Perkins Engine 1103 Service Manual

Name: Perkins Engine 1103
Brand: Perkins Engine
SKU: 4538011
Rating: 4.5 (18 reviews)

4.5 (18)

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

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.

3 Table of Contents

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

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.

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 1	g00952432
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).

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2	g00952432
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.

5 Disassembly and Assembly Section

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

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.

NOTICE

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	g01010637
Illustration 3
Typical example

Illustration 4	g01010595
Illustration 4
Typical example

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).

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.

Illustration 5	g01010637
Illustration 5
Typical example

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.

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.

Illustration 6	g01010595
Illustration 6
Typical example

7 Disassembly and Assembly Section

NOTICE

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.

Illustration 7	g00955826
Illustration 7
Typical example

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

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

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 8	g00955826
Illustration 8
Typical example

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).

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

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

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.

Fuel Injector Cover - Remove

and Install

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Illustration 9	g01011111
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).

Illustration 10	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).

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”.

9 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	g01011369
Illustration 12
Typical example

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).

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

Illustration 11	g00956204
Illustration 11
Typical example

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.

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

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.

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”.

Illustration 14	g00996409

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.

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

11 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.

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 17	g00996474	Illustration 18	g00956267

Typical example

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

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 19	g01011369
Illustration 19
Typical example

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).

Illustration 20	g00956204
Illustration 20
Typical example

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

7.Connect the harness assembly (2).

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	g01011369
Illustration 21
Typical example

13 Disassembly and Assembly Section

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)

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”.

Illustration 22	g00996474

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).

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

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).

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.

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

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:

a.Remove the cover for the fuel injectors. Refer to this Disassembly and Assembly Manual, “Fuel Injector Cover - Remove and Install”.

Illustration 25	g00996410

15 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.

NOTICE

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”.

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.

NOTICE

Dispose of all fluids according to local regulations and mandates.

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 29	g01038600

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.

Illustration 30	g01038396
Illustration 30
Typical example

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.

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).

Typical example

17 Disassembly and Assembly Section

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

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	g01038396
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).

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).

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 32	g01038406
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”.

Illustration 33	g01038456

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).

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”.

19 Disassembly and Assembly Section

Illustration 34	g01038601

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.

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	g01038601

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.

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.

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”.

Illustration 36	g00951398

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.

Installation Procedure for the Four Cylinder Engine

Disassembly and Assembly Section

Illustration 37	g00951398

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”.

i01946915

Exhaust Elbow - Remove and Install

(Option for Four Cylinder Engines Only)

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	g01013687
Illustration 38
Typical example

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).

21 Disassembly and Assembly Section

Installation Procedure

Illustration 39	g01013687
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).

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

Table 1

Required Tools

Part Number	Part Description	Qty

21825666	Valve Spring Compressor	1

27610235	Setscrew Adapter	1

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.

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.

Illustration 40	g01015085

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.

Installation Procedure

Table 2

Required Tools

Part Number	Part Description	Qty

21825666	Valve Spring Compressor	1

27610235	Setscrew	1

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).

NOTICE

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

23 Disassembly and Assembly Section

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”.

i01947652

Inlet and Exhaust Valves -

Remove and Install

Removal Procedure

Table 3

Required Tools

Part Number	Part Description	Qty

21825496	Valve Depth Gauge	1

21825666	Valve Spring Compressor	1

27610235	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.

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 42	g01015306
Illustration 42
Typical example

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.

Illustration 43	g01015303
Illustration 43
Typical example

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

Table 4
	Required Tools

Part Number	Part Description	Qty

21825666	Valve Spring Compressor	1

27610235	Setscrew Adapter	1

21825496	Valve Depth Gauge	1

		NOTICE
Illustration 44	g01015305
		Keep all parts clean from contaminants.

Typical example

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

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.

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).

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.

Illustration 45	g01015305
Illustration 45
Typical example

25 Disassembly and Assembly Section

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.

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.

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

10.Install the valve spring retainers (4).

Illustration 46	g01015303
Illustration 46
Typical example

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.

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

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).

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

Table 5

Required Tools

Part Number	Part Description	Qty

21825478	Valve Guide Remover/Replacer	1

21825479	Valve Guide Adapter	1

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.

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.

27 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

Table 6

Required Tools

Part Number	Part Description	Qty

21825478	Valve Guide Remover/Replacer	1

27610234	Valve Guide Adapter	1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

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).

Disassembly and Assembly Section

i01947654

Inlet and Exhaust Valve Seat

Inserts - Remove and Install

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.

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

Installation Procedure

Table 7

Required Tools

Part Number	Part Description	Qty

27610030	Valve Guide/Valve Seat	1
27610030	Reamer/Cutter	1
	Reamer/Cutter

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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.

Illustration 49	g01016768

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.

29 Disassembly and Assembly Section

Table 8

Tool for the Inlet Valve Seat Inserts

Callout	Dimension
1	1.5 mm (0.06 inch)

2	20 mm (0.80 inch)

3	6.8 mm (0.268 inch) to 7.1 mm (0.279 inch)

4	100 mm (3.94 inch)

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

646.25 mm (1.82 inch) to 46.5 mm (1.83 inch)

7Maximum radius 1.4 mm (0.055 inch)

8Maximum radius 1.5 mm (0.06 inch)

9	1.5 mm (0.06 inch)

10 8.77 mm (0.345 inch) to 8.80 mm (0.346 inch)

Table 9

Tool for the Exhaust Valve Seat Inserts

Callout	Dimension
1	1.5 mm (0.06 inch)

2	20 mm (0.80 inch)

3	7.2 mm (0.283 inch) to 7.5 mm (0.295 inch)

4	100 mm (3.94 inch)

5	34.38 mm (1.353 inch) to 34.58 mm
	(1.361 inch)

6	41.75 mm (1.643 inch) to 42.00 mm
	(1.653 inch)

7Maximum radius 1.4 mm (0.055 inch)

8Maximum radius 1.5 mm (0.06 inch)

9	1.5 mm (0.06 inch)

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

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.

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.

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.

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”.

i01958098

Engine Oil Filter Base -

Remove and Install

Removal Procedure for an Oil Filter with a Separate Filter Element

NOTICE

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.

Illustration 51	g01018261

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.

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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