Perkins Engine 1103 Service Manual

Perkins 1103 &1104 Series

WORKSHOP MANUAL Disassembly and Assembly

3 and 4 cylinder , naturally aspirated, and turbocharged diesel engines for agricultural and industrial use

Publication SENR9779-00 © Proprietary information of Perkins Engines Company Limited 2004, all rights reserved. The information is correct at the time of print. Published by Technical Publications. Perkins Engines Company Limited, Peterborough, PE1 5NA, England

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this product Perkins recommends using Perkins

replacement parts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or

death.

Table of Contents

Disassembly and Assembly Section

Fuel Priming Pump - Remove and Install .............. 4

Fuel Filter Base - Remove and Install .................... 5

Fuel Injection Lines - Remove ............................... 6

Fuel Injection Lines - Install ................................... 7

Fuel Injector Cover - Remove and Install ................ 8

Fuel Injection Pump - Remove (Delphi DP210) ...... 8

Fuel Injection Pump - Remove (Bosch EPVE for the

1104 engines only) .............................................. 10

Fuel Injection Pump - Install (Delphi DP210) ........ 11

Fuel Injection Pump - Install (Bosch EPVE for the

1104 engines only) .............................................. 13

Fuel Injector - Remove ......................................... 14

Fuel Injector - Install ............................................ 15

Turbocharger - Remove ........................................ 16

Turbocharger - Install ............................................ 17

Exhaust Manifold - Remove and Install ............... 18

Exhaust Elbow - Remove and Install (Option for Four

Cylinder Engines Only) ....................................... 20

Inlet and Exhaust Valve Springs - Remove and

Install ................................................................... 21

Inlet and Exhaust Valves - Remove and Install ..... 23

Inlet and Exhaust Valve Guides - Remove and

Install ................................................................... 26

Inlet and Exhaust Valve Seat Inserts - Remove and

Install ................................................................... 28

Engine Oil Filter Base - Remove and Install ........ 30

Engine Oil Cooler - Remove ................................. 34

Engine Oil Cooler - Install ..................................... 36

Engine Oil Relief Valve - Remove and Install (Engine

Oil Pump) ............................................................ 37

Engine Oil Relief Valve - Remove and Install

(Balancer Unit for the 1104 engines only) ........... 39

Engine Oil Pump - Remove (Engines Without a

Balancer) ............................................................. 40

Engine Oil Pump - Install (Engines Without a

Balancer) ............................................................. 40

Water Pump - Remove ......................................... 41

Water Pump - Disassemble ................................. 42

Water Pump - Assemble ...................................... 43

Water Pump - Install ............................................. 45

Water Temperature Regulator - Remove and Install

............................................................................. 46

Flywheel - Remove ............................................... 48

Flywheel - Install ................................................... 49

Crankshaft Rear Seal - Remove ........................... 50

Crankshaft Rear Seal - Install ............................... 50

Crankshaft Wear Sleeve (Rear) - Remove............ 52

Crankshaft Wear Sleeve (Rear) - Install ............... 53

Flywheel Housing - Remove and Install ............... 53

Crankshaft Pulley - Remove and Install ............... 55

Crankshaft Front Seal - Remove ........................... 55

Crankshaft Front Seal - Install .............................. 56

Crankshaft Wear Sleeve (Front) - Remove ........... 57

Crankshaft Wear Sleeve (Front) - Install ............... 58

Front Cover - Remove and Install ......................... 58

Gear Group (Front) - Remove ............................... 59

Gear Group (Front) - Install ................................... 61

Idler Gear - Remove and Install ............................ 63

Housing (Front) - Remove ..................................... 68

Housing (Front) - Install ........................................ 69

Accessory Drive - Remove and Install ................. 70

Crankcase Breather - Remove and Install ........... 72

Valve Mechanism Cover - Remove and Install ..... 74

Rocker Shaft and Pushrod - Remove ................... 76

Rocker Shaft - Disassemble ................................ 77

Rocker Shaft - Assemble ..................................... 77

Rocker Shaft and Pushrod - Install ....................... 78

Cylinder Head - Remove ....................................... 79

Cylinder Head - Install .......................................... 81

Lifter Group - Remove and Install ......................... 84

Camshaft - Remove and Install ............................ 85

Camshaft Gear - Remove and Install ................... 86

Camshaft Bearings - Remove and Install ............ 86

Engine Oil Pan - Remove and Install ................... 87

Balancer - Remove (Some 1104 Engines Only) ... 90

Balancer - Install (Some 1104 Engines Only) ....... 91

Piston Cooling Jets - Remove and Install ............. 92

Pistons and Connecting Rods - Remove .............. 93

Pistons and Connecting Rods - Disassemble ....... 94

Pistons and Connecting Rods - Assemble ........... 95

Pistons and Connecting Rods - Install .................. 96

Connecting Rod Bearings - Remove .................... 98

Connecting Rod Bearings - Install ........................ 98

Crankshaft Main Bearings - Remove .................... 99

Crankshaft Main Bearings - Install (Crankshaft in

Position) ............................................................ 101

Crankshaft - Remove .......................................... 103

Crankshaft - Install .............................................. 105

Crankshaft Gear - Remove and Install ............... 108

Bearing Clearance - Check ................................. 109

Glow Plugs - Remove and Install ....................... 110

V-Belts - Remove and Install .............................. 111

Fan - Remove and Install ................................... 112

Fan Drive - Remove and Install .......................... 113

Alternator - Remove ............................................ 113

Alternator - Install ................................................ 114

Electric Starting Motor - Remove and Install ..... 114

Vacuum Pump - Remove and Install (Some 1104

engines only) ..................................................... 115

Hydraulic Pump (Steering) - Remove ................. 116

Hydraulic Pump (Steering) - Install ..................... 116

Index Section

Index ................................................................... 117

4 Disassembly and Assembly Section

Disassembly and Assembly Section

i01939024

Fuel Priming Pump - Remove and Install

Removal Procedure

Start By:

a. Remove the assembly of the filter case and the

fuel filter element. Refer to this Disassembly and Assembly Manual, “Fuel Filter Base - Remove and Install”.

Note: There is an option for the three cylinder engine. The fuel priming pump and the fuel filter can be installed onto the application rather than onto the engine. If this is the case, refer to the appropriate OEM information as well as this text.

Note: Put identification marks on all fuel hose assemblies and on all tube assemblies for installation purposes. After being disconnected, plug all fuel hose assemblies and plug all tube assemblies. This helps prevent fluid loss, and this helps to keep contaminants from entering the system.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 Typical example

1. Disconnect the tube assembly (5). Disconnect

the tube assembly (6). Install dust covers onto the connectors for the fuel priming pump.

2. Disconnect the fuel return line from the connector

(3). Install a dust cover to the connector (3).

3. Disconnect the harness assembly from the

connector (2).

4. Support the fuel priming pump. Remove the

three setscrews (1) and discard the rubber washers. Remove the fuel priming pump (4).

g00952432

Installation 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 theproduct. 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 2 Typical example

1. Clean the external surfaces of the fuel priming pump (4). Position the fuel priming pump (4) and install the setscrews (1) and new rubber washers.

g00952432

2. Remove the dust covers from the fuel priming pump. Remove the plugs from the tube assemblies. Connect the tube assembly (5). Connect the tube assembly (6).

3. Connect the fuel return line to the connector (3).

4. Connect the harness assembly to the connector

(2).

5. Remove the air from the fuel system. Refer to the Operations and Maintenance Manual, “Fuel System - Prime”.

i01939067

Fuel Filter Base - Remove and Install

Disassembly and Assembly Section

Removal Procedure

Note: There is an option for the three cylinder engine. The fuel filter and the fuel priming pump can be installed onto the application rather than onto the engine. If this is the case, refer to the appropriate OEM information as well to this text.

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.

Note: The removal procedure is identical for the

four cylinder and the three cylinder engines. The illustrations show the four cylinder engine.

Illustration 3 Typical example

Illustration 4 Typical example

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1. Place a suitable container below the filter in order to collect the spilled fuel. Thoroughly clean the outside surfaces of the fuel filter. Open the drain (1) in order to drain the fuel from the filter.

2. Use a suitable strap wrench to loosen the filter case (2). Remove the filter case (2) from the filter head (5).

3. Push down against the spring pressure that is applied to the filter element (4). Rotate the filter element (4) counterclockwise in order to release the filter element from the filter case (2).

4. Discard the filter element (4) and the O-ring (3).

6 Disassembly and Assembly Section

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The installation procedure is identical for the

four cylinder and the three cylinder engines. The illustrations show the four cylinder engine.

1. Thoroughly clean the inside of the filter case (2) and thoroughly clean the lower face of the filter head (5).

2. Inspect the thread of a new filter element (4) in order to ensure that the thread is not damaged. Inspect the thread of the adapter in the filter head (5) in order to ensure that the thread is not damaged.

3. Inspect the condition of the spring and ensure that the spring is correctly located within the filter case (2).

4. Install the new filter element (4) into the filter case (2). Push the filter element against the spring pressure and rotate the filter element in a clockwise direction in order to secure the filter element within the filter case (2).

5. Lightly lubricate a new O-ring (3) with clean fuel oil. Install the new O-ring (3) into the recess within the filter case (2).

6. Close the drain (1).

7. Remove the air from the fuel system. Refer to

the Operations and Maintenance Manual, “Fuel System - Prime”. Remove the suitable container and dispose of the fuel that has drained as waste.

Illustration 5 Typical example

Illustration 6 Typical example

g01010637

g01010595

i01939856

Fuel Injection Lines - Remove

Removal Procedure

Start By:

a. Remove the cover for the fuel injectors. Refer to

this Disassembly and Assembly Manual, “Fuel Injector Cover - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Disassembly and Assembly Section

Dispose of all fluids according to local regulations and mandates.

Note: The removal procedure is identical for four

cylinder and three cylinder engines. The illustration shows the four cylinder engine.

Dispose of all fluids according to local regulations and mandates.

Note: The installation procedure is identical for the

four cylinder and the three cylinder engines. The illustration shows the four cylinder engine.

Illustration 7 Typical example

g00955826

1. Disconnect the fuel injection lines (1) at the fuel injectors (2).

2. Disconnect the fuel injection lines (1) at the fuel injection pump (3).

3. If it is necessary remove the clamps for the fuel injection lines or loosen the clamps for the fuel injection lines. Remove the fuel injection lines (1).

4. Install dust caps onto the ports of the fuel injectors and onto the ports of the fuel injection pump. Install dust caps onto both ends of the fuel injection lines.

i01939857

Fuel Injection Lines - Install

Installation Procedure

Illustration 8 Typical example

g00955826

1. Inspect the fuel injection lines (1) for wear and for damage. Replace any fuel injection line (1) that is worn or any fuel injection line that is damaged.

2. Loosely install the clamps for the fuel injection lines (1).

3. Remove the dust caps from the fuel injection pump (3) and from the fuel injectors (2). Remove the dust caps from the fuel injection lines (1).

4. Loosely connect the nuts at both ends of the fuel injection lines (1).

5. Ensure that each fuel injection line (1) does not contact any other fuel injection line or any other engine component. Tighten the fasteners for the clamps for the fuel injection lines (1). Check that the fuel injection lines (1) are still clear of other components.

6. Tighten the fuel injection lines (1) at the fuel injectors (2) to a torque of 30 N·m (22 lb ft).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

7. Tighten the fuel injection lines (1) at the fuel injection pump (3) to 30 N·m (22 lb ft).

8 Disassembly and Assembly Section

8. Remove the air from the fuel system. Refer to the Operations and Maintenance Manual, “Fuel System - Prime”.

End By:

a. Install the cover for the fuel injectors. Refer to

this Disassembly and Assembly Manual, “Fuel Injector Cover - Remove and Install”.

i01940979

Fuel Injector Cover - Remove and Install

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The installation procedure is identical for the

four cylinder and the three cylinder engines. The illustration shows the four cylinder engine.

Note: The removal procedure is identical for the four cylinder and the three cylinder engines. The illustration shows the four cylinder engine.

Illustration 9 Typical example

1. Thoroughly clean all of the outer surfaces of the cover (1) for the fuel injectors.

2. Remove the setscrews (2) from the cover (1).

3. Remove the cover (1).

g01011111

Illustration 10 Typical example

1. Thoroughly clean all of the inner surfaces of the cover (1) for the fuel injectors.

2. Install the cover (1).

3. Install the setscrews (2) for the cover (1). Tighten

the setscrews (2) to a torque of 9 N·m (7 lb ft).

g01011111

i01940997

Fuel Injection Pump - Remove (Delphi DP210)

Removal Procedure

Start By:

a. Remove the fuel injection lines. Refer to this

Disassembly and Assembly Manual, “Fuel Injection Lines - Remove”.

b. Remove the crankshaft pulley. Refer to this

Disassembly and Assembly Manual, “Crankshaft Pulley - Remove and Install”.

Disassembly and Assembly Section

c. Remove the front cover. Refer to this Disassembly

and Assembly Manual, “Front Cover - Remove and Install”.

Note: The removal procedure is identical for the four cylinder and the three cylinder engines. The illustrations show the four cylinder engine.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to the Testing and Adjusting Manual, “Finding Top Center Position for No. 1 Piston”.

4. Disconnect the fuel line (3).

5. Disconnect the harness assembly (2) from the

timing advance solenoid (7).

Illustration 12 Typical example

g01011369

6. Remove the nut (8) and the washer from the shaft of the fuel injection pump.

7. Use a suitable puller in order to remove the fuel injection pump gear (9).

Illustration 11 Typical example

g00956204

2. Loosen the locking screw (5). Rotate the spacer (6) in order to allow the locking screw (5) to tighten against the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten the locking screw (5) to a torque of 17 N·m (13 lb ft).

Note: The locking screw (5) must be tightened in order to prevent the shaft of the fuel injection pump from rotating. The shaft of the fuel injection pump must not be rotated after the fuel injection pump has been removed from the engine.

Note: Put identification marks on all fuel hose assemblies and on all tube assemblies for installation purposes. After being disconnected, plug all fuel hose assemblies and plug all tube assemblies with suitable plastic plugs. Also install dust caps on all of the connectors on the fuel injection pump. This helps prevent fluid loss, and this helps to keep contaminants from entering the system.

Note: Do not pry the fuel injection pump gear (9) from the shaft of the fuel injection pump.

Illustration 13

g00956267

8. Remove the nut (14). Remove the bolt (12).

9. If necessary, remove the setscrew (15) and the

bracket (11) from the cylinder block.

10. Remove the setscrews (13) in order to remove the fuel injection pump.

11. Remove the fuel injection pump from the front housing. Remove the O-ring (10) and discard the O-ring from the fuel injection pump.

3. Disconnect the fuel return line (1). Disconnect the tube assembly (4) from the fuel injection pump.

10 Disassembly and Assembly Section

i01941022

Fuel Injection Pump - Remove (Bosch EPVE for the 1104 engines only)

Removal Procedure

Start By:

a. Remove the fuel injection lines. Refer to this

Disassembly and Assembly Manual, “Fuel Injection Lines - Remove and Install”.

b. Remove the crankshaft pulley. Refer to this

Disassembly and Assembly Manual, “Crankshaft Pulley - Remove and Install”.

c. Remove the front cover. Refer to this Disassembly

and Assembly Manual, “Front Cover - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Illustration 14

Note: Put identification marks on all fuel hose

assemblies and on all tube assemblies for installation purposes. After being disconnected, plug all fuel hose assemblies and plug all tube assemblies with suitable plastic plugs. Also install dust caps on all of the connectors on the fuel injection pump. This helps prevent fluid loss, and this helps to keep contaminants from entering the system.

g00996409

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to the Testing and Adjusting Manual, “Finding Top Center Position for No. 1 Piston”.

2. Disconnect the tube assembly (1) from the fuel injection pump. Disconnect the tube assembly (2) from the fuel injection pump.

3. Disconnect the wiring harness assembly from the cold start advance unit (3). Disconnect the wiring harness assembly from the engine shutoff solenoid (4).

Illustration 15

g00996410

Disassembly and Assembly Section

4. Loosen the locking screw (6). Move the spacer (5) in order to allow the locking screw (6) to tighten against the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten the locking screw (6) to a torque of 31 N·m (23 lb ft).

Note: The locking screw (6) must be tightened in order to prevent the shaft of the fuel injection pump from rotating. The shaft of the fuel injection pump must not be rotated after the fuel injection pump has been removed from the engine.

Illustration 16

g01011474

5. Remove the nut (7) and the washer from the shaft of the fuel injection pump.

6. Use a suitable puller in order to remove the fuel injection pump gear (8).

Note: Do not pry the fuel injection pump gear from the shaft of the fuel injection pump.

8. If necessary, remove the setscrew and the bracket (10) from the cylinder block.

9. Remove the setscrews (12) in order to remove the fuel injection pump.

10. Remove the fuel injection pump from the front housing. Remove the O-ring (9) from the fuel injection pump and discard the O-ring.

i01943876

Fuel Injection Pump - Install (Delphi DP210)

Installation Procedure

Note: The installation procedure is identical for the four cylinder and the three cylinder engines. The illustrations show the four cylinder engine.

Note: The shaft of the fuel injection pump must remain locked until the timing gear (9) has been installed and tightened onto the shaft of the fuel injection pump. The locking screw (5) must remain locked until you are instructed to loosen the locking screw. The fuel injection pump must be returned to your Perkins Dealer if the shaft of the fuel injection pump was rotated accidentally.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 17

g00996474

7. Remove the nut (13). Remove the bolt (11).

1. Ensure that the No. 1 cylinder is at top dead

center on the compression stroke. Refer to the Testing and Adjusting Manual, “Fuel Injection Timing - Check”.

Illustration 18 Typical example

g00956267

12 Disassembly and Assembly Section

Note: Do not lubricate the new O-ring (10). The

O-ring should be installed dry.

2. Install the new O-ring (10) onto the fuel injection pump. Position the fuel injection pump onto the front housing. Install the setscrews (13). Tighten the setscrews (13) to a torque of 25 N·m (18 lb ft).

3. Install the setscrew (15) and the bracket (11) onto the cylinder block if the bracket was previously removed. Ensure that the bracket (11) supports the fuel injection pump without applying any other external force on the fuel injection pump. Tighten the setscrew (15) to a torque of 44 N·m (32 lb ft).

4. Install the bolt (12) and the nut (14).

Illustration 20 Typical example

g00956204

6. Connect the harness assembly to the timing advance solenoid (7).

7. Connect the harness assembly (2).

Illustration 19 Typical example

g01011369

Note: Ensure that the mating surfaces of the fuel injection pump gear and the shaft of the fuel injection pump are clean. Lubricate the threads of the shaft for the fuel injection pump. The nut (8) must turn freely until contact is made with the fuel injection pump gear.

5. Position the fuel injection pump gear (9) onto the shaft of the fuel injection pump. Install the washer and the nut (8). Rotate the fuel injection pump gear (9) in a counterclockwise direction in order to remove the backlash. Tighten the nut (8) to a torque of 24 N·m (17 lb ft).

8. Remove all of the dust caps from the connectors on the fuel injection pump. Remove all of the plugs from the fuel hose assemblies and from the tube assemblies.

9. Connect the fuel line (3), the fuel return line (1), and the tube assembly (4) to the fuel injection pump.

10. Loosen the locking screw (5). Move the spacer (6) in order to prevent the locking screw (5) from tightening against the shaft of the fuel injection pump. Tighten the locking screw (5) to a torque of 12 N·m (106 lb in).

Note: The spacer (6) must be correctly positioned and locking screw (5) must be tightened in order to prevent the locking screw from contacting the shaft of the fuel injection pump.

Illustration 21 Typical example

g01011369

11. Tighten the nut (8) to a torque of 88 N·m (65 lb ft).

End By:

a. Install the front cover. Refer to this Disassembly

and Assembly Manual, “Front Cover - Remove and Install”.

b. Install the crankshaft pulley. Refer to this

Disassembly and Assembly Manual, “Crankshaft Pulley - Remove and Install”.

c. Install the fuel injection lines. Refer to this

Disassembly and Assembly Manual, “Fuel Injection Lines - Install”.

i01943877

Fuel Injection Pump - Install (Bosch EPVE for the 1104 engines only)

Disassembly and Assembly Section

Illustration 22

2. Lightly lubricate a new O-ring (9) with Perkins

1766-501 Silicone Fluid MS200/1000. Install the new O-ring (9) onto the fuel injection pump. Position the fuel injection pump on the front housing. Install the setscrews (12). Tighten the setscrews to a torque of 25 N·m (18 lb ft).

g00996474

Installation Procedure

Note: The shaft of the fuel injection pump must remain locked until the timing gear (8) has been installed and tightened onto the shaft of the fuel injection pump. The locking screw (6) must remain locked until you are instructed to loosen the locking screw. The Bosch EPVE fuel injection pump can be timed to the engine by a technician. Refer to the Testing and Adjusting Manual, “Fuel Injection Pump Timing - Check and Fuel Injection Pump Timing Adjust” if the shaft of the fuel injection pump was rotated accidentally.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to the Testing and Adjusting Manual, “Fuel Injection Timing - Check”.

3. Install the setscrew and the bracket (10) onto the cylinder block if the bracket was previously removed. Ensure that the bracket (10) supports the fuel injection pump without applying any other external force on the fuel injection pump. Tighten the setscrew to a torque of 44 N·m (32 lb ft).

4. Install the bolt (11) and the nut (13).

Note: Ensure that the mating surfaces of the fuel injection pump gear (8) and the shaft of the fuel injection pump are clean. Lubricate the threads of the shaft for the fuel injection pump. The nut (7) must turn freely until contact is made with the fuel injection pump gear (8).

Illustration 23

g01011474

14 Disassembly and Assembly Section

5. Position the fuel injection pump gear (8) onto the shaft of the fuel injection pump. Install the washer and the nut (7). Rotate the fuel injection pump gear (8) in a counterclockwise direction in order to remove the backlash. Tighten the nut (7) to a torque of 24 N·m (17 lb ft).

10. Loosen the locking screw (6). Move spacer (5) in order to prevent the locking screw (6) from tightening against the shaft of the fuel injection pump. Tighten the locking screw (6) to a torque of 12 N·m (106 lb in).

Note: The spacer (5) must be installed and the locking screw (6) must be tightened in order to prevent the locking screw from contacting the shaft of the fuel injection pump.

Illustration 26

g01011474

Illustration 24

g00996409

6. Connect the wiring harness assembly to the engine shutoff solenoid (4).

7. Connect the wiring harness assembly to the cold start advance unit (3).

8. Remove all of the dust caps from the connectors on the fuel injection pump. Remove all of the plugs from the fuel hose assemblies and from the tube assemblies.

9. Connect the tube assembly (2) to the fuel injection pump. Connect the tube assembly (1) to the fuel injection pump.

11. Tighten the nut (7) to a torque of 88 N·m (65 lb ft).

End By:

a. Install the front cover. Refer to this Disassembly

and Assembly Manual, “Front Cover - Remove and Install”.

b. Install the crankshaft pulley. Refer to this

Disassembly and Assembly Manual, “Crankshaft Pulley - Remove and Install”.

c. Install the fuel injection lines. Refer to this

Disassembly and Assembly Manual, “Fuel Injection Lines - Install”.

i01938589

Fuel Injector - Remove

Removal Procedure

Start By:

Illustration 25

a. Remove the cover for the fuel injectors. Refer to

this Disassembly and Assembly Manual, “Fuel Injector Cover - Remove and Install”.

g00996410

Disassembly and Assembly Section

b. Remove the fuel injection lines. Refer to this

Disassembly and Assembly, “Fuel Injection Lines

- Remove”.

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.

1. Disconnect the tube assemblies from the fuel

filter base for the fuel inlet and the fuel outlet.

i01938672

Fuel Injector - Install

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 27

g00975056

2. Remove the fuel hose (2) from the fuel injector

(1).

3. Remove the setscrew (3). Remove the clamp (4)

from the fuel injector (1).

4. Remove the fuel injector (1) from the cylinder

head. Remove the O-ring seal (5) from the fuel injector (1) and discard the O-ring.

5. Remove the seat washer (6) from the cylinder

head and discard the seat washer.

Note: If the original seat washer is not removed, the projection of the fuel injector will be incorrect when a new seat washer is installed.

Illustration 28

g01008888

1. Lubricate the seat washer (6) with clean engine oil. Install a new seat washer (6) in the cylinder head.

Note: If the original seat washer (6) is reused, the projection of the fuel injector (1) will be incorrect.

2. Install a new O-ring seal (5) on fuel injector (1). Install the fuel injector (1) in the cylinder head.

Note: Alignment Pin (7) must be located opposite clamp (4).

3. Position clamp (4) on the fuel injector (1). Install setscrew (3). Tighten the setscrew to a torque of 27 N·m (20 lb ft).

4. Install hose (2) to the fuel injector (1).

End By:

a. Install the fuel injection lines. Refer to this

Disassembly and Assembly, “Fuel Injection Lines

- Install”.

b. Install the cover for the fuel injectors. Refer to

this Disassembly and Assembly Manual, “Fuel Injector Cover - Remove and Install”.

16 Disassembly and Assembly Section

i01944022

Turbocharger - Remove

Removal 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.

4. If an exhaust elbow is installed, remove the exhaust elbow. Refer to this Disassembly and Assembly Manual, “Exhaust Elbow - Remove and Install”.

5. Remove the nuts (2) and remove the exhaust adapter (3) from the turbocharger (1).

6. Place a suitable container below the turbocharger (1) in order to collect any spillage of oil.

Note: The removal procedure is identical for the three cylinder and the four cylinder engines.

1. Thoroughly clean the outer surfaces of the turbocharger (1).

2. Loosen the hose clamps and remove the air inlet hose at the turbocharger compressor housing.

Note: Exhaust elbows are only an option for the four cylinder engines.

3. Remove the exhaust pipe from the turbocharger outlet or remove the exhaust pipe from the exhaust elbow. Refer to the OEM provided information for the correct procedure in order to remove the exhaust pipe.

Illustration 30 Typical example

g01038396

7. Remove the banjo bolts (5). Remove the oil supply tube assembly (6) and the washers (7) from the turbocharger (1). Discard the washers (7). If necessary, remove the oil supply tube assembly (6) from the cylinder block and discard the washers.

8. Remove the setscrews (8). Remove the oil drain tube assembly (9) from the turbocharger (1). Remove the joint (10) and discard the joint. If necessary, remove the setscrews (11) and remove the oil drain tube assembly (9) from the cylinder block. Discard the joint.

Illustration 29 Typical example

g01038600

9. If necessary, remove the studs (12) from the turbocharger housing.

Note: Do not use the actuator rod of the wastegate (16) to lift the turbocharger (1).

10. Remove the nuts (13). Remove the turbocharger (1). Remove the gasket (14). Discard the gasket (14). If necessary, remove the studs (15) from the exhaust manifold.

11. Install suitable plastic plugs into the oil supply and into the oil drain ports of the turbocharger (1). Install suitable plastic covers to the inlet and to the outlet of the turbocharger (1). Install suitable plastic plugs to the oil supply tube assembly (6) and to the oil drain tube assembly (9). Install suitable plastic covers to the manifold ports.

i01944024

Turbocharger - Install

Installation Procedure

Disassembly and Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The installation procedure is identical for the

three cylinder and the four cylinder engines.

1. Remove all of the plastic plugs from all of the ports of the turbocharger (1). Clean the mating surfaces of the exhaust manifold and the turbocharger. Clean the mating surfaces of the turbocharger to the oil supply tube assembly (6) and the turbocharger to the oil drain tube assembly (9).

2. Ensure that all of the turbocharger inlet and outlet ports are clean and free from restrictions. The turbocharger shaft must rotate freely.

Illustration 31 Typical example

3. If the studs (15) were previously removed, install the studs into the exhaust manifold. Install a new gasket (14) over the studs (15).

Note: Do not use any sealant on the gasket (14).

Note: Do not use the actuator rod of the wastegate

(16) to lift the turbocharger (1).

4. Position the turbocharger (1) onto the exhaust manifold.

5. Install the nuts (13). Tighten the nuts (13) to a torque of 47 N·m (35 lb ft).

6. Lubricate the bearing housing of the turbocharger (1) with clean engine oil.

7. Inspect all of the oil hose assemblies (6 and

9). If necessary, replace the hose assemblies (6 and 9).

g01038396

Note: The top flange of the oil drain tube assembly (9) is secured to the turbocharger (1) with 6 mm setscrews (8). The bottom flange of the oil drain tube assembly (9) is secured to the cylinder block with 8 mm setscrews (11).

8. Position a new joint (10) and the oil drain tube assembly (9) onto the bottom of the turbocharger (1). Install the 6 mm setscrews (8). Tighten the 6 mm setscrews (8) to a torque of 9 N·m (80 lb in).

18 Disassembly and Assembly Section

9. Position a new joint and the oil drain tube assembly (9) onto the cylinder block. Tighten the 8 mm setscrews (11) to a torque of 22 N·m (16 lb ft).

10. Position the new washers (7) and the oil supply tube assembly (6) onto the turbocharger (1). Install the banjo bolt (5). Tighten the banjo bolt (5) to a torque of 22 N·m (16 lb ft).

Note: Ensure that the oil supply tube assembly (6) does not come into contact with any other component when the assembly is installed onto the engine.

11. Install the new washers and the oil supply tube assembly (6) to the cylinder block. Tighten the banjo bolt to a torque of 22 N·m (16 lb ft).

12. If the studs (12) were previously removed, install the studs into the turbocharger housing.

Illustration 33

15. Tighten the three nuts finger tight in the sequence (17), (18), and (19). Tighten the nuts (17), (18), and (19) in the same sequence to a torque of 25 N·m (18 lb ft).

16. Ensure that there is no restriction in the inlet hose. Position the air inlet hose on the turbocharger compressor housing. Install the hose clamps. Tighten the hose clamps to a torque of 5 N·m (44 lb in).

g01038456

Illustration 32 Typical example

13. Position the exhaust adapter (3) onto the studs (12). Install the nuts (2). Do not tighten the nuts (2) at this time.

Note: Exhaust elbows are only an option for the four cylinder engines.

14. If equipped, install the exhaust elbow onto the exhaust adapter (3). Refer to this Disassembly and Assembly Manual, “Exhaust Elbow - Remove and Install”.

g01038406

Note: The air inlet hose has a reflective heat shield that partially covers the hose. The reflective heat shield must be installed toward the engine. The reflective heat shield must be kept clean and free from dust, oil or paint.

Note: Apply a solution of water and 5% soap to the inlet of the turbocharger in order to install a new air inlet hose. Do not use oil or grease in order to install the air inlet hose.

17. Position the exhaust pipe onto the exhaust elbow or onto the turbocharger outlet (3). Refer to the OEM information for the correct procedure in order to install the exhaust pipe.

i01946913

Exhaust Manifold - Remove and Install

Removal Procedure for the Three Cylinder Engine

Start By:

a. Remove the turbocharger, if equipped. Refer

to this Disassembly and Assembly Manual, “Turbocharger - Remove”.

Illustration 34

1. Remove the setscrews (1) in the reverse numerical order to the Illustration 34. This will help to prevent any distortion of the exhaust manifold (2).

2. Remove the exhaust manifold gasket from the cylinder head and remove the exhaust manifold (2). Discard the exhaust manifold gasket.

g01038601

Disassembly and Assembly Section

3. Remove the two studs and install the remaining setscrews (1). Ensure that the setscrews (1) are tightened in the sequence that is shown in Illustration 35. Tighten the setscrews evenly to a torque of 33 N·m (24 lb ft).

End By:

a. Install the turbocharger, if equipped. Refer

to this Disassembly and Assembly Manual, “Turbocharger - Install”.

Removal Procedure for the Four Cylinder Engine

Start By:

a. Remove the turbocharger, if equipped. Refer

to this Disassembly and Assembly Manual, “Turbocharger - Remove”.

Installation Procedure for the Three Cylinder Engine

Note: The improper installation of the exhaust manifold (2) can result in a cracked exhaust manifold. The setscrews (1) for the exhaust manifold must be tightened in the correct sequence and tightened to the correct torque.

Illustration 35

1. Loosely install two suitable studs into the holes (5 and 6) as guides.

Note: Do not use any sealant on the exhaust manifold gasket.

g01038601

Illustration 36

1. Remove the setscrews (1) in the reverse numerical order to the Illustration 36. This will help to prevent any distortion of the exhaust manifold (2).

2. Remove the exhaust manifold gasket from the cylinder head and remove the exhaust manifold (2). Discard the exhaust manifold gasket.

g00951398

Installation Procedure for the Four Cylinder Engine

2. Position the new exhaust manifold gasket onto the studs in the cylinder head. Position the exhaust manifold (2) onto the studs. Install the setscrews (1) finger tight in order to secure the exhaust manifold to the cylinder head.

20 Disassembly and Assembly Section

i01946915

Exhaust Elbow - Remove and Install (Option for Four Cylinder Engines Only)

Illustration 37

1. Loosely install two suitable studs into the holes (5 and 8) as guides.

Note: Do not use any sealant on the exhaust manifold gasket.

3. Remove the two studs and install the remaining setscrews (1). Ensure that the setscrews (1) are tightened in the sequence that is shown in Illustration 37. Tighten the setscrews evenly to a torque of 33 N·m (24 lb ft).

End By:

a. Install the turbocharger, if equipped. Refer

to this Disassembly and Assembly Manual, “Turbocharger - Install”.

g00951398

Removal Procedure

Start By:

a. Remove the exhaust pipe. Refer to the OEM

information for the correct procedure in order to remove the exhaust pipe.

Illustration 38 Typical example

g01013687

1. Remove the setscrews (1) from the exhaust elbow (2). Remove the setscrews (3) and remove the bracket (4) from the cylinder block. Remove the exhaust elbow (2) from the exhaust adapter (5).

Disassembly and Assembly Section

Installation Procedure

Illustration 39 Typical example

1. Thoroughly clean the exhaust elbow (2) and the exhaust adapter (5).

2. Install the exhaust elbow (2) onto the exhaust adapter (5). Position the bracket (4) onto the cylinder block and install the setscrews (3). Tighten the setscrews (3) finger tight. Align the exhaust elbow with the bracket (4). Install the setscrews (1) in order to secure the exhaust elbow (2) to the bracket (4). Tighten the setscrews (3) and tighten the setscrews (1) to a torque of 44 N·m (33 lb ft).

g01013687

Start By:

a. Remove the rocker shaft assembly. Refer to this

Disassembly and Assembly Manual, “Rocker Shaft and Pushrod - Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The following procedure should be adopted in

order to remove the valve springs when the cylinder head is still installed onto the cylinder block. Refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valves - Remove and Install” for the correct procedure that should be used to remove the valve springs from a cylinder head that has been removed from the cylinder block.

Note: Ensure that the appropriate piston is at top dead center before the valve spring is removed. Failure to ensure that the piston is at top dead center may allow the valve to drop into the cylinder block.

1. Use the following procedure in order to find the top dead center position for the appropriate piston.

End By:

a. Install the exhaust pipe. Refer to the OEM

information for the correct procedure in order to install the exhaust pipe.

i01947651

Inlet and Exhaust Valve Springs - Remove and Install

Removal Procedure

Ta bl e 1

Required Tools

Part Number Part Description

21825666 27610235

Valve Spring Compressor Setscrew Adapter

Qty

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.

1 1

Illustration 40

g01015085

22 Disassembly and Assembly Section

a. Install 21825666 Valve Spring Compressor

(1) and the appropriate 27610235 Setscrew Adapter (2) in position on the cylinder head in order to compress the appropriate valve spring (5).

NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

b. Compress the valve spring (5) sufficiently in

order to open the valve only. Do not compress the valve spring sufficiently so that the valve keepers (3) could be removed from the recess in the valve stem.

c. Turn the crankshaft until the piston touches

the valve.

d. Continue to turn the crankshaft until the valve

stem is at the highest point. The piston is now at top dead center. Release the applied pressure of the valve spring compressor (1) at the top center position.

NOTICE Do not turn the crankshaft while the valve springs are removed.

2. Use the valve spring compressor (1) in order to

compress the valve spring (5). Remove the valve keepers (3).

3. Carefully release the pressure on the valve

spring compressor (1). Remove the valve spring retainer (4) and the valve spring (5).

Note: If you are replacing all of the valve springs, the procedure can be done on two cylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, and on cylinder 2 and cylinder 3. Remember that the crankshaft must not be turned while the valve springs are removed. Ensure that all of the valve springs are installed before changing from one pair of cylinders to the other pair of cylinders.

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 41

g01015085

1. Place the new valve spring (5) into position.

2. Install the valve spring retainer (4).

NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.

3. Install the valve spring compressor (1) in position

on the cylinder head in order to compress the appropriate valve spring (5). Compress the valve spring (5).

4. Install the valve keepers (3).

Installation Procedure

Ta bl e 2

Required Tools

Part Number Part Description

21825666 27610235

Valve Spring Compressor Setscrew

NOTICE Do not turn the crankshaft while the valve springs are removed.

Qty

1 1

5. Carefully release the pressure on the valve spring compressor (1). Remove the valve spring compressor (1). 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 (3) are properly installed.

Note: If you are replacing all of the valve springs the procedure can be done on two cylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, and on cylinder 2 and cylinder 3.

End By:

a. Install the rocker shaft assembly. Refer to this

Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”.

Disassembly and Assembly Section

i01947652

Inlet and Exhaust Valves Remove and Install

Removal Procedure

Ta bl e 3

Required Tools

Part Number Part Description

21825496 21825666 27610235

Valve Depth Gauge Valve Spring Compressor Setscrew Adapter 1

Start By:

a. Remove the cylinder head assembly. Refer to this

Disassembly and Assembly Manual, “Cylinder Head - Remove”.

Note: Ensure that the machined face of the cylinder head is kept on a clean, soft surface in order to prevent damage to the machined surface.

Qty

1 1

Illustration 42 Typical example

g01015306

1. Use a dial indicator to check the depth of the valves below the face of the cylinder head before the valve springs are removed. Refer to the illustration 42 and refer to Specifications, “Cylinder Head Valves” for the correct dimensions.

Note: The head of the inlet valve has a larger diameter than the head of the exhaust valve.

2. Place a numerical index mark on the heads of the inlet valves and on the exhaust valves so that each valve can be installed in the correct sequence during installation.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The removal procedure is identical for the

three cylinder and the four cylinder engines. The illustrations show the four cylinder engine.

Illustration 43 Typical example

g01015303

24 Disassembly and Assembly Section

9. Remove the valve stem seal (6). Discard the valve stem seal (6).

10. Remove the appropriate valve (7 or 8).

11. Repeat Step 3 to Step 10 for each inlet valve (7)

and for each exhaust valve (8).

Installation Procedure

Ta bl e 4

Required Tools

Part Number Part Description

21825666 27610235 21825496

Valve Spring Compressor Setscrew Adapter Valve Depth Gauge

Qty

1 1 1

Illustration 44 Typical example

g01015305

3. Install 21825666 Valve Spring Compressor (1) and the appropriate 27610235 Setscrew Adapter (2) in position on the cylinder head in order to compress the appropriate valve spring (5).

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.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The installation procedure is identical for the

three cylinder and the four cylinder engines. The illustrations show the four cylinder engine.

4. Compress the valve spring (5).

5. Remove the valve keepers (3).

6. Carefully release the pressure on the valve

spring compressor (1). Remove the valve spring compressor (1) and the setscrew adapter (2) from the cylinder head.

7. Remove the valve spring retainer (4).

8. Remove the valve spring (5).

Illustration 45 Typical example

g01015305

1. Carefully clean the bottom face of the cylinder

head. Ensure that there is no debris in the inlet and exhaust ports. Also ensure that there is no debris in the coolant passages and in lubrication passages. Inspect the cylinder head. Refer to the Testing and Adjusting Manual, “Cylinder Head Inspect” for further information.

2. Inspect all of the valve seats for wear and for

damage. Refer to the Specifications Manual, “Cylinder Head Valves” for further information. Also refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valve Seat Inserts

- Remove and Install” and refer to Testing and Adjusting Manual, “Valve Depth - Inspect ” for further information. Replace any worn parts.

3. Inspect all of the valve guides for wear and for

damage. Refer to the Specifications Manual, “Cylinder Head Valves” for further information. Also refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valve Guides Remove and Install” and refer to Testing and Adjusting Manual, “Valve Guide - Inspect” for further information. Replace any worn parts.

Disassembly and Assembly Section

Illustration 46 Typical example

g01015303

Personal injury can result from being struck by parts propelled by a released spring force.

Make sure to wear all necessary protective equipment.

4. Inspect the valves if the valves are not

replacement parts. Refer to the Specifications Manual, “Cylinder Head Valves” for further information.

5. Lubricate the stems of all of the inlet valves (7)

and lubricate the stems of all of the exhaust valves (8) with clean engine oil. Install the inlet valves (7) and the exhaust valves (8) in the appropriate positions.

6. Carefully turn over the cylinder head and ensure

that all of the valves remain in place. Place the machined surface of the cylinder head onto a clean, soft surface.

Note: The valve guides must be clean and dry before installing the valve stem seals (6).

7. Install a new valve stem seal (6) onto each of

the valve guides.

8. Inspect the valve springs (5) for wear and

for the correct installed length. Refer to the Specifications Manual, “Cylinder Head Valves ” for further information on the correct installed length of the valve springs (5). Replace any worn parts.

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.

11. Install 21825666 Valve Spring Compressor

(1) and the appropriate 27610235 Setscrew Adapter (2) in position on the cylinder head in order to compress the appropriate valve spring (5).

12. Install the valve keepers (3).

13. Carefully release the pressure on the valve

spring compressor (1). Remove the valve spring compressor (1) and the setscrew adapter (2) from the cylinder head. Gently strike the top of the appropriate valves with a soft hammer in order to ensure that the valve keepers (3) are properly installed.

14. Repeat Step 11 to Step 13 for all of the valves

(7 and 8).

9. Install the valve springs (5) onto the cylinder head.

10. Install the valve spring retainers (4).

26 Disassembly and Assembly Section

15. Turn over the cylinder head. Use a dial indicator to check the depth of the new valves below the face of the cylinder head. Refer to Illustration 42 and refer to the Specifications Manual, “Cylinder Head Valves” for more information on the inlet valves and the exhaust valves. If the depth of the new valves is below the correct depth, the valve seat inserts must be replaced. Refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valve Seat Inserts - Remove and Install”.

End By:

a. Install the cylinder head assembly. Refer to this

Disassembly and Assembly Manual, “Cylinder Head - Install”.

i01947653

Inlet and Exhaust Valve Guides

- Remove and Install

Removal Procedure

Ta bl e 5

Required Tools

Part Number Part Description

21825478 21825479

Valve Guide Remover/Replacer Valve Guide Adapter

Start By:

a. Remove the cylinder head. Refer to this

Disassembly and Assembly Manual, “Cylinder Head - Remove”.

b. Remove the inlet valves and the exhaust valves.

Refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valves - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Qty

1 1

Illustration 47

g01016267

1. Install the 21825479 Valve Guide Adapter (1) into the 21825478 Valve Guide Remover/Replacer (2).

2. Place the spacer (3) into the appropriate valve seat.

3. Pass the adapter (1) through the valve guide (4) and install the valve guide remover/replacer (2) onto the spacer (3).

4. Install the attachment (5) in order to secure the adapter (1) to the valve guide (4).

5. Hold the top handle (6) and turn the bottom handle (7) counterclockwise in order to push the valve guide (4) from the cylinder head.

6. Repeat Step 2 to Step 5 in order to extract each appropriate valve guide (4).

7. Discard all of the valve guides (4) that were removed from the cylinder head.

Disassembly and Assembly Section

Note: When new valve guides are installed, new

valves and new valve seat inserts must be installed.

8. Remove the valve seat inserts. Refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valve Seat Inserts - Remove and Install”.

Installation Procedure

Ta bl e 6

Required Tools

Part Number Part Description

21825478 27610234

Valve Guide Remover/Replacer Valve Guide Adapter

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Qty

1 1

2. Install the 27610234 Valve Guide Adaptor (8) into the 21825478 Valve Guide Remover/Replacer (2).

3. Install the spacer (3) into the appropriate valve seat.

4. Lubricate the outer surface of a new valve guide (4) with clean engine lubricating oil. Pass the adapter (8) through the parent bore for the valve guide (4) and position the valve guide remover/replacer (2) onto the spacer (3).

5. Install the adapter (10) beneath the valve guide (4). Install the attachment (5) in order to secure the adapter (10) to the valve guide (4).

Note: The valve guide (4) should protrude above the cylinder head. Ensure that the protrusion (9) is within limits.

6. Hold the top handle (6) and turn the bottom handle (7) clockwise in order to pull the valve guide (4) into the cylinder head. Continue to pull the valve guide (4) into the cylinder head until the correct amount of protrusion (9) is reached. The valve guides should protrude 12.35 to 12.65 mm (0.4862 to 0.4980 inch) above the valve spring recess.

7. Repeat the Step 3 to Step 6 in order to install each appropriate valve guide.

Note: The parent bores of the valve guides must be reamed to the correct size after the valve guides have been installed into the cylinder head. Also, the valve inserts must be inserted and the seat faces must be cut to the correct angle. The same tool is used to finish both components.

8. Install the valve seat inserts and finish both components. Refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valve Seat Inserts - Remove and Install”.

End By:

a. Install the inlet valves and the exhaust valves.

Refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valves - Remove and Install”.

Illustration 48

g01016462

1. Clean the parent bores in the cylinder head for all of the appropriate valve guides (4).

28 Disassembly and Assembly Section

i01947654

Inlet and Exhaust Valve Seat Inserts - Remove and Install

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Removal Procedure

Start By:

a. Remove the inlet valves and the exhaust valves.

Refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valves - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: When new valve seat inserts are installed,

new valves and new valve guides must be installed.

1. Remove the appropriate valve guides. Install partially finished valve guides. Refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valve Guides - Remove and Install”.

Note: The inserts for the inlet valves are a larger diameter than the exhaust valve inserts.

2. Use the partially finished bore of the valve guide as a pilot bore in order to remove the valve insert by machining. Also use the partially finished bore of the valve guide as a pilot bore in order to machine a recess for a new valve seat. Refer to the Specifications Manual, “Cylinder Head Valves” for the required dimensions of the recess for the valve seat. Remove all debris from the cylinder head ports and passages.

Note: If the cylinder head has been previously ground then the bottom face of valve seat must be ground in order to ensure that the valve seat will be installed correctly into the cylinder head. A 30 degree chamfer must be machined to the outer edge of the valve seat after the back face of the valve insert has been ground to the correct dimensions. The 30 degree chamfer must be within the tolerance of 0.91 mm (0.036 inch) to 1.3 mm (0.051 inch). Also, the chamfer must be inclined to the vertical face of the valve insert.

Note: Do not use a hammer in order to install the valve insert into the machined recess in the cylinder head.

Note: Do not apply any lubricant before the new valve seat insert is installed into the cylinder head.

1. Use a suitable tool to install the valve seat insert into the machined recess in the cylinder head.

3. Repeat the Step 2 for all of the appropriate valve seats.

Installation Procedure

Ta bl e 7

Required Tools

Part Number Part Description

27610030

Valve Guide/Valve Seat Reamer/Cutter

Qty

Illustration 49

2. If necessary, a suitable tool can be manufactured. Refer to the illustration 49. Also refer to the table 8 and refer to the table 9 for suitable dimensions.

g01016768

Disassembly and Assembly Section

Ta bl e 8

Callout

Ta bl e 9

Callout

1 2 3 4 5

8 9

Tool for the Inlet Valve Seat Inserts

Dimension

1 2 3 4 5

6 7

8 9

6.8 mm (0.268 inch) to 7.1 mm (0.279 inch)

38.1 mm (1.500 inch) to 38.3 mm (1.508 inch)

46.25 mm (1.82 inch) to 46.5 mm (1.83 inch) Maximum radius 1.4 mm (0.055 inch)

Maximum radius 1.5 mm (0.06 inch)

8.77 mm (0.345 inch) to 8.80 mm (0.346 inch)

Tool for the Exhaust Valve Seat Inserts

7.2 mm (0.283 inch) to 7.5 mm (0.295 inch)

34.38 mm (1.353 inch) to 34.58 mm

41.75 mm (1.643 inch) to 42.00 mm

Maximum radius 1.4 mm (0.055 inch)

Maximum radius 1.5 mm (0.06 inch)

8.77 mm (0.345 inch) to 8.80 mm (0.346 inch)

1.5 mm (0.06 inch) 20 mm (0.80 inch)

100 mm (3.94 inch)

1.5 mm (0.06 inch)

Dimension

1.5 mm (0.06 inch) 20 mm (0.80 inch)

100 mm (3.94 inch)

(1.361 inch)

(1.653 inch)

1.5 mm (0.06 inch)

5. After installing the valve guides and valve seat inserts, the valve guides must be reamed and the valve seat inserts must be cut to the finished diameter. The valve guides and valve seat inserts are cut and reamed in one operation. This procedure ensures the concentricity of the valve seat to the valve guide in order to create a good seal. Refer to the Specifications Manual, “Cylinder Head Valves” for the finished diameter of the valve guides and valve seat inserts.

3. Put the appropriate valve seat insert in position. Install the special tool that was manufactured previously, through the valve seat insert and use the pilot bore of the valve guide in order to center the tool and the insert into the recess. Lightly tap the valve seat insert in order to start the installation. Press the valve seat insert into the recess with a suitable press. Ensure that the bottom of the valve seat insert is against the bottom of the recess.

4. Repeat Step 3 for the remaining valve seat inserts.

Illustration 50

g01017975

Note: Ensure that the 27610030 Valve Guide/Valve Seat Reamer/Cutter is assembled correctly with the correct angle of cutter (3) for the valve seat toward the cylinder head.

Note: Ensure that the cutter (3) for the valve seat is not allowed to contact the valve seat insert until the valve guide has been reamed to the correct size.

30 Disassembly and Assembly Section

6. Set the diameter of the cutter (3) to the correct size for the valve seat to be cut. Refer to the Specifications Manual, “Cylinder Head Valves” for the correct diameter. Position the reamer (2) of the tool (1) into the appropriate valve guide. Carefully turn the handle in a clockwise direction and gradually move the reamer (2) into the valve guide until the valve guide is reamed to the finished size.

7. Continue to turn the handle in a clockwise direction in order to cut the valve seat insert. Remove the minimum amount of material in order to ensure a good valve seat. Keep the valve seat as narrow as possible.

8. Remove the tool (1). Clean the debris from the valve guide and the valve seat.

9. Repeat Step 6 to Step 8 in order to cut all of the appropriate valve seats.

End By:

a. Install the inlet valves and the exhaust valves.

Refer to this Disassembly and Assembly Manual, “Inlet and Exhaust Valves - Remove and Install”.

Dispose of all fluids according to local regulations and mandates.

1. Remove all dirt, oil, and grease from the engine

oil filter assembly and from the drain plug of the engine oil pan. Place a suitable container beneath the drain plug of the engine oil pan.

2. Operate the engine until the engine is warm.

Stop the engine.

3. Remove the oil drain plug and the O-ring from

the engine oil pan. Drain the engine oil into the container for storage or disposal.

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Engine Oil Filter Base Remove and Install

Removal Procedure for an Oil Filter with a Separate Filter Element

Note: This procedure is for the removal of an oil filter with an oil filter housing and a separate oil filter element.

Note: The oil filter can be installed vertically or the oil filter can be installed horizontally.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 51 Typical example

Note: The drain plug (1) in the horizontal type of oil

filter is installed in the filter head (4) instead of the oil filter housing (3). Do not remove the drain plug (1) from this type of oil filter.

4. Place a suitable container beneath the drain plug

(1) in the oil filter housing (3). Remove the drain plug (1) from the oil filter housing (3) and remove the O-ring from the drain plug (1). Discard the O-ring. Collect any engine oil that drains from the oil filter housing (3).

5. Install a ratchet with a 1/2 inch square drive into

the recess (2) in the base of the oil filter housing (3) in order to remove the oil filter housing.

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