torque of
52 N·m (38 lb ft). Ensure that the main bearing
assembly is free to rotate without binding.
Installation Procedure for

Crankshaft Bearing (Front)
Table 28
A 27610275 Driver 1

Rear main bearings and thrust washers
10. Inspect dowels (14) in the main bearing cap. If

necessary, replace dowels if the dowels are
damaged.
11. Install upper main bearing (10) to upper main
bearing cap (8). Ensure that the locating tab for
the main bearing is seated in the slot in the main
bearing cap.
Note: The upper bearing has a groove.
UENR4546-02 87
End By:
a. Install the crankshaft assembly. Refer to
Disassembly and Assembly, “Crankshaft -
i06507150
Crankshaft - Remove
Removal Procedure
Start By:
a. Remove the engine oil relief valve. Refer to
Disassembly and Assembly, “Engine Oil Relief
Valve - Remove and Install” for the correct
procedure.
b. Remove the crankshaft rear seal. Refer to
Illustration 153 g06035529 Seal - Remove and Install” for the correct
procedure.
1. Follow Steps 1.a through 1.cto install crankshaft
c. Remove the engine oil pump and the suction
bearing (16) to the cylinder block. pipe. Refer to Disassembly and Assembly,
“Engine Oil Pump - Remove” for the correct
a. Ensure that oil supply hole (18) is aligned with procedure.
the oil gallery in the cylinder block.
d. Remove the pistons and the connecting rods.
b. Ensure that crankshaft bearing joint (17) is Refer to Disassembly and Assembly, “Pistons
upward. and Connecting Rods - Remove” for the
correct procedure.
c. Ensure that chamfer (19) faces toward the
cylinder block. Use Tooling (A) to install NOTICE
crankshaft bearing (16) to the cylinder block. Keep all parts clean from contaminants.
component life.
1. The engine should be mounted in a suitable stand

with the rear end upward.
88 UENR4546-02
Note: Install the nut for the crankshaft pulley to

protect the nose of the crankshaft. Do not scratch any
of the finished surfaces on the crankshaft.
i06507153
Crankshaft - Install
Table 29
Required Tools
21825617 Dial Indicator 1

A
- Magnetic Base and Stand 1
1. The engine should be mounted in a suitable stand

Illustration 154 g06035537 with the rear end upward.
Typical example 2. Ensure that the crankshaft assembly is clean and
free from damage.
2. Remove bolts (1) from the cylinder block.
3. Remove Allen head bolts (2) from the cylinder
block.

Typical example

Typical example
4. Attach a suitable lifting device (3) to crankshaft

assembly (4).
5. Carefully lift crankshaft assembly (4) from the
cylinder block. If necessary, gently tap the nose of
the crankshaft with a soft faced hammer.
UENR4546-02 89
12. Check the crankshaft end play. Push the

crankshaft toward the front of the engine. Install
Tooling (A) to the cylinder block and the rear face
of the crankshaft. Push the crankshaft toward the
rear of the engine. Use Tooling (A) to measure the
crankshaft end play. Refer to Specifications,
“Crankshaft” for the maximum permissible
crankshaft end play.
End By:
a. Install the pistons and the connecting rods.
Refer to Disassembly and Assembly, “Pistons
and Connecting Rods - Install” for the correct
procedure.
b. Install the engine oil pump and the suction
pipe. Refer to Disassembly and Assembly,
“Engine Oil Pump - Install” for the correct
procedure.
c. Install the crankshaft rear seal. Refer to
Illustration 157 g06035537 Seal - Remove and Install” for the correct
Typical example procedure.
d. Install the engine oil relief valve. Refer to
3. Attach a suitable lifting device (3) to crankshaft Disassembly and Assembly, “Engine Oil Relief
assembly (4). Lubricate the front journal of the Valve - Remove and Install” for the correct
crankshaft with clean engine oil. procedure.
NOTICE i05980323
Ensure that the oil passages in the main bearings
align with the oil passages in the cylinder block. Bearing Clearance - Check
4. Align the holes in crankshaft assembly (4) for bolts
(2) with the holes in the cylinder block. If
necessary, gently tap the rear of the crankshaft Measurement Procedure
with a soft faced hammer. Table 30
5. Align the holes in the crankshaft assembly for Allen Required Tools
head bolts (2) with the holes in the cylinder block. Tool Part Number Part Description Qty
Carefully lower the crankshaft assembly (4) into
Plastigauge (Green)
the cylinder block. If necessary, gently tap the rear 0.025 to 0.076 mm
- 1
of the crankshaft with a soft faced hammer. (0.001 to 0.003 inch)
6. Remove lifting device (3) from crankshaft Plastigauge (Red)
assembly (4). - 0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
7. Install Allen head bolts (2) finger tight. A
Plastigauge (Blue)
8. Install bolts (1) finger tight. - 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
9. Tighten bolts (1) to a torque of 52 N·m (38 lb ft).
Plastigauge (Yellow)
10. Tighten Allen head bolts (2) to a torque of 27 N·m - 0.230 to 0.510 mm 1
(20 lb ft). (0.009 to 0.020 inch)
11. Rotate the crankshaft to ensure that there is no

binding. NOTICE
component life.
90 UENR4546-02
Note: Perkins does not recommend the checking of

the actual clearances of the bearing shells
particularly on small engines. Checking of the actual
clearances of the bearing shells is because of the
possibility of obtaining inaccurate results and of
damaging the bearing shell or the journal surfaces.
Each Perkins bearing shell is quality checked for
specific wall thickness.
Note: The measurements should be within
specifications and the correct bearings should be
used. If the crankshaft journals and the bores for the
block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
(0.004 inch).

NOTICE
Lead wire, shim stock or a dial bore gauge can dam- Typical Example
age the bearing surfaces.
4. Remove all of Tooling (A) before you install the
The technician must use Tooling (A) correctly. The bearing cap.
following points must be remembered:
Note: When Tooling (A) is used, the readings can
• Ensure that the backs of the bearings and the sometimes be unclear. For example, all parts of
bores are clean and dry. Tooling (A) are not the same width. Measure the
• Ensure that the bearing locking tabs are properly major width in order to ensure that the parts are
seated in the tab grooves. within the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and
• The crankshaft must be free of oil at the contact Specifications Manual, “Main Bearing Journal” for the
points of Tooling (A). correct clearances.
1. Put a piece of Tooling (A) on the crown of the i06595318

bearing that is in the cap.
Camshaft Position Sensor -
Note: Do not allow Tooling (A) to extend over the
edge of the bearing. Remove and Install
2. Use the correct torque-turn specifications in order (Camshaft Speed/Timing
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
Sensor)
when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A) is Removal Procedure
installed.
NOTICE
3. Carefully remove the cap, but do not remove Keep all parts clean from contaminants.
Tooling (A). Measure the width of Tooling (A) while
Tooling (A) is in the bearing cap or on the Contaminants may cause rapid wear and shortened
crankshaft journal. Refer to Illustration 158 . component life.
1. Turn the battery disconnect to the OFF position.
UENR4546-02 91
NOTICE
component life.
1. Ensure that all components of speed/timing sensor

are free from wear or damage. Replace any
component that is worn or damaged.
2. Disconnect harness assembly (1) from camshaft

speed/timing sensor (2).
3. Remove bolt (4) and remove camshaft speed/
timing sensor (2).
4. Remove O-ring seal (3) (not shown).
2. If necessary, follow Step 2.a through Step 2.c to

install adaptor (6) to housing (8).
a. Position a new gasket (7) onto adaptor (6).

b. Install adaptor (6) to housing (8). Ensure that

the adaptor is correctly orientated.
c. Install bolts (5) to adaptor (6). Tighten the bolts

to a torque of 10 N·m (89 lb in).
5. If necessary, follow Step 5.a through Step 5.b to

remove adaptor (6) from housing (8).
a. Remove bolts (5) and remove adaptor (6) from

housing (8).
b. Remove gasket (7).
92 UENR4546-02
3. Install a new O-ring seal (3) (not shown) to

camshaft speed/timing sensor (2).
4. Install camshaft speed/timing sensor (2) and install
bolt (4). Tighten the bolts to a torque of 10 N·m
(89 lb in).
5. Connect harness assembly (1) to camshaft speed/ 2. Disconnect harness assembly (1) from crankshaft
timing sensor (2). speed/timing sensor (3)
6. Turn the battery disconnect to the ON position. 3. Remove bolt (4) from crankshaft speed/timing
sensor (3).
i06595291
4. Remove crankshaft speed/timing sensor (3) from
Crankshaft Position Sensor - flywheel housing (5).
5. Remove shim (2) (not shown).
Remove and Install
(Crankshaft Speed/Timing Installation Procedure
Sensor) NOTICE
Removal Procedure component life.
NOTICE 1. Ensure that all components of the crankshaft

speed/timing sensor are free from wear or
Contaminants may cause rapid wear and shortened damage. Replace any component that is worn or
component life. damaged.
1. Turn the battery disconnect to the OFF position.
UENR4546-02 93
NOTICE
and mandates.

2. Position shim (2) (not shown) onto crankshaft

speed/timing sensor (3). Ensure that the shim is
3. Install crankshaft speed/timing sensor (3) to
flywheel housing (5). Install bolt (4) and tighten the
bolt to a torque of 10 N·m (89 lb in).
4. Connect harness assembly (1) to crankshaft Illustration 165 g06035624
speed/timing sensor (3)
2. Disconnect harness assembly (3) from coolant
5. Turn the battery disconnect to the ON position. temperature switch (2).
i06507044 3. Use a deep socket to remove coolant temperature

switch (2) from the water temperature regulator
Coolant Temperature Switch - housing.
Remove and Install 4. Remove sealing washer (1) (not shown)
Table 31
Removal Procedure Required Tools
NOTICE Tool Part Number Part Description Qty

A - Loctite 536 1
Contaminants may cause rapid wear and shortened A(1) - Loctite 567 1
component life.
(1) Use in Turkey Regions
94 UENR4546-02
5. Fill the cooling system with coolant to the correct

NOTICE
Keep all parts clean from contaminants. level. Refer to Operation and Maintenance
Manual, “Cooling System Coolant - Fill” for more
Contaminants may cause rapid wear and shortened information.
component life.
i06507049
1. Inspect the coolant temperature switch for damage

and correct operation. Refer to Systems
Engine Oil Pressure Switch -
Operation, Testing and Adjusting, “Coolant
Temperature Switch - Test” for more information. If
Remove and Install
necessary, replace the coolant temperature
switch.
Removal Procedure
NOTICE
component life.
NOTICE
and mandates.
2. Install a new sealing washer () (not shown) to

coolant temperature switch (2). Apply a thin layer
of Tooling (A) to the threads of the coolant
temperature switch.
3. Install coolant temperature switch (2) to the water
temperature regulator housing. Use a deep socket
to tighten the coolant temperature switch to a
torque of 27 N·m (20 lb ft).
4. Connect harness assembly (3) to coolant
1. Disconnect harness assembly (1) from engine oil

pressure switch (2).
UENR4546-02 95
2. Position a suitable tool onto adaptor (3) and 2. Connect harness assembly (1) to engine oil
remove engine oil pressure switch (2) from the pressure switch (2).
adaptor. Ensure that the adaptor is not loosened
as the engine oil pressure switch is removed. i06590830
Installation Procedure Oxygen Sensor - Remove and

Table 32
Required Tools
Install
A - Loctite 536 1 Removal Procedure

A(1) - Loctite 567 1
(1)
NOTICE
Use in Turkey Regions Keep all parts clean from contaminants.
component life.

position.
Note: If a used engine oil pressure switch (2) is

installed, apply a thin layer of Tooling (A) to the
threads of the engine oil pressure switch.
1. Install oil pressure switch (2) to adaptor (3). Illustration 169 g06037914
Position a suitable tool onto adaptor (3) and
tighten the engine oil pressure switch to a torque 2. Cut cable strap (2) and disconnect harness
of 11 N·m (97 lb in). assembly (1).
3. Use a suitable tool to remove oxygen sensor (3)
for exhaust adaptor (2).
Table 33
Required Tools
Bostik Pure Nickel Anti-Seize

A - 1
Compound
96 UENR4546-02
1. Ensure that all components of the oxygen sensor 1. Turn the battery disconnect to the OFF position.
are free from wear or damage. If any component is
worn or damaged replace the component.
Illustration 170 g06037914 2. Disconnect harness assembly (2) from inlet

manifold temperature and pressure sensor (4).
2. Apply Tooling (A) to the threads of oxygen sensor
3. Remove bolt (1) from inlet manifold temperature
(3).
and pressure sensor (4). Remove the inlet
3. Install oxygen sensor (3) to exhaust adaptor (2). manifold temperature and pressure sensor from
Tighten the oxygen sensor to a torque 50 N·m elbow (5).
(37 lb ft).
4. Remove O-ring seal () (not shown) from inlet
4. Connect harness assembly (1) and install a new manifold temperature and pressure sensor (4).
cable strap (2).
Note: Ensure that the cable straps meet Original
Equipment Manufacturers (OEM) specifications. NOTICE
position. Contaminants may cause rapid wear and shortened
component life.
i06595338
1. Ensure that all components of inlet manifold
Inlet Manifold Temperature and temperature and pressure sensor are free from
wear or damage. Replace any component that is
Pressure Sensor - Remove and worn or damaged.
Install 2. Turn the battery disconnect to the OFF position.
Removal Procedure
NOTICE
component life.
UENR4546-02 97
3. Install a new O-ring seal () (not shown) to inlet

manifold temperature and pressure sensor (4).
4. Install inlet manifold temperature and pressure
sensor (4) to elbow (5). Install bolt (1) to the inlet
manifold temperature and pressure sensor.
Tighten the bolt to a torque of 10 N·m (89 lb in).
5. Connect harness assembly (2) to inlet manifold
temperature and pressure sensor (4).
6. Turn the battery disconnect to the ON position.
i06507053
V-Belts - Remove and Install
Removal Procedure
NOTICE
component life.
1. If the engine is equipped with fan guards (1),

remove the fan guards. Refer to the Original
Equipment Manufacture (OEM) for the correct
procedure.
2. Loosen bolt (2), (4) for adjustment link (3).
98 UENR4546-02
3. Loosen nut (8) (not shown) and bolt (6) (not

shown). Loosen the nut and bolt sufficiently to
allow alternator (7) to move the alternator.
4. Push alternator (7) toward the engine and remove
V-belt (5). For V-belt that will be reused make
temporary mark on the V-belt to show direction of
rotation.
NOTICE
component life.
1. Check the condition of the V-belt . If the V-belt is

worn or damaged, use a new V-belt for
replacement.
2. Install V-belt (5) in position on the engine pulleys.

A used V-belt should be installed in the original
direction of rotation.
UENR4546-02 99
3. Slide alternator (3) away from the engine. Refer to Installation Procedure
Systems Operation, Testing and Adjusting, “Belt
Tension Chart” for information on the correct belt
from damage. Replace any components that are
tension.
worn or damaged.
4. Tighten bolt (4) and bolt(2) to a torque of 25 N·m
(221 lb in).
5. Tighten nut (8) (not shown) and bolt (6) (not
shown) to a torque of 25 N·m (221 lb in).
6. If the engine was equipped with fan guards (1),
install the fan guards. Refer to the OEM for the
correct procedure.
i06507057
Fan - Remove and Install
Removal Procedure
Start By:
a. Remove the V-Belt. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install” for
2. Position pulley (4) and spacer (3) on water pump

(5). Ensure that the bolt holes are aligned.
3. Install fan (2). Ensure the correct orientation of the
fan.
(97 lb in).
End By:
a. Install the V-Belt. Refer to Disassembly and
i06591373
Electronic Control Module -

Remove and Install
1. Remove bolts (1) and remove fan (2).

Removal Procedure
Note: Mark the orientation of the fan for installation. position.
2. Remove spacer (3) and pulley (4) from water pump 2. For the location of the Electronic Control Module
(5). (ECM) refer to the Original Equipment
Manufacture (OEM) for the correct location.
100 UENR4546-02
3. Disconnect harness assembly (2) from ECM (1). 2. Install isolation mounts (3) to ECM (1) and install
Ensure that the pins on the ECM are not damaged limiters (5) to the isolation mounts.
as the harness assembly is removed.
3. Install ECM (1) to the mounting point. Install the
4. Remove the bolt from isolation mounts (3) and bolts and tighten the bolts. Refer to the OEM for
remove ECM (1) from the mounting point. the correct torque value.
5. If necessary, remove limiters (5) from isolation 4. Connect harness assembly (2) to ECM (1). Ensure
mounts (3) and remove isolation mounts from the that the pins on the ECM are not damaged as the
ECM. harness assembly is installed.
1. Ensure that all components of the ECM are free
from wear or damage. Replace any component
that is worn or damaged.
UENR4546-02 101

position.
i06305792
Alternator - Remove and Install
Removal Procedure
Start By:
a. Remove the V-Belt. Refer to Disassembly and
NOTICE
component life.

position.
2. Make temporary identification marks on the
connections for the alternator harness assembly.
3. Disconnect the harness assembly from alternator

(5).
4. Remove bolt and washer (3) (not shown).
5. If necessary, remove bolt (1) and remove link
bracket (2).
102 UENR4546-02
6. Remove bolt (4) and nut (6) (not shown) from Installation Procedure
alternator (5).
7. Remove alternator (5) from bracket (7).
8. If necessary, remove bolt (8) and remove bracket
(7).
1. If necessary, position bracket (7) onto the cylinder

block and install bolts (8). Tighten the bolts to a
2. If necessary, Install link bracket (2) and install bolt
(1).
UENR4546-02 103
3. Position alternator (5) onto bracket (7).

4. Install bolt (4) and nut (6) (not shown) to alternator
(5).
5. Install bolt and washer (3) (not shown).
6. Install the V-Belt. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install” for the
correct procedure.
Note: Ensure that the alternator pulley is in alignment

with the crankshaft pulley. Ensure that all fasteners
are tightened.
7. Connect the harness assembly to alternator (5).

position.
i06507058
Electric Starting Motor -

Remove and Install
2. Make temporary identification marks on the
harness assemblies that are connected to electric
starting motor (3). Remove nut (1) and nut (2) and
Removal Procedure disconnect the harness assemblies from electric
starting motor (3).
3. Remove bolts (4) form electric starting motor (3).
Accidental engine starting can cause injury or Support the weight of the electric starting motor as
death to personnel working on the equipment. the bolts are removed.
To avoid accidental engine starting, disconnect 4. Remove electric starting motor (2) from the engine.
the battery cable from the negative (−) battery ter-
minal. Completely tape all metal surfaces of the
disconnected battery cable end in order to pre-
vent contact with other metal surfaces which
could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop
switch location to inform personnel that the
equipment is being worked on.

position.
104 UENR4546-02
Installation Procedure NOTICE

component life.
Start By:
a. Remove the ignition coils. Refer to
Disassembly and Assembly, Ignition Coils -
Remove and Install for the correct procedure.
1. Install electric starting motor (3) in position on the

engine.
2. Install bolts (4) and tighten the bolts hand tight.
Ensure that electric starting motor (3) is correctly
seated into the aperture of the back plate. Tighten
the bolts to a torque of 50 N·m (37 lb ft).
3. Connect the harness assemblies to electric
starting motor (3). Install nut (1) and nut (2) to the
electric starting motor. Tighten the nut securely. 1. Remove spark plugs (1) from the cylinder head.
position.
i06598690
Spark Plug - Remove and

Install
Removal Procedure
The ignition system may cause an electrical

shock hazard, which may cause personal injury
or death. Avoid contacting the ignition system
components and the ignition system wiring dur-
ing operation.
UENR4546-02 105
Installation Procedure For new spark plugs (1) check the gap (2) the gap
should be 0.70 mm (0.028 inch). For spark plugs
where the gap is outside the limits, replace with
new spark plugs.
3. Install spark plugs (1) into the cylinder head.
Note: Ensure that the threads of the spark plugs

are correctly started into the threads of the
cylinder. Failure the correctly start the threads of
the spark plugs into the cylinder head could
result to damage to the threads in the cylinder
head.
4. Tighten spark plugs () to a torque of 24 ± 2 N·m

(212 ± 18 lb in).
position.
End By:
a. Install the ignition coils. Refer to Disassembly
and Assembly, Ignition Coils - Remove and
Install for the correct procedure.
i06598812
Fuel Ratio Control - Remove

and Install
(Throttle Control Valve)
Removal Procedure
NOTICE
component life.
NOTICE
Comply with the local official gas regulations regard-
ing isolating the gas supply.
Illustration 189 g06039342 Start By:

a. Remove the mixing chamber and the trim
1. Ensure that spark plugs (1) are free from wear or control valve. Refer to Disassembly and
damage. Replace any spark plugs that are worn or Assembly, Fuel Ratio Control (Trim Control
damaged. Valve) - Remove and Install and Disassembly
and Assembly, Fuel Ratio Control (Mixing
2. For used spark plugs (1) check the Gap (2) the gap Chamber) - Remove and Install for the correct
should be 0.70 mm (0.028 inch). For spark plugs procedures.
where the gap is outside the limits, replace the
spark plug with new spark plugs. 1. Turn the battery disconnect switch to the OFF
position.
2. Turn the gas supply valve to the OFF position.
106 UENR4546-02
3. Disconnect harness assembly (1) from throttle 2. Place a new gasket (4) (not shown) onto throttle
control valve (5). control valve (5). Ensure that the gasket is
4. Remove Allen head bolts and nuts (3) from throttle
control valve (5). Support the throttle control valve 3. Install throttle control valve (5) onto elbow (2).
as the Allen head bolts and nuts are removed.
4. Loosely install bolts and nuts (3) to throttle control
5. Remove throttle control valve (5) from elbow (2). valve (5). Support the throttle control valve as the
Remove gasket (4) (not shown). Allen head bolts and nuts are installed.
Installation Procedure 5. Install the mixing chamber and the trim control
valve. Refer to Disassembly and Assembly, Fuel
1. Ensure that all components are free from wear or Ratio Control (Trim Control Valve) - Remove and
damage. Replace any component that is worn or Install and Disassembly and Assembly, Fuel Ratio
damaged. Control (Mixing Chamber) - Remove and Install for
the correct procedures.
6. Ensure all the Allen head bolts and nuts for the
mixing chamber and the trim control valve are
hand tightened before tightening to the correct
tightening value.
Tighten bolts and nuts (3) to a torque of 10 N·m
(89 lb in).
Tighten the Allen head bolts and nuts to a torque
of 10 N·m (89 lb in) for the mixing chamber and
the trim control valve.
7. Connect harness assembly () to throttle control
valve (5).
8. Turn the gas supply valve to the ON position.
UENR4546-02 107
9. Turn the battery disconnect switch to the ON 5. Remove Allen head bolts (4) from trim control
position. valve (3). Support the trim control valve as the
Allen head bolts are removed.
i06598813
6. Remove trim control valve (3) and remove gasket
Fuel Ratio Control - Remove (5) (not shown).
and Install Installation Procedure

1. Ensure that all components are free from wear or
(Trim Control Valve) damage. Replace any component that is worn or
damaged.
Removal Procedure
NOTICE
component life.
NOTICE

position.
2. Place a new gasket (4) (not shown) onto trim

control valve (3). Ensure that the gasket is
3. Install trim control valve (3). Ensure that the trim
control valve is correctly orientated.
4. Install Allen head bolts (4) to trim control valve (3).
Support the trim control valve as the Allen head
bolts are installed.
5. Tighten Allen head bolts (4) to a torque of 6 N·m
(53 lb in).
6. Connect harness assembly (1) to trim control valve
(3).
Illustration 192 g06039550 7. Connect the OEM hose assembly (2) to trim
control valve (5). Refer to the OEM for the correct
3. Disconnect the Original Equipment Manufacture procedures.
(OEM) hose assembly (2) from trim control valve
(5). Refer to the OEM for the correct procedures. 8. Turn the gas supply valve to the ON position.
4. Disconnect harness assembly (1) from trim control

valve (3).
108 UENR4546-02

position.
i06598901
Fuel Ratio Control - Remove

and Install
(Mixing Chamber)
Removal Procedure
NOTICE
component life.
NOTICE Illustration 194 g06039877

3. Remove Allen head bolts and nuts (2) from mixing
chamber (3). Support the mixing chamber as the
Start By: Allen head bolts and nuts are removed.
a. Remove the hose assembly from the air 4. Remove mixing chamber (3) from the throttle.
cleaner and the mixing chamber. Refer to
Disassembly and Assembly, Air Cleaner - 5. Remove gasket (1) (not shown).
Remove and Install for the correct procedures.
b. Remove the trim control valve from the mixing
chamber Disassembly and Assembly, Fuel 1. Ensure that all components are free from wear or
Ratio Control (Trim control valve) - Remove damage. Replace any component that is worn or
and Install for the correct procedures. damaged.
position.
UENR4546-02 109
2. Place a new gasket (1) (not shown) onto mixing

chamber (3). Ensure that the gasket is correctly
orientated.
3. Install mixing chamber (3) onto the throttle. Ensure
that the mixing chamber is correctly orientated.
4. Install Allen head bolts and nuts (2) to trim control
valve (3). Support the trim control valve as the
Allen head bolts and nuts are installed.
5. Tighten Allen head bolts and nuts (2) to a torque of
6 N·m (53 lb in).
6. Turn the gas supply valve to the ON position.
position.
End By:
a. Install the trim control valve to the mixing
chamber Disassembly and Assembly, Fuel
Ratio Control (Trim control valve) - Remove
and Install for the correct procedures.
b. Install the hose assembly to the air cleaner and
the mixing chamber. Refer to Disassembly and
Assembly, Air Cleaner - Remove and Install for
the correct procedures.
110 UENR4546-02
Index Section
Index
A Crankshaft Pulley - Remove and Install.................42
Installation Procedure ......................................43
Air Cleaner - Remove and Install ............................4 Removal Procedure .........................................42
Installation Procedure ........................................5 Crankshaft Rear Seal - Remove and Install ...........37
Removal Procedure ...........................................4 Installation Procedure ......................................37
Alternator - Remove and Install .......................... 101 Removal Procedure .........................................37
Installation Procedure .................................... 102 Crankshaft Wear Sleeve (Rear) - Remove and
Removal Procedure ....................................... 101 Install ...............................................................38
B Removal Procedure .........................................38
Cylinder Head - Install .........................................60
Bearing Clearance - Check ..................................89 Installation Procedure for Type One Cylinder Head
Measurement Procedure ..................................89 Bolts .............................................................61
Installation Procedure for Type Two Cylinder Head
Bolts .............................................................63
C Cylinder Head - Remove......................................58
Camshaft - Assemble ..........................................69 Removal Procedure .........................................59
Assembly Procedure ........................................69
Camshaft - Disassemble......................................68 D
Disassembly Procedure ...................................68
Camshaft - Install ................................................69 Disassembly and Assembly Section .......................4
Camshaft - Remove ............................................67
Removal Procedure .........................................67 E
Camshaft Bearings - Remove and Install ..............71 Electric Starting Motor - Remove and Install ........ 103
Installation Procedure ......................................72 Installation Procedure .................................... 104
Removal Procedure .........................................71 Removal Procedure ....................................... 103
Camshaft Position Sensor - Remove and Install Electronic Control Module - Remove and Install.....99
(Camshaft Speed/Timing Sensor) .......................90 Installation Procedure .................................... 100
Installation Procedure ......................................91 Removal Procedure .........................................99
Removal Procedure .........................................90 Engine Oil Line - Remove and Install ....................15
Connecting Rod Bearings - Install (Connecting Installation Procedure ......................................16
rods in position) .................................................82 Removal Procedure .........................................15
Installation Procedure ......................................82 Engine Oil Pan - Remove and Install.....................74
Connecting Rod Bearings - Remove Installation Procedure ......................................74
(Connecting rods in position) ..............................81 Removal Procedure .........................................74
Removal Procedure .........................................81 Engine Oil Pressure Switch - Remove and Install...94
Coolant Temperature Switch - Remove and Installation Procedure ......................................95
Install ...............................................................93 Removal Procedure .........................................94
Installation Procedure ......................................93 Engine Oil Pump - Install (Installation of Engine
Removal Procedure .........................................93 Oil Pump and Idler Hub with the Engine
Crankcase Breather - Remove and Install .............48 Removed from the Application)...........................21
Installation Procedure ......................................49 Installation Procedure ......................................21
Removal Procedure .........................................48 Engine Oil Pump - Remove (Removal of Engine
Crankshaft - Install ..............................................88 Oil Pump and Idler Hub with the Engine
Installation Procedure ......................................88 Removed from the Application)...........................19
Crankshaft - Remove...........................................87 Removal Procedure .........................................19
Removal Procedure .........................................87 Engine Oil Pump - Remove and Install
Crankshaft Front Seal - Remove and Install...........44 (Removal of Engine Oil Pump and Idler Hub
Alternative Removal Procedure.........................44 with the Engine Installed in the Application) .........24
Removal Procedure .........................................44 Removal Procedure .........................................24
Crankshaft Main Bearings - Install ........................85 Engine Oil Relief Valve - Remove and Install .........17
Installation Procedure for Crankshaft Bearing Removal Procedure .........................................17
(Front) ...........................................................86 Exhaust Manifold - Remove and Install ...................7
Crankshaft Main Bearings - Remove.....................83 Installation Procedure ........................................8
Removal Procedure .........................................83 Removal Procedure ...........................................7
Removal Procedure for Crankshaft Main Bearing
(Front) ...........................................................84
Crankshaft Position Sensor - Remove and F
Install (Crankshaft Speed/Timing Sensor)............92
Installation Procedure ......................................92 Fan - Remove and Install .....................................99
Removal Procedure .........................................92 Installation Procedure ......................................99
UENR4546-02 111
Index Section
Removal Procedure .........................................99 Pistons and Connecting Rods - Remove ...............75

Flywheel - Install .................................................35 Removal Procedure .........................................75
Flywheel - Remove..............................................34
Removal Procedure .........................................34 R
Flywheel Housing - Remove and Install.................40 Rocker Shaft - Assemble .....................................56
Installation Procedure ......................................41 Assembly Procedure ........................................56
Removal Procedure .........................................40 Rocker Shaft - Disassemble .................................55
Fuel Ratio Control - Remove and Install (Mixing Disassembly Procedure ...................................55
Chamber) ....................................................... 108 Rocker Shaft and Pushrod - Install........................57
Installation Procedure .................................... 108 Installation Procedure ......................................57
Removal Procedure ....................................... 108 Rocker Shaft and Pushrod - Remove ....................55
Fuel Ratio Control - Remove and Install Removal Procedure .........................................55
(Throttle Control Valve) .................................... 105
Installation Procedure .................................... 106
Removal Procedure ....................................... 105 S
Fuel Ratio Control - Remove and Install (Trim
Control Valve) ................................................. 107 Spark Plug - Remove and Install......................... 104
Installation Procedure .................................... 107 Installation Procedure .................................... 105
Removal Procedure ....................................... 107 Removal Procedure ....................................... 104
H T
Housing (Front) - Install .......................................46 Table of Contents ..................................................3
Housing (Front) - Remove....................................45
Removal Procedure .........................................45 V
V-Belts - Remove and Install ................................97
I Removal Procedure .........................................97
Ignition Coil - Remove and Install ...........................6 Valve Mechanism Cover - Remove and Install .......50
Installation Procedure ........................................7 Installation Procedure ......................................52
Removal Procedure ...........................................6 Removal Procedure .........................................50
Important Safety Information ..................................2
Inlet and Exhaust Valve Springs - Remove and
Install ...............................................................10 W
Installation Procedure ...................................... 11 Water Pump - Remove and Install ........................28
Removal Procedure .........................................10 Installation Procedure ......................................29
Inlet and Exhaust Valves - Remove and Install.......12 Removal Procedure .........................................28
Installation Procedure ......................................14 Water Temperature Regulator - Remove and
Removal Procedure .........................................12 Install ...............................................................32
Inlet Manifold Temperature and Pressure Installation Procedure ......................................33
Sensor - Remove and Install...............................96 Removal Procedure .........................................32
Installation Procedure ......................................96 Water Temperature Regulator Housing -
Removal Procedure .........................................96 Remove and Install ............................................31
Removal Procedure .........................................31
L
Lifter Group - Remove and Install .........................66
O
Oxygen Sensor - Remove and Install ....................95
P
Pistons and Connecting Rods - Assemble.............78
Assembly Procedure ........................................78
Pistons and Connecting Rods - Disassemble ........76
Disassembly Procedure ...................................76
Pistons and Connecting Rods - Install...................80
©2017 Perkins Engines Company Limited
All Rights Reserved

UENR4546-02

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Disassembly and Assembly

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Bearing Clearance - Check ..................................89

Air Cleaner - Remove and

1. Loosen hose clamp (1) and hose clamp (3).

1. Ensure all components of the assembly of the air

2. If necessary, install bracket (6) onto the engine.

5. Tighten hose clamp (1) and hose clamp (3) to a

Ignition Coil - Remove and

The ignition system may cause an electrical

1. Turn the battery disconnect switch to the OFF

2. Disconnect harness assembly (3) from ignition coil

Installation Procedure 5. Connect harness assembly (3) to ignition coil (1).

Exhaust Manifold - Remove

1. Disconnect the Original Equipment Manufacture

2. Remove nuts (1) from the Allen head bolts.

8. Remove exhaust manifold (11) from the cylinder

4. Cut cable strap (5) and disconnect harness Illustration 13 g06035114

7. Remove heat shield (7) from exhaust manifold

1. Ensure that the gasket surfaces of the cylinder

2. If necessary, install studs (14) to exhaust manifold Tightening sequence

Tool Part Number Part Description Qty

21825739 Valve Spring Compressor 1

Personal injury can result from being struck by

Note: Ensure that the appropriate piston is at the top

3. Apply sufficient pressure to Tooling (A) to allow

Illustration 19 g06035166 4. Slowly release the pressure on Tooling (A).

3. Install Tooling (A) in the appropriate position on the

6. Remove Tooling (A). Ensure that all the valves are

Inlet and Exhaust Valves -

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

Tool Part Number Part Description Qty

1. Clean the bottom face of the cylinder head. Check

Note: Do not stamp the heads of the valves.

Personal injury can result from being struck by

3. Use Tooling (A) to compress the appropriate valve

Note: Do not compress the valve spring so that valve

4. Remove Tooling (A).

8. Repeat Step 3 through Step 7 for the remaining

Tool Part Number Part Description Qty

A - Valve Spring Compressor 1

B 21825623 Valve Stem Seal Installer 1

Note: The installation procedure is identical for the

a. Inspect the cylinder head for wear and for

b. Inspect the valve seats for wear and for

e. Inspect the valve springs for the correct length.

3. Lubricate the stem of valve (5) with clean engine

5. Use Tooling (A) to compress valve spring (3).

Note: Do not compress the spring so that valve

The valve spring keepers can be thrown from the

6. Remove Tooling (A).

3. Remove adaptor (4) and remove sealing washers

1. If necessary, remove engine oil pressure switch

4. Install a new sealing washer (3) (not shown) to

Engine Oil Relief Valve -

Illustration 30 g06035579 Illustration 31 g06035579

Engine Oil Pump - Remove

Note: This removal procedure of the engine oil • Shims (5)

3. Remove idler gear (2) from idler hub (7).

Removal of Idler Hub

6. To remove the assembly of oil strainer (13), follow

a. Remove the engine oil pan. Refer to