Disassembly and Assembly Section
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Disassembly and Assembly Section i02748528
Fuel Priming Pump and Fuel Filter Base - Remove and Install Removal Procedure
Illustration 1
g01324908
Typical example
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
3. Drain fuel filter (4). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter/Water Seperator - Drain”. 4. Disconnect harness assembly (1) from fuel priming pump (2). 5. Disconnect the tube assemblies (not shown) from fuel filter base (3). 6. Remove bolts (5) and remove fuel filter base (3).
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Put identification marks on all hose assemblies and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This helps prevent fluid loss, and this helps to keep contaminants from entering the system. 1. Turn the fuel supply to the OFF position.
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the assembly of the fuel priming pump and the fuel filter base is clean and free from damage. If necessary, replace any components that are damaged.
2. Turn the battery disconnect switch to the OFF position.
Illustration 2
g01324908
Typical example
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5 Disassembly and Assembly Section
2. Position fuel filter base (3) on the mounting bracket. Install bolts (5) to the fuel filter base. Tighten the bolts to a torque of 35 N·m (26 lb ft). 3. Connect the tube assemblies for the fuel inlet and the fuel outlet (not shown) to fuel filter base (3). 4. If necessary, install a new fuel filter (4) to fuel filter base (3). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter/Water Seperator - Drain”. 5. Connect harness assembly (1) to fuel priming pump (2). 6. Turn the fuel supply to the ON position. 7. Turn the battery disconnect switch to the ON position. 8. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime”.
Illustration 3
g01332971
Typical example
i02748531
Fuel Injection Lines - Remove and Install (Naturally Aspirated Engines) Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 4
g01332972
Typical example
Note: Place identification marks on all tube assemblies for installation. Plug all lines and tube assemblies in order to prevent contamination. 1. Turn the fuel supply to the OFF position. 2. If necessary, loosen the dipstick tube (not shown).
3. Disconnect hose (4) from tube assembly (6). 4. Disconnect fuel injection lines (1) from fuel injectors (3). 5. Disconnect fuel injection lines (1) from fuel injection pump (5).
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6 Disassembly and Assembly Section
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Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are loosened. Use two wrenches in order to disconnect the fuel injection lines from the fuel injection pump. 6. Remove fuel injection lines (1). 7. Use suitable caps in order to plug the open ports of the fuel injection pump immediately. 8. Disconnect tube assembly (6) from fuel return line (2). 9. Remove banjo bolt (9) and sealing washers (10) from fuel injection pump (5). 10. Remove bolt (11) and remove tube assembly (6). 11. Remove nuts (7) from fuel injectors (3). Remove fuel return line (2) and sealing washers (8) from fuel injectors (3). 12. Use suitable caps in order to plug the open ports of the fuel injectors immediately.
Illustration 5
g01332971
Typical example
Installation Procedure Table 1
Required Tools Tool
Part Number
Part Description
Qty
A
27610294
Injector Pipe Nut Tool
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 6
g01332972
Typical example
1. Remove the caps from fuel injectors (3) and install new sealing washers (8) to the fuel injectors. Note: Washers (8) have two small holes. The position of the holes is not important.
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7 Disassembly and Assembly Section
2. Position fuel return line (2) onto fuel injectors (3). 3. Install nuts (7) onto each fuel injector. Tighten the nuts to a torque of 23 N·m (17 lb ft). 4. Position tube assembly (6) onto the engine. Loosely connect the tube assembly to fuel return line (2). 5. Install banjo bolt (9) and new sealing washers (10) to fuel injection pump (5). 6. Install bolt (11). Tighten the bolt to a torque of 11 N·m (97 lb in).
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Place identification marks on all tube assemblies for installation. Plug all lines and tube assemblies in order to prevent contamination. 1. Turn the fuel supply to the OFF position.
7. Tighten banjo bolt (9) to a torque of 18 N·m (13 lb ft). Tighten the nut to fuel return line (2) to a torque of 20 N·m (15 lb ft). 8. Remove the caps from the fuel injection pump. Install fuel injection lines (1) to fuel injection pump (5) and to fuel injectors (3). 9. Use Tooling (A) to tighten the nuts on fuel injection lines (1) to a torque of 30 N·m (22 lb ft). Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are tightened. 10. Connect hose (4) to tube assembly (6). 11. If necessary, tighten the dipstick tube (not shown) to a torque of 9 N·m (80 lb in). 12. Turn the fuel supply to the ON position. 13. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for more information. i02748529
Fuel Injection Lines - Remove and Install (Turbocharged Engines)
Illustration 7
g01332532
Typical example
Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
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8 Disassembly and Assembly Section
KENR6241
Installation Procedure Table 2
Required Tools Tool
Part Number
Part Description
Qty
A
27610294
Injector Pipe Nut Tool
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 8
g01324910
Typical example
2. If necessary, loosen the dipstick tube (not shown). 3. Disconnect fuel injection lines (1) from fuel injectors (3). 4. Disconnect fuel injection lines (1) from fuel injection pump (5). Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are loosened. Use two wrenches in order to disconnect the fuel injection lines from the fuel injection pump. 5. Remove clamps (4) and remove fuel injection lines (1).
Illustration 9
g01332532
Typical example
6. Use suitable caps in order to plug the open ports of the fuel injection pump and the fuel injectors immediately. 7. Disconnect tube assembly (6) from fuel injector (3). Disconnect tube assembly (6) from fuel injection pump (5). Remove bolts (7) and remove tube assembly (6). 8. Remove hoses (2) from fuel injectors (3).
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9 Disassembly and Assembly Section
i02748534
Fuel Injection Pump - Remove Removal Procedure Table 3
Required Tools Tool
Part Number
A
-
Part Description Combination Puller
Qty 1
Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.
Illustration 10
g01324910
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Typical example
1. Install hoses (2) to fuel injectors (3).
Dispose of all fluids according to local regulations and mandates.
2. Position tube assembly (6) onto the engine and install bolts (7). Tighten the bolts to a torque of 18 N·m (13 lb ft).
NOTICE Keep all parts clean from contaminants.
3. Connect tube assembly (6) to fuel injectors (3). Connect tube assembly (6) to fuel injection pump (5). 4. Remove the caps from fuel injectors and from the fuel injection pump. Loosely install fuel injection lines (1) to fuel injection pump (5) and to fuel injectors (3).
Contaminants may cause rapid wear and shortened component life. 1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.
5. Install clamps (4). Tighten the clamps securely. 6. Use Tooling (A) to tighten the nuts on fuel injection lines (1) to a torque of 30 N·m (22 lb ft). Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are tightened. 7. If necessary, tighten the dipstick tube (not shown) to a torque of 9 N·m (80 lb in). 8. Turn the fuel supply to the ON position. 9. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for more information.
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10 Disassembly and Assembly Section
Illustration 11
KENR6241
g01335768
Illustration 13
g01375471
Typical example
Typical example
2. Remove bolts (4).
6. Loosen bolt (7).
3. Remove plate (2) from front housing (1).
7. Remove fasteners (8), bolt (10) and bracket (9).
4. Remove O-ring seal (3) from plate (2).
8. Support fuel injection pump (6) and remove bolt (7). 9. Remove the assembly of housing (5) and fuel injection pump (6).
Illustration 12
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Timing marks on the gears
5. Ensure that Timing marks (X) on the teeth of the gears are aligned or make temporary marks on the gears for installation purposes.
Illustration 14
g01335808
Typical example
10. Remove O-ring seal (13) from housing (5). 11. Loosen nut (11).
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11 Disassembly and Assembly Section
Note: Do not remove the nut at this time. 12. Use Tooling (A) to loosen gear (12). Remove nut (11) and gear (12).
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 - Change” for more information.
13. If the original fuel injection pump will be installed, mark the flange of fuel injection pump (6) and housing (5). Remove nuts (15). Note: Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check” for the correct method of setting the fuel injection pump timing after installation. 14. Remove housing (5) from fuel injection pump (6). Remove O-ring seal (14) from housing (5). i02748532 g01366198
Fuel Injection Pump - Remove (Fuel Injection Pumps With a Water Heated Cold Start Device)
Illustration 15
Removal Procedure
4. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.
Table 4
Required Tools Tool
Part Number
A
-
Part Description Combination Puller
Typical example
2. Loosen the hose clamps and disconnect hoses (1) and (4) from fuel injection pump (2). 3. Loosen the hose clamps and remove hose (3) from fuel injection pump (2).
Qty 1
Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Illustration 16
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
g01366190
Typical example
5. Remove bolts (8). 6. Remove plate (6) from front housing (5). 7. Remove O-ring seal (7) from plate (6).
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12 Disassembly and Assembly Section
Illustration 17
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g01375914
Timing marks on the gears
8. Ensure that Timing marks (X) on the teeth of the gears are aligned or make temporary marks on the gears for installation purposes. Illustration 19
g01375949
Typical example
13. Remove O-ring seal (16) from housing (9). 14. Loosen nut (14). Note: Do not remove the nut at this time. 15. Use Tooling (A) to loosen gear (15). Remove nut (14) and gear (15). 16. If the original fuel injection pump will be installed, mark the flange of fuel injection pump (2) and housing (9). Remove nuts (18). Note: Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check” for the correct method of setting the fuel injection pump timing after installation. Illustration 18
g01375476
Typical example
17. Remove housing (9) from fuel injection pump (2). Remove O-ring seal (17) from housing (9).
9. Loosen bolt (10). 10. Remove fasteners (11), bolt (13) and bracket (12). 11. Support fuel injection pump (2) and remove bolt (10). 12. Remove the assembly of housing (9) and fuel injection pump (2).
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13 Disassembly and Assembly Section
i02748536
Fuel Injection Pump - Install (Fuel Injection Pumps With a Water Heated Cold Start Device)
6. Install a new O-ring seal (16) to housing (9). Install gear (15) to fuel injection pump (2). Install nut (14) finger tight.
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”. Illustration 21
g01375476
Typical example
Illustration 22
g01375914
Timing marks on the gears Illustration 20
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Typical example
2. Ensure that the mating surfaces of housing (9) and fuel injection pump (2) are clean and free from damage. 3. Install a new O-ring seal (17) to housing (9). 4. Position housing (9) on fuel injection pump (2). If the original fuel injection pump is installed, ensure that the appropriate marks on the flange of the fuel injection pump and the housing are aligned. Install nuts (18) finger tight.
7. Install the assembly of housing (9) and fuel injection pump (2) to the engine. Ensure that Timing marks (X) on the teeth of the gears are in the correct position. Install bolt (10) finger tight. 8. Position bracket (12) on fuel injection pump (2). Install fasteners (11) and bolt (13) finger tight. 9. Tighten nut (14) to a torque of 90 N·m (66 lb ft). Refer to Illustration 20.
5. Tighten nuts (18) to a torque of 18 N·m (13 lb ft).
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14 Disassembly and Assembly Section
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15. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. 16. Adjust the fuel injection pump timing. Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check”. End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. i02748535
Fuel Injection Pump - Install Illustration 23
g01366190
Typical example
Installation Procedure
10. Install a new O-ring seal (7) to plate (6).
NOTICE Keep all parts clean from contaminants.
11. Position plate (6) on front housing (5). Install bolts (8). Tighten the bolts to a torque of 18 N·m (13 lb ft).
Contaminants may cause rapid wear and shortened component life.
12. Tighten bolt (10) to a torque of 18 N·m (13 lb ft). Tighten bolt (13) to a torque of 18 N·m (13 lb ft). Tighten fasteners (11) to a torque of 35 N·m (26 lb ft). Refer to Illustration 21.
1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.
Illustration 24
g01366198
Typical example
13. Install hose (3) to fuel injection pump (2). Tighten the hose clamps securely. 14. Connect hoses (1) and (4) to fuel injection pump (2). Tighten the hose clamps securely.
Illustration 25
g01335808
Typical example
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15 Disassembly and Assembly Section
2. Ensure that the mating surfaces of housing (5) and fuel injection pump (6) are clean and free from damage. 3. Install a new O-ring seal (14) to housing (5).
8. Position bracket (9) on fuel injection pump (6). Install fasteners (8) and bolt (10) finger tight. 9. Tighten nut (11) to a torque of 90 N·m (66 lb ft). Refer to Illustration 25.
4. Position housing (5) on fuel injection pump (6). If the original fuel injection pump is installed, ensure that the appropriate marks on the flange of the fuel injection pump and the housing are aligned. Install nuts (15) finger tight. 5. Tighten nuts (15) to a torque of 18 N·m (13 lb ft). 6. Install a new O-ring seal (13) to housing (5). Install gear (12) to fuel injection pump (6). Install nut (11) finger tight.
Illustration 28
g01335768
Typical example
10. Install a new O-ring seal (3) to plate (2). 11. Position plate (2) on front housing (1). Install bolts (4). Tighten the bolts to a torque of 18 N·m (13 lb ft).
Illustration 26
g01375471
Typical example
12. Tighten bolt (7) to a torque of 18 N·m (13 lb ft). Tighten bolt (10) to a torque of 18 N·m (13 lb ft). Tighten fasteners (8) to a torque of 35 N·m (26 lb ft). Refer to Illustration 26. 13. Adjust the fuel injection pump timing. Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check”. End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.
Illustration 27
g01375914
Timing marks on the gears
7. Install the assembly of housing (5) and fuel injection pump (6) to the engine. Ensure that Timing marks (X) on the teeth of the gears are in the correct position. Install bolt (7) finger tight.
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16 Disassembly and Assembly Section
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i02748539
Fuel Injector - Remove and Install (Naturally Aspirated Engines)
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean the bore for the fuel injector in the cylinder head. Ensure that no debris enters the cylinder. Clean the threads on the body of the fuel injector.
Removal Procedure Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
Illustration 30
g01325773
Typical example
2. Install new seat washers (1) into the bore for the fuel injector in the cylinder head. 3. Install fuel injectors (2) into the cylinder head. Use a deep socket to tighten fuel injectors (2) to a torque of 59 N·m (44 lb ft). End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. i02748538
Illustration 29
g01325773
Fuel Injector - Remove and Install (Turbocharged Engines)
Typical example
1. Use a deep socket to remove fuel injectors (2) from the cylinder head. 2. Remove seat washers (1).
Removal Procedure Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.
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17 Disassembly and Assembly Section
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
Illustration 32
g01325781
Typical example
2. Install new seat washers (1) to the bores for the fuel injectors in the cylinder head. 3. Install fuel injectors (2) into the cylinder head. 4. Position clamps (4) onto fuel injectors (2) and install bolts (3). Tighten bolts (3) to a torque of 22 N·m (16 lb ft). End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.
Illustration 31
g01325781
1. Remove bolts (3) and clamps (4) from fuel injectors (2).
i02748540
Turbocharger - Remove
2. Remove fuel injectors (2) from the cylinder head. 3. Remove seat washers (1).
Removal Procedure
Installation Procedure
NOTICE Keep all parts clean from contaminants.
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Contaminants may cause rapid wear and shortened component life. 1. Clean the bores for the fuel injectors in the cylinder head. Ensure that no debris enters the cylinders. Clean the fuel injectors.
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
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18 Disassembly and Assembly Section
Illustration 33
KENR6241
g01336694
Typical example
1. Loosen hose clamps (6) and remove hose (4). Plug the connection on the inlet manifold with a suitable plug. 2. Remove bolts (5) and remove air pipe (3) from turbocharger (1). Remove gasket (2). 3. Plug the opening in the inlet manifold and the opening in the turbocharger with suitable plugs. Illustration 34
g01336699
Typical example
Illustration 35
g01337174
4. Follow Steps 4.a through 4.c in order to remove tube assembly (9) for the oil feed. a. Remove tube clamp (17) that secures tube assembly (9) to tube assembly (12). Note the position of the clamp.
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19 Disassembly and Assembly Section
b. Remove banjo bolt (14) and sealing washers (15). Disconnect tube assembly (9) from adapter (16) in the cylinder block. Note: Do not allow adapter (16) to turn in the cylinder block when the banjo bolt is loosened. Use two wrenches in order to disconnect the tube assembly. c. Remove banjo bolt (7) and sealing washers (8). Remove tube assembly (9) from turbocharger (1). 5. Follow Steps 5 through 5.c in order to remove the tube assembly (12) for the oil drain. a. Remove bolts (13). Disconnect tube assembly (12) from turbocharger (1). b. Remove joint (11). c. If necessary, loosen the hose clips and remove tube assembly (12) from the adapter in the cylinder block. 6. Remove the double nuts (not shown) that secure turbocharger (1) to the exhaust manifold. 7. Remove turbocharger (1) from the exhaust manifold. Remove gasket (10). 8. Plug the oil supply and the oil drain ports in the turbocharger and in the cylinder block with suitable plugs. i02748541
2. Clean the mating surface of the exhaust manifold. Install a new gasket (10) over the studs. Apply Tooling (A) to the studs.
Installation Procedure
3. Position turbocharger (1) onto the exhaust manifold and install the double nuts. Tighten the nuts to a torque of 18 N·m (13 lb ft).
Table 5
Required Tools Part Number
Part Description
A
CV60889
Anti-Seize Compound
g01336699
Typical example
Turbocharger - Install
Tool
Illustration 36
Qty 1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect” for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Note: Do not allow the lower nuts to turn when the upper nuts are tightened. 4. Ensure that tube assemblies (9) and (12) are clean and free from damage. If necessary, replace the tube assemblies. 5. Remove the plugs from the ports in the turbocharger and from the cylinder block. 6. If necessary, install the lower end of tube assembly (12) to the adapter in the cylinder block. Position a new joint (11) onto tube assembly (12). Connect the tube assembly to turbocharger (1) and install bolts (13). Tighten the bolts to a torque of 9 N·m (80 lb in). If necessary, tighten the hose clips.
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20 Disassembly and Assembly Section
KENR6241
7. Lubricate the bearings of turbocharger (1) with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant. 8. Install new sealing washers (8) and banjo bolt (7) to tube assembly (9). Position tube assembly (9) onto turbocharger (1). Tighten the banjo bolt finger tight. Install new sealing washers (15) and banjo bolt (14) to tube assembly (9). Connect the tube assembly to adapter (16) in the cylinder block. 9. Tighten banjo bolts (7) and (14) to a torque of 16 N·m (12 lb ft). Note: Do not allow adapter (16) to turn in the cylinder block.
11. Position a new joint (2) and air pipe (3) onto turbocharger (1). Install bolts (5). Tighten the bolts to a torque of 18 N·m (13 lb ft). 12. Remove the plugs from the connection on the inlet manifold and from the turbocharger. Install hose (4) and tighten hose clamps (6) securely. i02748542
Exhaust Manifold - Remove and Install Removal Procedure Start By: a. If the engine is equipped with a turbocharger, remove the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Remove”.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. Illustration 37
g01337174
10. Install clamp (17) to tube assemblies (9) and (12). Tighten the fasteners securely.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 39
g01333088
Exhaust manifold from a naturally aspirated engine
Illustration 38 Typical example
g01336694
1. Loosen bolts (1). Note: In order to prevent distortion of the exhaust manifold, Loosen the outer bolts first.
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21 Disassembly and Assembly Section
2. Remove bolts (1) and remove exhaust manifold (2) from the cylinder head. 3. Remove gasket (3).
Note: Tighten the center bolts first. End By: a. If the engine is equipped with a turbocharger, install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install”.
Installation Procedure Table 6
Required Tools Tool
Part Number
A
-
Part Description Guide Stud (M8 x 1.25 by 100 mm)
i02748543
Qty 2
Inlet Manifold - Remove and Install Removal Procedure
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the exhaust manifold is clean and free from damage. Clean the joint surface of the cylinder head.
Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 40
g01333101
Exhaust manifold from a naturally aspirated engine
2. Install Tooling (A) to the cylinder head in positions (X). 3. Position a new exhaust manifold gasket (3) onto Tooling (A).
Illustration 41
g01333458
Typical example
Note: Ensure that the exhaust manifold gasket is correctly oriented. 4. Align exhaust manifold (2) with Tooling (A). Install the exhaust manifold to the cylinder head. 5. Install bolts (1) finger tight. 6. Remove Tooling (A). Install the remaining bolts (1) finger tight. 7. Tighten bolts (1) to a torque of 30 N·m (22 lb ft).
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22 Disassembly and Assembly Section
Illustration 42
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g01333457
Typical example
Illustration 43
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Typical example
1. Loosen the hose clamps and disconnect the air hose (not shown) from connection (3). 2. For naturally aspirated engines, disconnect the hose for the crankcase breather (not shown) from inlet manifold (1). For turbocharged engines, remove the bolt that secures the hose for the crankcase breather (not shown) from the inlet manifold (1). 3. Remove bolts (6) from inlet manifold (1). Note the position of any brackets that are retained by the bolts for installation. Illustration 44
4. Remove inlet manifold (1) and gasket (5) from the cylinder head.
g01333457
Typical example
5. If necessary, remove bolts (4) and remove connection (3) from inlet manifold (1). Remove gasket (2).
2. If necessary, position a new gasket (2) and connection (3) onto inlet manifold (1). Install bolts (4). Tighten the bolts to a torque of 11 N·m (97 lb in).
Installation Procedure
Note: Ensure correct orientation of the connection.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all mating surfaces are clean and free from debris.
3. Place a new gasket (5) in position on inlet manifold (1). 4. Position inlet manifold (1) on the cylinder head. 5. Install bolts (6). Ensure that bolts of different lengths are installed in the correct positions. Also ensure that any brackets that are retained by the bolts are installed in the correct positions. 6. Tighten bolts (6) to a torque of 18 N·m (13 lb ft). 7. For naturally aspirated engines, connect the hose for the crankcase breather (not shown) to inlet manifold (1).
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KENR6241
23 Disassembly and Assembly Section
For turbocharged engines, install the bolt that secures the hose for the crankcase breather (not shown) to the inlet manifold (1). Tighten the bolt to a torque of 11 N·m (97 lb in). 8. Connect the air hose (not shown) to connection (3) and tighten the hose clamps securely. End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and install”.
Note: The following procedure should be adopted in order to remove the valve springs when the cylinder head is installed to the engine. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install” for the procedure to remove the valve springs from a cylinder head that has been removed from the engine. 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.
i02748544
Inlet and Exhaust Valve Springs - Remove and Install Removal Procedure Table 7
Required Tools Tool
Part Number
A
21825666
Valve Spring Compressor
1
B
27610235
Adapter
1
Part Description
Qty
Start By: a. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”.
Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine.
Illustration 45
g01358696
Typical example
1. Follow Steps 1.a through 1.d in order to position the appropriate piston at top center. a. Install Tooling (A) and (B) in position on the cylinder head in order to compress a valve spring for the appropriate piston. b. Use Tooling (A) in order to compress valve spring (3) and open the valve slightly. Note: Do not compress the spring so that the valve spring retainer (2) touches the valve stem seal. c. Carefully rotate the crankshaft until the piston touches the valve. Note: Do not use excessive force to turn the crankshaft. The use of force can result in bent valve stems. 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 spring to be safely removed. NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
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24 Disassembly and Assembly Section
KENR6241
2. Use Tooling (A) in order to compress valve spring (3). Remove valve keepers (1). Note: Do not compress the valve spring so that the valve spring retainer (2) touches the valve stem seal. 3. Slowly release the pressure on Tooling (A). 4. Remove valve spring retainer (2) and remove valve spring (3). NOTICE Do not turn the crankshaft while the valve springs are removed. Illustration 46
Note: If all valve springs require replacement 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 all of the valve springs are installed before changing from one pair of cylinders to another pair of cylinders. 5. Remove Tooling (A) and (B).
Typical example
2. Install valve spring (3) onto the cylinder head. Position valve spring retainer (2) onto valve spring (3).
Improper assembly of parts that are spring loaded can cause bodily injury.
Installation Procedure
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Table 8
Required Tools Tool
Part Number
A
21825666
Valve Spring Compressor
1
B
27610235
Adapter
1
Part Description
g01358696
Qty
NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
NOTICE Keep all parts clean from contaminants.
3. Install Tooling (A) and (B) in the appropriate position on the cylinder head in order to compress the valve spring.
Contaminants may cause rapid wear and shortened component life.
4. Apply sufficient pressure to Tooling (A) in order to install valve keepers (1).
NOTICE Do not turn the crankshaft while the valve springs are removed. 1. Inspect the valve springs for the correct length. Refer to Specifications, “Cylinder Head Valves ”.
Note: Do not compress the spring so that valve spring retainer (2) touches the valve stem seal. Install the valve spring keepers. 5. Carefully release the pressure on Tooling (A). Note: Ensure that the valve keepers are correctly seated.
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KENR6241
25 Disassembly and Assembly Section
The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves. 6. Remove Tooling (A). Ensure that all of the valves are secured in place by a valve spring and valve keepers. Rotate the crankshaft through about 45 degrees in order to clear the piston from the valve. Lightly strike the top of the valve with a soft hammer in order to ensure that the valve keepers are properly installed.
2. Place a temporary identification mark on the heads of the valves in order to identify the correct position. Note: Do not stamp the heads of the valves. Stamping or punching the heads of the valves could cause the valves to fracture.
Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.
End By: a. Install the rocker shaft assembly. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”.
NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
i02748545
Inlet and Exhaust Valves Remove and Install Removal Procedure Table 9
Required Tools Tool
Part Number
Part Description
Qty
A
21825663
Valve Spring Compressor
1
B
-
Seal Remover
1
Start By: a. Remove the cylinder head assembly. Refer to Disassembly and Assembly, “Cylinder Head Remove”.
Illustration 47
g01333469
Typical example
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean the bottom face of the cylinder head. Check the depth of the valves below the face of the cylinder head before the valve springs are removed. Refer to Specifications, “Cylinder Head Valves” for the correct dimensions.
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26 Disassembly and Assembly Section
KENR6241
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Clean all components of the cylinder head assembly. Ensure that all ports, all coolant passages and all lubrication passages in the cylinder head are free from debris. Follow Steps 1.a through 1.e in order 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”.
g01333471
Illustration 48 Typical example
3. Use Tooling (A) in order 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). 4. Remove Tooling (A). 5. Remove valve spring retainer (2). Remove valve spring (3).
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”.
6. Remove valve (5). 7. Use Tooling (B) to remove valve stem seal (4). 8. Repeat Steps 3 through 7 in order to remove the remaining inlet and exhaust valves.
Installation Procedure Table 10
Required Tools Tool
Part Number
A
21825663
Valve Spring Compressor
1
27610261
Seal Installer
1
27610262
Valve Guide Driver
1
C
Part Description
Qty
Illustration 49
g01333472
Typical example
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KENR6241
27 Disassembly and Assembly Section
2. Use Tooling (C) to install new valve stem seals (4) onto each of the valve guides.
Illustration 51 Illustration 50
g01333471
Typical example
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. 4. Install valve spring (3) to the cylinder head. Position valve spring retainer (2) onto valve spring (3).
Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
g01333469
Typical example
5. Use Tooling (A) in order 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 released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves. 6. Remove Tooling (A). 7. Repeat Steps 3 to 6 for the remaining valves. 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 in order to ensure that valve keepers (1) are properly installed. End By: a. Install the cylinder head assembly. Refer to Disassembly and Assembly, “Cylinder Head Install”.
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28 Disassembly and Assembly Section
KENR6241
i02748546
Engine Oil Filter Base Remove and Install
1. Use Tooling (A) to remove engine oil filter (6) from engine oil filter base (5). Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change”. 2. Mark the orientation of engine oil filter base (5) for installation. Remove bolt (2).
Removal Procedure
Note: The engine oil filter base can be oriented in different positions.
Table 11
Required Tools Tool
Part Number
A
-
Part Description Strap Wrench
Qty
3. Remove bolt (4) and remove engine oil filter base (5) from the cylinder block. Plug the oil galleries in the cylinder block with suitable plugs.
1
4. Remove O-ring seal (1) from engine oil filter base (5).
NOTICE Keep all parts clean from contaminants.
5. Remove O-ring seal (3) from bolt (4).
Contaminants may cause rapid wear and shortened component life.
Installation Procedure
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
Illustration 53
g01333853
Typical example
1. Ensure that the engine oil filter base is clean and free from damage. Clean the mating surfaces of the cylinder block. 2. Install a new O-ring seal (1) to engine oil filter base (5). Install a new O-ring seal (3) to bolt (4). 3. Position engine oil filter base (5) against the cylinder block. Install bolt (4) finger tight. Illustration 52 Typical example
g01333853
4. Ensure the correct orientation of engine oil filter base (5). Install bolt (2) finger tight. Note: The engine oil filter base can be oriented in different positions.
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KENR6241
29 Disassembly and Assembly Section
5. Tighten bolt (4) to a torque of 50 N·m (37 lb ft). Tighten bolt (2) to a torque of 11 N·m (97 lb in). 6. Install a new engine oil filter (6). Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change” for the correct procedure. i02748547
Engine Oil Cooler - Remove Removal Procedure Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Illustration 54
g01361343
Typical example
3. For turbocharged engines, remove crankcase breather (2). Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install”. 4. Remove dipstick tube (1).
Dispose of all fluids according to local regulations 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 - Change” for the correct procedure. 2. Drain the engine lubricating oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change” for the procedure.
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30 Disassembly and Assembly Section
KENR6241
i02748549
Engine Oil Cooler - Install Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 55
g01333881
Typical example
5. Gradually loosen bolts (11). Note the position of any brackets that are secured by the bolts. 6. Support the assembly of engine oil cooler (3). Remove bolts (11) and remove the assembly of engine oil cooler (3) from the cylinder block. 7. Remove joint (5). 8. Remove O-ring seals (4) from the recesses in the cylinder block. Illustration 56
9. If necessary, follow Steps 9.a through 9.d in order to disassemble the engine oil cooler. a. Remove nuts (8). b. Remove cooler matrix (6) from cover (7). c. Remove O-ring seals (12) and (13). d. Remove plate (10) and joint (9) from cover (7).
g01333881
Typical example
1. If necessary, follow Steps 1.a through 1.e in order to assemble the engine oil cooler. a. Ensure that cooler matrix (6) is clean and free from damage. Ensure that cover (7) is clean and free from damage. b. Position new O-ring seals (12) and (13) onto cover (7).
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KENR6241
31 Disassembly and Assembly Section
c. Install cooler matrix (6) to cover (7).
End By:
d. Install nuts (8). Tighten the nuts to a torque of 18 N·m (13 lb ft).
a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Install”.
e. Install joint (9) and plate (10).
i02748550
2. Clean the mating surface of the cylinder block. 3. Install new O-ring seals (4) to the recesses in the cylinder block. 4. Install two bolts (11) to the upper corners of the assembly of engine oil cooler (3). Install a new joint (5) to the assembly of engine oil cooler (3). 5. Install the assembly of engine oil cooler (3) to the cylinder block. Install the remaining bolts (11). Note: Ensure that any brackets that are secured by the bolts are installed in the correct location. 6. Tighten bolts (11) evenly to a torque of 18 N·m (13 lb ft).
Engine Oil Relief Valve Remove and Install Removal Procedure Table 12
Required Tools Tool
Part Number
A
-
Part Description Strap Wrench
Qty 1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
Illustration 57
g01361343
Typical example
7. Install dipstick tube (1). 8. For turbocharged engines, install crankcase breather (2). Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install”. 9. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. 10. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change” for the correct procedure.
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32 Disassembly and Assembly Section
Illustration 58
KENR6241
g01334417
Illustration 59
g01334417
Typical example
Typical example
1. If necessary, use Tooling (A) in order to remove engine oil filter (3). Refer to Operation and Maintenance Manual, “Engine Oil and Filter Change”.
1. Install a new sealing washer (1) to engine oil relief valve (2).
2. Remove engine oil relief valve (2). 3. Remove sealing washer (1).
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
2. Install engine oil relief valve (2) to the cylinder block. Tighten the engine oil relief valve to a torque of 49 N·m (36 lb ft). 3. If necessary, install a new engine oil filter (3). Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change” for the correct procedure. i02748551
Engine Oil Bypass Valve Remove and Install Removal Procedure Start By: a. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
This document has been printed from SPI². Not for Resale
KENR6241
Worldwide Parts Source LLC Phone 269 673 2313 Engine Parts
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”.
Illustration 61
g01334433
Typical example
2. Install a new sealing washer (2) to engine oil bypass valve (1). 3. Install engine oil bypass valve (1) to the cylinder block. Tighten the engine oil bypass valve to a torque of 69 N·m (51 lb ft). 4. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”. End By: Illustration 60
g01334433
Typical example
2. Remove engine oil bypass valve (1).
a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.
3. Remove sealing washer (2).
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Inspect the components of the engine oil bypass valve for wear or damage. Check the valve and the valve seat for an abnormal contact pattern. Check the spring for weakness or damage. If necessary, replace the engine oil bypass valve.
i02748553
Engine Oil Pump - Remove Removal Procedure Start By: a. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
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34 Disassembly and Assembly Section
KENR6241
i02748554
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
Engine Oil Pump - Install Installation Procedure Table 13
Required Tools Tool
Part Number
A
21825617
Part Description Dial Indicator Group
Qty 1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 63
Illustration 62
g01334537
g01334869
1. Ensure that bushing (8) is free from wear or damage. Refer to Specifications, “Engine Oil Pump” for more information. If necessary, replace the bushing.
1. Remove nut (5) and washer (4). 2. Remove gear (3) from the shaft of engine oil pump (1). 3. Remove bolts (6) and remove engine oil pump (1) from the cylinder block. 4. Remove O-ring seal (2).
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KENR6241
35 Disassembly and Assembly Section
i02748555
Water Pump - Remove and Install Removal Procedure Start By: a. If the engine is equipped with a fan, remove the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. If the engine is not equipped with a fan, remove the V-belt. Refer to Disassembly and Assembly, “V-belts - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 64
g01334537
2. Ensure that engine oil pump (1) is clean and free from wear or damage. Refer to Specifications, “Engine Oil Pump” for more information. If necessary, replace the engine oil pump. 3. Install a new O-ring seal (2) to engine oil pump (1). Lubricate the rotors of the engine oil pump with clean engine oil.
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
4. Align engine oil pump (1) with dowels (7). Install the engine oil pump to the cylinder block.
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 - Change” for more information.
5. Install bolts (6). Tighten the bolts to a torque of 11 N·m (97 lb in).
2. Loosen the hose clamp and disconnect the hose (not shown) from the water pump inlet.
6. Position oil pump gear (3) onto the shaft of engine oil pump (1). Ensure that the oil pump gear is aligned with the flat on the shaft. Install washer (4) and nut (5). Tighten the nut to a torque of 33 N·m (24 lb ft). 7. Use Tooling (A) to check the backlash between oil pump gear (3) and the idler gear. Ensure that the backlash is within specified values. Refer to Specifications, “Gear Group (Front)” for further information. End By: a. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”.
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36 Disassembly and Assembly Section
KENR6241
1. Ensure that the mating surfaces of the water pump and the cylinder block are clean and free from damage. If the cover was removed, ensure that the mating surfaces of the cover are clean and free from damage.
Illustration 67 Illustration 65
g01335213
Illustration 66
g01335205
g01335205
2. If necessary, align a new joint (6) and cover (7) with the holes in water pump (2). Install bolts (5). Tighten the bolts to a torque of 10 N·m (89 lb in).
3. Loosen the hose clamp and disconnect hose (1) from water pump (2). 4. Remove bolts (4) and remove water pump (2). Do not remove bolts (5) at this time. Note: If necessary, gently tap the water pump with a soft faced hammer in order to loosen the water pump. 5. Remove joint (3).
Illustration 68
g01335213
6. If necessary, remove bolts (5), and remove cover (7). Remove joint (6).
3. Place water pump (2) in position and install bolts (4). Ensure that bolts of different lengths are installed in the correct positions. Tighten bolts (4) to a torque of 18 N·m (160 lb in).
Installation Procedure
4. Connect hose (1) and tighten the hose clamp.
NOTICE Keep all parts clean from contaminants.
5. Connect the hose (not shown) to the water pump inlet and tighten the hose clamp.
Contaminants may cause rapid wear and shortened component life.
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KENR6241
37 Disassembly and Assembly Section
6. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. End By: a. If the engine is equipped with a fan, install the fan. Refer to Disassembly and Assembly, “Fan Remove and Install”. If the engine is not equipped with a fan, install the V-belt. Refer to Disassembly and Assembly, “V-belts - Remove and Install”. i02748556
Water Temperature Regulator Housing - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 69
g01335249
Typical example
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure.
2. Remove bolts (1) and remove outlet connection (2). 3. Remove joint (3) and remove water temperature regulator (4). Note the orientation of the water temperature regulator for installation. 4. Loosen the hose clamp and disconnect hose (8) from water temperature regulator housing (6). 5. Remove bolts (7) and remove water temperature regulator housing (6) from the cylinder head. 6. Remove joint (5).
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened 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.
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38 Disassembly and Assembly Section
KENR6241
2. Ensure that the mating surfaces of the outlet connection, the water temperature regulator housing and the cylinder head are clean and free from damage.
5. Install water temperature regulator (4) to water temperature regulator housing (6). Ensure the correct orientation of the water temperature regulator. 6. Position a new joint (3) and outlet connection (2) onto water temperature regulator housing (6). 7. Install bolts (1). Tighten the bolts to 18 N·m (13 lb ft). 8. Connect hose (8) to water temperature regulator housing (6). Tighten the hose clamps securely. 9. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant -Change” for the correct procedure. i02748557
Flywheel - Remove Removal Procedure Table 14
Required Tools
Illustration 70
Tool
Part Number
A
-
g01335249
Typical example
Part Description Guide Stud (M12 x 1.25 by 100 mm)
Qty 2
3. Position bolts (7) and a new joint (5) onto water temperature regulator housing (6).
Start By:
4. Position water temperature regulator housing (6) onto the cylinder head. Tighten bolts (7) to a torque of 18 N·m (13 lb ft).
a. Remove the starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 71
g01335282
Orientation of the water temperature regulator
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KENR6241
39 Disassembly and Assembly Section
i02748558
Flywheel - Install Installation Procedure Table 15
Required Tools
Illustration 72
Tool
Part Number
A
-
g01335288
Part Description Guide Stud (M12 x 1.25 by 100 mm)
Qty 2
Typical example
1. Make a temporary mark in order to show the orientation of the flywheel on the crankshaft. 2. Install a suitable lifting device to flywheel (2). The weight of the flywheel is approximately 23 kg (50 lb). 3. Remove two bolts (1) from Positions (X) on the flywheel. 4. Install Tooling (A) in positions (X) on the flywheel.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Always wear protective gloves when handling parts that have been heated.
5. Remove the remaining bolts (1) and remove flywheel (2).
Illustration 74
g01369129
Typical example Illustration 73
g01360927
Typical example
1. If the ring gear was removed, follow Steps 1.a through 1.c in order to install ring gear (3) to flywheel (2).
6. Inspect ring gear (3) and flywheel (2) for wear or damage. If the ring gear or the flywheel is worn or damaged, use new parts for replacement.
a. Identify the orientation of the new ring gear in order to install the ring gear correctly onto the flywheel.
7. To remove ring gear (3) from flywheel (2), place the flywheel on a suitable support. Use a hammer and a punch in order to remove the ring gear from the flywheel.
Note: The chamfered side of gear teeth (Y) must face toward the starting motor when the flywheel is installed. This will ensure the correct engagement of the starting motor. b. Heat ring gear (3) in an oven to a maximum temperature of 150°C (302°F) prior to installation.
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40 Disassembly and Assembly Section
KENR6241
Note: Do not use a torch to heat the ring gear. c. Ensure that the orientation of ring gear (3) is correct and quickly install the ring gear onto flywheel (2).
End By: a. Install the starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”. i02748559
Crankshaft Rear Seal - Remove and Install Removal Procedure Table 16
Required Tools Illustration 75
g01335288
Typical example
2. Thoroughly clean the flywheel housing. Inspect the crankshaft rear seal for leaks. If there are any oil leaks replace the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”. 3. Ensure that the dowels are installed to the crankshaft. Install Tooling (A) to positions (X) in the crankshaft. 4. Install a suitable lifting device to flywheel (2). The weight of the flywheel is approximately 23 kg (50 lb). 5. Align flywheel (2) with Tooling (A). Install the flywheel to the crankshaft. Note: Ensure the correct orientation of the flywheel on the crankshaft.
Tool
Part Number
A
-
B
27610311
Part Description
Qty
Drill Bit (4.10 mm)
1
Slide Hammer Puller
1
Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
6. Install bolts (1) finger tight.
NOTICE Keep all parts clean from contaminants.
7. Remove Tooling (A) and install the two remaining bolts (1).
Contaminants may cause rapid wear and shortened component life.
8. Remove the lifting device from the flywheel. 9. Use a suitable tool to prevent flywheel (2) from rotating. Tighten bolts (1) to a torque of 83 N·m (61 lb ft). 10. Check the concentricity of the flywheel. Refer to Systems Operation, Testing and Adjusting, “Flywheel - Inspect”.
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KENR6241
41 Disassembly and Assembly Section
1. Ensure that the flange of the crankshaft and the inside of the flywheel housing are clean and free of damage. It is possible to reclaim a crankshaft flange that has a worn seal surface, or a damaged seal surface by installing a wear sleeve. Refer to Disassembly and Assembly, “Crankshaft Wear Sleeve (Rear) - Remove and Install” for more information.
g01335312
Illustration 76 Typical example
1. Use Tooling (A) to drill three evenly spaced holes in crankshaft rear seal (2). 2. Use Tooling (B) to carefully remove crankshaft rear seal (2) from flywheel housing (1). Alternate the position of Tooling (B) from one hole to another hole. This will allow you to evenly remove the crankshaft rear seal from the flywheel housing.
Illustration 77
g01335312
Typical example
Installation Procedure Table 17
Required Tools Tool
C
Part Number
Part Description
Qty
27610266
Oil Seal Installer
1
27610345
Oil Seal Locator
1
27610346
Bolt
1
28710476
Hard Washer
1
27610347
Bolt (M12 x 1.25 by 20 mm)
2
Illustration 78
g01368204
Sectional view of the crankshaft rear seal, the crankshaft and the installation tool
NOTICE Keep all parts clean from contaminants.
2. Apply a thin coat of clean engine oil to the lip of crankshaft rear seal (2).
Contaminants may cause rapid wear and shortened component life.
3. Use Tooling (C) in order to install crankshaft rear seal (2), as follows: a. Align the locator with the dowels in crankshaft (3). Install the locator to the crankshaft. Ensure the correct orientation of the locator. Note: Check that the installer will slide freely over the locator.
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42 Disassembly and Assembly Section
KENR6241
b. Carefully slide crankshaft rear seal (2) over the locator until the crankshaft rear seal contacts the rear of crankshaft (3). Note: Ensure that the lip of the crankshaft rear seal that is spring loaded is facing toward the flywheel housing.
Note: Wear sleeves are used to reclaim worn seal surfaces or damaged seal surfaces. Wear sleeves are not original equipment. The wear sleeve is supplied with a crankshaft rear seal that has a larger internal diameter than a standard crankshaft rear seal. A standard crankshaft rear seal cannot be used if a wear sleeve is installed.
c. Assemble the installer to the locator and install the bolt and the washer. Ensure that the face of the installer with the deep counterbore is toward crankshaft rear seal (2). d. Tighten the bolt until the installer bottoms out on the locator in order to pull crankshaft rear seal (2) into flywheel housing (1). e. Remove Tooling (C). End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”. i02748560
Crankshaft Wear Sleeve (Rear) - Remove and Install
g01384938
Illustration 79
1. Use Tooling (A) in order to remove crankshaft wear sleeve (1) from crankshaft (2).
Installation Procedure Table 19
Required Tools Tool
Removal Procedure Table 18
Required Tools Tool
Part Number
A
-
Part Description Puller
Qty 1
Start By: a. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
B
Part Number
Part Description
Qty
27610266
Oil Seal Installer
1
27610345
Oil Seal Locator
1
27610346
Bolt
1
28710476
Hard Washer
1
27610266
Bolt (M12 x 1.25 by 20 mm)
2
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Wear sleeves are used to reclaim worn seal surfaces or damaged seal surfaces. Wear sleeves are not original equipment. The wear sleeve is supplied with a crankshaft rear seal that has a larger internal diameter than a standard crankshaft rear seal. A standard crankshaft rear seal cannot be used if a wear sleeve is installed. 1. Ensure that the crankshaft is thoroughly clean and dry. Remove any areas of raised damage.
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KENR6241
43 Disassembly and Assembly Section
2. Lubricate the inner surface of the crankshaft wear sleeve with clean engine oil.
i02748561
Flywheel Housing - Remove and Install Removal Procedure Table 20
Required Tools
Illustration 80
g01377790
Tool
Part Number
A
-
Sectional view of the crankshaft, the wear sleeve and the installation tool
3. Use Tooling (A) in order to install the crankshaft wear sleeve, as follows: a. Align the locator with the dowels in crankshaft (2). Install the locator to the crankshaft. Ensure the correct orientation of the locator. Note: Check that the installer will slide freely over the locator. b. Carefully slide crankshaft wear sleeve (3) over the locator until the crankshaft wear sleeve contacts the rear of crankshaft (2). c. Assemble the installer to the locator and install the bolt and the washer. Ensure that the face of the installer with the deep counterbore is toward crankshaft wear sleeve (3).
Part Description Guide Stud (M10 x 1.25 by 100 mm)
Qty 2
Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
d. Tighten the bolt until the installer bottoms out on the locator in order to pull crankshaft wear sleeve (3) onto crankshaft (2).
Dispose of all fluids according to local regulations and mandates.
e. Remove Tooling (A).
1. Support the engine.
End By: a. Install the new crankshaft rear seal that was supplied with the crankshaft wear sleeve. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”.
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44 Disassembly and Assembly Section
KENR6241
7. Remove joint (1). 8. Remove crankshaft rear seal (4) from flywheel housing (2).
Installation Procedure Table 21
Required Tools Tool
Part Number
Part Description
Qty
A
-
Guide Stud (M10 x 1.25 by100 mm)
2
B
21825617
Dial Indicator Group
1
NOTICE Keep all parts clean from contaminants. Illustration 81
g01335374
Typical example
Contaminants may cause rapid wear and shortened component life. 1. Ensure that the mating surfaces of the cylinder block and the flywheel housing are clean and free from damage.
Illustration 82
g01366220
Typical example
2. Remove two bolts (5) from positions (X) on flywheel housing (2). 3. Install Tooling (A) to positions (X) on flywheel housing (2). 4. Attach a suitable lifting device to flywheel housing (2). The weight of the flywheel housing is approximately 32 kg (71 lb). 5. Remove the remaining bolts (5). 6. Carefully remove flywheel housing (2) from dowels (3) and from the cylinder block.
Illustration 83
g01335383
Typical example
2. Inspect dowels (3) in the cylinder block. If necessary, replace the dowels.
Note: If necessary, tap the flywheel housing with a soft faced hammer in order to separate the flywheel housing from the cylinder block.
This document has been printed from SPI². Not for Resale
KENR6241
45 Disassembly and Assembly Section
i02748562
Crankshaft Pulley - Remove and Install Removal Procedure Table 22
Required Tools
Illustration 84
g01335381
Tool
Part Number
A
27610267
B
-
Part Description
Qty
Socket
1
Puller Group
1
3. Install Tooling (A) to the cylinder block. 4. Install a new joint (1) to the cylinder block. 5. Install a suitable lifting device to flywheel housing (2). The weight of the flywheel housing is approximately 32 kg (71 lb). 6. Use the lifting device to align flywheel housing (2) with Tooling (A). Install the flywheel housing to the cylinder block.
Start By: a. Remove the V-belt. Refer to Disassembly and Assembly, “V-belts - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
7. Install bolts (5) finger tight. 8. Remove Tooling (A). Install the remaining bolts (5).
1. Use a suitable method to prevent the crankshaft from rotating.
9. Tighten bolts (5) to a torque of 35 N·m (26 lb ft). 10. Remove the lifting device. 11. Use Tooling (B) to check the alignment of the flywheel housing with the crankshaft. Refer to Systems Operation, Testing and Adjusting, “Flywheel Housing - Inspect”. 12. Install a new crankshaft rear seal (4). Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Install”. End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”.
Illustration 85
g01335388
Typical example
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46 Disassembly and Assembly Section
KENR6241
g01335508
Illustration 86 Typical example
2. Use Tooling (A) in order to loosen nut (3). Note: Do not remove the nut at this time. 3. Install Tooling (B) to crankshaft pulley (2). Use Tooling (B) to loosen the crankshaft pulley. Remove Tooling (B). 4. Remove nut (3) and remove crankshaft pulley (2). g01368691
5. If necessary, remove woodruff key (1) from crankshaft (4).
Illustration 87
Installation Procedure
1. Ensure that the threads of crankshaft (4) and nut (3) are clean and free from damage. If necessary, install woodruff key (1) to the crankshaft.
Typical example
Table 23
Required Tools Tool C
Part Number 1861108
Part Description POWERPART Silicon RTV Sealing and Jointing Compound
Qty 1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
2. Apply a continuous bead of Tooling (C) around the threads of crankshaft (4) at position (X) approximately 10 mm (0.4 inch) from the shoulder of the crankshaft. 3. Install pulley (2) to crankshaft (4). 4. Use a suitable method to prevent the crankshaft from rotating. 5. Install nut (3). Tighten the nut to a torque of 490 N·m (361 lb ft). End By: a. Install the V-belt. Refer to Disassembly and Assembly, “V-belts - Remove and Install”.
This document has been printed from SPI². Not for Resale
KENR6241
47 Disassembly and Assembly Section
i02748563
Crankshaft Front Seal Remove and Install
Installation Procedure Table 25
Required Tools Tool
Part Number
Removal Procedure C
Table 24
27610268
Required Tools Tool
Part Number
A
-
B
27610311
Part Description
Part Description
Qty
Seal Installer Stud
1
Washer
1
Seal Installer Sleeve
1
Qty
Drill Bit (4.10 mm)
1
Slide Hammer Puller
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Start By: a. Remove the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Ensure that the main lip is used in order to remove the crankshaft front seal. Do not damage the edge of the housing for the crankshaft front seal.
Illustration 89
g01335757
Typical example
1. Ensure that the bore in front housing (1) and the nose of the crankshaft are clean and free from damage. 2. Lubricate the outside diameter of a new crankshaft front seal (2) with clean engine oil. 3. Position crankshaft front seal (2) in the bore of front housing (1).
Illustration 88
g01335759
Typical example
1. Use Tooling (A) to drill three evenly spaced holes in crankshaft front seal (2). 2. Use Tooling (B) to carefully remove crankshaft front seal (2). Alternate the position of Tooling (B) from one hole to another hole. This will allow you to evenly remove the crankshaft front seal from front housing (1).
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 Tooling (C) to install crankshaft front seal (2) into front housing (1). 5. Remove Tooling (C) and check for correct installation of crankshaft front seal (2). 6. Apply clean engine oil to the lip of crankshaft front seal (2).
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48 Disassembly and Assembly Section
KENR6241
End By: a. Install the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”. i02748564
Front Cover - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
g01335768
Illustration 91 Typical example
1. Ensure that the mating surface of front housing (1) and plate (2) are clean and free from damage. 2. Install a new O-ring seal (3) to plate (2). 3. Position plate (2) onto front housing (1). 4. Install bolts (4) and tighten to 18 N·m (13 lb ft). i02748565
Idler Gear - Remove and Install Removal Procedure Table 26 Illustration 90
g01335768
Required Tools
Typical example
1. Remove bolts (4).
Tool
Part Number
A
27610269
Part Description Idler Shaft Puller
Qty 1
2. Remove plate (2) from front housing (1). 3. Remove O-ring seal (3) from plate (2).
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Start By: a. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. b. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.
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KENR6241
49 Disassembly and Assembly Section
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.
g01337783
Illustration 93 Typical example
4. Remove bolt (2), washer (3), and plate (4). 5. Remove idler gear (5) from shaft (1).
Illustration 92
g01337345
Alignment of timing marks
2. Ensure that timing marks (X) on the gears are aligned. Refer to Illustration 92.
g01337810
Illustration 94 Extracting the shaft from the cylinder block
Alternatively, make temporary timing marks on the gears in order to show alignment. 3. Loosen the nuts on all rocker arms. Unscrew the adjusters on all rocker arms until all valves are fully closed. Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.
6. If necessary, follow Steps 6.a and 6.b in order to remove shaft (1). a. Make a temporary mark on the cylinder block in order to show the position of oil hole (Y). b. Use Tooling (A) to extract shaft (1) from the cylinder block.
Installation Procedure Table 27
Required Tools Tool
Part Number
Part Description
Qty
B
21825617
Dial Indicator Group
1
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50 Disassembly and Assembly Section
KENR6241
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 96
g01337345
Alignment of timing marks
4. Lubricate shaft (1) with clean engine oil. Position idler gear (5) onto shaft (1). Ensure that timing marks (X) on the gears are aligned. Refer to Illustration 96. 5. Lubricate the bearing surface of plate (4) with clean engine oil. Install plate (4), washer (3), and bolt (2).
Illustration 95
g01364486
Typical example
1. If necessary, follow Steps 1.a and 1.b in order to install shaft (1). a. Align oil hole (Y) on shaft (1) with the temporary mark on the cylinder block. b. Use a soft faced hammer and a hard wooden drift to install shaft (1) into the cylinder block. Note: Install shaft (1) squarely into the cylinder block. Ensure that oil hole (Y) is aligned with the temporary mark and that the shoulder on the shaft is seated against the face of the cylinder block. 2. Ensure that plate (4) and idler gear (5) are clean and free from wear or damage. If necessary, replace any components that are worn or damaged. 3. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.
Note: Ensure that the bearing surface of the plate is toward the idler gear. 6. Tighten bolt (2) to a torque of 34 N·m (25 lb ft). 7. Use a feeler gauge in order to check the end play of idler gear (2). Refer to Specifications, “Gear Group (Front)” for more information. 8. Use Tooling (B) in order to inspect the backlash of the gear group. Refer to Systems Operation, Testing and Adjusting, “Gear Group - Inspect”. 9. Lightly lubricate all of the gears with clean engine oil. 10. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. 11. Adjust the engine valve lash. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Inspect/Adjust”. End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.
This document has been printed from SPI². Not for Resale
KENR6241
51 Disassembly and Assembly Section
i02748567
Housing (Front) - Remove and Install Removal Procedure Start By: a. Remove the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. b. Remove the alternator. Refer to Disassembly and Assembly, “Alternator - Remove and Install”. c. Remove the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”. d. Remove the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install”.
Illustration 97
e. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.
1. Remove bolts (2).
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
g01349330
Typical example
2. Remove front housing (4) from plate (6). Note: Avoid damage to crankshaft front seal (3) when the front housing is removed. 3. Remove joint (5). Note: It is not necessary to remove dowels (1).
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Dispose of all fluids according to local regulations and mandates.
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52 Disassembly and Assembly Section
KENR6241
d. Install the alternator. Refer to Disassembly and Assembly, “Alternator - Remove and Install”. e. Install the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. i02748568
Front Plate - Remove Removal Procedure Start By: a. Remove the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump - Remove”. Illustration 98
g01349330
Typical example
1. Ensure that front housing (4) and the nose of the crankshaft are clean and free from damage. Clean the mating surface of plate (6). 2. Inspect crankshaft front seal (3) for wear or damage. If necessary, replace the crankshaft front seal. Refer to Disassembly and Assembly, “Crankshaft Front Seal - Remove and Install”. Apply clean engine oil to the lip of the crankshaft front seal.
b. Remove the idler gear. Refer to Disassembly and Assembly, “Idler Gear - Remove and Install”. c. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
3. Install a new joint (5) to plate (6). Ensure that the joint is correctly seated on dowels (1). 4. Align front housing (4) with dowels (1). Install the front housing to plate (6). Note: Ensure that the crankshaft front seal is not damaged when the front housing is installed. 5. Install bolts (2). Tighten the bolts to a torque of 18 N·m (13 lb ft). End By:
Illustration 99
a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.
1. Remove nut (3) and washer (2).
b. Install the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install”.
g01365310
2. Remove gear (1) from the shaft of engine oil pump (4).
c. Install the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”.
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KENR6241
Illustration 100
53 Disassembly and Assembly Section
g01365307
Illustration 101
g01365307
Typical example
Typical example
3. Remove bolts (5).
1. Ensure that plate (7) and the mating surface of the cylinder block are clean and free from damage. Ensure that dowels (6) are located in the cylinder block.
4. Remove plate (7) from the cylinder block. 5. Remove joint (8). Note: It is not necessary to remove dowels (6). 6. If necessary, remove the bracket for the alternator (not shown) from plate (7). i02748569
2. Install a new joint (8) to the cylinder block. 3. Align plate (7) with dowels (6) and install the plate to the cylinder block. 4. Install bolts (5). Tighten the bolts to a torque of 12 N·m (106 lb in).
Front Plate - Install Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 102
g01365310
5. Position gear (1) onto the shaft of engine oil pump (4). Ensure that the gear is aligned with the flat on the shaft. Install washer (2) and nut (3). Tighten the nut to a torque of 33 N·m (24 lb ft). 6. If necessary, Install the bracket for the alternator (not shown) to plate (7).
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54 Disassembly and Assembly Section
KENR6241
End By: a. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. b. Install the idler gear. Refer to Disassembly and Assembly, “Idler Gear - Remove and Install”. c. Install the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump - Install”. i02748570
Crankcase Breather - Remove and Install (Turbocharged Engines) g01344989
Removal Procedure
Illustration 103
NOTICE Keep all parts clean from contaminants.
1. Loosen the hose clamp and disconnect hose (3) from crankcase breather (1).
Contaminants may cause rapid wear and shortened component life.
2. Loosen the hose clamp and disconnect hose (4) from crankcase breather (1).
Typical example
3. Remove bolts (2) and remove crankcase breather (1).
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
NOTICE Keep all parts clean from contaminants.
Dispose of all fluids according to local regulations and mandates.
Contaminants may cause rapid wear and shortened component life.
Installation Procedure
This document has been printed from SPI². Not for Resale
KENR6241
Illustration 104
55 Disassembly and Assembly Section
g01344989
Illustration 105
g01336694
Typical example
Typical example
1. Connect hose (4) to crankcase breather (1) and tighten the hose clamp.
1. If the engine is equipped with a turbocharger, follow Steps 1.a through 1.c in order to remove the air pipe.
2. Position crankcase breather (1) and install bolts (2). Tighten the bolts to a torque of 18 N·m (13 lb ft). 3. Connect hose (3) to crankcase breather (1) and tighten the hose clamp. i02748571
a. Loosen hose clamps (6) and remove hose (4). b. Remove bolts (5) and remove air pipe (3) from turbocharger (1). Remove gasket (2). c. Plug the opening in the inlet manifold and the opening in the turbocharger with suitable plugs.
Valve Mechanism Cover Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
Illustration 106
g01345049
2. Loosen the hose clamp and disconnect hose (10) from valve mechanism cover (8).
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56 Disassembly and Assembly Section
KENR6241
3. Remove bolts (7). Remove valve mechanism cover (8) from the cylinder head. 4. Remove seal (9) from valve mechanism cover (8).
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Thoroughly clean the valve mechanism cover. Clean the mating surfaces of the cylinder head.
Illustration 108
g01336694
Typical example
6. If the engine is equipped with a turbocharger, follow Steps 6.a through 6.c in order to install the air pipe. a. Remove the plugs from the inlet manifold and from the turbocharger. b. Position a new joint (2) and air pipe (3) onto turbocharger (1). Install bolts (5). Tighten the bolts to a torque of 18 N·m (13 lb ft). c. Install hose (4) and tighten hose clamps (6) securely. Illustration 107
g01345049
2. Install a new seal (9) to valve mechanism cover (8). Note: Ensure that the joint is fully seated into the groove of the valve mechanism cover. 3. Place valve mechanism cover (8) in position on the cylinder head. 4. Install bolts (7). Tighten the bolts to a torque of 12 N·m (106 lb in). 5. Connect hose (10) to valve mechanism cover (8) and tighten the hose clamp.
i02748572
Rocker Shaft and Pushrod Remove Removal Procedure Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
This document has been printed from SPI². Not for Resale
KENR6241
57 Disassembly and Assembly Section
i02748573
Rocker Shaft - Disassemble Disassembly Procedure Table 28
Required Tools Tool
Part Number
A
-
Part Description Retaining Ring Pliers
Qty 1
Start By: a. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”. Illustration 109
g01345395
Typical example
1. Loosen the nuts and adjustment screws (1) on all rocker arms.
Personal injury can result from being struck by parts propelled by a released spring force.
2. Remove bolts (5).
Make sure to wear all necessary protective equipment.
3. Progressively loosen bolts (3). Begin at the ends of the rocker shaft assembly and work toward the center.
Follow the recommended procedure and use all recommended tooling to release the spring force.
Note: Damage to the rocker shaft may occur if the long bolts are loosened first. To avoid distortion of the rocker shaft assembly, each bolt should be loosened by a quarter of a turn at one time. Repeat the procedure until all bolts are loosened.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
4. Remove bolts (3). 5. Remove rocker shaft assembly (2) from the cylinder head. 6. Place temporary identification marks on pushrods (4) and pads (6). Note: Identification will ensure that the pushrods and pads can be reinstalled in the correct position. Do not interchange the positions of used pushrods or pads. 7. Remove pushrods (4) from the cylinder head. Remove pads (6) from the valve stems.
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58 Disassembly and Assembly Section
KENR6241
i02748575
Rocker Shaft - Assemble Assembly Procedure Table 29
Required Tools Tool
Part Number
A
-
Part Description Retaining Ring Pliers
Qty 1
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. Note: Ensure that all oil holes are free from blockages. 2. Lubricate all of the components with clean engine oil before assembly. Illustration 110
g01345402
1. Make an identification mark on each rocker arm assembly in order to show the location. Note the mark at position (X) for installation purposes. Note: The components must be reinstalled in the original location. Do not interchange components. 2. Use Tooling (A) to remove retaining rings (8). 3. Remove rocker arm assembly (5). 4. Remove pedestal (6) from rocker shaft (3). 5. Remove rocker arm assembly (7). 6. Remove spring (4). 7. Repeat Steps 3 through 6 in order to remove the remaining rocker arm assemblies from rocker shaft (3). 8. If necessary, remove nuts (1) and adjusters (2) from the rocker arms. Make a temporary identification mark on each adjuster in order to show the location. Illustration 111
Note: The components must be reinstalled in the original location. Do not interchange components.
g01345402
3. If necessary, install nuts (1) and adjusters (2) to rocker arm assemblies (5) and (7). If the original adjusters are reused, ensure that the adjusters are installed in the original positions.
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KENR6241
59 Disassembly and Assembly Section
4. Use Tooling (A) to install retaining ring (8) to the front end of rocker shaft (3). The front end of the rockershaft is identified by the mark at Position (X). Ensure that the mark at position (X) is upward. 5. Install rocker arm assembly (5) to rocker shaft (3). 6. Install bracket (6) to rocker shaft (3). Note: Ensure correct orientation of the bracket. Refer to Illustration 111. 7. Install rocker arm assembly (7) to rocker shaft (3).
Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Illustration 112
g01345395
Typical example
8. Install spring (4) to rocker shaft (3). 9. Repeat Steps 5 through 8 in order to assemble the remaining components of the rocker shaft assembly. 10. Use Tooling (A) to install retaining ring (8) to the rear end of rocker shaft (3).
2. Apply clean engine lubricating oil to both ends of pushrods (4). Install the pushrods to the engine with the cup upward. Ensure that the pushrods are installed correctly in the socket of the valve lifters. Note: If the pushrods have been used, ensure that the pushrods are installed in original positions.
End By:
3. Lubricate the top of the valve stems with clean engine oil. Install caps (6) to the valve stems.
a. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”.
Note: If the caps have been used, ensure that the caps are installed in original positions. 4. Install rocker shaft (2) to the cylinder head.
i02748576
Rocker Shaft and Pushrod Install
Note: Ensure that the ends of adjustment screws (1) are correctly seated in ends of pushrods (4). Also ensure that valve caps (6) are in position under the rocker arms.
Installation Procedure
5. Install bolts (3) to the rocker shaft. Tighten the bolts to a torque of 15 N·m (11 lb ft). Begin at the center of the rocker shaft assembly and work outward.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components are clean and free from wear or damage. Refer to Specifications, “Rocker Shaft” for more information. Replace any components that are worn or damaged.
Note: Damage to the rockershaft may occur if the short bolts are tightened first. 6. Install bolts (5) to the rocker shaft. Tighten the bolts to a torque of 15 N·m (11 lb ft). 7. Adjust the valve lash. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash Inspect/Adjust” for the correct procedure.
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60 Disassembly and Assembly Section
KENR6241
End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.
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 - Change” for the correct procedure.
i02748577
Cylinder Head - Remove Removal Procedure Table 30
Required Tools Tool
Part Number
A
-
Part Description Lifting Bracket
Qty 2
Start By: a. Remove the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold - Remove and Install”. Illustration 113
b. Remove the fuel injectors. Refer to Disassembly and Assembly, “Fuel Injectors - Remove and Install”. c. Remove the glow plugs. Refer to Disassembly and Assembly, “Glow Plugs - Remove and Install”. d. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”.
g01362487
Typical example
2. Disconnect hose (2) from water temperature regulator housing (1). 3. Remove breather hose (4). 4. If necessary, remove inlet manifold (3). Refer to Disassembly and Assembly, “Inlet Manifold Remove and Install”.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Illustration 114
Dispose of all fluids according to local regulations and mandates.
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The cylinder head tightening sequence
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KENR6241
61 Disassembly and Assembly Section
Illustration 116
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9. Note the position of dowels (8) in the cylinder block. Do not remove the dowels unless the dowels are damaged. Illustration 115
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5. Gradually loosen cylinder head bolts (5) in reverse numerical order to the sequence that is shown in Illustration 114. This will prevent distortion of the cylinder head. 6. Remove cylinder head bolts (5) from cylinder head (6). 7. Attach Tooling (A) and a suitable lifting device to cylinder head (6). Carefully lift the cylinder head off the cylinder block. The weight of the cylinder head is approximately 34 kg (75 lb). 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. Illustration 117
g01346658
NOTICE Place the cylinder head on a surface that will not scratch the face of the cylinder head.
Typical example
8. Remove gasket (7).
11. If necessary, remove water temperature regulator housing (1). Refer to Disassembly and Assembly, “Water Temperature Regulator Housing - Remove and Install”.
10. If necessary, remove bolts (11) and remove lifting bracket (10). Remove joint (9).
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62 Disassembly and Assembly Section
KENR6241
i02748578
Cylinder Head - Install Installation Procedure Table 31
Required Tools Tool
Part Number
Part Description
Qty
A
-
Lifting Bracket
2
B
-
Guide Stud (M12 x 1.75 by 100 mm)
2
C
-
Straight Edge
1
NOTICE Keep all parts clean from contaminants.
Illustration 119
Contaminants may cause rapid wear and shortened component life. 1. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Ensure that there is no debris in the cylinder bores, the coolant passages or the lubricant passages.
g01346658
Typical example
5. If necessary, install a new joint (9), lifting bracket (10) and bolts (11) to cylinder head (6). Tighten the bolts to a torque of 11 N·m (97 lb in).
2. Inspect the mating surface of the cylinder head for distortion. Refer to Specifications, “Cylinder Head” for more information.
Illustration 118
g01352861
3. Inspect dowels (8) for damage. If necessary, replace the dowels in the cylinder block. 4. Install Tooling (B) to the cylinder block. Refer to Illustration 118.
Illustration 120
g01346253
6. Align cylinder head gasket (7) with Tooling (B) and install the cylinder head gasket onto the cylinder block. Note: Ensure that the word UP on the cylinder head gasket is upward.
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KENR6241
63 Disassembly and Assembly Section
7. Use Tooling (A) and a suitable lifting device to lift cylinder head (6). The weight of the cylinder head is approximately 34 kg (75 lb). Align cylinder head (6) with Tooling (B) and install the cylinder head to the cylinder block. Note: Ensure that the cylinder head is correctly seated on dowels (8). 8. Remove Tooling (B).
Illustration 123
g01362487
Typical example Illustration 121
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9. Clean cylinder head bolts (5). Inspect the threads of the bolts. Use Tooling (C) in order to check the bolts. The bolts must be renewed if there is any visual reduction in the diameter over area (X). 10. Lubricate the threads and the shoulder of cylinder head bolts (5) with clean engine oil before installation. 11. Install cylinder head bolts (5) to cylinder head (6).
13. If necessary, install water temperature regulator housing (1). Refer to Disassembly and Assembly, “Water Temperature Regulator Housing - Remove and Install”. 14. Connect hose (2) to water temperature regulator housing (1). 15. If necessary, install inlet manifold (3). Refer to Disassembly and Assembly, “Inlet Manifold Remove and Install”. 16. Install breather hose (4). 17. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”. 18. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. End By: a. Install the glow plugs. Refer to Disassembly and Assembly, “Glow Plugs - Remove and Install”.
Illustration 122
g01001090
The cylinder head tightening sequence
b. Install the fuel injectors. Refer to Disassembly and Assembly, “Fuel Injectors - Remove and Install”.
12. Tighten cylinder head bolts (5) in numerical order to the sequence that is shown in Illustration 122. Tighten the cylinder head bolts to a torque of 118 N·m (87 lb ft).
c. Install the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold - Remove and Install”.
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64 Disassembly and Assembly Section
KENR6241
i02748579
Lifter Group - Remove and Install
3. Repeat Steps 1 and 2 in order to remove the remaining lifters.
Installation Procedure Table 33
Required Tools
Removal Procedure Table 32
Tool
Part Number
A
-
Part Description Telescoping Magnet
Qty 1
Required Tools Tool
Part Number
A
-
Part Description Telescoping Magnet
Qty 1
Start By: a. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. If the engine is not equipped with a balancer, remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. b. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE It is strongly recommended that all lifters should be replaced when a new camshaft is installed. 1. Clean the lifters. Follow Steps 1.a through 1.c in order to inspect the lifters. Replace lifters that are worn or damaged. a. Inspect the seat of the pushrod in the lifter for visual wear or damage. b. Inspect the shank of the lifter for wear or damage. Refer to Specifications, “Lifter Group” for more information. c. Inspect the face of the lifter that runs on the camshaft for visual wear or damage. 2. If the crankshaft is installed, rotate the crankshaft to access to the cylinder block in order to install lifters (1). 3. Lubricate lifters (1) with clean engine oil.
Illustration 124
g01343537
Typical example
1. If the crankshaft is installed, rotate the crankshaft in order to gain access to lifters (1). 2. Use Tooling (A) to remove lifters (1). Note: Make a temporary identification mark on each lifter in order to identify the correct location.
Illustration 125
g01343537
Typical example
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KENR6241
65 Disassembly and Assembly Section
4. Use Tooling (A) to install lifters (1) to the cylinder block. Ensure that used lifters are installed in the correct location. Note: The lifters should be free to rotate. 5. Repeat Steps 2 through 4 in order to install the remaining lifters. End By: a. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. b. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”. If the engine is not equipped with a balancer, install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. i02748580
Camshaft - Remove and Install
g01349741
Illustration 126 Typical example
4. Ensure that gears (2) and (3) are marked in order to show alignment. Refer to Illustration 126. Note: Identification will ensure that the camshaft can be installed in the original position. 5. Remove bolts (1).
Removal Procedure Start By: a. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
g01350309
Illustration 127 Typical example
1. The engine should be mounted on a suitable stand and placed in the inverted position. 2. Rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No.1 Piston”. 3. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”.
NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed. 6. Carefully remove camshaft assembly (4) from the cylinder block. 7. If necessary, remove the camshaft gear. Refer to Disassembly and Assembly, “Camshaft Gear.Remove and Install”.
Installation Procedure Table 34
Required Tools Tool
Part Number
A
21825617
Part Description Dial Indicator Group
Qty 1
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66 Disassembly and Assembly Section
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4. Install bolts (1). Tighten the bolts to a torque of 12 N·m (106 lb in).
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the camshaft assembly is clean and free from wear or damage. If necessary, install the camshaft gear. Refer to Disassembly and Assembly, “Camshaft Gear.- Remove and Install”. 2. Lubricate the camshaft assembly with clean engine oil prior to installation.
5. Use Tooling (A) to check the backlash between gears (2) and (3). Ensure that the backlash for the gears is within specified values. Refer to the Specifications, “Gear Group (Front)” for further information. 6. Use Tooling (A) to check the end play for camshaft gear (3). Ensure that the end play is within specified values. Refer to the Specifications, “Camshaft” for further information. 7. Lubricate the teeth of the gears with clean engine oil. End By: a. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. b. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”. i02748582
Illustration 128
g01349741
Camshaft Gear - Remove and Install
Typical example
Removal Procedure Start By: a. Remove the camshaft assembly from the engine. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. NOTICE Keep all parts clean from contaminants.
Illustration 129
g01350309
Contaminants may cause rapid wear and shortened component life.
Typical example
NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed. 3. Carefully install camshaft assembly (4) to the cylinder block. Ensure that the timing marks on gears (2) and (3) are in alignment and that the mesh of the gears is correct. Refer to Illustration 128.
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KENR6241
67 Disassembly and Assembly Section
Always wear protective gloves when handling parts that have been heated. 3. Raise the temperature of camshaft gear (1). Align the camshaft gear with woodruff key (3) and install the camshaft gear to camshaft (4). End By:
Illustration 130
g01350917
1. Place the camshaft assembly on a suitable support. Use a press to remove camshaft gear (1) from camshaft (4). 2. Remove thrust plate (2) and woodruff key (3) from camshaft (4). Note the orientation of the thrust plate for installation.
a. Install the camshaft assembly to the engine. Refer to Disassembly and Assembly, “Camshaft - Remove and Install”. i02748583
Engine Oil Pan - Remove and Install Removal Procedure for the Engine Oil Pan
Installation Procedure NOTICE Keep all parts clean from contaminants.
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components of the camshaft assembly are clean and free from damage.
Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
Illustration 131
g01350917
2. Install woodruff key (3) and thrust plate (2) to camshaft (4). Note: Ensure that the machined face of the thrust plate is toward the camshaft.
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68 Disassembly and Assembly Section
Illustration 132
KENR6241
g01347462
1. Remove oil drain plug (3). Drain the engine oil into a suitable container for storage or disposal.
Illustration 133
g01347459
The oil strainer for engines without a balancer
2. Remove sealing washer (2) from oil drain plug (3). 3. Remove bolts (4) from engine oil pan (1). 4. Carefully separate engine oil pan (1) from the cylinder block. Note: Avoid damage to the engine oil pan during removal.
Removal Procedure for the Oil Strainer NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 134
g01347461
The oil strainer for engines that are equipped with a balancer
1. Remove bolts (7). 2. Remove oil strainer (6). 3. Remove O-ring seal (5) from oil strainer (6).
This document has been printed from SPI². Not for Resale
KENR6241
69 Disassembly and Assembly Section
Installation Procedure for the Oil Strainer NOTICE Keep all parts clean from contaminants.
4. Tighten bolts (7) to a torque of 18 N·m (13 lb ft).
Installation Procedure for the Engine Oil Pan Table 35
Contaminants may cause rapid wear and shortened component life. 1. Clean all mating surfaces thoroughly.
Required Tools Tool
Part Number
Part Description
Qty
A
21826038
POWERPART Silicon Adhesive
1
B
21820117
POWERPART Threadlock and Nutlock
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the engine oil pan is clean and free from damage. Clean the mating surface of the cylinder block.
Illustration 135
g01347459
The oil strainer for engines without a balancer
Illustration 137
Illustration 136
g01347462
g01347461
The oil strainer for engines that are equipped with a balancer
2. Install a new O-ring seal (5) to oil strainer (6). 3. Install oil strainer (6) and install bolts (7).
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70 Disassembly and Assembly Section
KENR6241
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 138
g01347865
The pattern of application of sealant to the engine oil pan.
2. Apply a continuous bead of Tooling (A) to the mating surface of engine oil pan (1) on the inside of the bolt holes. Refer to Illustration 138 for the correct pattern of application. The bead of Tooling (A) should be approximately 2 mm (0.080 inch) in diameter.
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.
3. Ensure that bolts (4) are clean and dry. Apply Tooling (B) to the threads of the bolts. 4. Position engine oil pan (1) onto the cylinder block and install bolts (4). 5. Tighten bolts (4) to a torque of 11 N·m (97 lb in). 6. Install a new sealing washer (2) to oil drain plug (3). 7. Install oil drain plug (3) to engine oil pan (1). Tighten the oil drain plug to a torque of 39 N·m (29 lb ft). 8. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change” for the correct procedure. i02748584
Balancer - Remove Removal Procedure Start By: a. Remove the engine oil pan and remove the oil strainer. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.
Illustration 139
g01344508
Note: If the balancer will be disassembled, loosen bolts (4) before the balancer is removed from the engine. 2. Support the weight of the balancer. The balancer weighs approximately 23 kg (51 lb). Remove bolts (3) and remove balancer (1) from the engine.
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KENR6241
71 Disassembly and Assembly Section
3. Do not remove dowels (2) unless the dowels are damaged. i02748586
Balancer - Disassemble Disassembly Procedure Table 36
Required Tools Tool
Part Number
A
-
Combination Puller
1
B
-
Retaining Ring Pliers
1
C
27610275
Bearing Installer Group
1
Part Description
Qty
Illustration 141
g01344528
Illustration 142
g01344665
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Timing marks
1. Remove bolts (4) and washers (5). Use Tooling (A) in order to remove gears (6). Ensure that balancer shaft (10) is protected from damage. Note: Gears (6) have different Markings (X). Refer to Illustration 142. Identify the position of the gears for installation. 2. Remove keys (7). Use Tooling (B) in order to remove retaining rings (8).
Illustration 140
g01344515
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72 Disassembly and Assembly Section
KENR6241
1. Ensure that all components of the balancer are clean and free from damage.
g01344533
Illustration 143
3. Carefully tap the assembly of bearing (9) and balancer shaft (10) forward until the shaft is clear of bushing (11). Refer to Illustration 143. 4. Use Tooling (A) in order to remove bearing (9) from balancer shaft (10). Note: Ensure that the balancer shaft is protected from damage. 5. Slide balancer shaft (10) back through bushing (11) until the shaft is clear of the balancer. 6. If necessary, use Tooling (C) in order to remove bushing (11) from balancer (1). i02748588
Balancer - Assemble
Illustration 144
g01344574
2. If new bushing (11) is installed to the balancer, follow Steps 2.a and 2.b. a. Align oil holes (Z) in bushing (11) to drilling (Y) in balancer (1). b. Use Tooling (C) to install bushing (11) to balancer (1). Ensure that the oil holes (Z) are correctly aligned to drilling (Y).
Assembly Procedure Table 37
Required Tools Tool
Part Number
B
-
C D
Part Description
Qty
Retaining Ring Pliers
1
27610275
Bearing Installer Group
1
21820117
POWERPART Threadlock and Nutlock
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
This document has been printed from SPI². Not for Resale
KENR6241
73 Disassembly and Assembly Section
g01344665
Illustration 146 Timing marks
7. Align gears (6) with keys (7) and install the gears to balancer shafts (10). Ensure that the gears are installed in the correct position. Illustration 145
g01344515
3. Use Tooling (C) in order to press bearings (9) into balancer (1). Note: Do not press on the inner race of the bearing as this could result in damage to the bearing.
Note: The gears have different Markings (X). The right hand gear is marked 1,1 and 2,2. The left hand gear is marked 2. Refer to Illustration 146. 8. Apply Tooling (D) to the threads of bolts (4). Install bolts (4) and washers (5). Tighten the bolts to a torque of 33 N·m (24 lb ft).
4. Use Tooling (B) to install retaining rings (8). Note: Ensure that the retaining rings are fully located into the grooves in the balancer. 5. Lubricate balancer shafts (10) and bushing (11) with clean engine oil. Carefully install the balancer shafts to balancer (1). 6. Install keys (7).
i02748589
Balancer - Install Installation Procedure Table 38
Required Tools Tool
Part Number
F
21825617
Part Description Dial Indicator Group
Qty 1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
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74 Disassembly and Assembly Section
KENR6241
g01344971
Illustration 149 Alignment of the timing marks
Illustration 147
g01344665
Timing marks
2. Align dowels (2) with the holes in the cylinder block. Align mark 1,1 on gear (6) to mark 1 on crankshaft gear (12). Refer to Illustration 149. Position balancer (1) on the engine. The balancer weighs approximately 23 kg (51 lb). 3. Install bolts (3). Tighten the bolts to a torque of 30 N·m (22 lb ft). 4. Use Tooling (F) in order to check the backlash between gears (6). Refer to Specifications, “Gear Group (Front)”. 5. Use Tooling (F) in order to check the backlash between gears (6) and (12). Refer to Specifications, “Gear Group - Front” for further information. End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, “ Engine Oil Pan - Remove and Install”. i02748590
Pistons and Connecting Rods - Remove Removal Procedure Illustration 148
g01344983
1. Ensure that dowels (2) are seated in balancer (1). Ensure that marks 2,2 and 2 on gears (6) are aligned. Refer to Illustration 147.
Table 39
Required Tools Tool
Part Number
A
27610274
Part Description Ridge Reamer
Qty 1
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KENR6241
75 Disassembly and Assembly Section
Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Remove”. b. Remove the engine oil pan and remove the oil strainer. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. 2. Rotate the crankshaft until the piston that is being removed is at the bottom center position. 3. Use Tooling (A) to remove the carbon ridge from the top inside surface of the cylinder bore.
Note: Use tape or rubber tubing on the connecting rod bolts to protect the crankshaft journals from damage. 7. Carefully push the piston and the connecting rod assembly out of the cylinder bore. Lift the piston out of the top of the cylinder block. 8. Repeat Steps 2 through 7 in order to remove the remaining pistons and connecting rods. i02748591
Pistons and Connecting Rods - Disassemble Disassembly Procedure Table 40
Required Tools Tool
Part Number
Part Description
Qty
A
-
Retaining Ring Pliers
1
B
-
Ring Expander
1
C
27610275
Driver Group
1
Start By: a. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, “Piston and Connecting Rods - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 150
g01352319
4. The connecting rod and the connecting rod cap have matching numbers (X) on the side. Note the location of the connecting rod for installation. If necessary, make a temporary mark on the connecting rod and the connecting rod cap in order to identify the cylinder number. 5. Remove nuts (2). 6. Remove connecting rod cap (1) from the connecting rod.
Illustration 151
g01359107
(X) Number (Y) Number
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76 Disassembly and Assembly Section
KENR6241
2. Place the piston and connecting rod assembly on a suitable surface with the connecting rod upward. Use Tooling (A) in order 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.
Illustration 152
g01359108
(X) Number (Y) Number
1. Make a temporary mark on the components of the piston and connecting rod assembly. This will ensure that the components of each piston and connecting rod assembly can be reinstalled in the original cylinder. Note the correct orientation of the connecting rod in relation to the piston. Number (X) and number (Y) must be on the same side. Refer to Illustration 151. Do not interchange components.
Illustration 153
g01311807
Illustration 154
g00829406
Illustration 155
g01351357
Typical example
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KENR6241
77 Disassembly and Assembly Section
4. Place piston (2) on a suitable surface with the crown upward. Use Tooling (B) in order to remove compression rings (5) and (6), and oil control ring (7) from the piston. Note: Identify the orientation of the piston rings for installation.
7. Inspect piston pin bearing (12) for wear or damage. Refer to Specifications, “Pistons and Rings” for more information. If necessary, replace connecting rod (1) or replace piston pin bearing (12). If necessary, use Tooling (C) and a suitable press to remove piston pin bearing (12) from connecting rod (1). 8. Repeat Steps 1 through 7 in order to disassemble the remaining pistons and connecting rods. i02748593
Pistons and Connecting Rods - Assemble Assembly Procedure Table 41
Required Tools
Illustration 156
g01362961
Typical example
5. If necessary, remove nuts (11) and connecting rod cap (10) from connecting rod (1). 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 Perkins distributor.
Illustration 157
Tool
Part Number
Part Description
Qty
A
-
Retaining Ring Pliers
1
B
-
Ring Expander
1
C
27610275
Driver Group
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components are clean and free from wear or damage. If necessary, replace any components that are worn or damaged. NOTICE Removal of the piston pin bushing in the connecting rod must be carried out by personnel with the correct training. Also special machinery is required. For more information refer to your authorized Perkins distributor.
g01351358
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78 Disassembly and Assembly Section
Illustration 158
KENR6241
g01352211
2. If necessary, use Tooling (C) and a suitable press to install piston pin bearing (12) into connecting rod (1). Ensure that oil hole (Z) in the piston pin bearing is aligned with the oil hole at the top of the connecting rod.
Illustration 160
g01359107
(X) Number (Y) Number
Illustration 161
g01359108
(X) Number (Y) Number
4. Place piston (2) on a suitable surface with the crown downward. Ensure the correct orientation of the connecting rod in the piston. Number (X) and number (Y) must be on the same side. Refer to Illustration 160 or Illustration 161. Install connecting rod (1) and piston pin (3) to the piston. Note: If the piston pin cannot be installed by hand, heat the piston to a temperature of 45 ± 5 °C (113 ± 9 °F). Do not use a torch to heat the piston. Illustration 159
g01311807
Typical example
3. Lubricate piston pin bearing (12) and lubricate the bore for the piston pin in piston (2) with clean engine oil.
5. Use Tooling (A) in order 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. 6. Follow Steps 6.a through 6.e in order to install the piston rings to the piston.
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KENR6241
79 Disassembly and Assembly Section
Illustration 164
g00829406
Piston from a turbocharged engine
b. Use Tooling (B) to install oil control ring (7) over the spring. Note: Ensure that the central wire is 180 degrees from the ring gap.
Illustration 162
g01351357
d. Use Tooling (B) to install top compression ring (5) into the top groove in the piston. The letter “T” must be upward.
Piston from a turbocharged engine
Illustration 163
c. Use Tooling (B) to install intermediate compression ring (6) into the second groove in the piston. The letter “T” and the chamfer on the inner face of the ring must be upward.
g01352230
Piston from a turbocharged engine
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.
Illustration 165
g01359137
The correct position of the piston ring gaps (AA) Ring gap of the top compression ring (BB) Ring gap of the intermediate compression ring (CC) Ring gap of the oil control ring
e. Align the piston ring gaps to the positions that are shown in Illustration 165.
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80 Disassembly and Assembly Section
KENR6241
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the assemblies of the pistons and connecting rods are clean and free from damage. 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. g01362961
Illustration 166 Typical example
3. Rotate the crankshaft until the crankshaft pin is in the bottom center position. Lubricate the crankshaft pin with clean engine oil.
7. Install the upper half of connecting rod bearing (8) to connecting rod (1). 8. Install the lower half of connecting rod bearing (9) to connecting rod cap (10). 9. Repeat Steps 2 through 8 in order to assemble the remaining pistons and connecting rods. End By: a. Install the pistons and connecting rods. Refer to Disassembly and Assembly, “Piston and Connecting Rods - Install”. Illustration 167 i02748594
g01352295
Piston from a turbocharged engine
Pistons and Connecting Rods - Install Installation Procedure Table 42
Required Tools Tool
Part Number
Part Description
Qty
B
21825491
Piston Ring Compressor
1 Illustration 168
g01359137
The correct position of the piston ring gaps (AA) Ring gap of the top compression ring (BB) Ring gap of the intermediate compression ring (CC) Ring gap of the oil control ring
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Worldwide Parts Source LLC Phone 269 673 2313 Parts Source
4. Align the piston ring gaps to the positions that are shown in Illustration 168. Install Tooling (B) onto piston (3). Ensure that Tooling (B) is installed correctly and that the piston can easily slide from the tool.
10. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”.
Note: Use tape or rubber tubing on the connecting rod bolts to protect the crankshaft pin from damage. Ensure that the piston and the connecting rod assembly are installed in the correct cylinder.
a. Install the oil strainer and install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.
5. Carefully push the piston and the connecting rod assembly into the cylinder bore and onto the crankshaft pin. Note: Use tape or rubber tubing on the connecting rod bolts to protect the crankshaft pin from damage. Ensure that the piston and the connecting rod assembly are installed in the correct cylinder.
End By:
b. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. i02748595
Connecting Rod Bearings Remove (Connecting rods in position) Removal Procedure Start By: a. Remove the engine oil pan and remove the oil strainer. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”. b. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 169
g01352319
Typical example
6. Remove the tape or rubber tubing on the connecting rod bolts. Install connecting rod cap (1). Note: Ensure that number (X) on the connecting rod cap matches number (X) on the connecting rod. Ensure that the numbers are on the same side. 7. Install nuts (2). Tighten the nuts to a torque of 54 N·m (40 lb ft).
Note: If all connecting rod bearings require replacement, 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 - Install” for the correct procedure.
8. Ensure that the installed connecting rod assembly has tactile side play. Rotate the crankshaft in order to ensure that there is no binding. 9. Repeat Steps 2 through 8 in order to install the remaining pistons and connecting rods.
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82 Disassembly and Assembly Section
KENR6241
i02748597
Connecting Rod Bearings Install (Connecting rods in position) Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 170
g01361963
Typical example
Note: The connecting rod and the connecting rod cap have matching numbers at position (X). Note the location of the connecting rod cap (5) for installation. 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).
1. Inspect the pins of the crankshaft for damage. Refer to Specifications, “Connecting Rod Bearing Journals” for more information. If the crankshaft is worn or damaged, replace the crankshaft or recondition the crankshaft. Refer to Disassembly and Assembly, “Crankshaft - Remove” and Disassembly and Assembly, “Crankshaft - Install”. 2. Ensure that the connecting rod bearings are clean and free from wear or damage. If necessary, replace the connecting rod bearings.
2. Remove lower connecting rod bearing (4) from connecting rod cap (5). Note: Use tape or rubber tubing on connecting rod bolts (2) in order to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals. 3. Carefully push connecting rod (1) into the cylinder bore. Remove upper connecting rod bearing (3) from the connecting rod.
Illustration 171
g01361963
Typical example
3. Clean the bearing surface of connecting rod (1) and connecting rod cap (5). 4. Install upper connecting rod bearing (3) to connecting rod (1). Lubricate the bearing surface of the connecting rod bearing with clean engine oil.
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KENR6241
Note: Use tape or rubber tubing on connecting rod bolts (2) in order to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals. 5. Carefully pull connecting rod (1) against the crankshaft pin. 6. Install lower connecting rod bearing (4) to connecting rod cap (5). 7. Lubricate the pin of the crankshaft and lubricate lower connecting rod bearing (4) with clean engine oil. NOTICE When the connecting rod caps are installed, ensure that the identification marks are aligned. 8. Ensure that the numbers at position (X) on connecting rod cap (5) and on connecting rod (1) match. Install connecting rod cap (5). 9. Install nuts (6). Tighten the nuts evenly to a torque of 54 N·m (40 lb ft). 10. Repeat Steps 2 through 9 for the remaining connecting rod bearings. Note: If all connecting rod bearings require replacement, 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 the correct procedure. 11. Ensure that the installed connecting rod assemblies have tactile side play. Carefully rotate the crankshaft in order to ensure that there is no binding.
83 Disassembly and Assembly Section
i02748598
Crankshaft Main Bearings Remove and Install (Crankshaft in position) Removal Procedure Start By: a. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. If the engine is not equipped with a balancer, remove the oil strainer. Refer to Disassembly and Assembly, “Engine Oil Pan Remove and Install”. b. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. NOTICE This procedure must only be used to remove and install the main bearing shells with the crankshaft in position. The removal procedure and the installation procedure must be completed for each pair of main bearing shells before the next pair of main bearing shells are removed. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the main bearing caps are marked for the correct location and orientation.
End By: a. If the engine is equipped with a balancer, Install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”. b. Install the oil strainer and the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.
Illustration 172
g01353474
Typical example
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84 Disassembly and Assembly Section
Worldwide Parts Source LLC Phone 269 673 2313 Engine Parts
2. Remove bolts (1). Remove main bearing cap (2) from the cylinder block.
Note: The lower main bearing is a plain bearing that has no oil holes.
Note: Number five main bearing cap must be removed squarely from the cylinder block. Do not twist the main bearing cap during removal as damage may result.
g01353517
Illustration 175 Typical example
5. Push out upper main bearing (6) with a suitable tool from the side opposite the locating tab. Carefully rotate the crankshaft while you push on the bearing. Remove upper main bearing (6) from the cylinder block. Keep the bearings together.
Illustration 173
g01353478
Number five main bearing cap
3. For number five main bearing cap, remove lower thrust washers (4) and remove seals (3). Note: It is not possible to remove the upper thrust washer from the cylinder block with the crankshaft in position. If the upper thrust washer requires removal, the crankshaft must be removed. Refer to Disassembly and Assembly, “Crankshaft - Remove”.
Note: Do not damage the machined surfaces of the crankshaft during removal of the upper main bearing. The upper main bearing has a groove and two oil holes.
Installation Procedure Table 43
Required Tools Tool
Part Number
Part Description
Qty
A
218260238
POWERPART Silicone Sealant Adhesive
1
B
27610013
Seal Installer
1
C
21825617
Dial Indicator Group
1
NOTICE This procedure must only be used to remove and install the main bearing shells with the crankshaft in position. The removal procedure and the installation procedure must be completed for each pair of main bearing shells before the next pair of main bearing shells are removed. Illustration 174
g01353475
Number five main bearing cap
4. Remove lower main bearing (5) from main bearing cap (2). Keep the main bearing and the main bearing cap together.
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KENR6241
Worldwide Parts Source LLC Phone 269 673 2313 Engine Parts 4. Install lower main bearing (5) into main bearing cap (2). Ensure that the locating tab for the lower main bearing is correctly seated into the slot in the bearing cap.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: The lower main bearing is a plain bearing that has no oil holes.
1. Ensure that the main bearings are clean and free from wear or damage. If necessary, replace the main bearings. 2. Clean the journal of the crankshaft. Inspect the journal of the crankshaft for damage. If necessary, replace the crankshaft or recondition the crankshaft. Refer to Disassembly and Assembly, “Crankshaft - Remove” for more information.
Illustration 178
g01353916
Number five main bearing cap
5. For number five main bearing cap, follow Steps 5.a through 5.c in order to install the lower thrust washers (4) to the main bearing cap.
Illustration 176
g01353517
Typical example
3. Lubricate the crankshaft journal and the upper main bearing (6) with clean engine oil. Slide the upper main bearing into position between the crankshaft journal and the cylinder block. Ensure that the locating tab for the upper main bearing is correctly seated in the slot in the cylinder block. Note: The upper main bearing has a groove and two oil holes.
Illustration 177
Note: It is not possible to install the upper thrust washer to the cylinder block with the crankshaft in position. If the upper thrust washer requires removal and installation, the crankshaft must be removed. Refer to Disassembly and Assembly, “Crankshaft Remove”. a. Ensure that lower thrust washers (4) are clean and free from wear or damage. If necessary, replace the thrust washers. Lubricate the thrust washers with clean engine oil. b. Install lower thrust washers (4) to main bearing cap (2). Ensure that holes (X) in the thrust washers are aligned with dowels (Y) in the main bearing cap. Ensure that the grooves in the thrust washers face toward the crankshaft.
g01353475
Number five main bearing cap
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Worldwide Parts Source LLC Phone 269 673 2313 Engine Parts 86 Disassembly and Assembly Section
Illustration 179
g01354237
c. Ensure that the recess in the cylinder block for number five main bearing cap is clean and dry. Apply a bead of Tooling (A) to the corners of the recess at positions (Z).
Illustration 181
g01354238
Typical example
8. Use Tooling (B) in order to push seals (3) fully into the grooves.
6. Lubricate the crankshaft journal and the lower main bearing with clean engine oil. Install main bearing cap (2) to the cylinder block. Ensure the correct orientation of the main bearing cap. The locating tab for the upper and the lower bearing should be on the same side of the engine.
Illustration 182
g01353474
Typical example
9. Lubricate the threads of bolts (1) with clean engine oil. Lubricate the underside of the heads of the bolts with clean engine oil. Illustration 180
g01359531
Typical example
7. Inject a small quantity of Tooling (A) into the two grooves in number five main bearing cap. Position new seals (3) in the grooves. Ensure that rounded edges of the seals are outward. Push the first 25 mm (1 inch) of the seal into the grooves by hand.
10. Install bolts (1) to main bearing cap (2). Evenly tighten the bolts in order to pull the main bearing cap into position. Ensure that the main bearing cap is correctly seated. For number five main bearing cap, Ensure that the rear face of the main bearing cap is flush with the rear face of the cylinder block. Note: Do not tap the main bearing cap into position as the bearing may be dislodged.
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KENR6241
87 Disassembly and Assembly Section
11. Tighten bolts (1) to a torque of 103 N·m (76 lb ft).
Start By:
12. Rotate the crankshaft in order to ensure that there is no binding.
a. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”. b. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”. If the engine is not equipped with a balancer, remove the oil strainer. Refer to Disassembly and Assembly, “Engine Oil Pan Remove and Install”. c. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”.
g01359530
Illustration 183 Typical example
13. Check the crankshaft end play. Refer to Specifications, “Crankshaft” for more information. Push the crankshaft toward the front of the engine. Install Tooling (C). Push the crankshaft toward the rear of the engine in order to measure the end play.
d. Remove the front plate. Refer to Disassembly and Assembly, “Front Plate - Remove”. NOTICE If the crankshaft has been reground or if the crankshaft has been replaced, the height of the piston above the cylinder block must be inspected. It is necessary to remove the cylinder head in order to inspect the height of the piston above the cylinder block. NOTICE Keep all parts clean from contaminants.
End By: a. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”. If the engine is not equipped with a balancer, install the oil strainer and install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.
Contaminants may cause rapid wear and shortened component life.
b. Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”.
Note: Use tape or rubber tubing on the connecting rod bolts to protect the crankshaft journals from damage.
i02748599
Crankshaft - Remove
Table 44
Required Tools Part Number
A
-
Part Description Lifting Sling
2. If necessary, remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head Remove”. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove”. If the cylinder head, the pistons and the connecting rods have not been removed, remove the connecting rod caps. Refer to Disassembly and Assembly, “Connecting Rod Bearings - Remove”. Carefully push the piston and connecting rod assemblies into the cylinder bores.
Removal Procedure
Tool
1. The engine should be mounted on a suitable stand and placed in the inverted position.
Qty 1
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88 Disassembly and Assembly Section
Illustration 184
KENR6241
g01359995
3. Ensure that bearing caps (2) are marked for the location and orientation. 4. Remove bolts (1) from bearing caps (2). 5. Remove bearing caps (2) from the cylinder block. Note: Number five main bearing cap must be removed squarely from the cylinder block. Do not twist the main bearing cap during removal as damage may result.
Illustration 186
g01359996
7. Attach a Tooling (A) and a suitable lifting device to crankshaft (3). Carefully lift the crankshaft out of the cylinder block. The weight of the crankshaft is approximately 32 kg (70 lb). Note: Do not damage the finished surfaces on the crankshaft.
Illustration 187
g01359993
Typical example
8. Remove upper main bearings (7). Keep the upper main bearings and the upper thrust washer with the respective main bearing caps. For number five main bearing, remove the upper thrust washer from the rear of the cylinder block. Illustration 185
g01359992
Number five main bearing cap
Note: The upper main bearings have a groove and two oil holes.
6. Remove lower main bearings (4) from main bearing caps (2). Keep the main bearings and the main bearing caps together. For number five main bearing cap, remove lower thrust washers (5) and remove seals (6). Note: The lower main bearings are plain bearings with no oil holes.
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KENR6241
89 Disassembly and Assembly Section
i02748601
Crankshaft - Install Installation Procedure Table 45
Required Tools Tool
Part Number
Part Description
Qty
A
21826038
POWERPART Silicone Sealant Adhesive
1
B
27610013
Seal Installer
1
C
21825617
Dial Indicator Group
1
Illustration 188
g01360029
Typical example
NOTICE Keep all parts clean from contaminants.
5. Install upper bearings (7) to the cylinder block. Ensure that the locating tabs for the upper bearings are seated in the slots in the cylinder block.
Contaminants may cause rapid wear and shortened component life.
Note: The upper bearings have a groove and two oil holes.
Note: The engine should be mounted on a suitable stand and placed in the inverted position. 1. Clean the crankshaft and inspect the crankshaft for wear or damage. Refer to Specifications, “Crankshaft” for more information. If necessary, replace the crankshaft or recondition the crankshaft.
6. Lubricate upper thrust washer (8). Install the upper thrust washer to the rear of the cylinder block with the oil grooves toward the outside. Ensure that holes (X) in the thrust washer are aligned with dowels (Y) in the cylinder block. 7. Lubricate upper bearings (7) with clean engine oil.
2. Ensure that the parent bores for the crankshaft bearings in the cylinder block are clean. Ensure that the threads for the bearing bolts in the cylinder block are clean and free from damage. 3. Clean the crankshaft bearings and the thrust washers. Inspect the bearings and the thrust washers for wear or damage. If necessary, replace the bearings and the thrust washers. Note: If the crankshaft bearings are replaced, check whether oversize bearings were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed. 4. Ensure that all of the lubrication passages are clean and free of debris.
Illustration 189
g01359996
Typical example
8. Attach Tooling (A) and a suitable lifting device to crankshaft (3). Carefully lift the crankshaft into the cylinder block. The weight of the crankshaft is approximately 32 kg (70 lb). Remove Tooling (A). Note: Do not damage any of the finished surfaces on the crankshaft. Do not damage the bearings.
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90 Disassembly and Assembly Section
Illustration 190
KENR6241
g01359992
Number five main bearing cap
9. Install lower bearings (4) to main bearing caps (2). Ensure that the locating tabs for the lower bearings are seated in the slots in the bearing caps. Note: The lower bearings are plain bearing with no oil holes. 10. For number five main bearing cap, follow Steps 10.a through 10.c in order to install the lower thrust washers (5) to the main bearing cap.
Illustration 191
g01354237
c. Apply a bead of Tooling (A) to the corners of the recess in the cylinder block at positions (Z). 11. Lubricate the crankshaft journals and the lower main bearings with clean engine oil. Install main bearing caps (2) to the cylinder block. Ensure the correct orientation of the main bearing caps. The locating tab for the upper and the lower bearing should be on the same side of the engine. Note: For number five main bearing cap, ensure that the rear face of the main bearing cap is flush with the rear face of the cylinder block.
a. Ensure that lower thrust washers (5) are clean and free from wear or damage. If necessary, replace the thrust washers. Lubricate the thrust washers with clean engine oil. b. Install lower thrust washers (5) to main bearing cap (2). Ensure that holes (X) in the thrust washers are aligned with dowels (Y) in the main bearing cap.
Illustration 192
g01359531
Typical example
12. Inject a small quantity of Tooling (A) into the two grooves in number five main bearing cap. Position new seals (3) in the grooves. Ensure that rounded edges of the seals are outward. Push the first 25 mm (1 inch) of the seal into the grooves by hand.
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KENR6241
91 Disassembly and Assembly Section
Illustration 195
g01359530
Typical example
Illustration 193
g01354238
Typical example
13. Use Tooling (B) in order to push seals (3) fully into the grooves.
18. Check the crankshaft end play. Refer to Specifications, “Crankshaft” for more information. Push the crankshaft toward the front of the engine. Install Tooling (A). Push the crankshaft toward the rear of the engine in order to measure the end play. 19. If the crankshaft has been replaced or the crankshaft has been reconditioned, inspect the height of the pistons above the cylinder block. Refer to Systems Operation, Testing and Adjusting, “Piston Height - Inspect” for more information. First install the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. If the crankshaft has not been replaced or the crankshaft has not been reconditioned, install the connecting rod caps. Refer to Disassembly and Assembly, “Connecting Rod Bearings - Install”.
Illustration 194
g01353474
Typical example
14. Lubricate the threads of bolts (1) with clean engine oil. Lubricate the underside of the heads of the bolts with clean engine oil. 15. Install bolts (1) to main bearing caps (2). Evenly tighten the bolts in order to pull the main bearing caps into position. Ensure that the caps are correctly seated. Note: Do not tap the main bearing caps into position as the bearing may be dislodged. 16. Tighten bolts (1) to a torque of 103 N·m (76 lb ft). 17. Rotate the crankshaft in order to ensure that there is no binding.
End By: a. Install the front plate. Refer to Disassembly and Assembly, “Front Plate - Install”. b. Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housng - Remove and Install”. c. If the engine has a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer Install”. If the engine does not have a balancer, install the oil strainer and install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Install”. d. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Push Rod - Install”.
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92 Disassembly and Assembly Section
KENR6241
i02748602
Crankshaft Gear - Remove and Install
4. If necessary, remove the keys (not shown) from crankshaft (2).
Installation Procedure NOTICE Keep all parts clean from contaminants.
Removal Procedure
Contaminants may cause rapid wear and shortened component life.
Table 46
Required Tools Tool
Part Number
A
-
Part Description
Qty
Combination Puller
1
Start By: a. Remove the idler gear. Refer to Disassembly and Assembly, “Idler Gear - Remove and Install”. Note: In this procedure, the crankshaft gear is removed with the crankshaft in the engine. NOTICE Keep all parts clean from contaminants.
Illustration 197
Contaminants may cause rapid wear and shortened component life. 1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”. 2. If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, “Balancer - Remove”.
g01344011
Typical example
1. If necessary, install the keys (not shown) to crankshaft (2).
Always wear protective gloves when handling parts that have been heated. 2. Raise the temperature of crankshaft gear (1) in an oven to 100 °C (212 °F). 3. Align the keyway in crankshaft gear (1) with the keys in crankshaft (2). Install crankshaft gear (1). Ensure that the crankshaft gear is seated squarely against the crankshaft. 4. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.
Illustration 196
g01343991
5. If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, “Balancer - Install”.
Typical example
End By:
3. Use Tooling (A) to remove crankshaft gear (1) from crankshaft (2).
a. Install the idler gear. Refer to Disassembly and Assembly, “Idler Gear- Remove and Install”.
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KENR6241
93 Disassembly and Assembly Section
i02748526
• Ensure that the bearing locking tabs are properly seated in the tab grooves.
Bearing Clearance - Check
• The crankshaft must be free of oil at the contact points of Tooling (A).
Measurement Procedure
1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.
Table 47
Note: Do not allow Tooling (A) to extend over the edge of the bearing.
Required Tools Tool
Part Number
Part Description
Qty
-
Plastic Gauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch)
1
-
Plastic Gauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch)
1
-
Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)
1
-
Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)
1
A
2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. Note: Do not turn the crankshaft when Tooling (A) is installed. 3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 198.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Perkins does not recommend the checking of the actual clearances of the bearing shells particularly on small engines. This is because of the possibility of obtaining inaccurate results and of damaging the bearing shell or the journal surfaces. Each Perkins bearing shell is quality checked for specific wall thickness. Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch). NOTICE Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
Illustration 198
g01152855
Typical Example
4. Remove all of Tooling (A) before you install the bearing cap. Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, “Connecting Rod Bearing Journal” and Specifications Manual, “Main Bearing Journal” for the correct clearances.
The technician must be very careful to use Tooling (A) correctly. The following points must be remembered:
• Ensure that the backs of the bearings and the bores are clean and dry.
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94 Disassembly and Assembly Section
KENR6241
i02748603
Coolant Temperature Sensor Remove and Install Removal Procedure
Installation Procedure Table 48
Required Tools Tool
Part Number
A
21820122
Part Description POWERPART Pipe Sealant
Qty 1
1. Ensure that the coolant temperature sensor is clean and free from damage.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.
Illustration 200
g01343990
Typical example
2. Apply a thin layer of Tooling (A) to the threads of coolant temperature sensor (1). 3. Install coolant temperature sensor (1) into the cylinder head. Tighten the coolant temperature sensor to a torque of 11 N·m (97 lb in). 4. Connect the harness assembly (not shown) to coolant temperature sensor (1). 5. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. i02748604
Illustration 199
g01343990
Typical example
2. Disconnect the harness assembly (not shown) from coolant temperature sensor (1). 3. Remove coolant temperature sensor (1) from the cylinder head.
Engine Oil Pressure Sensor Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
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KENR6241
95 Disassembly and Assembly Section
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
Illustration 202
g01343988
Typical example
2. Apply a thin layer of Tooling (A) to the threads of engine oil pressure sensor (1). 3. Install engine oil pressure sensor (1) to the cylinder block. Use a deep socket in order to tighten the engine oil pressure sensor to a torque of 11 N·m (97 lb in). g01343988
Illustration 201 Typical example
1. Remove the harness assembly (not shown) from engine oil pressure sensor (1). 2. Use a deep socket in order to remove engine oil pressure sensor (1) from the cylinder block.
Installation Procedure Required Tools Part Number
A
21820122
Part Description
i02748605
Glow Plugs - Remove and Install Removal Procedure
Table 49
Tool
4. Connect the harness assembly (not shown) to engine oil pressure sensor (1).
Qty
POWERPART Pipe Sealant
1
NOTICE Keep all parts clean from contaminants.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn the battery disconnect switch to the OFF position.
Contaminants may cause rapid wear and shortened component life. 1. Ensure that the engine oil pressure sensor is clean and free from damage.
This document has been printed from SPI². Not for Resale
96 Disassembly and Assembly Section
KENR6241
g01343974
Illustration 203 Naturally aspirated engine
Illustration 205
g01343974
Naturally aspirated engine
g01343965
Illustration 204
Illustration 206
g01343965
Turbocharged engine
Turbocharged engine
2. Remove nuts (1) and bus bar (2).
2. Install glow plugs (3) to the cylinder head.
3. Use a deep socket in order to remove glow plugs (3) from the cylinder head.
3. For naturally aspirated engines, use a deep socket in order to tighten the glow plugs to a torque of 18 N·m (13 lb ft).
Installation Procedure
For turbocharged engines, use a deep socket in order to tighten the glow plugs to a torque of 25 N·m (18 lb ft).
Table 50
Required Tools Tool
Part Number
A
27610296
Part Description Torque Wrench
Qty 1
NOTICE Keep all parts clean from contaminants.
4. Position bus bar (2) onto glow plugs (3) and install nuts (1). Use Tooling (A) to tighten the nuts to a torque of 1.2 N·m (11 lb in). 5. Turn the battery disconnect switch to the ON position.
Contaminants may cause rapid wear and shortened component life. 1. Ensure that the threads of the glow plugs are clean and free from damage. Replace any damaged glow plugs.
This document has been printed from SPI². Not for Resale
KENR6241
97 Disassembly and Assembly Section
i02748606
V-Belts - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 208
g01343666
Typical example
1. Install V-belt (3) onto the pulleys. Note: A used V-belt should be installed in the original direction of rotation. 2. Adjust the tension of V-belt (3) by moving the alternator away from the engine. Use Tooling (A) in order to achieve the correct belt tension. Refer to Specifications, “Belt Tension Chart” for more information. g01343666
Illustration 207 Typical example
3. Tighten bolts (1), and (2) to a torque of 11 N·m (97 lb in). Tighten bolt (4), to a torque of 35 N·m (26 lb ft).
1. Loosen bolts (1), (2) and (4). Slide the alternator toward the engine.
i02748608
Fan - Remove and Install
2. Remove V-belt (3). Note: Mark the direction of rotation if the V-belt will be reused.
Removal Procedure
Installation Procedure
Start By:
Table 51
Required Tools Tool
Part Number
A
-
Part Description Belt Tension Gauge
Qty
a. Remove the V-Belt. Refer to Disassembly and Assembly, “V-Belts - Remove and Install”.
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
This document has been printed from SPI². Not for Resale
98 Disassembly and Assembly Section
Illustration 209
KENR6241
g01343637
Illustration 210
g01343637
Typical example
Typical example
1. Remove bolts (5) and plate (6).
2. Position fan pulley (3) onto water pump (4).
2. Remove fan (1). Note the orientation of the fan for installation.
3. If the engine is equipped with a spacer, position spacer (2) onto pulley (3).
3. If the engine is equipped with a spacer, remove spacer (2).
4. Install fan (1), plate (6), and bolts (5).
4. Remove pulley (3) from water pump (4).
Installation Procedure 1. Ensure that all components are free from wear or damage. If necessary, replace any components that are worn or damaged.
Note: Ensure that the fan is correctly oriented. 5. Tighten bolts (5) to a torque of 18 N·m (13 lb ft). End By: a. Install the V-Belt. Refer to Disassembly and Assembly, “V-Belts - Remove and Install”. i02748609
Alternator - Remove and Install Removal Procedure Start By: a. Remove the V-Belt. Refer to Disassembly and Assembly, “V-Belts - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
This document has been printed from SPI². Not for Resale
KENR6241
99 Disassembly and Assembly Section
1. Turn the battery disconnect switch to the OFF position.
Installation Procedure
2. Make temporary identification marks on the connections of the harness assembly.
Illustration 212
g01343570
Typical example
Illustration 211
g01343570
Typical Example
3. Disconnect the harness assembly from alternator (3). 4. Loosen bolt (4). Remove bolt (1) and washer (2) from alternator (3). 5. Remove bolt (5) from alternator (3). Remove the alternator from alternator bracket (6).
1. Position alternator (3) on bracket (6) and install bolt (5) finger tight. 2. Install bolt (1) and washer (2) finger tight. 3. Install the V-belt. Refer to Disassembly and assembly, “V-belts - Remove and Install” for the correct procedure. 4. Tighten bolts (1) and (4) to a torque of 11 N·m (97 lb in). Tighten bolt (5) to a torque of 35 N·m (26 lb ft). 5. Connect the harness assembly to alternator (3). 6. Turn the battery disconnect switch to the ON position.
This document has been printed from SPI². Not for Resale
100 Disassembly and Assembly Section
Worldwide Parts Source LLC Phone 269 673 2313 Engine Parts
i02748611
Installation Procedure
Electric Starting Motor Remove and Install Removal Procedure
Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. 1. Disconnect the battery. 2. Make temporary identification marks on the harness assemblies that are connected to the electric starting motor. Disconnect the harness assemblies from the electric starting motor.
Illustration 213
Illustration 214
g01343546
Typical example
1. If necessary, install studs (2). 2. Align electric starting motor (1) to studs (2). Install the electric starting motor. 3. Install nuts (3). Tighten the nuts to a torque of 35 N·m (26 lb ft). 4. Connect the harness assemblies to the electric starting motor. Refer to Specifications, “Electric Starting Motor” for the tightening torques of the terminal nuts. 5. Connect the battery.
g01343546
Typical example
3. Remove nuts (3) from electric starting motor (1). Note: Support the weight of the electric starting motor as the nuts are removed. 4. Remove electric starting motor (1). 5. If necessary, remove studs (2).
This document has been printed from SPI². Not for Resale
