Perkins Engine 1106D Disassembly and Assembly

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Page 1

Disassembly and Assembly

SENR9983

October 2005

1106D Ind

PJ (Engine )

ustrial Engine

Page 2

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.

Page 3

SENR9983 3

Table of Contents

Disassembly and Assembly Section

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

Fuel Filter Base - Remove and Install (Secondary

Fuel Filter) ............................................................. 7

Fuel Transfer Pump - Remove ................................ 8

Fuel Transfer Pump - Install .................................. 10

Fuel Injection Lines - Remove .............................. 11

Fuel Injection Lines - Install ................................. 12

Fuel Manifold (Rail) - Remove and Install ............. 14

Fuel Injection Pump - Remove ............................ 16

Fuel Injection Pump - Install ................................ 18

Fuel Injection Pump Gear - Remove .................... 22

Fuel Injection Pump Gear - Install ........................ 23

Electronic Unit Injector - Remove ......................... 25

Electronic Unit Injector - Install ............................. 28

Turbocharger - Remove ........................................ 32

Turbocharger - Disassemble ................................ 35

Turbocharger - Assemble .................................... 35

Turbocharger - Install ............................................ 36

Wastegate Solenoid - Remove and Install ............ 40

Exhaust Manifold - Remove and Install ............... 41

Exhaust Elbow - Remove and Install ................... 45

Inlet Manifold - Remove and Install ..................... 46

Inlet and Exhaust Valve Springs - Remove and

Install ................................................................... 48

Inlet and Exhaust Valves - Remove and Install .... 52

Engine Oil Filter Base - Remove and Install ........ 55

Engine Oil Cooler - Remove ................................. 56

Engine Oil Cooler - Install ..................................... 58

Engine Oil Relief Valve - Remove and Install ....... 61

Engine Oil Pump - Remove .................................. 63

Engine Oil Pump - Install ...................................... 64

Water Pump - Remove ......................................... 65

Water Pump - Install ............................................. 66

Water Temperature Regulator - Remove and Install

............................................................................. 67

Flywheel - Remove ............................................... 69

Flywheel - Install ................................................... 70

Crankshaft Rear Seal - Remove ........................... 71

Crankshaft Rear Seal - Install ............................... 72

Crankshaft Wear Sleeve (Rear) - Remove and

Install ................................................................... 75

Flywheel Housing - Remove and Install .............. 76

Vibration Damper and Pulley - Remove .............. 81

Vibration Damper and Pulley - Install .................. 82

Crankshaft Front Seal - Remove and Install ......... 84

Crankshaft Wear Sleeve (Front) - Remove and

Install ................................................................... 85

Front Cover - Remove and Install ......................... 86

Gear Group (Front) - Remove and Install ............. 88

Idler Gear - Remove ............................................. 91

Idler Gear - Install ................................................. 93

Housing (Front) - Remove .................................... 96

Housing (Front) - Install ........................................ 98

Accessory Drive - Remove and Install ............... 100

Crankcase Breather - Remove ........................... 101

Crankcase Breather - Install ............................... 104

Valve Mechanism Cover - Remove and Install ... 108

Valve Mechanism Cover Base - Remove and

Install ................................................................. 109

Rocker Shaft and Pushrod - Remove .................. 111

Rocker Shaft - Disassemble ............................... 112

RockerShaft-A

Rocker Shaft and Pushrod - Install ...................... 114

Cylinder Head - Remove ..................................... 116

Cylinder Head -

Lifter Group - Remove and Install ....................... 122

Camshaft - Remove and Install ......................... 123

Camshaft Gear - R

Camshaft Bearings - Remove and Install .......... 127

Engine Oil Pan - Remove .................................. 129

Engine Oil Pan - In

Piston Cooling Jets - Remove and Install ........... 138

Pistons and Connecting Rods - Remove ............ 139

Pistons and Conne

Pistons and Connecting Rods - Assemble ......... 142

Pistons and Connecting Rods - Install ................ 144

Connecting Rod Bea

rods in position) ................................................. 145

Connecting Rod Bearings - Install (Connecting rods

in position) ......................................................... 146

Crankshaft Main Bearings - Remove and Install

(Crankshaft in position) ..................................... 148

Crankshaft - Remo

Crankshaft - Install .............................................. 152

Crankshaft Timing Ring - Remove and Install .... 155

Crankshaft Gear - R

Bearing Clearance - Check ................................. 158

Crankshaft Position Sensor - Remove and

Install ................................................................. 159

Coolant Temperature Sensor - Remove and

Install ................................................................. 159

Engine Oil Pressur

........................................................................... 161

Position Sensor (Fuel Injection Pump) - Remove and

Install ................................................................. 162

Fuel Pressure Sensor - Remove and Install ....... 163

Boost Pressure Sensor - Remove and Install ..... 164

Inlet Air Temperat

Install ................................................................. 165

Glow Plugs - Remove and Install ....................... 166

Alternator Belt - R

Fan - Remove and Install ................................... 168

Fan Drive - Remove and Install ......................... 169

Electronic Control

ECM Mounting Bracket - Remove and Install ..... 172

Alternator - Remove ............................................ 175

Alternator - Instal

Electric Starting Motor - Remove and Install ..... 177

ssemble .................................... 113

Install ......................................... 118

emove and Install ................ 125

stall ...................................... 131

cting Rods - Disassemble ..... 140

rings - Remove (Connecting

ve .......................................... 151

emove and Install .............. 156

e Sensor - Remove and Install

ure Sensor - Remove and

emove and Install .................. 167

Module - Remove and Install .. 170

l ................................................ 176

Index Section

Index ................................................................... 178

Page 4

4 SENR9983 Disassembly and Assembly Section

Disassembly an

d Assembly

Section

i02295884

FuelPrimingPump-Remove and Install

Removal Procedure (Manual Priming Pump

Ensure that all adjustments and repairs that are carried out t authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Lines” for safety information.

Refer to Tes liness of Fuel System Components” for detailed information on the standards of cleanliness that must be obs system.

o the fuel system a re performed by

Information and High Pressure Fuel

ting and Adjusting Manual, “Clean-

erved during ALL work on the fuel

)

NOTICE

Illustration 1

Typical example

4. Disconnect the plastic tube assemblies (1). Plug

the tube assemblies with new plugs. Cap the open connectors (2) on the fuel priming pump with new caps.

5. Remove the primary filter (7) from the fuel priming

pump (4). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter (Water Seperator) Element - Replace”.

g01181971

1. Isolate th

2. Makeatemporaryidentificationmarkonthe

plastic tu correct position of the tube assemblies.

3. Place a sui pump in order to catch any fuel that might be spilled. Drain the primary filter (7). Refer to Operat System Primary Filter (Water Seperator) Element

-Replace”.

Note: Clean up any spillage of fuel immediately.

e fuel supply.

be assemblies (1) in order to show the

table container below the fuel priming

ion and Maintenance Manual, “Fuel

6. Remove the two setscrews (6) from the fuel priming pump (4). Remove the fuel priming pump (4) from the mounting bracket.

7. If necessary, follow Steps 7.a through 7.c in order to disassemble the fuel priming pump (4).

a. Remove the connectors (2) from the fuel

priming pump (4).

b. Remove the plugs (5) from the fuel priming

pump (4).

c. Remove the O-ring seals (3) from the

connectors (2) and the plugs (5). Discard the O-ring seals.

Page 5

SENR9983 5

Disassembly and Assembly Section

Removal Procedure (Electric Fuel Priming Pump)

NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to Testing and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Isolate the fuel supply.

7. Remove the e lectric priming pump (4) from the

mounting brack

Installation P

et.

rocedure (Manual

Priming Pump)

NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised pe ing.

Before begin fer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for sa

Refer to Testing and Adjusting Manual, “Cleanliness of Fue information on the standards of cleanline ss that must be observed during ALL work on the fuel system.

1. Ensure that the fuel priming pump (4) is clean and

free from we the fuel priming pump.

rsonnel that have the correct train-

ing ANY work on the fuel system, re-

fety information.

l System Components” for detailed

ar or damage. If necessary, replace

Illustration 2

Typical exam p le

2. Isolate the electrical supply.

3. Disconnect the electrical lead (3) for the electric

priming pump (4).

4. Makeatemporaryidentificationmarkonthe plastic tube assemblies (1) and (2) in order to show the correct position of the tube assemblies.

5. Disconnect the plastic tube assemblies (1) and (2). Plug the tube assemblies with new plugs. Cap the ports in the fuel priming pump (4) with new caps.

6. Remove the four setscrews (5) from the electric priming pump (4).

g01186418

Illustration 3

Typical example

2. If necessary, follow Steps 2.a through 2.d in order to assemble the fuel priming pump (4).

a. Install new O-ring seals (3) to the connectors

(2) and to the plugs (5).

b. Install the connectors (2) to the fuel priming

pump (4).

c. Install the plugs (5) to the fuel priming pump (4).

g01181971

Page 6

6 SENR9983 Disassembly and Assembly Section

d. Tighten the plugs and the connectors to a

torque of 20 N·m

3. Position the fuel priming pump (4) on the mounting bracket. Inst primingpump.Tightenthesetscrewstoatorque of 44 N·m (32 lb ft).

4. Remove the plugs from the plastic tube assemblies. Remove the caps from the connectors.

5. Connect the plastic tube assemblies (1) to the connectors (

Note: Ensure that the plastic tube assemblies are installed in

6. Install a new primary filter (7) to the fuel priming pump (4). Ref Manual, “Fuel System Primary Filter (Water Seperator) Element - Replace”.

7. Restore the fuel supply.

8. Prime the fu

Maintenance Manual, “Fuel System - Prime”.

all the two setscrews (6) to the fuel

2).

the original positions.

el system. Refer to Operation and

(14 lb ft).

er to Operation and Maintenance

Illustration 4

Typical example

2. Position the electric priming pump (4) on the mounting bracket. Install the four setscrews (5) to the electric priming pump (4).

g01186418

Installation Procedure (Electric Fuel Primin

Ensure that all adjustments and repairs that are carried out authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazar Lines” for safety information.

Refer to T liness of Fuel System Components” for detailed information on the standards of cleanliness that must be ob system.

1. Ensure th

and free from wear or damage. If necessary, replace the electric priming pump.

g Pump)

NOTICE

to the fuel system a re performed by

d Information and High Pressure Fuel

esting and Adjusting Manual, “Clean-

served during ALL work on the fuel

at the electric priming pump (4) is clean

3. Tighten the setscrews (5) to a torque of 9 N·m (79 lb in).

4. Remove the plugs from the plastic tube assemblies. Remove the caps from the electric priming pump.

5. Connect the plastic tube assemblies (1) and (2) to the electric priming pump (4).

Note: Ensure that the plastic tube assemblies are installed in the original positions.

6. Connect the electrical lead (3) for the electric priming pump (4).

7. Restore the electrical supply.

8. Restore the fuel supply.

9. Prime the fuel system. Refer to Operation and

Maintenance Manual, “Fuel System - Prime”.

Page 7

SENR9983 7

Disassembly and Assembly Section

i02295889

Fuel Filter Base - Remove and Install (Secondary Fue

Removal Procedure

Ensure that all adjustments and repairs that are carried out to t authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard In Lines” for safety information.

Refer to Test liness of Fuel System Components” for detailed information on the standards of cleanliness that must be obser system.

he fuel system are performed by

formation and High Pressure Fuel

ing and Adjusting Manual, “Clean-

ved during ALL work on the fuel

l Filter)

NOTICE

4. Disconnect the plastic tube assemblies (3), (4) and (5) from the tube assemblies with new plugs. Cap the ports in the fuel filter base with new caps.

5. Remove the fuel filter (6). Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Repl

6. Remove the two setscrews (2) from the fuel filter base (1). Rem mounting bracket.

Note: Do not d

Installatio

Ensure that al carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Opera eral Hazard Information and High Pressure Fuel Lines” for s afety information.

fuel filter base (1). Plug the plastic

ace”.

ove the fuel filter base from the

isassemble the fuel filter base.

n Procedure

NOTICE

l adjustments and repairs that are

tion and Maintenance Manual, “Gen-

1. Isolate the f

Illustration 5

Typical exam p le

2. Make temporary identification marks on the plastic tube assemblies (3), (4) and (5) in order to show the correct position of the tube assemblies.

uel supply.

g01165584

Refer to Testing and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed informatio must be observed during ALL work on the fuel system.

1. Ensure that the fuel filter base (1) is clean and free

from damage. If necessary, replace the complete fuel filte

n on the standards of cleanliness that

r base and filter assembly.

3. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.

Note: Clean up any spillage of fuel immediately.

Illustration 6

Typical example

g01165584

Page 8

8 SENR9983 Disassembly and Assembly Section

2. Position the fuel filter base (1) on the mounting bracket. Insta setscrews to a torque of 44 N·m (32 lb ft).

3. Remove the plu assemblies. Remove the caps from the ports in the fuel filter base.

Ensure that th in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to en cause serious damage to the engine.

4. Connect the p (5) to the fuel filter base (1).

Note: Ensure installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow c Contaminated fuel will cause serious damage to the engine.

5. If necessary, install a new fuel filter (6) to the fuel filter base (1). Refer to Operation and Maintenanc Filter - Replace” for the correct procedure.

6. Restore th

End By:

ll the setscrews (2). Tighten the

gs from the plastic tube

NOTICE

e plastic tube assemblies are installed

ter the fuel system. Contaminated fuel will

lastic tube assemblies (3), (4) and

that the plastic tube assemblies are

ontamination to enter the fuel system.

e Manual, “Fuel System Secondary

e fuel supply.

i02296828

Fuel Transfer Pump - Remove

Removal Proced

Ensure that all carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operati eral Hazard Information and High Pressure Fuel Lines” for s afety information.

Refer to Testing and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information must be observed during ALL work on the fuel system.

1. Isolate the fuel supply.

2. Place a suita

pump (1) in order to catch any fuel that might be spilled.

Note: Clean up any spillage of fuel immediately.

adjustments and repairs that are

on and Maintenance Manual, “Gen-

on the standards of cleanliness that

ble container below the fuel transfer

ure

NOTICE

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

Operation and Maintenance Manual, “Fuel System

- Prime”.

Page 9

SENR9983 9

Disassembly and Assembly Section

ion 7

Illustrat

Typical exam p le

g01162545

3. Remove the plastic tube assembly (2) from the fuel transfer pump (1).

4. Disconnect the plastic tube assembly (3) from the outlet of the fuel transfer pump (1).

5. Remove the connector (4) from the fuel transfer pump (1). Remove the O-ring seal (not shown) from the c

onnector (4). Discard the O-ring seal.

If necessary, remove the connector (7) from the fuel tran

sfer pump (1). Remove the O-ring seal (not shown) from the connector (7). Discard the O-ring seal.

Illustration 8

g01162543

10. Remove fuel transfer pump (1) from the fuel injection pump (8).

Note: Do not remove the dowels (10) from the fuel injection pump.

Illustrat

ion 9

g01162544

11. Remove the O-ring seal (11) from the fuel transfer pump (1). D

iscard the O-ring seal.

6. Remove the tube assembly (6) for the fuel return from the fuel transfer pump and the cylinder head.

Note: Disconnect the tube assembly at the fuel transfer pump first in order to drain the fuel from the cylinde

r head.

7. Remove the tube assembly (5) for the engine oil supply f

rom the fuel injection pump (8).

8. Plug or cap all open ports and tube assemblies immedi

ately with new plugs or caps.

9. Use an allen wrench with a ball end in order to remove

the five allen head screws (9) that secure the fuel transfer pump to the fuel injection pump (8).

Page 10

10 SENR9983 Disassembly and Assembly Section

i02296829

Fuel Transfer Pump - Install

Installation P

rocedure

NOTICE

Ensure that all

adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operati

on and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to Testing and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information

on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Ensure that the mating faces of the fuel injection

pump (8) and the fuel transfer pump (1) are clean and free fro

m damage.

Illustration 11

g01162543

3. Align the holes in the fuel transfer pump (1) with thedowels(10)inthefuelinjectionpump(8). Install the fuel transfer pump to the fuel injection pump.

Illustration 10

g01162544

2. Install a new O-ring seal (11) to fuel transfer pump (1). Lubricate the O-ring seal with clean engine oil.

ration 12

Illust

Typical example

g01162545

4. Use an allen wrench with a ball end to install the five allen head screws (9). Tighten the allen head screws

toatorqueof30N·m(22lbft).

5. Remove the plugs and the caps from the ports and tub

e assemblies.

Page 11

SENR9983 11

Disassembly and Assembly Section

6. Install the tube assembly (5) for the engine oil supply to the fu cylinder block.

7. Install the tu the fuel transfer pump (1) and to the cylinder head.

el injection pump (8) and to the

be assembly (6) for the fuel return to

NOTICE

Ensure that all adjustments and repairs that are carried out to t

he fuel system are performed by authorised personnel that have the correct training.

8. Install a new O

-ring seal (not shown) to the connector (4). Install the connector (4) to the fuel transfer pump (1). Tighten the connector to torque of 15 N·m (11 l

b ft).

9. If necessary, install a new O-ring seal (not shown) to the connec

tor (7) and install the connector (7) to the fuel transfer pump (1). Tighten the connector to torque of 15 N·m (11 lb ft).

10. Connect the plastic tube assembly (3) to the outlet of the fuel transfer pump (1).

11. Install the plastic tube assembly (2) to the fuel transfer pump (1).

12. Restore the fuel supply.

13. Remove the a

ir from the fuel system. Refer to Testing and Adjusting Manual, “Fuel System Prime”.

i02295890

Fuel Injection Lines - Remov e

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard In

formation and High Pressure Fuel

Lines” for s afety information.

Refer to Testi

ng and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be obser

ved during ALL work on the fuel

system.

1. Isolate the f

uel supply.

2. Isolate the electrical supply.

Removal Procedure

Table 1

Required Tools

Too l

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

Part

Number

U5MK1124

Part Name Qty

Cap Kit 1

Illustration 13

Typical example

g01178882

3. Remove the two plastic clamps (2) from the fuel

injection lines (1). Discard the plastic clamps.

4. Slide the dust seal (3) from the nut on the fuel

injection line (1).

5. Disconnect the fuel injection line (1) at the

electronic unit injector (4).

6. Disconnect the fuel injection line (1) at the fuel

manifold (5).

7. Remove the fuel injection line (1). Discard the fuel

injection line.

Note: Clean up any spillage of fuel immediately.

Page 12

12 SENR9983 Disassembly and Assembly Section

8. Plug the open port in the fuel manifold (5) immediately. U

se Tooling (A) in order to plug the

open port in the fuel manifold.

9. Remove the sea

l (6) from the electronic unit injector (4) and the base of the valve mechanism cover (not shown).

Note: The seal can be damaged by contact with fuel.

10. Plug the open p

ort in electronic unit injector (4) immediately. Use Tooling (A) in order to plug the open port in the electronic unit injector.

11. Repeat Steps 4 through 11 in order to remove the remaining fuel injection lines from the fuel manifold to t

Illustration 14

Typical Exam ple

he electronic unit injectors.

g01198424

12. Disconnect the harness assembly (9) from the fuel injection pump (8). Slide the locking tab (10) into the unlocked position. Disconnect the harness assembly (9) from the position sensor (11). Position the harness assembly (9) so that the harness assembly is clear of the fuel injection line (7).

Illustration 16

Assembly of the tube clip

g01208399

13. Remove the fasteners (12) from the three tube clips (13) that secure the fuel injection line (7). Loosen the three allen head screws (14). Position the tube clips in order to allow removal of the fuel injection line.

14. Disconnect the fuel injection line (7) at the fuel injection pump (8).

15. Disconnect the fuel injection line (7) at the fuel manifold (5).

16. Plug all open ports immediately. Use Tooling (A) in order to plug the open ports in the fuel manifold (5) and in the fuel injection pump (8).

17. Remove the fuel injection line (7).

Note: Clean up any spillage of fuel immediately.

18. Remove the allen head screws (14) and the

assemblies of the three tube clips (13) from fuel injection line (7). Discard the fuel injection line.

i02295912

Illustration 15

g01208398

Fuel Inje

ction Lines - Install

Installation Procedure

Table 2

Tools

Part Name

Tool

Part

Number

27610294

Required

Injector Pipe Nut Tool 1

Qty

Page 13

SENR9983 13

Disassembly and Assembly Section

1. Loosely install the assemblies of the three tube

NOTICE

Ensure that all adjustments and repairs that are carried out to t

he fuel system are performed by

authorised personnel that have the correct train-

clips (13) and t fuel injection line (7).

2. Place the fuel

he allen head screws (14) to the

injection line (7) in position.

ing.

3. Remove the caps from the port in the fuel injection

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard In

formation and High Pressure Fuel

pump (8) and fr manifold (5). Remove the caps from the new fuel injection line (7).

om the appropriate port in the fuel

Lines” for safety information.

4. Loosely connect the nuts at both ends of the fuel

Refer to Testi

ng and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be obser

ved during ALL work on the fuel

injection line (7), to the fuel manifold (5) and to the fuel inje

ction pump (8). Ensure that the ends of the fuel injection line are correctly seated in the fuel injection pump and in the fuel manifold.

system.

5. Use Tooling (A) to tighten the nuts on the fuel

injectionline(7)toatorqueof30N·m(22lbft).

Note: The fol in order to install the fuel injection lines when the electronic unit injectors or the fuel manifold have not been rem or the fuel manifold have been removed, refer to Disassembly and Assembly Manual, “Electronic Unit Injector-I

lowing procedure should be adopted

oved. If the electronic unit injectors

nstall” and Disassembly and Assembly

6. Install the setscrews (12) for the three tube clips (13) that secure the fuel injection line (7). Tighten the setscre

ws (12) to a torque of 22 N·m (16 lb ft). Tighten the M5 allen head screws (14) to a torque of 10 N·m (89 lb in). Ensure that fuel injection line does not co

ntact any other engine component.

Manual, “Fuel Manifold - Install” for more information.

Illustration 17

Assembly o f the tube clip

Illustration 18

g0120839

g01208398

Illustration 19

Typical example

g01198424

7. Connect the harness assembly (9) to the position sensor (11). Slide the locking tab (10) into the locked position. Connect the harness assembly (9) to the fuel injection pump (8).

Page 14

14 SENR9983 Disassembly and Assembly Section

15. Install two new clamps (2) to the fuel injection lines. Ensure t order to retain the fuel injection lines.

hat the clamps are fully closed in

Illustration 20

Typical exam p le

8. Thoroughly clean the seal (6). Inspect the seal for damage. If necessary, replace the seal.

Note: The seal can be damaged by contact with fuel. If the seal has been in contact with fuel for a prolonged period, the seal should be replaced.

g01178882

Note: Ensure t any other engine component.

16. Restore the fu

17. Restore the electrical supply.

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

the Operations and Maintenance Manual, “Fuel System - Prim

hat fuel injection lines do not contact

el supply.

e”.

i02403286

Fuel Ma nifold ( R ail) - Remove and Install

Removal Procedure

Start By:

a. Remove the fuel injection lines. Refer to

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

9. Install the seal (6) to the electronic unit injector (4). Ensure that the flange on the seal is flush with the valve mechanism cover base.

10. Remove the caps from the new fuel injection line (1). Ensure that a new dust seal (3) is installed to the fuel injection line.

11. Remove the caps from the electronic unit injector (4) and from the appropriate port in the fuel manifold (5).

12. Loosely connect the nuts at both ends of the fuel injection line (1), to the electronic unit injector (4) and to the appropriate port in the fuel manifold (5). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector andinthefuelmanifold.

13. Use Tooling (A) to tighten the nuts on the fuel injectionline(1)toatorqueof30N·m(22lbft). Slide the dust seal (3) into position over the nut on the fuel injection line. Ensure that the dust seal (3) is in contact with the seal (6).

14. Follow Steps 8 through 13 in order to install the remaining fuel injection lines.

b. If necessary, remove the fuel pressure sensor.

Refer to Disassembly and Assembly Manual, “Fuel Pressure Sensor - Remove and Install”.

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuelspraymaycauseafirehazard.Failuretofollow these inspection, maintenance and service instructions ma y cause personal injury or death.

NOTICE

Ensure that all adjustments and repairs that are carried ou authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Haza Lines” for s afety information.

Refer to T liness of Fuel System Components” for detailed information on the standards of cleanliness that must be ob system.

t to the fuel system are performed by

rd Information and High Pressure Fuel

esting and Adjusting Manual, “Clean-

served during ALL work on the fuel

Page 15

SENR9983 15

Disassembly and Assembly Section

1. Ensure that all ports on the fuel manifold are capped. Ensure

that the fuel manifold is externally

clean and free from damage.

Illustration 21

The fuel m anifold is shown with fuel injection lines in position.

g01190733

1. If the fuel sensor (4) has not been removed from the fuel manifold (1), slide the locking tab (3) into the unlocked position. Disconnect the plug on the harness assembly (6) from the fuel pressure sensor (4).

2. Disconnect the tube assembly (5) from the fuel pressure relief valve on the fuel manifold (1). Immediately cap the open port in the fuel manifold (1) with a new cap. Immediately plug the open end of the tube assembly (5) with a new plug.

3. Remove the three setscrews (2) from the fuel manifold (1).

4. Remove the fuel manifold (1) from the mounting bracket (7).

Note: Do not in

stall a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines or the fuel pressure sensor are installed.

Illustration 22

The fuel manifold is shown with fuel injection lines in position.

g01190733

2. Position the fuel manifold (1) on the mounting

bracket (7).

3. Install the three setscrews (2) to the fuel manifold

(1)fingertight.

4. Install a new set of fuel injection lines and seals.

Refer to Disassembly and Assembly Manual, “Fuel Injection Lines - Install” for more information.

Installation Procedure

NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to Testing and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

5. Tighten the setscrews (2) to a torque of 22 N·m

(16 lb ft).

6. Removetheplugfromthetubeassembly(5).

Remove the cap from the appropriate port in the fuel manifold (1). Connect the tube assembly (5) to the fuel pressure relief valve on the fuel manifold (1).

7. If the fuel pressure sensor (4) was not removed

from the fuel manifold (1), connect the plug on the harness assembly (6) to the fuel pressure sensor (4). slide the locking tab (3) into the locked position.

Page 16

16 SENR9983 Disassembly and Assembly Section

If the fuel pressure sensor (4) was removed from the fuel manifo sensor (4) and a new sealing washer. Refer to Disassembly and Assembly Manual, “Fuel Pressure Sens information.

ld (1), install the fuel pressure

or - Revove and Install” for more

NOTICE

Ensure that all adjustments and repairs that are carried out to t

he fuel system are performed by authorised personnel that have the correct training.

8. Remove the ai

r from the fuel system. Refer to

Operation and Maintenance Manual, “Fuel System

-Prime”formoreinformation.

i02295929

Fuel Injection Pump - Remove

Removal Procedure

Table 3

Required Tools

Tool

Part

Number

21825576

27610289

27610290

27610212

27610286

Part Name Qty

Crankshaft Turning Tool 1

Gear 1

Camshaft Timing Pin 1

Crankshaft Timing Pin 1

Cap

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard In

formation and High Pressure Fuel

Lines” for s afety information.

Refer to Testi

ng and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be obser

ved during ALL work on the fuel

system.

1. Isolate the f

uel supply.

2. Isolate the electrical supply.

3. Use Tooling (A) in order to rotate the crankshaft

so that number one piston is at top dead center on the compr

ession stroke. Refer to Testing and Adjusting Manual, “Finding Top Centre Position for No.1 Piston”.

4. Use Tooling (B) in order to lock the camshaft in the correct position. Use Tooling (C) in order to lock the cra

nkshaft in the correct position. Refer to

Disassembly and Assembly, “Gear Group (Front)

- Remove” for the correct procedure.

Start By:

a. If necessary, remove the fuel filter base. Refer to

Disassembly and Assembly Manual, “Fuel Filter Base - Remove and Install”.

b. If necessary, remove the fuel priming pump. Refer

to Disassembly and Assembly Manual, “Fuel PrimingPump-Remove”.

c. Remove the front cover. Refer to Disassembly

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

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

5. Remove the backlash from the fuel pump gear.

Lock the fuel injection pump in the correct position a

nd remove the fuel pump gear. Refer to Disassembly and Assembly, “Fuel Pump Gear Remove and Install” for the correct procedure.

Page 17

SENR9983 17

Disassembly and Assembly Section

6. Place a suitable container below the fuel injection pump (1) in orde

r to catch any fuel that might be

spilled.

ion 2 3

Illustrat

Typical exam p le

g01173307

Note: Clean up

any spillage of fuel immediately.

7. Disconnect the plastic tube assembly (2) from the fuel injectio

n pump (1).

8. Disconnect the engine wiring harness (7) from the solenoid (3) o

f the fuel injection pump. Disconnect the engine wiring harness (7) from the position sensor (4) for the fuel injection pump.

Note: The engine wiring harness should be positioned in order to avoid an obstruction to the fuel injection pu

mp.

9. Remove the plastic tube assembly (11) from the fuel transfe

r pump (8).

10. Disconnect the plastic tube assembly (10) from the outlet o

f the fuel transfer pump (8).

11. Disconnect the plastic tube assembly (5) from the fuel inject

ion pump (1).

12. Remove the tube assembly (12) for the fuel return from the fue

l transfer pump and the cylinder head.

Note: Disconnect the tube assembly at the fuel transfer pu

mp first in order to drain the fuel from the

cylinder head.

Illustration 24

Typical exam p le

g01173310

13. Remove the t

ube assembly (9) for the engine oil

supply to the fuel injection pump (1).

14. Plug or cap

all open ports and tube assemblies

immediately with new plugs or caps.

15. Remove the

fuel injection line (6) that connects the fuel injection pump to the fuel manifold. Refer to Disassembly and Assembly Manual, “Fuel Injection

Lines - Remove”. Use Tooling (D) in order to plug the open ports in the fuel injection pump and in the fuel manifold. Discard the fuel injectio

nline.

Page 18

18 SENR9983 Disassembly and Assembly Section

19. Remove the O-ring seal (21) from the fuel injection pump

(1). Discard the O-ring seal.

20. If necessary, remove the position sensor (4) from the fuel injec

tion pump (1). Refer to Disassembly and Assembly Manual, “Position Sensor (Fuel Injection Pump) - Remove and Install”.

21. If necessary, remove the fuel transfer pump (8) from the fuel injection pump (1). Refer to Disassembly

and Assembly Manual, “Fuel

Transfer Pump - Remove”.

i02295933

Illustration 25

g01208416

16. Remove the two setscrews (15). Remove the two setscrews (14) and remove the support bracket (13) from the fuel injection pump (1).

Fuel Inject

ionPump-Install

Installation Procedure

Table 4

Required To

Too l

B 27610212

E 27610302

F 21820221

Part

Number

21825576

27610289

27610290

27610286

Crankshaft Turning Tool

Gear

Camshaft Timing Pin

Crankshaft Timing Pin

Fuel Injection Pump Timing Tool

POWERPART Rubber Grease

Note: EitherTooling(A)canbeused.UsetheTooling that is most suitable.

ols

Part Description Qty

Illustration 26

Typical exam p le

g01173314

17. Remove the three setscrews (17) and sealing washers (18). Discard the sealing washers.

Note: The fuel injection pump should be supported by hand as the setscrews are removed.

18. Carefully remove the fuel injection pump (1) from the front housing (19). Ensure that the bore (20) in the front housing is not damaged as the fuel injection pump is removed.

NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for s afety information.

Refer to Testing and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Page 19

SENR9983 19

Disassembly and Assembly Section

3. If the fuel injection pump timing has been lost follow Steps 3.

a through 3.e in order to reset the

fuel injection pump timing.

Illustration 27

1. If the fuel injection pump was previously disassembled, follow Steps 1.a and 1.b in order to assemble the fuel injection pump.

a. Install the fuel transfer pump (8) to the fuel

injection pump (1). Refer to Disassembly and Assembly Manual, “Fuel Transfer Pump Install”.

b. Install the position sensor (4) to the fuel

injection pump (1). Refer to Disassembly and Assembly Manual, “Position Sensor (Fuel Injection Pump) - Remove and Install”.

g01174932

a. If necessary,

loosen the locking screw (25) on the fuel injection pump. Slide the spacer (26) into position (X). Tighten the locking screw (25) toatorqueof

9N·m(80lbin).Thiswillprevent the locking screw from tightening against the shaft (22).

The fuel injection pump is now unlocked.

b. Position Too

ling (E) onto the shaft (22) of the fuel injection pump. Align the lever of Tooling (E) with the key slot (23) in the fuel injection pump. Engage

the lever into the key slot.

c. Use the lever of Tooling (E) to rotate the shaft

(22) until t

he pin of Tooling (E) can be engaged into the hole (24). Engage the pin of Tooling (E) into the hole.

d. Loosen the locking screw (25) in the fuel

injection pump. Slide the spacer (26) into position (

Y). Tighten the locking screw (25) against the shaft of the fuel injection pump to a torqueof9N·m(80lbin).

The fuel injection pump is now locked.

e. Remove too

ling (E).

Note: A new fuel injection pump assembly includes the fuel transfer pump and the position sensor.

2. To check the fuel injection pump timing, follow Steps 2.a and 2.b.

a. Position Tooling (E) onto the shaft (22) of the

fuel injection pump. Align the lever of Tooling (E) with the key slot (23). Engage the lever into the key slot.

b. Insert the locking pin of Tooling (E) into the

hole (24) in fuel injection pump.

If the locking pin can be inserted into the hole, the fuel injection pump timing is correct.

If the locking pin cannot be inserted into the hole, the fuel injection pump timing is not correct.

Note: There should be no resistance when the locking pin is inserted.

Illustration 28

Typical example

g01173314

4. Inspect the bore (20) in the front housing (19) for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly Manual, “Housing (Front) - Remove” and Disassembly and Assembly Manual, “Housing (Front) - Install”.

Page 20

20 SENR9983 Disassembly and Assembly Section

5. Use Tooling (F) to lubricate a new O-ring seal (21). Install t

he O-ring seal onto the fuel injection

pump (1).

6. Align the hole

s in the fuel injection pump (1) with the holes in the front housing (19). Carefully install the fuel injection pump to the front housing.

Note: The fuel injection pump should be supported by hand until the setscrews are installed.

7. Install the three setscrews (17) and three new sealing washers (18). Tighten the setscrews to a torque of 25 N

·m(18lbft).

8. If necessary, use Tooling (A) in order to rotate the crankshaft s

o that number one piston is at top dead center on the compression stroke. Refer to Testing and Adjusting Manual, “Finding Top Centre Posi

tion for No.1 Piston”.

9. Use Tooling (B) in order to lock the camshaft in the correct

position. Use Tooling (C) in order to lock the crankshaft in the correct position. Refer to Disassembly and Assembly, “Gear Group (Front)

- Remove” f

or the correct procedure.

10. Install the fuel injection pump gear to the fuel injection

pump. Refer to Disassembly and Assembly Manual, “Fuel Injection Pump Gear Install” and refer to Disassembly and Assembly Manual, “G

ear Group (Front) - Install”.

Note: Ensure that the spacer (26) on the fuel injection

pump is in the unlocked position (X) after the installation of fuel injection pump gear is completed. Refer to Illustration 27.

Illustration 29

Typical example

g01208416

12. Position the support bracket (13) onto the fuel injection pump (1). Install the two setscrews (14) finger tight.

13. Install the two setscrews (15) finger tight.

14. Tighten the setscrews (15) to a torque of 22 N·m

(16 lb ft). the setscrews (14) to a torque of 22 N·m (16 lb ft).

Some engines have a single M10 nut and a bolt in place of the two setscrews (15). Tighten the nut and bolt to a torque of 44 N·m (32.5 lb ft).

11. Install the front cover. Refer to Disassembly and Assembly Manual, “Front Cover - Remove and

Install”

Note: Ensure that the fuel injection pump is not stressed as the fasteners for the bracket are tightened.

Page 21

SENR9983 21

Disassembly and Assembly Section

15. Remove the appropriate plugs and caps in order to install tube

assembly (9) for the engine oil supply to the fuel injection pump. Install the tube assembly (9). Tighten the nuts at both ends of the tube assembly

16. Remove the appropriate caps in order to install the fuel inje

ction line (6). Install a new fuel injection line (6) to the fuel injection pump and to the fuel manifold. Refer to Disassembly and Assembly Manual, “Fue

l Injection Lines - Install”.

17. Remove the plugs and caps from the remaining ports and tub

eassemblies.

18. Install the tube assembly (12) for the fuel return to the fuel tr

ansfer pump and to the cylinder head. Tighten the nuts at both ends of the tube assembly.

19. Install the plastic tube assembly (5) to the fuel injection pump (1).

ion 3 0

Illustrat

Typical exam p le

g01173307

20. Install the plastic tube assembly (10) for the fuel outlet to the fuel transfer pump (8).

21. Install the plastic tube assembly (11) to the fuel transfer pump (8).

22. Connect the harness assembly (7) to the solenoid (3) on the fuel injection pump. Connect the harness as

sembly (7) to the position sensor (4) on the fuel injection pump. Slide the locking tab (not shown) into the locked position.

23. If necessary, install the fuel priming pump. Refer to Disassembly and Assembly Manual, “Fuel Priming P

ump - Remove and Install”.

24. If necessary, install the fuel filter base. Refer to Disassem

bly and Assembly Manual, “Fuel Filter

Base - Remove and Install”.

25. Restore t

he fuel supply.

26. Restore the electrical supply.

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

Operation and Maintenance Manual, “Fuel System

-Prime”f

or more information.

Illustration 31

Typical exam p le

g01173310

Page 22

22 SENR9983 Disassembly and Assembly Section

i02296762

Fuel Injection Pump Gear Remove

Removal Procedure

Table 5

Required Tools

Too l

Start By:

a. Remove the front cover. Refer to Disassembly

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

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

Part

Number

21825576

27610289

27610290

27610212

27610286

Part Name Qty

Crankshaft Turning Tool 1

Gear 1

Camshaft Timing Pin 1

Crankshaft Timing Pin 1

Puller (Two Leg)

1. Use Tooling (A) in order to rotate the crankshaft so that number o

ne piston is at top dead center on the compression stroke. Refer to Testing and Adjusting Manual, “Finding Top Centre Position for No.1 Piston”.

Illustration 32

g01194629

2. Install Tooling (B) through the hole (X) in the camshaft gear (1) into the front housing. Use Tooling (B) in order to lock the camshaft in the correct position.

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.

Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the fuel pump gear. Carefully follow the procedure in order to remove the fuel pump gear.

Illustration 33

g01195325

3. Remove the plug (4) from the cylinder block. Install Tooling (C) into the hole (Y) in the cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position.

Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.

Page 23

SENR9983 23

Disassembly and Assembly Section

Illustration 34

g01196435

4. Apply sufficient pressure to the fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash. Lock the fuel injection pump (5) in this position.

In order to lock the fuel injection pump (5), loosen the locking screw (6) in the fuel injection pump. Slide the spacer (7) into position (Z). Tighten the locking screw (6) against the shaft of the fuel injection pump to a torque of 9 N·m (80 lb in).

Illustration 36

g01196132

6. Loosen the nut (8) for the fuel pump gear (3).

7. Install Tooling (D) through two opposite holes in

the fuel pump gear (3). Tighten Tooling (D) until the fuel pump gear (3) is released.

8. Remove Tooling (D) from the fuel pump gear (3).

9. Remove the nut (8) and washer (not shown) from

the fuel pump gear (3). Remove the fuel pump gear.

i02296767

Fuel Inje ctio n Pump Gear Install

Installation Procedure

Table 6

Required Tools

Too l

Part

Number

27610212

27610286

Part Name Qty

Camshaft Timing Pin 1

Crankshaft Timing Pin 1

Illustration 35

Alignment of timing marks

g01196142

5. Mark the gears (1), (2) and (3) in order to show alignment. Refer to Illustration 35.

Note: Identification will ensure that the gears can be installed in the original alignment.

NOTICE

Keep all p

arts clean from contaminants.

Contaminants may cause rapid wear and shortened componen

tlife.

Note: The fuel injection pump must remain locked until the procedure instructs you to unlock the fuel injection pump.

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

Page 24

24 SENR9983 Disassembly and Assembly Section

7. Install the fuel pump gear (3) to the shaft (9) of the fuel injection

pump. Ensure that the timing marks on the gears (2) and (3) are in alignment and that the mesh of the gears is correct.

Illustration 37

g01195325

2. Ensure that Tooling (C) is installed in hole (Y) in the cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position.

Illustration 38

g01196475

3. Ensure that Tooling (B) is installed into the hole (X) in the camshaft gear (1).

4. Ensure that the shaft (9) of the fuel injection pump is clean and free from damage.

Illustration 40

Typical example

g01196488

5. Ensure that the fuel injection pump is locked in the correct position. Refer to Disassembly and Assembly Manual, “Fuel Injection Pump - Install”.

6. Ensure that the fuel pump gear is clean and free from wear of damage. If necessary, replace the fuel pump gear.

Illustration 39

Alignment of timing marks

g01194949

Illustration 41

g01196435

8. Install a new spring washer (10) and install the nut (8) to the shaft (9) of the fuel injection pump. Apply sufficient pressure to the fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash. Tighten the nut (8) toatorqueof25N·m(18lbft).Unlockthefuel injection pump (5).

In order to unlock the fuel injection pump (5), loosen the locking screw (5) in the fuel injection pump. Slide the spacer (7) into position (Z1). Tighten the locking screw (6) against the spacer to a torque of 9 N·m (80 lb in). This will prevent the locking screw from tightening against the shaft of the fuel injection pump.

Page 25

SENR9983 25

Disassembly and Assembly Section

9. RemoveTooling(B)and(C).Installtheplug (4) into hole (Y Illustration 37.

10. Tighten the nu (66.4lbft).

) in the cylinder block. Refer to

t(8)toatorqueof90N·m

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuelspraymaycauseafirehazard.Failuretofollow these inspection, maintenance and service instructions ma y cause personal injury or death.

NOTICE

Ensure that al

l adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operati

on and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for s afety information.

Illustration 42

Checking backlash

g00944084

11. Ensure that the backlash for the gears (2) and (3) is within specified values. Refer to the Specifications Manual, “Gear Group (Front)” for further information.

12. Lubricate the teeth of the gears with clean engine oil.

End By:

a. Install the front cover. Refer to Disassembly and

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

i02295935

Electronic Unit Injec tor Remove

Removal Procedure (One Injector)

Table 7

Required Tools

Tool Part Number Part Description Qty

21825576

27610288

Start By:

a. Remove the valve mechanism cover. Refer

to Disassembly and Assembly Manual, “Valve Mechanism Cover - Remove and Install”.

Engine Turning Tool 1

T40 T orx Socket

Pry Bar 1

Refer to Testing and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed informatio

n on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Isolate the fuel supply to the engine.

Illustration 43

Typical example

g01193285

2. Use Tooling (A) in order to rotate the crankshaft

until the rocker arms (1) for the appropriate cylinder are in the correct position in order to adjust the valve lash. Refer to Testing and Adjusting Manual, “Engine Valve Lash - Inspect/Adjust”.

3. Follow Steps 3.a through 3.c in order to gain

access to the assembly of the electronic unit injector.

a. Loosen the nuts (3) on the appropriate cylinder.

Unscrew the adjusters (2) on the appropriate cylinder until the pushrods (4) can be withdrawn from the balls of the adjusters.

b. Withdraw the cups of the pushrods (4) from the

balls of the adjusters (2).

Page 26

26 SENR9983 Disassembly and Assembly Section

c. Make a temporary mark on the valve bridges

(5) in order to s

how the location and orientation.

Remove valve bridges from the cylinder head.

Note: Identif

ication will ensure that the valve bridges can be reinstalled in the original location and the original orientation. Do not interchange the location or the orient

ation of used valve bridges.

4. Place a suitable container below the fuel transfer

pump in order

to catch any fuel that might be

spilled.

Note: Clean u

p any spillage of fuel immediately.

6. Remove the fuel injection line (not shown) and the seal (7) fro

m the appropriate electronic unit injector (10). Refer to Disassembly and Assembly Manual, “Fuel Injecton Lines - Remove”.

Note: Cap all open ports immediately with new caps.

7. Place a tempor

ary identification mark on the

connections (9) for the harness assembly (8).

8. Use a deep sock

et to remove the connections (9)

from the electronic unit injectors (10).

9. Slide the roc

ker arms (1) to one side in order to gain access to the torx screw (11). Use Tooling (B) in order to remove the torx screw from the clamp (12). Discar

d the t orx screw.

10. Place a temporary identification mark on the electronic u

nit injector (10). The electronic unit injector must be reinstalled in the original location in the cylinder head.

Illustration 44

Typical exam p le

g01193839

5. Disconnect the tube assembly (6) for the injector leak-off from the fuel transfer pump. Allow the fuel to drain from the tube assembly.

Illustration 46

The rocker shaft is not shown for clarity.

g01193295

11. Use Tooling (C) to pry beneath the clamp (12) and free the electronic unit injector (10) from the cylinder head.

12. Remove the electronic unit injector (10) and the clamp (12) from the cylinder head.

Illustration 45

The rocker shaft is not shown for clarity.

g01193293

Page 27

SENR9983 27

Disassembly and Assembly Section

NOTICE

Ensure that all adjustments and repairs that are carried out to t

he fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard In

formation and High Pressure Fuel

Lines” for s afety information.

Illustration 47

g01193297

13. Remove the sealing washer (13) from the base of the electronic unit injector (10) or from the bore in the cylinder head. Discard the sealing washer.

14. Remove the O-ring seal (14) from the electronic unit injector (10). Discard the O-ring seal.

Removal Procedure (All Injectors)

Table 8

Required Tools

Tool Part Number Part Description Qty

27610288

T40 T orx Socket

Pry Bar 1

Start By:

a. Remove the rocker shaft assembly. Refer to

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

Refer to Testi

ng and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanline ss that must be obser

ved during ALL work on the fuel

system.

1. Isolate the f

uel supply to the engine.

2. Place a suitable container below the fuel transfer

pumpinorde

r to catch any fuel that might be

spilled.

Note: Clean

up any spillage of fuel immediately.

b. Remove the fuel injection lines. Refer to

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

Illustration 48

Typical example

g01193839

3. Disconnect the tube assembly (6) for the injector

leak-off from the fuel transfer pump. Allow the fuel to drain from the tube assembly.

Page 28

28 SENR9983 Disassembly and Assembly Section

8. Use Tooling (C) to pry beneath the clamp (12)

and free the ele

ctronic unit injector (8) from the

cylinder head.

Illustration 49

g01193293

4. Place a temporary identification mark on the connections (9) for the harness assembly (8).

5. Use a deep socket to remove the connections (9) from the electronic unit injectors (10).

6. Use Tooling (B) in order to remove the torx screw (11) from the clamp (12). Discard the torx screw.

7. Place a temporary identification mark on the electronic unit injector (10). The electronic unit injector must be reinstalled in the original location in the cylinder head.

9. Remove the ele

ctronic unit injector (10) and the

clamp (12) from the cylinder head.

Illustration 51

g01193297

10. Remove the sealing washer (13) from the base of the electronic unit injector (10) or from the bore in the cylinder head. Discard the sealing washer.

11. Remove the O-ring seal (14) from the electronic unit injector (8). Discard the O-ring seal.

12. Repeat Steps 4 through 11 in order to remove the remaining electronic unit injectors.

i02295941

Electroni

c Unit Injector - Install

Illustration 50

g01193295

Installation Procedure (One Injector)

Table 9

Required Tools

Too l Part

F 2761029

Number

27610294

Part Description

T40 Torx Socket 1

Vac u um Pum p 1

Tube

7.9 mm (0.31 inch) OD

Injector Pipe Nut Tool 1

Tor q u e W re n ch 1

Qty

Page 29

SENR9983 29

Disassembly and Assembly Section

NOTICE

Ensure that all adjustments and repairs that are carried out to t

he fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard In

formation and High Pressure Fuel

Lines” for safety information.

Refer to Testi

ng and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be obser

ved during ALL work on the fuel

system.

Illustration 53

g01193297

4. Install a new O-ring seal (14) to the electronic unit injector (10).

Note: Do not lubricate the O-ring seal.

5. Ensure that the seat for the electronic unit injector

in the cylinder head is clean and free from damage. Position a new sealing washer (13) onto the seat for the electronic unit injector in the cylinder head.

Illustration 52

The location of the calibration code

g01194240

1. If a replacement electronic unit injector is installed, the calibration code that is located at position (X) must be programmed into the electronic control module. Refer to Troubleshooting Guide, “Injector Trim File” for more information.

2. Use Tooling (D) in order to remove any fuel from the cylinder.

Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.

3. Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.

Illustration 54

The rocker shaft is not shown for clarity.

g01193293

6. Install the clamp (12) to the electronic unit injector (10). Install the electronic unit injector assembly into the cylinder head.

Note: Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.

7. Install a new torx screw (11) to the clamp (12). Tighten the torx screw finger tight.

8. Thoroughly clean the seal (7). Inspect the seal for damage. If necessary, replace the seal.

Page 30

30 SENR9983 Disassembly and Assembly Section

Note: The seal can be damaged by contact with fuel.

9. Remove the cap from the electronic unit injector

(10). Install the seal (7) to the electronic unit injector (10)

. Ensure that the flange on the seal is

flush with the valve mechanism cover base.

10. Remove the plu

gs from the new fuel injection line. Loosely install the fuel injection line (not shown). Refer to Disassembly and Assembly Manual, “Fuel Inject

on Lines - Install”.

Note: Ensure that the ends of the fuel injection line are seated in

the electronic unit injector and the fuel

manifold. Tighten the nuts finger tight.

11. UseTooling(

B) to tighten the torx screw (11) to a

torque of 27 N·m (20 lb ft).

12. Use Tooling (

E) to tighten the fuel injection line (notshown)toatorqueof30N·m(22lbft).Refer to Disassembly and Assembly Manual, “Fuel Injecton Li

nes - Install”.

13. Use a deep socket to install the harness assembly (8) to the el

ectronic unit injector (10). Use Tooling

(F) to tighten the connections to a torque of

2.4N·m(21lbin).

Illustration 56

Typical example

g01193839

16. Connect the tube assembly (6) for the injector leak-off to the fuel transfer pump.

17. Restore the fuel supply to the engine.

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

Operation and Maintenance Manual, “Fuel System

- Prime” for more information.

End By:

a. Install the valve mechanism cover. Refer to

Disassembly and Assembly Manual, “Valve Mechanism Cover - Remove and Install”.

Installation Procedure (All Injectors)

Illustration 55

Typical exam p le

g01193285

14. Install bridges (5) to the cylinder head.

Note: Ensure that used valve bridges are reinstalled

in the original location and the original orientation. Do not interchange the location or the orientation of used valve bridges.

15. Ensure that the bottoms of the pushrod are seated in the cups of the valve lifters. Locate the balls of the adjusters (2) into the cups of the pushrods (4). Adjust the valve lash. Refer to Testing and Adjusting Manual, “Engine Valve Lash

- Inspect/Adjust”.

Table 10

Too l Part

Number

27610294

27610296

Required Tools

Part Descr

T40 Torx Socket

Vac u um Pum p 1

Tube

7.9 mm (0.31 inch) OD

Injector Pipe Nut Tool 1

Tor q ue W r en ch 1

iption

Qty

Page 31

SENR9983 31

Disassembly and Assembly Section

NOTICE

Ensure that all adjustments and repairs that are carried out to t

he fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard In

formation and High Pressure Fuel

Lines” for safety information.

Refer to Testi

ng and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be obser

ved during ALL work on the fuel

system.

Illustration 58

g01193297

4. Install a new O-ring seal (14) to the electronic unit injector (10).

Note: Do not lubricate the O-ring seal.

5. Ensure that the seat for the electronic unit injector

in the cylinder head is clean and free from damage. Position a new sealing washer (13) on the seat for the electronic unit injector in the cylinder head.

Illustration 57

The location of the calibration code

g01194240

2. Use Tooling (D) to remove any fuel from the cylinder.

Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.

3. Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.

Illustration 59

g01193293

6. Install the clamp (12) to the electronic unit injector (10). Install the electronic unit injector assembly into the original location in the cylinder head.

Note: Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.

7. Install a new torx screw (11) to the clamp (12). Tighten the torx screw finger tight.

8. Thoroughly clean the seal (7). Inspect the seal for damage. If necessary, replace the seal.

Page 32

32 SENR9983 Disassembly and Assembly Section

Note: The seal can be damaged by contact with fuel.

9. Remove the cap from the electronic unit injector

(10). Install the seal (7) to the electronic unit injector (10) flush with the valve mechanism cover base.

10. Remove the plu Loosely install the fuel injection line (not shown). Refer to Disassembly and Assembly Manual, “Fuel Inject

Note: Ensure that the ends of the fuel injection line are seated in manifold. Tighten the nuts finger tight.

11. UseTooling( torque of 27 N·m (20 lb ft).

12. Use Tooling ( (notshown)toatorqueof30N·m(22lbft).Refer to Disassembly and Assembly Manual, “Fuel Injecton Li

13. Use a deep socket to install the harness assembly (8) to the el (F) to tighten the connections to a torque of

2.4N·m(21lbin).

14. Repeat Steps 2 through 13 in order to install the remaining electronic unit injectors.

. Ensure that the flange on the seal is

gs from the new fuel injection line.

on Lines - Install”.

the electronic unit injector and the fuel

B) to tighten the torx screw (11) to a

E) to tighten the fuel injection line

nes - Install”.

ectronic unit injector (10). Use Tooling

i02295944

Turbocharger - R emo v e

Removal Proced Turbochargers)

Keep all parts clean from contaminants.

Contaminants component life.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjustin collect the fluid with suitable containers before opening any compartment or disassembling any component contain

Dispose of all fluids according to local regulations and mandates.

1. Disconnect the air hose for the turbocharger inlet and for the turbocharger outlet (not shown). Refer to OEM inform

may cause rapid wear and shortened

g and repair of t he product. Be prepared to

ing fluids.

ation for the correct procedure.

ure (Side Mounted

NOTICE

15. Install the rocker shaft assembly. Refer to Disassembly and Assembly, “Rocker Shaft Install”.

Illustration 60

Typical exam p le

16. Connect the tube assembly (6) for the injector leak-off to the fuel transfer pump.

17. Restore the fuel supply to the engine.

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

Operation and Maintenance Manual, “Fuel System

-Prime”formoreinformation.

g01193839

2. If the turbocharger has a remote wastegate solenoid, di shown) from the turbocharger.

3. Disconnect OEM information for the correct procedure.

4. If the turbo remove the exhaust elbow (not shown). Refer to Disassembly and Assembly Manual, “Exhaust Elbow - Rem

sconnect the hose to the solenoid (not

the exhaust pipe (not shown). Refer to

charger has an exhaust elbow,

ove and Install”.

Page 33

SENR9983 33

Disassembly and Assembly Section

Illustration 61

g01165546

5. Follow Steps 5.a through 5.c in order to remove the tube assembly (4) for the oil feed.

a. Remove the setscrew (5).

b. Remove the banjo bolt (1) and remove the

two sealing washers (2). Discard the sealing washers.

c. Remove the tube assembly (3) from the

cylinder block. Remove the O-ring seal (4) from the t ube assembly. Discard the O-ring seal.

Note: Plug the port for the oil feed to the turbocharger withasuitableplug.

6. Follow Steps 6 through 6.c in order to remove the tube assembly (10) for the oil drain.

Illustrat

ion 62

g01171991

7. Remove the four nuts (15) from the turbocharger (6) and re

move the turbocharger (6) from the

exhaust manifold (12).

Note: Ens

ure that the weight of the turbocharger is

supported as the nuts are loosened.

8. Remove th

e joint (14). Discard the joint.

9. If necessary, rem ove the four studs (13) from the exhaust m

Removal P

anifold (12).

rocedure (Top Mounted

Turbochargers)

NOTICE

Keep all parts clean from contaminants.

Contami component life.

nants may cause rapid wear and shortened

a. Remove the two setscrews (11).

b. Remove the two setscrews (8) and remove the

tube assembly (10) from the turbocharger (6).

c. Remove the joint (7) and remove the joint (9).

Discard the joints.

Page 34

34 SENR9983 Disassembly and Assembly Section

6. Remove the setscrew (8) in order to disconnect

NOTICE

thetubeassemb

ly (7) from the cylinder block.

Care must be taken to ensure that fluids are contained during perform

ance of inspection, maintenance, test-

7. Remove the fasteners for the tube clips (2).

ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar

tment or disassembling any compo-

nent containing fluids.

8. Loosen the four nuts (11). Refer to Illustration 64.

9. Remove the exh

aust manifold (1) and the

assembly of the turbocharger from the cylinder

Dispose of all mandates.

fluids according to local regulations and

head. Refer to Disassembly and Assembly Manual, “Exha

ust Manifold - Remove and Install”

for the correct procedure.

1. Disconnect the air hose for the turbocharger inlet andforthetur

bocharger outlet (not shown). Refer

to OEM information for the correct procedure.

2. If the turboc

harger has a remote wastegate solenoid, disconnect the hose to the solenoid (not shown) from the turbocharger.

3. Disconnect the exhaust pipe (not shown). Refer to OEM information for the correct procedure.

4. If the turbocharger has an exhaust elbow, remove the exhaust elbow (not shown). Refer to Disassembl

y and Assembly Manual, “Exhaust

Elbow - Remove and Install”.

ration 63

Illust

5. Remove the two setscrews (5) in order to

nect the tube assembly (4) from the cylinder

discon block. Remove the joint (3). Discard the joint.

g01183875

Illustration 64

g01185011

10. Remove the banjo bolt (9) and remove the tube assembly (7) for the oil feed from the turbocharger (12). Remove the two sealing washers (10). Discard t he sealing washers.

Note: Plug the port for the oil feed to the turbocharger with a suitable plug.

11. RemovetheO-ringseal(6)fromthetube assembly (7). Refer to Illustration 63. Discard the O-ring seal.

Page 35

SENR9983 35

Disassembly and Assembly Section

12. Remove the two setscrews (14) and remove thetubeassemb turbocharger (12).

13. Remove the joi

14. Remove the four nuts (11) and remove the

turbocharger

ly (4) for the oil drain from the

nt (13). Discard the joint.

(12) from the exhaust manifold (1).

NOTICE Do not attempt to disassemble the turbocharger cartridge asse the compressor wheel. The turbocharger cartridge assembly and the wastegate are not field serviced, and should be r

mbly or wastegate. Do not remove

eplaced only as a unit.

Note: Ensure that the exhaust manifold and the turbocharger removal of the turbocharger.

15. Remove the jo (1). Discard the joint.

16. If necessary exhaust manifold (1).

are adequately supported during the

int (15) from the exhaust manifold

, remove the four studs (16) from the

i02347778

Turbocharger - Disassemble

Disassembly Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Turbocharger

- Assemble

Assembly Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants component life.

may cause rapid wear and shortened

i02347770

Illustration 65

1. Disconne the actuator (6).

2. Remove th rod (4).

3. Remove th

4. Remove the nuts (5) from the bracket (3).

5. Remove the actuator (6) from the bracket (3).

ct the pipe for the boost sensor (7) at

e circlip (1) that retains the actuator

e actuator rod (4) from the pin (2).

g01176032

Illustration 66

1. Install the actuator (6) to the bracket (3). Install the nuts (5) to the bracket (3).

2. Tighten the nuts to a torque of 5 N·m (44 lb in).

3. Connect the bottom of the actuator (6) to a

suitable air supply with an accurate gauge.

4. Operate the arm of the actuator by hand in order to check that the valve is free to move.

5. Push the arm of the wastegate valve toward the actuator (6) and hold the arm in position. Slowly apply air pressure to the actuator (6) until the pin (2) will fit into the actuator rod (4). Install the circlip (1) into the groove in the pin (2).

Note: Do not apply an air pressure of more than 205 kPa (29 psi) to the actuator. High pressures may damage the actuator.

6. Install the pipe for the boost pressure (7) to the actuator (6).

g01176032

Page 36

36 SENR9983 Disassembly and Assembly Section

End By:

a. To check the wastegate actuator for correct

operation, refer to Testing and Adjusting, “Wastegate - I

nspect”.

Turbocharger - Install

Installation Procedure (Side Mounted Turbochargers)

Table 11

Required Tools

Tool

Keep all parts clean from contaminants.

Part

Number

21820221

Part Description Qty

POWERPART Rubber Grease

NOTICE

i02295957

2. Test the wastegate actuator (19) for correct operation. Ref

er to T esting and Adjusting Manual, “Turbocharger Inspect”. If the wastegate actuator is damaged or the wastegate actuator does not operate withi

n the specified limits, the wastegate actuator must be replaced. Refer to Disassembly and Assembly Manual, “Turbocharger Dissassembl

e” and refer to Disassembly and Assembly Manual, “Turbocharger - Assemble” for more information.

Contaminants may cause rapid wear and shortened component life.

ation 67

Illustr

Typical exam p le

g01187836

Illustration 68

example

Typical

g01171991

3. Clean the mating surfaces of the exhaust manifold (12). If

necessary, install the four studs (13) to the exhaust manifold. Tighten the studs to a torque of 18 N·m (13 lb ft).

4. Install a new joint (14) to the exhaust manifold (12).

5. Position the turbocharger (6) on the exhaust manifold.

Note: Ensure that the turbocharger is correctly oriented.

1. Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Re

fer to Testing and Adjusting Manual, “Turbocharger Inspect” for more information. If any part of the turbocharger is worn or damaged, the comp

lete turbocharger must be replaced.

6. Install the four nuts (15). Tighten the nuts to a torque of 44 N·m (32 lb ft).

Page 37

SENR9983 37

Disassembly and Assembly Section

7. If a new turbocharger is installed, the bearing housing (18) an

d the compressor housing (20) must be oriented to the correct positions. Follow Steps 7.a through 7.d in order to orient the bearing housing and th

e compressor housing.

a. Loosen the two band clamps (21) sufficiently in

order to allo

w the housings to rotate.

Note: If the band clamps are damaged, replace the band clamps.

b. Carefully turn the bearing housing (18) until the

port for the o

il feed (17) is upward.

c. Rotate the compressor housing (20) until the

compressor o

utlet is in the correct position. Refer to the turbocharger that was originally installed for the correct orientation.

d. Ensure that the band clamps (21) are correctly

oriented. Refer to the turbocharger that was originally

installed for the correct orientation.

Tighten the band clamps finger tight.

8. Ensure that the tube assemblies (3) and (10) are clean and fr

ee from damage. Replace any

damaged components.

9. Positionanew

joint (7) and the two setscrews (8)

onto the tube assembly (10).

10. Install the tu

be assembly (10) to the turbocharger

(6). Tighten the setscrews (8) finger tight.

11. Position a new

joint (9) between the flange of the tube assembly (10) and the cylinder block. Install the two setscrews (1 1) finger tight.

12. If a new turbocharger has been installed, check that the orientation of the bearing housing (18) is correct. If t

he orientation of the bearing housing is not correct, rotate the bearing housing until the tube assembly (10) fits correctly. Tighten the two band clamps

(21) to a torque of 13 N·m (9.6 lb ft).

13. Tighten the setscrews (8) and (1 1) to a torque of 22 N·m (16 lb

ft).

14. Remove the plug from the oil inlet port (17). Lubricate t

he turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate

the bearings.

Illustration 69

g01165546

15. Use Tooling (A) in order to lubricate a new O-ring seal (4). I

nstall the O-ring seal (4) to the tube

assembly (3).

16. Install th

e banjo bolt (1) and two new sealing

washers (2) to the tube assembly (3).

17. Install t

he tube assembly (3) to the cylinder block and to the turbocharger (6). Tighten the banjo bolt (1)fingertight.

18. Install the setscrew (5) finger tight. Ensure that the tube assembly (3) fits correctly.

19. Tighten the banjo bolt (1) to a torque of 20 N·m (14 lb ft). Tighten the setscrew (5) and (11) to a torque of

22 N·m (16 lb ft).

20. If the turbocharger has an exhaust elbow, install the exhau

st elbow. Refer to Disassembly and Assembly Manual, “Exhaust Elbow - Remove and Install”.

21. Connect the exhaust pipe (not shown). Refer to OEM information for the correct procedure.

22. If the turbocharger has a remote wastegate solenoid, connect the hose for the solenoid (not shown) t

o the turbocharger.

23. Connect the air inlet hose and connect the air

hose (not shown) to the turbocharger. Refer

outlet to OEM information for the correct procedure.

Page 38

38 SENR9983 Disassembly and Assembly Section

Installation Procedure (Top Mounted Turbochargers)

Table 12

Required Tools

Tool

A 218200221

Part

Number

Part Descript

POWERPART Rubber Grease

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

ion

Qty

Illustration 70

Typical e

xample

g01187836

1. Ensure that the turbocharger is clean and free from dama

ge. Inspect the turbocharger for wear. Refer to Testing and Adjusting Manual, “Turbocharger Inspect” for more information. If the turbocha

rger is worn, the complete turbocharger

must be replaced.

2. Te st th e

wastegate actuator (19) for correct operation. Refer to T esting and Adjusting Manual, “Turbocharger Inspect”. If the wastegate actuator is damag

ed or the wastegate actuator does not operate within the specified limits, the wastegate actuator must be replaced. Refer to Disassembly and Ass

embly Manual, “Turbocharger Dissassemble” and refer to Disassembly and Assembly Manual, “Turbocharger - Assemble” for more in

formation.

Illustration 71

g01185011

3. Clean the mating surfaces of the exhaust manifold (1). If necessary, install the four studs (16) to the exhaust manifold. Tighten the studs to a torque of 18 N·m (13 lb ft).

Note: Support the exhaust manifold during installation of the turbocharger.

4. Install a new joint (15) to the exhaust manifold (1).

5. Position the turbocharger (12) on the exhaust

manifold (1).

Note: Ensure that the turbocharger is correctly oriented.

6. Install the four nuts (11). Tighten the nuts to a torque of 44 N·m (32 lb ft).

Page 39

SENR9983 39

Disassembly and Assembly Section

7. If a new turbocharger is installed, the bearing housing (18) an

d the compressor housing (20) must be oriented to the correct positions. Refer to Illustration 70. Follow Steps 7.a through 7.d in order to ori

ent the bearing housing and the

compressor housing.

a. Loosen the tw

o band clamps (21) sufficiently in

order to allow the housings to rotate.

Note: If the b

and clamps are damaged, replace the

band clamps.

b. Carefully tu

rn the bearing housing (18) until the

port for the oil feed (17) is upward.

c. Rotate the co

mpressor housing (20) until the compressor outlet is in the correct position. Refer to the turbocharger that was originally installed f

or the correct orientation.

d. Ensure that the band clamps (21) are correctly

oriented. R

efer to the turbocharger that was originally installed for the correct orientation. Tighten the band clamps finger tight.

8. Ensure that the tube assemblies (4) and (7) are clean and free from damage. Replace any damaged co

mponents.

9. Position a new joint (13) and the two setscrews (14) onto t

he tube assembly (4).

10. Install the tube assembly (4) to the turbocharger (12). Tigh

ten the setscrews (14) finger tight.

Illustrat

ion 72

g01183875

15. Install the exhaust manifold (1) and the assembly of the tur

bocharger to the cylinder head. Refer to Disassembly and Assembly Manual, “Exhaust Manifold - Remove and Install” for the correct procedur

11. Remove the plug from the oil inlet port (17). Refer to I

llustration 70. Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in o

rder to lubricate the bearings.

12. Install the banjo bolt (9) and two new sealing washers (

10) to the tube assembly (7).

13. Use Tooling (A) in order to lubricate a new O-ring seal (6).

Install the O-ring seal (6) to the tube

assembly (7). Refer to Illustration 72.

14. Install t

he tube assembly (7) to the turbocharger

(12). Tighten the banjo bolt (9) finger tight.

16. Install the setscrew (8) finger tight. Ensure that the tube

assembly (7) fits correctly.

17. Position a new joint (3) between the flange of the tube ass

embly (4) and the cylinder block. Install

the two setscrews (5) finger tight.

18. If a new t

urbocharger has been installed, check that the orientation of the bearing housing (18) is correct. If the orientation of the bearing housing is not corr

ect, rotate the bearing housing until the tube assemblies (4) and (7) fit correctly. Tighten the two band clamps (21) to a torque of 13 N·m (9.6 lb

ft).

19. Tighten the banjo bolt (9) to a torque of 20 N·m (14lbf

t). Tighten the setscrew (5) and (8) to a

torque of 22 N·m (16 lb ft).

20. Instal

l the fasteners for the tube clips (2) to the

cylinder block.

21. If the t

urbocharger has an exhaust elbow, install the exhaust elbow. Refer to Disassembly and Assembly Manual, “Exhaust Elbow - Remove and

ll”.

Insta

Page 40

40 SENR9983 Disassembly and Assembly Section

22. Connect the exhaust pipe (not shown). Refer to OEM informatio

23. If the turbocharger has a remote wastegate solenoid, con shown) to the turbocharger.

24. Connect the ai outlet hose (not shown) to the turbocharger. Refer to OEM information for the correct procedure.

n for the correct procedure.

nect the hose for the solenoid (not

r inlet hose and connect the air

i02347765

Wastegate Solenoid - Remove and Install

Removal Procedure

Note: Thetubeclipsmustbelooseinordertorelease

thetubeassemb

4. Remove the two setscrews (5) and remove the wastegate sol

5. Plug or cap all open ports and tube assemblies with new plugs

Installation

1. Remove the plugs or caps from all ports and tube

assemblies.

ly from the wastegate solenoid.

enoid (3) from the cylinder block.

or caps.

Procedure

Illustration 73

Typical exam p le

1. Follow Steps 1.a through 1.c in order to disconnect thewirelead(1).

a. Disconnect the wire lead (1) from the harness

assembly (not shown).

b. If the harness assembly (1) is secured with a

cable tie, remove the cable tie.

c. Remove the wire lead (1) from the tube

assembly (2).

Note: The wire lead is secured to the tube assembly with clips.

2. Disconnect the tube assembly (2) from the wastegate solenoid (3).

3. Disconnect the tube assembly (4) from the wastegate solenoid (3). If the tube assembly (4) is secured with tube clips, loosen the fasteners for the tube clips.

g01165640

Illustration 74

Typical example

2. Loosely install the wastegate solenoid (3) to the tube assembly (2).

3. Loosely install the tube assembly (4) to the wastegate solenoid (3).

4. Install the two setscrews (5) to the wastegate solenoid (3). Tighten the setscrews (5) to a torque of 44 N·m (32.5 lb ft).

5. Tighten tube assemblies (2) and (4) to a torque of 22 N·m (16 lb ft).

6. If the tube assembly (4) is secured with tube clips, tighten the fasteners for the tube clips.

Tighten M8 fasteners to a torque of 22 N·m (16 lb ft). Tighten M10 fasteners to a torque of 44 N·m (32.5 lb ft).

7. Follow Steps 7 through 7.c in order to connect the wire lead (1).

a. Install the wire lead (1) to the tube assembly

(2).

b. Connect the wire lead (1) to the harness

assembly for the engine (not shown).

g01165640

Page 41

SENR9983 41

Disassembly and Assembly Section

c. Ifthewirelead(1)issecuredwithacabletie,

install a new ca

ble tie.

i02295960

Exhaust Manifo

ld - Rem ove

and Install

Removal Proce Exhaust Manifold)

Start By:

a. Remove the tur

and Assembly Manual, “Turbocharger - Remove”.

dure (Side Mounted

bocharger. Refer to Disassembly

Illustration 75

Illustration 7 6

1. Loosen the setscrews (2) and (5) in reverse numerical order. Refer to Illustration 76.

Note: This will help prevent distortion of the exhaust manifold.

g01174489

g01176473

2. Remove the center four setscrews (2) from the exhaust manifold (3). Remove the outer eight setscrews (5) and the spacers (4) from the exhaust manifold (3).

Page 42

42 SENR9983 Disassembly and Assembly Section

Note: Support the manifold as the setscrews are removed.

3. Remove the exhaust manifold (3).

4. Remove the two exhaust manifold gaskets (1).

Discard the gaskets.

5. If necessary, remove the four studs (6) from the exhaust manifold (3).

Removal Procedure (Top Mounted Exhaust Manifold)

1. Disconnect al

l hoses, tube assemblies and wire leads from the turbocharger. Refer to Disassembly and Assembly Manual, “Turbocharger - Remove” Steps 1 throu

Illustration 77

gh 7.

g01176186

Illustration 78

2. Loosen the setscrews (2) and (5) in reverse numerical order. Refer to Illustration 78.

g01176487

Note: This will help prevent distortion of the exhaust manifold.

Page 43

SENR9983 43

Disassembly and Assembly Section

3. Remove the center four setscrews (2) from the exhaust manifo

ld (3). Remove the outer eight setscrews (5) and the spacers (4) from the exhaust manifold (3).

Note: Support the manifold as the setscrews are removed.

4. Remove the assembly of the exhaust manifold (3) and the turbocharger.

5. Remove the two exhaust manifold gaskets (1). Discard the gaskets.

6. Remove the turbocharger from the exhaust manifold (3). Refer to Disassembly and Assembly Manual, “Tur

bocharger - Remove” Steps 8 through

15.

7. If necessary

, remove the four studs (6) from the

exhaust manifold (3).

Installation Procedure (Side Mounted Exh

Table 13

Too l

Part

Number

aust Man ifold)

Required Tools

Part Description Qty

Guide Stud (M10 by 100 mm)

Loctite 575

Illustration 79

g01176473

Page 44

44 SENR9983 Disassembly and Assembly Section

End By:

a. Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Install”.

Installation Procedure (Top Mounted Exhaust Manifold)

Table 14

Required Tools

Tool

Part

Number

Part Description Qty

Guide Stud (M10 by 100 mm)

Loctite 575

Illustration 80

g01174489

1. Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the joint face of the cylinder head.

2. If necessary, install the four studs (6) to the exhaust manifold (3). Tighten the studs to a torque of 18 N·m (13 lb ft).

3. Install Tooling (A) to the cylinder head in the positions (X). Refer to Illustration 79.

4. Position two new exhaust manifold gaskets (1) onto Tooling (A).

Note: Ensure that the word TOP is outward and upward.

5. Align the exhaust manifold (3) with Tooling (A). Install the exhaust manifold to the cylinder head.

6. If the setscrews (2) and (5) have been previously used, the setscrews should be thoroughly cleaned. Tooling (B) should be applied to the first two threads of the setscrews.

Note: Do not apply Tooling (B) to new setscrews.

7. Install the setscrews (2) finger tight. Install the

setscrews (5) and the spacers (4) finger tight.

8. Remove Tooling (A). Install the remaining setscrews (2) finger tight. Install the remaining setscrews (5) and spacers (4) finger tight.

9. Tighten the setscrews (2) and (5) to a torque of 44 N·m (32 lb ft). Tighten the setscrews in the sequence that is shown in Illustration 79.

Page 45

SENR9983 45

Disassembly and Assembly Section

Illustration 8 1

Illustration 82

1. Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the joint face of the cylinder head.

g01176186

g01176487

7. If the setscrews (2) and (5) have been previously used, the setscrews should be thoroughly cleaned. Tooling (B) should be applied to the first two threads of the setscrews.

Note: Do not apply Tooling (B) to new setscrews.

8. Install the setscrews (2) finger tight. Install the

setscrews (5) and the spacers (4) finger tight.

9. Remove Tooling (A). Install the remaining setscrews (2) finger tight. Install the remaining setscrews (5) and spacers (4) finger tight.

10. Tighten the setscrews (2) and (5) to a torque of 44 N·m (32 lb ft). Tighten the setscrews in the sequence that is shown in Illustration 81.

11. Connect all hoses, tube assemblies and wire leads from the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install” Steps 16 through 24.

i02296079

Exhaust Elbow - R emove and

2. If necessary, install the four studs (6) to the

exhaust manifold (3). Tighten the studs to a torque of 18 N·m (13 lb ft).

3. Install the turbocharger to the exhaust manifold. Refer to Disassembly and Assembly, “Turbocharger - Install” Steps 1 through 14.

4. Install Tooling (A) to the cylinder head in the positions (X). Refer to Illustration 81.

5. Position two new exhaust manifold gaskets (1) onto Tooling (A).

Note: Ensure that the word TOP is outward and upward.

6. Align the exhaust manifold (3) with Tooling (A). Install the exhaust manifold to the cylinder head.

Install

Removal Procedure

Start By

a. Remove the exhaust pipe. Refer to OEM

informa remove the exhaust pipe.

tion for the correct procedure in order to

Page 46

46 SENR9983 Disassembly and Assembly Section

4. Some types of exhaust elbow have a separate support bracke

t. If necessary, install the bracket and install the setscrews that secure the bracket to the exhaust elbow finger tight.

5. Install setscrews (1) finger tight.

Illustration 83

Typical exam p le

g01163679

1. Remove the setscrews (1) that secure the exhaust elbow (2) to the engine. Remove the exhaust elbow (2) from the engine.

2. Remove the coupling (4) that connects exhaust elbow (2) to the turbocharger (3).

3. Some types of exhaust elbow have a separate support bracket. If necessary, remove the setscrews that secure the bracket to the exhaust elbow. Remove the support bracket.

Installation Procedure

6. Ensure that th

e coupling (4) is fully engaged into the outlet of the turbocharger (3) and into the exhaust elbow (2). Ensure that the gap between the turbocha

rger and the exhaust elbow is evenly

spaced.

7. Tighten the s

etscrews (1) to a torque of 44 N·m

(33 lb ft).

8. If the exhaus

t elbow has a separate support bracket, tighten the setscrews that secure the bracket to the exhaust elbow to a torque of 44 N·m (33 lb ft).

End By:

a. Install the exhaust pipe. Refer to OEM information

for the correct procedure in order to install the exhaust pip

i02352176

Inlet Manifold - Re move and Install

tion 84

Illustra

Typical exam p le

g01163679

1. Thoroughly clean the exhaust elbow (2), the coupling (4) and the outlet of the turbocharger (3). Inspect t

he sealing faces of the components for wear or damage. Replace any components that are worn or damaged.

2. Install the coupling (4) to the exhaust elbow (2).

3. Align the

coupling (4) to the outlet of the turbocharger (3). Install the assembly of the coupling (4) and the exhaust elbow (2) to the turboch

arger (3).

Removal Procedure

Start By:

a. If necessa

Disassembly and Assembly Manual, “Fuel Filter Base - Remove and Install”.

b. Remove the fuel manifold. Refer to Disassembly

and Assembly Manual, “Fuel Manifold - Remove”.

c. Remove the ECM mounting bracket. Refer

to Disassembly and Assembly Manual, “ECM Mounting

d. Remove the boost pressure sensor. Refer to

Disasse Pressure Sensor - Remove and Install”.

e. Remove t

to Disassembly and Assembly Manual, “Inlet Air Temperature Sensor - Remove and Install”.

ry, remove the fuel filter base. Refer to

Bracket - Remove and Install”.

mbly and Assembly Manual, “Boost

he air inlet temperature sensor. Refer

Page 47

SENR9983 47

Disassembly and Assembly Section

8. Do not remove the two dowel pins (7).

NOTICE

Keep all parts clean from contaminants.

Installation Procedure

Contaminants may cause rapid wear and shortened component life.

1. Disconnect the breather hose from the separator for the crankcase breather (not shown). Refer to Disassembly and Assembly Manual, “Crankcase Breather - Remove”.

Table 15

Required Tools

Too l

Part

Number

Part Name

3 bond 1368D 1

Qty

NOTICE

Keep all parts

clean from contaminants.

Contaminants may cause rapid wear and shortened component lif

Illustration 85

g01208825

2. Cut the cable ties that secure the harness assembly (not shown) to the inlet manifold (4). Position the harness assembly away from the inlet manifold.

3. Remove the setscrews (1) from the inlet connection (2).

4. Remove the inlet connection (2) and the gasket (3) from the inlet manifold (4). Discard the gasket.

5. Remove the setscrews (5).

6. Remove the inlet manifold (4) from the cylinder

head. Use a suitable tool to pry the inlet manifold from the cylinder head. Use the recess at position (X) to pry the inlet manifold.

7. Remove the inlet manifold seal (6) from the recess in the inlet manifold (4). Discard the seal.

Illustration 86

1. Ensure th

at the inlet manifold is clean and free

g01215536

from damage. If necessary, replace the inlet manifold. If a new inlet manifold is installed, install two new d

owel pins (7) to the inlet manifold (4).

Note: Do not install dowel pins to the cylinder head.

2. Clean the joint face of the cylinder head.

3. Align th

e tag (8) to the slot at position (Y) on the inlet manifold. Install the new seal (6) to the groove in the inlet manifold (4). Ensure that the seal is c

orrectly located.

Page 48

48 SENR9983 Disassembly and Assembly Section

4. Align the dowel pins (7) to the holes in the cylinder head. Install t

he inlet manifold (4) to the cylinder

head.

5. Apply Tooling

(A) to the setscrews (5). Install the

setscrews to the inlet manifold (4).

Illustration 8 7

6. Tighten the

setscrews to a torque of 22 N·m (16 lb ft) in the sequence that is shown in Illustration 87.

7. Ensure that the inlet connection (2) is clean and free from damage. If necessary, replace the inlet connectio

b. Install the

fuel manifold. Refer to Disassembly and

Assembly Manual, “Fuel Manifold - Install”.

c. If necessa

ry, install the fuel filter base. Refer to Disassembly and Assembly Manual, “Fuel Filter Base - Remove and Install”.

g01175792

8. Position a new gasket (3) onto the inlet manifold. Install th

e inlet connection (2) to the inlet manifold

(4).

9. Install se

tscrews (1) to the inlet connection (2). Tighten the setscrews to a torque of 22 N·m (16 lb ft).

10. Install the air temperature sensor. Refer to Disassembly and Assembly Manual, “Inlet Air Temperat

ure Sensor - Remove and Install”.

11. Install the boost pressure sensor. Refer to Disassem

bly and Assembly Manual, “Boost

Pressure Sensor - Remove and Install”.

12. Positio

n the harness assembly (not shown) on the inlet manifold. Use new cable ties in order to secure the harness assembly.

13. Connect the breather hose to the separator for the crankcase breather (not shown). Refer to Disasse

mbly and Assembly Manual, “Crankcase

Breather - Install”.

End By:

Inlet and Exhaust Valve Springs - R

Removal Procedure

Table 16

Too l

Part

Number

21825739

27610235

27610295

21825576

27610289

27610290

emove and Install

ools

Part Description

Required T

Circlip Pliers 1

Valve Spring Compressor

Adapter 1B

Head 1

Crankshaft Turning Tool 1

Gear 1

i02296083

Qty

a. Install the ECM mounting bracket. Refer to

embly and Assembly Manual, “ECM

Disass Mounting Bracket - Remove and Install”.

Page 49

SENR9983 49

Disassembly and Assembly Section

Start By:

a. Remove the rocker shaft assembly. Refer to

Disassembly and Assembly Manual, “Rocker Shaft and Push

rod - Remove”.

Note: Either Tooling (A) can be used. Use the Tooling that is most su

itable.

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 installed to the engine. Refer to Disassembly and Assembly Manual, “Inlet and Exhaust Valves Remove and Install” for the procedure to remove the valve springs from a cylinder head that has been removed from the engine.

Note: Ensure that the appropriate piston is at 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 bore.

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 88

g01163262

1. Follow Steps 1.a through 1.h in order to remove the harness assemblies for the electronic unit injectors.

a. Place a temporary identification mark on the

connections (1) for the harness assembly (4) for the electronic unit injectors (2).

b. Use a deep socket to remove the connections

(1) from the electronic unit injectors (2).

c. Cut the cable ties (3).

d. Disconnect the plug (6) from the harness

assembly (4).

e. Use Tooling (A) to remove the circlip (5).

NOTICE Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine

f. From the outside of the valve mechanism

cover base (7), push the harness assembly (4) inward. Withdraw the harness assembly from the valve mechanism cover base.

g. Remove the O-ring seal (8) from the harness

assembly (4). Discard the O-ring seal.

h. Repeat Steps 1.a through 1.g in order to

remove the remaining harness assemblies.

Page 50

50 SENR9983 Disassembly and Assembly Section

Note: Valve springs must be replaced in pairs for the inlet valve or t

he exhaust valve of each cylinder. If all valve springs require replacement the procedure can be carried out on two cylinders at the same time. The procedure can

be carried out on the following pairs of cylinders. 1 with 6, 2 with 5, and 3 with 4. Ensure that all of the valve springs are installed before changing from one pair

of cylinders to another pair of cylinders.

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

3. Apply sufficient pressure to Tooling (B) in order to

allow removal of the valve keepers (8).

Note: Do not compress the spring so that the valve spring retainer (9) touches the valve stem seal (not shown).

Illustration 89

g01182190

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

2. Follow Steps 2.a through 2.d in order to position

the appropriate piston at top dead center.

a. Install Tooling (B) in position on the cylinder

head in order to compress a valve spring (10) for the appropriate piston.

b. Use Tooling (B) in order to compress the valve

spring (10) and open the valve slightly.

Note: Do not compress the spring so that the valve spring retainer (9) touches the valve stem seal (not shown).

c. Use Tooling (C) in order to rotate the crankshaft

carefully, until the piston touches the valve.

Note: Not use excessive force to turn the crankshaft. The use of force can result in bent valve stems.

d. Continue to rotate the crankshaft and gradually

release the pressure on Tooling (B) until the piston is at the top dead center position. The valveisnowheldinapositionthatallowsthe valvespringtobesafelyremoved.

Remove the valve keepers (8).

4. Slowly release the pressure on Tooling (B).

5. Remove the v

alve spring retainer (9) and remove

the valve spring (10).

6. If necessar

y, remove the valve stem seals (not

shown).

7. Repeat Step

s3through6inordertoremove the remaining valve springs from the appropriate cylinder.

8. Remove Tooling (B).

Installation Procedure

Table 17

Required Tools

Tool

D 21820221

Part

Number

21825739

27610235 Adapter 1B

27610295

21825576

27610289

27610290

27610296

Part Description Qty

Circlip Pliers 1

ValveSpringCompressor 1

Head 1

Crankshaft Turning Tool 1

Gear 1

POWERPART Rubber G

Torque Wrench 1

rease

Page 51

SENR9983 51

Disassembly and Assembly Section

Note: Either Tooling (A) can be used. Use the Tooling that is most sui

table.

Improper assembly of parts that are spring loaded

NOTICE

can cause bodily injury.

Keep all parts clean from contaminants.

T o prevent possible injury, follow the established

Contaminants m component life.

ay cause rapid wear and shortened

assembly procedure and wear protective equipment.

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

NOTICE Plug the appatures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine

Illustration 90

g01182190

1. Inspect the valve springs (10) for damage and for

the correct length. Refer to Specifications Manual, “Cylinder Head Valves ”.

2. If necessary, install a new valve stem seal (not

shown) onto the valve guide.

Note: The outer face of the valve guide must be clean and dry before installing the valve stem seal.

3. Install the valve spring (10) onto the cylinder head.

Position the valve spring retainer (9) on the valve spring (10).

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

4. Install Tooling (B) in the appropriate position on

the cylinder head in order to compress the valve spring (10).

5. Apply sufficient pressure to Tooling (B) in order to

install the va

lve keepers (8).

Note: Do not compress the spring so that the valve spring retai

ner (9) touches the valve stem seal (not

shown).

Install the v

alve spring keepers.

6. Carefully release the pressure on the Tooling (B).

7. Repeat steps 2 to 6 for the remaining valves.

The valve keepers can be thrown from the valve when the val

ve spring compressor is released. Ensure that the valve keepers are properly installed on the valve stem. To help prevent personal injury, keep away fr

om the front of the valve keepers and

valve springs during the installation of the valves.

8. Remove the T

ooling (B).

9. Use Tooling (C) to rotate the crankshaft through

approximat

ely 45 degrees. This will ensure that the appropriate valve is clear of the piston. Lightly strike the top of the valve with a soft hammer in order to en

sure that the valve keepers (10) are properly installed.

Note: If al

l valve springs require replacement the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the fol

lowing cylinders. 1 and 6, 2 and 5, and 3 and 4. Remember that the crankshaft must not be turned while the valve springs are removed. Ensure that all o

f the valve springs are installed before changing from one pair of cylinders to the other pair of cylinders. If all valve springs do not require replace

ment, the springs must be replaced in pairs.

Page 52

52 SENR9983 Disassembly and Assembly Section

End By:

a. Install the rocker shaft assembly. Refer to

Disassembly and Assembly Manual, “Rocker Shaft and Push

rod - Insta ll”.

i02296088

Illustration 91

10. Follow Steps 10.a through 10.g in order to install the harness assemblies for the electronic unit injectors.

a. Ensure that the harness assembly (4) for the

electronic unit injectors and the bore in the valve mechanism cover base (7) are clean and free from damage. Replace any damaged components.

b. Use Tooling (D) to lubricate a new O-ring seal.

Install the new O-ring seal (8) onto the harness assembly (4) for the electronic unit injectors.

g01163262

Inlet and Exha

ust Valves -

Remove and Ins tall

Removal Proce

Table 18

Too l Part Number Part Description Qty

21825666

27610235

27610295 Head 1

Start By:

move the cylinder head. Refer to Disassembly

a. Re

and Assembly Manual, “Cylinder Head - Remove”.

ep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

mponent life.

dure

Required Tools

ValveSpringCompressor 1

Adapter 1A

NOTICE

c. From the inside of the valve mechanism cover

base (7), push the harness assembly (4) into the valve mechanism cover base.

d. Use Tooling (A ) to install the circlip (5).

e. Connect the plug (6) to the harness assembly

(4) for the electronic unit injectors.

f. Use a deep socket to install the connections (1)

to the electronic unit injectors (2). Use Tooling (E) to tighten the connections to a torque of

2.5N·m(22lbin).

g. Install a new cable tie (3).

Note: Ensure that cable ties to OE specification are

used.

h. Repeat Steps 10.a through 10.g for the

remaining harness assemblies.

1. Clean the bottom face of the cylinder head. Check the depth of the valves below the face of the cylinder head before the valve springs are removed. Refer to Specifications Manual, “Cylinder Head Valves” for the correct dimensions.

2. Place a temporary identification mark on the heads of the valves in order to identify the correct position.

Note: Inlet valves have a recess in the center of the head.

3. Use a suitable lifting device to position the cylinder head with the valve springs upward. The weight of the cylinder head is approximately 65 kg (143 lb).

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

Page 53

SENR9983 53

Disassembly and Assembly Section

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 92

Typical exam p le

g01162648

4. Install T ooling (A) in position on the cylinder head in order to compress the appropriate valve spring (3).

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

5. Apply sufficient pressure to Tooling (A) in order to

remove the valve keepers (1).

Note: Do not compress the spring so that the valve spring retainer (2) touches the valve stem seal (4).

6. Slowly release the pressure on Tooling (A).

Illustration 93

g01162650

7. Remove the valve spring retainer (2). Remove the valve spring (3).

8. Repeat steps 4 to 7 for the remaining valves.

9. Remove Tooling (A).

10. Remove the valve stem seals (4).

11. Use a suitable lifting device to carefully turn over

the cylinder head.

12. Remove the valves (5).

Installation Procedure

Table 19

Required Tools

Too l Part Number Part Description Qty

21825666

27610235 Adapter 1A

27610295 Head 1

Keep all parts clean from contaminants.

ValveSpringCompressor 1

NOTICE

Contaminants may cause rapid wear and shortened component life.

1. Clean all components of the cylinder head assembly. Ensure that all ports, all coolant passages and all lubrication passages in the cylinder head are free from debris. Follow Steps

1.a through 1.d in order to inspect the components of the cylinder head assembly. Replace any components that are worn or damaged.

Page 54

54 SENR9983 Disassembly and Assembly Section

a. Inspect the cylinder head for wear and for

damage. Refer t

o Testing and Adjusting

Manual, “Cylinder Head Inspect”.

b. Inspect the va

lve seats for wear and for damage. Refer to Specifications Manual, “Cylinder Head Valves” for further information.

c. Inspect the valve guides for wear and for

damage. Refer to Specifications Manual, “Cylinder He

ad Valves” and Testing and Adjusting Manual, “Valve Guide - Inspect” for further information.

d. Inspect the valves for wear and for damage.

Refer to Specifications Manual, “Cylinder Head Val v es ”.

e. Inspect the valve springs (3) for damage and

for the corr

ect length. Refer to Specifications

Manual, “Cylinder Head Valves ”.

Note: The outer face of the valve guides must be clean and dry be

fore installing the valve stem seals

(4).

5. Install the va

lve spring (3) onto the cylinder head. Position the valve spring retainer (2) on the valve spring (3).

Personal inj

ury can result from being struck by

parts propelled by a released spring force.

Make sure to w

ear all necessary protective equip-

ment.

Follow t he re

commended procedure and use all

recommended t ooling to release the spring force.

Illustration 94

g01162650

2. Lubricate the stems of the valves (5) with clean engine oil. Install the valves (5) in the appropriate positions in the cylinder head. Check the depth of the valves below the face of the cylinder head. Refer to Testing and Adjusting Manual, “Valve Depth - Inspect” for more information.

3. Use a suitable lifting device to carefully turn over the cylinder head. The weight of the cylinder head is approximately 65 kg (143 lb).

Note: Ensure that all of the valves remain in place.

4. Install new valve stem seals (4) onto each of the

valve guides.

Illustration 95

g01162648

6. Install Tooling (A) in the appropriate position on the cylinder head in order to compress the valve spring (3).

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

7. Apply sufficient pressure to Tooling (A) in order to

install the valve keepers (1).

Note: Do not compress the spring so that the valve spring retainer (2) touches the valve stem seal (4).

Page 55

SENR9983 55

Disassembly and Assembly Section

NOTICE

The valve keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve keepers and valve springs during the installation of the valves.

Care must be taken to ensure that fluids are contained during perform ing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any co ponent containing fluids.

ance of inspection, maintenance, test-

mpartment or disassembling any com-

8. Carefully release the pressure on Tooling (A).

9. Repeat steps 5 to 8 for the remaining valves.

10. Remove Tooling (A) from the cylinder head.

11. Use a suitable lifting device to position the cylinder

head on a support. Ensure that the heads of the valves are not obstructed. Gently strike the top of thevalveswithasofthammerinordertoensure that the valve keepers (1) are properly installed.

End By:

a. Install the cylinder head. Refer to Disassembly

and Assembly Manual, “Cylinder Head - Install”.

i02296099

Engine Oil Filter Base Remove and I

Removal Procedure

Table 20

Tool Part Number Part Description Qty

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

Keep all parts clean from contaminants.

ontaminants may cause rapid wear and shortened

C component life.

nstall

Required T

ools

Strap Wrench 1

OTICE

Dispose of all mandates.

1. Place a suitable container below the engine oil

filter base (3 be spilled.

Note: Clean u

Illustration 96

Typical example

2. If the engine oil filter base has a horizontal engine

oil filter, follow Steps 2.a to 2.b in order to drain the engine oil filter.

a. Remove the drain plug (6) from the engine oil

filter base (2).

b. Remove the O-ring seal (5) from the drain plug

(6). Discard the O -ring seal.

3. Use Tooling (A) to remove the engine oil filter (3).

Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change”.

4. Remove the setscrews (4). If setscrews of different

lengths are installed, identify the correct position of the setscrews.

fluids according to local regulations and

) in order to catch any oil that might

p any spillage of oil immediately.

g01162867

Note: If necessary, remove the spacers and slide the bracket for the wiring loom to one side.

5. Remove the engine oil filter base (2).

6. Remove the joint (1). Discard the joint.

Page 56

56 SENR9983 Disassembly and Assembly Section

7. If necessary, remove the plug (8) from the engine oil filter base theplug(8).DiscardtheO-ringseal.

(2). Remove the O-ring seal (7) from

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants component life.

may cause rapid wear and shortened

i02296106

Engine Oil Cooler - Remove

Removal Proced

Start By:

a. Remove the bracket for the Electronic Control

Module. Refer to Disassembly and Assembly Manual, “ECM M Install”.

Ensure that all adjustments and repairs that are carried out to authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard I Lines” for s afety information.

the fuel system are performed by

nformation and High Pressure Fuel

ure

ounting Bracket - Remove and

NOTICE

Illustration 97

Typical exam p le

1. Clean the engine oil filter base (2). Clean the mating surfaces of the cylinder block or the engine oil cooler.

2. If necessary, install new O-ring seals (5) and (7) to the plugs (6) and (8). Install the plugs (6) and (8) to the engine oil filter base (2). Tighten the plugs toatorqueof12N·m(106lbin).

Note: Drain plug (8) is only installed to engines with a horizontal engine oil filter.

3. Install the setscrews (4) to the engine oil filter base (2). Ensure that setscrews of different lengths are installed in the correct positions.

Note: If necessary, install the spacers and the bracket for the wiring loom.

4. Install a new joint (1) onto the setscrews (4). Install the assembly of the engine oil filter base to the cylinder block or the engine oil cooler.

5. Tighten the setscrews (4) to a torque of 22 N·m (16 lb ft).

g01162867

Refer to Test liness of Fuel System Components” for detailed information on the standards of cleanliness that must be obse system.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a suitable container. Refer to Operation and Maintenance Manual, “Cooling System Coolant Drain” for the correct procedure.

ing and Adjusting Manual, “Clean-

rved during ALL work on the fuel

NOTICE

6. Install a new engine oil filter (3) and check the level of the engine lubricating oil. Refer to Operation and Maintenance Manual, “Engine Oil Level Check” for the correct procedure.

2. Place a suitable container below the engine oil cooler in order to catch any fluids that might be spilled.

Page 57

SENR9983 57

Disassembly and Assembly Section

Note: Clean up any spillage immediately.

Illustration 98

Typical example of an engine oil cooler with a blanking plate

g01181109

c. Remove the joint (not shown). Discard the joint.

4. Make temporary identification marks on the plastic

tube assemblies (3) in order to show the correct position of th

etubeassemblies.

5. Remove the plastic tube assemblies (3). Plug all plastic tube a

ssemblies with new plugs. Cap all

open ports with new caps.

6. Follow Steps 6

.a through 6.d in order to disconnect

the engine wiring harness (4).

a. Disconnect t

he engine wiring harness (4) from the position sensor (2) for the fuel injection pump.

b. Disconnect the engine wiring harness (4) from

the solenoid (1) for the fuel injection pump.

c. Disconnect the engine wiring harness (4) from

the oil pressure sensor (13).

d. Cut the cable ties that secure the engine wiring

harness (4) to the assembly of the oil cooler (6). Position th

e harness away from the assembly

of the oil cooler.

Illustration 99

example of an engine oil cooler with a high mounted filter

Typical base

g01204901

3. If the engine has a left hand side oil filter, remove the oil f

ilter base. Refer to Disassembly and Assembly Manual, “Oil Filter Base - Remove and Install”.

If the engine has a right hand side oil filter, follow Steps 3.a through 3.c in order to remove the

ng plate (12). Refer to Illustration 98.

blanki

a. Remove the four setscrews (11).

b. Removetheblankingplate(12).

7. Remove the t

ube assembly (9) for the fuel return from the cylinder head (not shown) and from the transfer pump (8). Plug the tube assembly with new plugs.

Illustration 100

Typical example of engine oil cooler with a blanking plate or with a low m ounted filter base

Cap all open ports with new caps.

g01205285

8. If necessary, loosen the two setscrews (15). Remove the setscrews (7) and re move the brackets (5) and (10) for the tube assemblies. Remove the assembly of the oil cooler (6) from the cylinder block.

Note: The setscrews are different lengths. Note the position of the different setscrews. Note the location and the orientation of the brackets for the tube assemblies.

Page 58

58 SENR9983 Disassembly and Assembly Section

9. Remove the joint (16). Refer to Illustration 101 and Illustrati

Disassembly Pr

on 102. Discard the joint.

ocedure (Engine Oil Cooler with a Low Mounted Filter Base)

Disassembly Procedure (Engine Oil Cooler with a High Mounted Filter Base)

Illustration 102

g01180538

Illustration 101

Typical exam p le

1. Remove the two setscrews (15).

2. Remove the cooler matrix (19) from the spacer

plate (17).

3. Remove the joint (18). Discard the joint.

g01174007

1. Remove the four nuts (23) from the assembly of the oil cooler (6).

2. Remove the cooler matrix (20) from the housing (22).

3. Remove the two joints (21). Discard the joints.

i02296110

Engine Oil Cooler - Install

Assembly Procedure (Engine Oil Cooler with a Low Mounted Filter Base)

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Page 59

SENR9983 59

Disassembly and Assembly Section

Note: The holes in the joint have serrations that hold the setscrews c

aptive.

Illustration 103

g01174007

1. Ensure that the cooler matrix (19) is clean and free from damage. Ensure that the spacer plate (17) is clean and free from damage. Replace any damaged components.

2. Position a new joint (18) onto the spacer plate (17). Install the cooler matrix (19) to the spacer plate.

3. Install the two setscrews (15) finger tight.

Assembly Proce

dure (Engine Oil Cooler with a High Mounted Filter Base)

Illustration 105

1. Ensure that the cooler matrix (20) and the housing

(22) are clean and free from damage. Replace any damaged components.

g01180538

Illustration 104

g01205285

4. Position the brackets (5) and (10) onto the assembly of the oil cooler (6). Install the setscrews (7).

Note: Ensure that brackets for the tube assemblies are installed in the correct location and the correct orientation. The setscrews are different lengths. Ensure that the different setscrews are installed in the correct location.

5. Install the joint (16) to the assembly of the oil cooler (6). Push the setscrews (7) through the holes in the joint.

2. Install two new joints (21) to the cooler matrix (20).

3. Install the cooler matrix (20) to the housing (22).

4. Install the four nuts (23) to the assembly of the oil

cooler (6). Tighten the nuts to a torque of 22 N·m (16 lb ft).

Illustration 106

g01205691

5. Install the setscrews (7) to the assembly of the oil cooler (6).

Page 60

60 SENR9983 Disassembly and Assembly Section

Note: The setscrews are different lengths. Ensure that the differ

ent setscrews are installed in the correct

location.

6. Install the jo

int (16) to the assembly of the oil cooler (6). Push the setscrews (7) through the holes in the joint.

Note: The holes in the joint have serrations that hold the setscrews captive.

Installation Procedure

1. Clean the joint face of the cylinder block.

Illustration 108

Typical example of an engine oil cooler with a high mounted filter base

g01204901

2. Install the assembly of the oil cooler (6) to the cylinder block. Tighten the setscrews (7) finger tight.

If the engine has a high mounted oil filter base, install the oil filter base (14) finger tight. Refer to Illustration 108 and refer to Disassembly and Assembly Manual, “Engine Oil Filter Base Remove and Install”.

Illustration 107

Typical example of an engine oil cooler with a blanking plate

g01181109

Illustration 109

Tightening sequence for an engine oil cooler with a blanking plate or with a low mounted oil filter base

g01179352

Page 61

SENR9983 61

Disassembly and Assembly Section

If the engine has a right hand side oil filter, follow Steps 7.a throu blanking plate (12).

gh 7.d in order to install the

Illustration 110

Tightening sequence for an engine oil cooler with a high mounted oil filter base

3. If the engine has a low mounted oil filter base or a blanking plate, tighten the setscrews to a torque of 22 N·m (16 lb ft) in the sequence that is shown in Illustration 109.

If the engine has a high mounted oil filter base, tighten the setscrews to a torque of 22 N·m (16 lb ft) in the sequence that is shown in Illustration 110. Tighten the remaining setscrews that secure the oil filter base to a torque of 22 N·m (16 lb ft).

g01180321

a. Install the fo

plate (12).

b. Positionanew

blanking plate (12).

c. Install the as

assembly of the oil cooler (6).

d. Tighten the s

22 N·m (16 lb ft).

8. Fill the cool to Operation and Maintenance Manual, “Cooling System Coolant - Fill” for the correct procedure.

9. Check the level of the engine lubricating oil. Refer to Operation and Maintenance Manual, “Engine Oil Level - C

End By:

a. Install the bracket for the Electronic Control

Module. Refer to Disassembly and Assembly Manual, “EC

ur setscrews (11) to the blanking

joint (not shown) onto the

sembly of the blanking plate to the

etscrews (11) to a torque of

ing system to the correct level. Refer

heck” for the correct procedure.

M Bracket - Remove”.

4. Remove t he plugs from the tube assembly (9). Remove the caps for the fuel return from the cylinder head and from the transfer pump (8). Install the tube assembly (9) to the cylinder head and to the transfer pump (8).

5. Follow Steps 5.a through 5.e in order to connect the engine wiring harness (4).

a. Place the harness in position.

b. Connect the engine wiring harness (4) to the

position sensor (2) for the fuel injection pump.

c. Connect the engine wiring harness (4) to the oil

pressure sensor (13).

d. Connect the engine wiring harness (4) to the

solenoid (1) for the fuel injection pump.

e. Install new cable ties in order to secure the

engine wiring harness (4) to the assembly of the oil cooler (6).

6. Remove the plugs from all plastic tube assemblies (3). Remove the caps from the appropriate ports. Install the plastic tube assemblies (3).

i02296785

Engine Oil R

elief Valve -

Remove and Ins tall

Removal Pr

Start By:

a. Remove the engine oil pan. Refer to Disassembly

and Assembly Manual, “Engine Oil Pan Remove”.

Keep all parts clean from contaminants.

Contamina component life.

ocedure

NOTICE

nts may cause rapid wear and shortened

7. If the engine has a low mounted oil filter on the left hand side, install the oil filter base. Refer to Disassembly and Assembly Manual, “Oil Filter Base - Remove and Install”.

Page 62

62 SENR9983 Disassembly and Assembly Section

NOTICE

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

Make sure to wear all necessary protective equip-

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

ment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Illustration 111

g01158341

1. Useanallenwrenchtoloosenthecap(1). Carefully remove the cap (1) from the housing of theengineoilpump(4).

Note: The spring force will be released when the cap is removed.

2. Remove the spring (2) from the bore for the relief valve in the housing of the engine oil pump (4).

3. Use long nose pliers to remove the plunger (3) from the bore for the relief valve in the housing of theengineoilpump(4).

Installation Procedure

Table 21

Required Tools

Tool

Part

Number

Part Description Qty

Loctite 577 1

Illustration 112

g01158341

1. Ensure that all components are clean and free from wear or damage. If necessary, replace any components that are worn or damaged. If the bore for the relief valve in the housing of the engine oil pump (4) is worn or damaged, the complete assembly of the engine oil pump must be replaced.

Improper assembly of parts that are spring loaded can cause bodily injury.

T o prevent possible injury, follow the established assembly procedure and wear protective equipment.

2. Lubricate the plunger (3) with clean engine oil.

Use long nose pliers to install the plunger (3) and thespring(2)intotheboreforthereliefvalvein the housing of the engine oil pump (4).

Note: The plunger must slide freely in the bore for the relief valve.

3. Apply Tooling (A) to the threads of the cap (1). Use an allen wrench to install the cap (1) to the engine oil pump (4). Tighten the cap to a torque of 21 N·m (15.5 lb ft).

Page 63

SENR9983 63

Disassembly and Assembly Section

Note: Ensure that the spring is properly located inside the plun

ger and the cap. Ensure that Tooling (A) does not contaminate the bore for the relief valve in the housing of the engine oil pump.

End By:

a. Install the en

gine oil pan. Refer to Disassembly

and Assembly Manual, “Engine Oil Pan - Install”.

i02296116

Engine Oil Pump - Rem ov e

Removal Procedure

Start By:

a. Remove the engine oil pan. Refer to Disassembly

and Assembly Manual, “Engine Oil Pan Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 113

Typical example

g01158368

2. Remove the two setscrews (1) and the suction pipe (2).

3. Remove the joint (not shown) from the suction pipe. Discard the joint.

4. Remove the setscrews (3). Remove the assembly of the engine oil pump from the cylinder block.

5. If necessary, remove the pressure relief valve (5) from the housing of the engine oil pump (4). Refer to Disassembly and Assembly Manual, “Engine Oil Relief Valve - Remove and Install”.

Dispose of all fluids according to local regulations and mandates.

1. If the suction pipe has a support bracket, remove the support bracket.

Note: Note the position and orientation of the components for the support bracket.

Illustration 114

g01160736

Page 64

64 SENR9983 Disassembly and Assembly Section

6. If necessary, remove the allen head screws (6) and the front co

ver assembly (7). Remove the outer rotor (8) from the housing of the engine oil pump (4).

Note: Do not remove the dowels (9) from the housing of the engine oil pump unless the dowels are damaged.

i02296126

Engine Oil Pump - Install

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE If any part of the engine oil pump is worn or damaged, the complete assembly of the engine oil pump must be replaced.

1. Ensure that all components of the engine oil pump

are clean and to Testing and Adjusting Manual, “Engine Oil Pump - Inspect” for more information. Replace the complete as of the components are worn or damaged.

free from wear or damage. Refer

sembly of the engine oil pump if any

2. If necessary, install the pressure relief valve (5). Refer to Disass

embly and Assembly Manual, “Engine Oil Relief Valve - Remove and Install” for further information.

Illustration 116

g01160744

3. If necessary, lubricate the internal components for the assembly of the engine oil pump with clean engine oil. Install the outer rotor (8) and the front cover (7) to the housing of the engine oil pump (4). Install the allen head screws (6). Tighten the allen head screws to a torque of 22 N·m (16 lb ft).

4. Ensure that the two dowels (9) are correctly located in the housing of the engine oil pump (4). Position the assembly of the engine oil pump onto the cylinder block.

Illustration 115

Typical exam p le

g01158368

Note: Ensure that the dowels in the housing of the engine oil pump are aligned with the holes in the cylinder block.

5. Install the setscrews (3). Tighten the setscrews to a torque of 22 N·m (16 lb ft).

6. Check the backlash between the idler gear (10) and the crankshaft gear. Refer to Specifications Manual, “Gear Group (Front)” for further information.

7. Install the suction pipe (2) and a new joint (not shown) to the assembly of the engine oil pump.

8. Install the setscrews (1). Tighten the setscrews to a torque to 22 N·m (16 lb ft).

9. If the suction pipe has a support bracket follow Steps 9.a through 9.c.

Page 65

SENR9983 65

Disassembly and Assembly Section

a. Install the components of the support bracket.

Ensure the corr

ect location and orientation of

the bracket and the retaining clip.

b. Tighten the se

tscrews finger tight in order to

align the components of the support bracket.

c. Tighten the M1

0setscrewtoatorqueof44N·m (32.5 lb ft). Tighten the M8 fasteners to a torque of 22 N·m (16 lb ft).

End By:

a. Install the e

ngine oil pan. Refer to Disassembly

and Assembly Manual, “Engine Oil Pan - Install”.

i02296130

Water Pump - Remove

Removal Procedure

Start By:

a. Remove the fan and the fan pulley. Refer to

Disassembly and Assembly Manual, “Fan Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustrat

ion 117

g01212581

3. Remove t he setscrews (4).

Note: The setscrews are three different lengths. Note

the positions of the different setscrews.

4. Remove the water pump (3) from the front cover (1).

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a

suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Drain” for the correct procedure.

2. Loosen the hose clamps and remove the hose

(not shown) from the water pump inlet.

Note: If necessary, tap the water pump with a soft hammer in order to loosen the water pump.

5. Remove the joint (2). Discard the joint.

6. If necess

ary, remove the cover (6) from the water pump. Follow Steps 6.a through 6.c in order to remove the cover.

a. Remove the two setscrews (7).

b. Remove th

e cover (6).

c. Remove the joint (5). Discard the joint.

Page 66

66 SENR9983 Disassembly and Assembly Section

i02296136

Water Pump - Install

Installation P

Table 22

Part

Tool

Number Part Description Qty

rocedure

Required Tools

Guide Stud (M8by70mm)

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. Ensure that the water pump is clean and free from

wear or damage. If necessary, replace the water pump.

Illustrat

ion 118

g01204002

2. If necessary, install the cover (6) to the water pump (3).

Follow Steps 2.a through 2.d in order

to install the cover.

a. Clean the

joint face of the cover (6).

b. Position a new joint (5) on the water pump (3).

c. Install the cover (6) to the water pump (3).

d. Install t

he two setscrews (7) to the cover (6).

Tighten the setscrews finger tight.

3. Clean the

jointfaceofthefrontcover(1).

Page 67

SENR9983 67

Disassembly and Assembly Section

Illustration 119

4. Install Tooling (A) in position (X).

5. Use Tooling (A) in order to align the new joint (2)

to the front cover (1). Install the joint to the front cover.

6. Align the water pump (3) to Tooling (A). Install the water pump to t he front cover (1).

Note: Ensure that the gear of the water pump and the gear of the fuel injection pump mesh.

7. Install the setscrews (4). Refer to Illustration 118. Tighten the setscrews finger tight.

Note: Ensure that all setscrews of different lengths are installed in the correct positions.

8. Remove Tooling (A) and install the two remaining setscrews (4).

g01204116

Illustration 120

9. Tighten the setscrews (4) and (7) in the sequence that is shown in Illustration 120 to a torque of 22 N·m (16 lb ft).

10. Install the hose (not shown) to the water pump inlet. Tighten the hose clamps.

11. Fill the cooling system with coolant. Refer to the Operation and Maintenance Manual, “Cooling System Coolant - Fill” for the correct procedure.

End By:

a. Install the fan and the fan pulley. Refer to

Disassembly and Assembly Manual, “Fan Remove and Install”.

g01183807

i02296653

Water Temperature Regulator Remove and Ins tall

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Page 68

68 SENR9983 Disassembly and Assembly Section

NOTICE Care must be taken to ensure that fluids are contained during perform

ance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compar

tment or disassembling any compo-

nent containing fluids.

Dispose of all

fluids according to local regulations and

mandates.

1. Drain the coolant from the cooling system to a

level below th

e water temperature regulator, into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling Sys

tem Coolant - Drain” for the correct

draining procedure.

2. Loosen the ho

se clamps from the upper radiator hose and disconnect the upper radiator hose from the water temperature regulator housing (2).

Illustration 121

Typical exam p le

g01158622

3. Remove the two setscrews (1) from the water temperature regulator housing (2).

Illustration 122

Typical example

g01158625

5. Remove the O-ring seal (3) from the water temperature regulator housing (2). Discard the O-ring seal.

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that a temperature regulator housing (2) are clean and free of wear or damage. Check the water temperatur Refer to Testing and Adjusting Manual, “Water Temperature Regulator - Test” for the procedure to test the components of the water temperature regulator housing are worn or damaged, the complete assembly m

ll components of the water

e regulator for correct operation.

water temperature regulator. If any

ust be replaced.

4. Remove the water temperature regulator housing (2) from the cylinder head.

Note: Note the orientation of the water temperature regulator housing.

Illustration 123

Typical example

g01158625

Page 69

SENR9983 69

Disassembly and Assembly Section

2. If the original water temperature regulator housing is installed, p

osition a new O-ring seal (3) into the groove in the water temperature regulator housing (2).

A new water temperature regulator housing is supplied with a new O-ring seal.

3. Install the water temperature regulator housing (2) to the cylinder head.

Note: Ensure the correct orientation of the water temperature regulator housing.

Start By:

a. Remove the electric starting motor. Refer to

Disassembly and Assembly Manual, “Electric Starting Moto

r - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 124

Typical exam p le

g01158622

4. Install the setscrews (1). Tighten the setscrews (1) toatorqueof44N·m(32.5lbft).

5. Connect the upper radiator hose and tighten the hose clamps.

6. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Check” and Operation and Maintenance Manual, “Cooling System Coolant Fill” for the correct filling procedure.

i0229665

Flywheel - Remove

Removal Procedure

Table 23

Required Tools

Tool

Part

Number

Part Description Qty

Guide Stud (1/2 inch - UNF by 4 inch)

Illustration 125

g01159176

1. Remove two setscrews from position (X) on the flywheel (1).

2. Install Tooling (A) in position (X) on the flywheel (1).

3. Attach a suitable lifting device to the flywheel (1). Support the weight of the flywheel. The flywheel

canweigh70.6kg(155lb).

4. If necessary, remove the four setscrews (2) that secure the housing for the pilot bearing (3) to the flywheel (1). Remove the housing for the pilot bearing (3).

5. Remove the remaining setscrews (4).

6. Use the lifting device to remove the flywheel from

the engine.

Page 70

70 SENR9983 Disassembly and Assembly Section

Illustration 126

g01162553

7. Inspect the flywheel (1) and the ring gear (5) for wear or damage. Replace any worn components or damaged components.

8. To remove the flywheel ring g ear (5), follow steps

8.a and 8.b.

a. Place the flywheel assembly on a suitable

support.

b. Use a hammer and a punch in order to remove

the ring gear (5) from the flywheel (1).

Note: Identify the orientation of the teeth on the flywheel ring gear.

i02296655

Flywheel - Install

Installation Procedure

Table 24

Required Tools

Tool

Part

Number

Part Description Qty

Guide Stud (1/2 inch - 20 UNF by 4 inch)

Illustration 127

g01163617

Always wear protective gloves when handling parts that ha

ve been heated.

1. If the flywheel ring gear was removed, follow

Steps 1.a thr

ough 1.c in order to install the ring

gear (5) to the flywheel (1).

a. Identify th

e orientation of the teeth (6) on the

new ring gear (5).

Note: The ch

amfered side of the ring gear teeth (6) must face toward the starting motor when the flywheel is installed. This will ensure the correct engagement

of the starting motor.

b. Heat the flywheel ring gear (5) in an oven to a

maximum te

mperature of 250 °C (482 °F) prior

to installation.

Note: Do no

t use a torch to heat the ring gear.

c. Ensure that the orientation of the ring gear (5)

is correct

and quickly install the ring gear onto

the flywheel (1).

2. Inspect th

e crankshaft rear seal for leaks. If there are any oil leaks, replace the crankshaft rear seal. Refer to Disassembly and Assembly Manual, “Cranksh

aft Rear Seal - Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Page 71

SENR9983 71

Disassembly and Assembly Section

i02296656

Crankshaft Rear Seal - Remove

Illustration 128

g01159176

3. Install a suitable lifting device to the flywheel (1). The flywheel can weigh 70.6 kg (155.6 lb).

4. Install Tooling (A) in position (X) on the crankshaft.

5. Use the lifting device to position the flywheel (1)

onto Tooling (A).

6. If necessary, install the pilot bearing (3) and the setscrews (2) to the flywheel (1).

7. Install setscrews (4) to the flywheel (1).

8. Remove Tooling (A) and install the remaining

setscrews (4) to the flywheel (1).

9. Useasuitabletooltopreventtheflywheelfrom rotating. Tighten the setscrews (2) and (4) to a torque of 120 N·m (88 lb ft).

Removal Proced

Table 25

Too l

Part

Number

ure

Required Tools

Part Description Qty

T40 Torx Socket

Start By:

a. Remove the flywheel housing. Refer to

Disassembly and Assembly Manual, “Flywheel Housing - Remove and Install”.

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.

10. Remove the lifting device from the flywheel (1).

11. Check the run out of the flywheel. Refer to

Specifications Manual, “Flywheel” for further information.

End By:

a. Install the electric starting motor. Refer to

Disassembly and Assembly Manual, “Electric Starting Motor - Remove and Install”.

Illustration 129

g01174488

Page 72

72 SENR9983 Disassembly and Assembly Section

Note: The assembly of the crankshaft rear seal is nonserviceabl

e. If the assembly of the crankshaft

rear seal is removed, the assembly must be replaced.

1. Remove the tor

x screws (1) from the assembly of

the crankshaft rear seal (2).

2. Use Tooling (A

) in order to remove the torx screws

(3) from the assembly of the crankshaft rear seal.

3. Remove the ass

embly of the crankshaft rear seal (2) from the cylinder block. Discard the assembly of the crankshaft rear seal (2).

Note: It is not necessary to remove the adapter for the engine oil pan in order to remove the crankshaft rear seal.

i02296657

Crankshaft R

ear Seal - Install

Installation Procedure With Oil Pan in Position

Table 26

Required Tools

Tool

Note: The crankshaft rear seal and the housing for

the crankshaft rear seal are manufactured as one assembly. The crankshaft rear seal is lubricated during manufacture. Do not lubricate the seal or the crankshaft palm before installation. Never install a used crankshaft rear seal.

Part

Number

Part Description Qty

T40 Torx Socket 1

Illustration 130

g01182868

1. Ensure that the crankshaft palm (1) is clean, dry and free from damage. If the crankshaft palm is worn or damaged, install a crankshaft wear sleeve. Refer to Disassembly and Assembly Manual, “Crankshaft Wear Sleeve (Rear) Remove and Install”.

2. Ensure that the mating face of the cylinder block is clean and dry. Ensure that the mating face of the isolating frame (7) is clean and dry.

3. Ensure that the plastic sleeve (3) is squarely installed within the new crankshaft rear seal (2).

Note: The plastic sleeve (3) is included in order to protect the lip of the seal as the crankshaft rear seal is pushed over the crankshaft palm (1). Do not attempt to install a crankshaft rear seal without the plastic sleeve.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 131

Typical example

g01183033

Page 73

SENR9983 73

Disassembly and Assembly Section

4. Place the assembly of the crankshaft rear seal over the cranks with the slot in the crankshaft rear seal (2).

haft palm (1). Align the dowel (5)

NOTICE

Keep all parts clean from contaminants.

5. Ensure that th

e plastic sleeve (3) is engaged on the crankshaft palm (1). Push the crankshaft rear seal (2) squarely onto the crankshaft. Ensure that the cranksha

ft rear seal is seated against the cylinder block. During this process, the plastic sleeve (3) will be forced out of the crankshaft rear seal. Discar

d the plastic sleeve.

Note: Ensure that the dowel (5) is engaged in the slot in the cr

ankshaft rear seal.

6. Use Tooling (A) in order to install the two outer torx screws (

6) at the base of the crankshaft rear seal (2). Tighten the torx screws (6) to a torque of 15 N·m (11 lb ft).

7. Install two torx screws (4) to the crankshaft rear seal (2) at position (X). Tighten the two torx screws (4)toator

queof22N·m(16lbft).

8. Use Tooling (A) in order to unscrew the two torx screws (6)

at the base of the crankshaft rear seal

(2) one complete turn.

9. Install th

e remaining torx screws (4). Tighten the

torxscrews(4)toatorqueof22N·m(16lbft).

Contaminants may cause rapid wear and shortened component life.

10. Use Toolin

g (A) in order to install the remaining torx screws (6). Tighten all torx screws (6) at the base of the crankshaft rear seal to a torque of 22 N·m (16 l

b ft).

End By:

a. Install the flywheel housing. Refer to Disassembly

and Assembly Manual, “Flywheel Housing Remove an

Installa

dInstall”.

tion Procedure Without

Isolating Frame for the Oil Pan

Table 27

Required

Tool

Part

Number

Alignment Tool 1

Setscrew(M8by20mm) 4

Note: The crankshaft rear seal and the housing for the crankshaft rear seal are manufactured as one assembly. The crankshaft rear seal is lubricated during manufacture. Do not lubricate the seal or the crankshaft palm before installation. Never install a used crankshaft rear seal.

Tools

Part Description

Qty

Page 74

74 SENR9983 Disassembly and Assembly Section

ion 132

Illustrat

Alignment tool

1. To install the crankshaft rear seal without the isolating frame for the oil pan in position, Tooling (B) must b

e used. The tool should be fabricated from 8 mm (5/16 inch) steel stock. The dimensions for the tool are given in Illustration 132. All dimensi

ons are shown in millimeters.

g01183431

2. Ensure that the crankshaft palm (1) is clean, dry and free from damage. If the crankshaft palm is worn or

damaged, install a crankshaft wear sleeve. Refer to Disassembly and Assembly Manual, “Crankshaft Wear Sleeve (Rear) Remove a

nd Install”.

3. Ensure that the mating face of the cylinder block is clean

and dry.

4. Ensure that the plastic sleeve (3) is squarely

ed within the new crankshaft rear seal (2).

install

Note: The plastic sleeve (3) is included in order to prote

ct the lip of the seal as the crankshaft rear seal is pushed over the crankshaft palm (1). Do not attempt to install a crankshaft rear seal without the

c sleeve.

plasti

Illustration 133

g01201564

Page 75

SENR9983 75

Disassembly and Assembly Section

i02403282

Crankshaft Wear Sleeve (Rear)

- Remove and Install

Removal Procedure

Start By:

a. Remove the crankshaft rear seal. Refer to

nd Assembly Manual, “Crankshaft

NOTICE

Illustration 134

5. Place the assembly of the crankshaft rear seal over the crankshaft palm (1). Align the dowel (5) with the slot in the crankshaft rear seal.

6. Ensure that the plastic sleeve (3) is engaged on the crankshaft palm (1). Push the crankshaft rear seal (2) squarely onto the crankshaft. Ensure that the crankshaft rear seal is seated against the cylinder block. During this process, the plastic sleeve (3) will be forced out of the crankshaft rear seal. Discard the plastic sleeve.

g01201892

Disassembly a Rear Seal - Remove”.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Wear sleeves are used to reclaim worn seal surfaces or damaged seal surfaces. Wear sleeves are not original equipment.

Note: Ensure that the dowel (5) is engaged in the hole in the crankshaft rear seal.

7. Install the Tooling (B) to the cylinder block and to the crankshaft rear seal (2). Tighten the four M8 setscrews to a torque of 15 N·m (11 lb ft).

8. Install two torx screws (4) to the crankshaft rear seal (3) in position (X). Tighten the two torx screws (4)toatorqueof22N·m(16lbft).

9. Unscrew the two M8 screws of Tooling (B) that are installed to the base of the crankshaft rear seal (2) one complete turn.

10. Install the remaining torx screws (4). Tighten all torxscrews(4)toatorqueof22N·m(16lbft).

11. Remove Tooling (B).

Illustration 135

1. Use a sharp crankshaft wear sleeve (1).

Note: Tak e

2. Insert a thin blade between the crankshaft wear

sleeve (1) line. The crankshaft wear sleeve will separate along the line.

3. Remove the crankshaft wear sleeve (1) from the crankshaft (2).

tool to score a deep line across the

care to avoid damaging the crankshaft.

and the crankshaft (2) below the scored

g01200315

4. Discard the crankshaft wear sleeve.

Page 76

76 SENR9983 Disassembly and Assembly Section

Installation P

Table 28

Too l Part Number Part Description

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the crankshaft is thoroughly clean and dry.

21820518

rocedure

Required Tools

POWERPART Liquid Gasket

NOTICE

3. Align the crankshaft wear sleeve (1) with the crankshaft (2) that is provided with the crankshaft wear sleeve over the crankshaft. Use a hammer to drive the crankshaft we Ensure that the flange of the crankshaft wear sleeveis0.40to0.60mm(0.017to0.024inch) from the cyli

Note: Measure the distance (Y) between the flange of the cranksha in two places that are 180 degrees from each other.

4. Remove the in

5. Ensure that the crankshaft wear sleeve has no

rough edges.

End By:

a. Install a new crankshaft rear seal. Refer to

Disassembly and Assembly Manual, “Crankshaft Rear Seal - I

Flywheel Ho

. Position the installation tool (3)

ar sleeve onto the crankshaft.

nder block.

ft wear sleeve (1) and the cylinder block

stallation tool (3).

nstall”.

i02296661

using - Remove

and Install

Illustration 136

2. Apply a small continuous bead of Tooling (A) to the inner surface of crankshaft wear sleeve (1) at position X. Apply the bead of Tooling (A) 5.00 mm (0.2 inch) from the flange end of crankshaft wear sleeve.

Illustration 137

g01200285

g01200290

Removal Pro

cedure (Standard

Housing)

Start By:

a. Remove the

Assembly Manual, “Flywheel - Remove”.

Keep all pa

Contaminants may cause rapid wear and shortened component

1. Install a suitable lifting device to the flywheel housing in order to support the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb).

flywheel. Refer to Disassembly and

NOTICE

rts clean from contaminants.

life.

Page 77

SENR9983 77

Disassembly and Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Install a suitable lifting device to the flywheel housing in order to support the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb).

Illustration 138

g01165544

2. Remove the two M12 setscrews (2) and six M10 setscrews (3) from the flywheel housing (1).

3. Use the lifting device in order to remove the flywheel housing (1) from the cylinder block.

Illustration 139

Typical exam p le

g01202952

4. If the engine has an aluminum oil pan, remove the dust seal (5).

Illustration 140

g01202953

2. Remove the two M16 setscrews (2). Remove the two M12 setscrews (4). Remove the four M10 setscrews (3) from the flywheel housing (1).

3. Use the lifting device in order to remove the flywheel housing (1) from the cylinder block.

5. If necessary, remove the two dowels (4) from the cylinder block.

Removal Procedure (Wet Back End Housing)

Start By:

a. Remove the flywheel. Refer to Disassembly and

Assembly Manual, “Flywheel - Remove”.

Illustration 141

Typical example

g01215182

4. If the engine has an aluminum oil pan, remove the dust seal (6).

Page 78

78 SENR9983 Disassembly and Assembly Section

Illustration 142

g01215183

5. Remove the joint (7). Discard the joint.

6. If necessary, remove the two dowels (5) from the

cylinder block.

7. Remove the oil seal (8) from the flywheel housing (1). Discard the oil seal.

Installation Procedure (Standard Housing)

Table 29

Required Tools

Too l

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the flywheel housing is clean and free from damage. If necessary, replace the flywheel housing.

Part

Number

1861117

Part Description

Guide Stud (M10 by 100 mm)

POWERPART Universal Jointing Compound

NOTICE

Qty

Illustration 143

Engine with an aluminum oil pan

Illustration 144

Engine with a cast iron oil pan

g01202954

g01202955

2. Inspect the crankshaft rear seal (8) for leaks. If there are any oil leaks, replace the crankshaft rear seal. Refer to Disassembly and Assembly Manual, “Crankshaft Rear Seal - Remove” and refer to Disassembly and Assembly Manual, “Crankshaft Rear Seal - Install”.

3. Clean the rear face of the cylinder block. If necessary, install the two dowels (4) to the cylinder block.

4. Install the Tooling (A) to the cylinder block.

5. If the engine has an aluminum oil pan, install the

dust seal (5).

If the engine has a cast iron oil pan, apply a bead of Tooling (B) to positions (X).

Page 79

SENR9983 79

Disassembly and Assembly Section

Installation Procedure (Wet Back End Housing)

Table 30

Required Tools

Illustration 145

g01165544

6. Install a suitable lifting device to the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb).

Too l

B 1861117

Part

Number

Part Descript

Guide Stud (M10 by 100 mm)

POWERPART Universal Jointing Compound

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the flywheel housing is clean and free from damage

. If necessary, replace the flywheel

housing.

ion

Qty

7. Use the lifting device to align the flywheel housing (1) with Tooling (A). Install the flywheel housing to the cylinder block.

8. Install the two M12 setscrews (2) and four M10 setscrews (3).

9. Remove Tooling (A). Install the remaining two M10 setscrews (3).

10. Tighten the setscrews (3) to a torque of 63 N·m (46 lb ft).

11. Tighten the setscrews (2) to a torque of 78 N·m (57.5lbft).

12. Check the alignment of the flywheel housing (1) with the crankshaft. Refer to Testing and Adjusting Manual, “Flywheel Housing - Inspect”.

End By:

a. Install the flywheel. Refer to Disassembly and

Assembly Manual, “Flywheel - Install”.

Illustration 146

g01215183

2. Install a new oil seal (8) to the flywheel housing (1).

Note: Press the oil seal into the flywheel housing from the rear. Ensure that the front edge of the oil seal is flush with the joint face of the flywheel housing .

3. Inspect the crankshaft rear seal (9) for leaks. If there are any oil leaks, replace the crankshaft rear seal. Refer to Disassembly and Assembly Manual, “Crankshaft Rear Seal - Remove” and refer to Disassembly and Assembly Manual, “Crankshaft Rear Seal - Install”.

Page 80

80 SENR9983 Disassembly and Assembly Section

Illustration 147

Engine with an aluminum oil pan

Illustration 148

Engine with cast iron oil pan

g01215184

g01215185

4. Clean the rear face of the cylinder block. If necessary, install the two dowels (5) to the cylinder block.

5. Install the Tooling (A) to the cylinder block.

6. Align a new joint (7) with Tooling (A). Install the

joint to the cylinder block.

7. If the engine has an aluminum oil pan, install the dust seal (6).

Illustration 149

g01202953

9. Use the lifting device to align the flywheel housing (1) with Tooling (A). Install the flywheel housing to the cylinder block.

10. Install the two M16 setscrews (2), two M12 setscrews (4) and two M10 setscrews (3).

11. Remove Tooling (A). Install the remaining two M10 setscrews (3).

12. Tighten the M16 setscrews (2) to a torque of 190 N·m (140 lb ft).

TightentheM12setscrews(4)toatorqueof 115N·m(85lbft).

TightentheM10setscrews(3)toatorqueof 63 N·m (46 lb ft).

13. Check the alignment of the flywheel housing (1) with the crankshaft. Refer to Testing and Adjusting Manual, “Flywheel Housing - Inspect”.

End By:

a. Install the flywheel. Refer to Disassembly and

Assembly Manual, “Flywheel - Install”.

If the engine has a cast iron oil pan, apply a bead of Tooling (B) to positions (X).

8. Install a suitable lifting device to the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb).

Page 81

SENR9983 81

Disassembly and Assembly Section

i02296662

Vibration Damp er and Pulley Remove

Removal Procedure (Pulleys with Split Lock Rin

Table 31

Part

Tool

Start By:

Number Part Description Qty

27610299

gs)

Required Tools

Guide Stud (M12 by 70 mm)

E18 Torx socket 1

a. Remove the Alternator belt. Refer to Disassembly

and Assembly, “Alternator Belt - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The weight of the assembly of the crankshaft pulley, the vibration damper and the crankshaft adapter is approximately 22 kg (48 lb). Remove the vibration damper and the crankshaft pulley before the crankshaft adapter is removed from the engine.

Illustrat

ion 150

g01171908

1. Install Tooling (A) into one of the unused threads in the ass

embly of the crankshaft pulley, the

vibration damper and the crankshaft adapter.

2. Remove th

e setscrews (4).

3. Remove the vibration damper (3) and the cranksha

ft pulley (2) from the crankshaft adapter (1). Remove Tooling (A) from the crankshaft adapter (1).

4. Use a suitable tool in order to prevent the crankshaft from rotating. Use Tooling (B) to remove t

he three torx screws (5).

5. Hold a wood block against the crankshaft adapter (1). Str

ike the wood block with a hammer in order

to loosen the split lock rings (9).

6. Careful

ly remove the crankshaft adapter (1) from the crankshaft. Remove the thrust block (6) from the crankshaft ad apter (1). Remove the O-ring

) from the thrust block (6). Discard the

seal (7 O-ring seal. Remove the split lock rings (9) and the spacer (8) from the crankshaft adapter (1). Note th

e position and orientation of the split lock rings and the spacer.

Page 82

82 SENR9983 Disassembly and Assembly Section

Removal Procedure (Pulleys without Split Lock Rings)

Table 32

Required Tools

Tool

Start By:

a. Remove the alternator belt. Refer to Disassembly

and Assembly Manual, “Alternator Belt - Remove and Install”.

Part

Number

27610299

Part Description Qty

Guide Stud (M12 by 70 mm)

E18 Torx socket 1

4. Use a suitable tool in order to prevent the crankshaft fro

m rotating. Use Tooling (B) to

remove the three torx screws (5).

5. Remove the cra

nkshaft adapter (1) from the

crankshaft.

i02296663

Vibration Damper and Pulley Install

Installation Procedure (Pulleys with Split Lock Ri

Table 33

Part

Tool

Number Part Description Qty

27610299

ngs)

Required Tools

Guide Stud (M12 by 70 mm)

E18 Torx socket 1

Illustration 151

g01167596

1. Remove one of the setscrews (4). Install Tooling (A) into the assembly of the crankshaft pulley, the vibration damper and the crankshaft adapter.

2. Remove the five remaining setscrews (4).

3. Remove the vibration damper (3) and the

crankshaft pulley (2) from the crankshaft adapter (1). Remove Tooling (A) from the crankshaft adapter (1).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Page 83

SENR9983 83

Disassembly and Assembly Section

9. Repeat Step 8 two more times in order to ensure correct torque

10. Install Tooling (A) to the crankshaft adapter (1).

11. Align the crankshaft pulley (2) with Tooling (A).

Install the crankshaft pulley to the crankshaft adapter (1).

12. Inspect the vibration damper for damage. If necessary, re

place the vibration damper.

13. Align the vibration damper (3) with Tooling (A). Install the v

ibration damper to the crankshaft

adapter (1).

Illustrat

ion 152

g01171908

1. Ensure that the crankshaft adapter, the split lock rings, th

e spacer and the thrust block are clean and free from damage. Replace any components that are damaged.

2. Install a new O-ring seal (7) to the thrust block (6).

3. Install t

he spacer (8) to the crankshaft adapter (1).

4. Install both pairs of split lock rings (9) to the cranksha

ft adapter (1). There is an internal split lock ring and an external lock ring. Ensure that the split lock rings are installed in the correct position. Refer to

Illustration 152.

14. Install the f

our setscrews (4) to the assembly of the crankshaft pulley, the vibration damper and the crankshaft adapter. The setscrews should be evenly space

d. Remove Tooling (A).

15. Use a suitable tool in order to prevent the crankshaft

from rotating. Tighten the setscrews (4)

toatorqueof115N·m(85lbft).

End By:

a. Install the alternator belt. Refer to Disassembly

and Assembl

y Manual, “Alternator Belt - Remove

and Install”.

Installation Procedure (Pulleys without Sp

Table 34

Tool

27610299

lit Lock Rings)

Required Tools

Part

Number

Guide Stud (M12 by 70 mm)

E18 Torx socket 1

Part Description Qty

Note: Position the gap in the split lock rings at 180 degrees

away from each other.

5. Ensure that the front of the crankshaft is clean and free fro

m damage. Install the crankshaft adapter

(1) onto the crankshaft.

6. Align th

e holes in the thrust block with the holes in the crankshaft. Install the thrust block (6) into the crankshaft adapter (1).

7. Install the three torx screws (5) to the thrust block (6).

8. Use a suitable tool in order to prevent the crankshaft from rotating. Use Tooling (B) to tighten

x screws to a torque of 200 N·m (147 lb ft).

the tor

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Page 84

84 SENR9983 Disassembly and Assembly Section

End By:

a. Install the alternator belt. Refer to Disassembly

and Assembly Manual, “Alternator Belt - Remove and Install”.

i02403280

Illustration 153

1. Ensure that the crankshaft adapter and the front of the crankshaft are clean and free from damage. Install the crankshaft adapter (1) to the crankshaft.

2. Install the three torx screws (3) to the crankshaft adapter (1).

3. Use a suitable tool in order to prevent the crankshaft from rotating. Use Tooling (B) to tighten the torx screws to a torque of 200 N·m (147 lb ft).

4. Repeat Step 3 two more times in order to ensure correct torque.

g01167596

Crankshaft Fr

ont Seal -

Remove and Ins tall

Removal Proce

Table 35

Too l

Start By:

a. Remove the crankshaft pulley. R efer to

Disassembly and Assembly, “Crankshaft Pulley

- Remove and Install”.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Part

Number

27610301

dure

Required Tools

Part Description Qty

Front Oil Seal Removal Tool

NOTICE

5. Install Tooling (A) to the crankshaft adapter (1).

6. Align the crankshaft pulley (2) with Tooling (A).

Install the crankshaft pulley to the crankshaft adapter (1).

7. Inspect the vibration damper for damage. If necessary, replace the vibration damper.

8. Align the vibration damper (3) with Tooling (A). Install the vibration damper to the crankshaft adapter (1).

9. Install the setscrews (4) to the assembly of the crankshaft pulley, the vibration damper and the crankshaft adapter. Remove Tooling (A). Install the remaining setscrew (4).

Note: The setscrews should be evenly spaced.

10. Use a suitable tool in order to prevent the

crankshaft from rotating. Tighten the setscrews (4) to a torque of 115 N·m (85 lb ft).

Illustration 154

1. Position Tooling (A) on the nose of the crankshaft. Screw Tooling (A) into crankshaft front seal (1).

Note: Do not damage the edge of the housing for the crankshaft front seal.

g01195333

Page 85

SENR9983 85

Disassembly and Assembly Section

2. Screw the setscrew (2) into Tooling (A) in order to remove the cran

kshaft front seal (1). Discard the

crankshaft front seal (1).

Installation Procedure

Table 36

Required Tools

Tool

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Part

Number

27610284

21825577

21825578 Plate 1

27610292

21825576

Part Description Qty

Front Seal Installer 1

Stud 1

Anchor Plat

Setscrews 3

Sleeve 1

NOTICE

5. Remove T ooling (B) from the crankshaft.

End By:

a. Install the cra

nkshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”.

i02403281

Crankshaft Wear Sleeve (F ront)

- Remove and In

Removal Procedure

Start By:

a. Remove the ass

Refer to Disassembly and Assembly Manual, “Vibration Damper and Pulley - Remove”.

b. Remove the crankshaft front seal . Refer to

Disassembly and Assembly Manual, “Crankshaft Front Seal - R

embly of the crankshaft pulley.

emove and Install”.

stall

1. Ensure that the bore for the crankshaft front seal in

the front housing is clean and free from damage.

Illustration 155

Typical exam p le

g01200784

2. Assemble Tooling (B).

3. Align the new crankshaft front seal (1) to the front

housing.

Note: If the crankshaft front seal is supplied with a sleeve, remove the sleeve from the crankshaft front seal before installation.

4. Use Tooling (B) to install the crankshaft front seal (1). Ensure that the front face of the sealisinstalledtoadepthof6.5±0.2mm (0.256 ± 0.008 inch) into the front housing.

NOTICE

Keep all parts clean from contaminants.

Contaminant

s may cause rapid wear and shortened

component life.

Note: Wear sleeves are used to reclaim worn seal surfaces. Wear sleeves are not original equipment. A new crankshaft front seal must be installed when a new wear sleeve is installed.

Illustra

tion 156

g01200363

1. Useasharptooltoscoreadeeplineacrossthe wear slee

ve (1).

Note: T ake care to avoid damaging the crankshaft adapter.

Page 86

86 SENR9983 Disassembly and Assembly Section

2. Insert a thin blade between the wear sleeve (1) and the cranksh

aft adapter (2) below the scored

line. The wear sleeve will separate along the line.

3. Remove the wea

r sleeve (1) from the crankshaft

adapter (2).

Installation Procedure

Table 37

Required Tools

Tool Part Number Part Description

21820518

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the crankshaft adapter is thoroughly clean and dry.

POWERPART Liquid Gasket

NOTICE

Illustration 158

g01191372

3. Align the wear sleeve (1) with the crankshaft adapter (2). Use the installation tool that is provided with the wear sleeve and use a press in order to install the wear sleeve (1) onto the crankshaft adapter (2).

4. Remove the installation tool from the wear sleeve (1).

Illustration 157

g01200285

2. Apply a small continuous bead of Tooling (A) to the inner surface of the wear sleeve (1) at position X. Apply the bead of Tooling (A) 5.00 mm (0.2 inch) from the flange end of the wear sleeve.

5. Ensure that the wear sleeve (2) has no rough edges.

End By:

a. Install a new crankshaft front seal. Refer to

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

b. Install the assembly of the crankshaft pulley. Refer

to Disassembly and Assembly Manual, “Vibration Damper and Pulley - Install”.

i02296668

Front Co ver - Remove a nd Install

Removal Procedure

Start By:

a. If the engine has a fan, remove the fan. Refer

to Disassembly and Assembly Manual , “Fan Remove and Install”.

Page 87

SENR9983 87

Disassembly and Assembly Section

b. Remove the water pump. Refer to Disassembly

and Assembly Ma

nual, “Water Pump - Remove”.

Note: In order to remove the front cover, it is not necessary to r

emove the crankshaft pulley or the

alternator.

Illustration 159

Typical exam p le

g01156385

1. Remove the M8 set screws (3) and (4). Remove the M10 setscrew (5). Identify the positions of the different setscrews.

Note: The M10 setscrew (5) may not be installed to some engines.

2. Remove the front cover (1) from the front housing.

3. Remove the joint (2) from the front cover (1).

Discard the joint.

Installation Procedure

Table 38

Required Tools

Tool

Part

Number

Part Name Qty

Guide Stud (M8 by 70 mm)

ion 160

Illustrat

Typical example

g01172809

1. Thoroughly clean the joint face of the front housing.

2. If the original front cover is installed, follow Steps

2.a through 2.b.

a. Thoroughly clean the front cover (1).

b. Install a

new joint (2) to the front cover (1). Engage the three locators (Y) into the holes in the front cover.

3. Install Tooling (A) into holes (X) in the front housing.

4. Use Tooling (A) in order to position the front cover assembly onto the front housing.

5. Install the M8 setscrews (3) and (4). Install the M10 setscrew (5) finger tight. Ensure that the

nt setscrews are installed in the correct

differe positions.

Note: Th

e M10 setscrew (5) may not be installed to

some engines.

6. Loosely

install the water pump assembly and remove Tooling (A). Refer to Disassembly and Assembly Manual, “Water Pump - Install” for the

t procedure.

correc

Page 88

88 SENR9983 Disassembly and Assembly Section

7. Tighten the setscrews (3), (4) and (5) to a torque of 22 N·m (16 lb f

t).

NOTICE

Care must be taken to ensure that fluids are contained

8. Tighten the setscrews for the water pump to a torque of 22 N·

m (16 lb ft).

during perform ing, adjusting and repair of the product. Be prepared to

ance of inspection, maintenance, test-

collect the fluid with suitable containers before open-

End By:

ing any compar

tment or disassembling any compo-

nent containing fluids.

a. If the engine has a fan, install the fan. Refer

to Disassembly and Assembly Manual, “Fan Remove and Ins

tall”.

Dispose of all mandates.

fluids according to local regulations and

i02296792

Gear Group (Fr

ont) - Remove

and Install

Removal Proc

Table 39

Too l

Start By:

a. Remove the front cover. Refer to Disassembly

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

Part

Number

21825576

27610289

27610290

27610212

27610286

edure

Required Tools

Part Name Qty

Crankshaft Turning Tool

Crankshaft

Gear 1

Camshaft Timing Pin 1

Crankshaft Timing Pin 1

Turning Tool

Note: EitherTooling(A)canbeused.UsetheTooling that is most su

itable. Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the pr

ocedure in order to remove the gear

group.

1. Use Tooling (

A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to Testing and Adjusting M

anual, “Finding Top Centre Position for

No.1 Piston”.

b. Remove the valve mechanism cover. Refer

to Disassembly and Assembly Manual, “Valve Mechanism Cover - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 161

Typical example

g01194629

2. Install Tooling (B) through the hole (X) in the camshaft gear (1) into the front housing. Use Tooling (B) in order to lock the camshaft in the correct position. Refer to Testing and Adjusting Manual, “Finding Top Centre Position for No.1 Piston”.

Page 89

SENR9983 89

Disassembly and Assembly Section

Illustration 162

g01195325

3. Remove the plug (4) from the cylinder block. Install Tooling (C) into the hole (Y) in the cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position. Refer to Testing and Adjusting Manual, “Finding Top Centre Position for No.1 Piston”.

Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.

Illustration 163

g01198767

4. Loosen the nuts (6) on all rocker arms (7). Unscrew the adjusters (5) on all rocker arms (7) until all valves are fully closed.

Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.

5. Apply sufficient pressure to the fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash. Lock the fuel injection pump in this position. Refer to Disassembly and Assembly, “Fuel Pump Gear - Remove” for the correct procedure.

Illustration 164

Typical example

g01194949

6. Mark the gears (1), (2) and (3) in order to show alignment. Refer to Illustration 164.

Note: Identification will ensure that the gears can be installed in the original alignment.

7. Remove the fuel pump gear (3). Refer to Disassembly and Assembly, “Fuel Pump Gear Remove and Install” for the correct procedure.

8. Remove the camshaft gear (1). Refer to Disassembly and Assembly Manual, “Camshaft Gear - Remove and Install”.

9. Remove the idler gear (2). Refer to Disassembly and Assembly Manual, “Idler Gear - Remove and Install”.

Installation Procedure

Table 40

Required Tools

Tool

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Part

Number

27610212

27610286

Part Name Qty

Camshaft Timing Pin 1

Crankshaft Timing Pin 1

NOTICE

Note: The fuel injection pump must remain locked until the procedure instructs you to unlock the fuel injectio

npump.

1. Ensure that number one piston is at top dead center o

n the compression stroke. Refer to the Testing and Adjusting Manual, “Finding Top Center for No. 1 Piston”.

Page 90

90 SENR9983 Disassembly and Assembly Section

Illustration 165

g01195325

2. If necessary, install Tooling (C) into the hole (Y) in the cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position. Refer to Testing and Adjusting Manual, “Finding Top Centre Position for No.1 Piston”.

Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.

3. Ensure that all of the components of the front gear group are clean and free from wear of damage. If necessary, replace any components that are worn or damaged.

Illustration 167

Typical example

g01194629

5. Install Tooling (B) through the hole (X) in the camshaft gear (1) into the front housing.

Illustration 166

g01198768

4. Install the camshaft gear (1). Loosely install the setscrew (6) and the washer (5) for the camshaft gear. Refer to Disassembly and Assembly Manual, “Camshaft Gear - Remove and Install” for more information.

Illustration 168

Typical example

Illustration 169

Alignment of timing marks

g01194951

g01194949

Page 91

SENR9983 91

Disassembly and Assembly Section

6. Install the idler gear (2). Ensure that the timing marks on the gea

rs (1) and (2) are in alignment and that the mesh of the gears is correct. Refer to Disassembly and Assembly Manual, “Idler Gear

- Remove and In

stall”. Check the end play of the idler gear. Refer to the Specifications Manual, “Gear Group (Front)” and refer to Disassembly and Assembly

Manual, “Idler Gear - Remove and

Install” for further information.

7. Tighten the s

etscrew (6) for the camshaft gear to a torque of 95 N·m (70 lb ft). Check the end play of the camshaft gear. Refer to Specifications Manual, “Ca

mshaft” for more information.

8. Ensure that the fuel injection pump is locked in the correct

position. Refer to Disassembly and

Assembly Manual, “Fuel Injection Pump - Install”.

9. Install the

fuel injection pump gear (3). Ensure that the timing marks on the gears (2) and (3) are in alignment. See Illustration 169. Ensure that the mesh of the

gears is correct. Refer to Disassembly

and Assembly Manual, “Fuel Injection Pump Gear

-Install”formoreinformation.

10. RemovetheTooling(B)and(C).Installtheplug (4) into hole (Y) in the cylinder block. Refer to

tion 165.

Illustra

b. Install the front cover. Refer to Disassembly and

Assembly Manua

l, “Front Cover - Remove and

Install”.

i02403283

Idler Gear - Remove

Removal Proce Gear)

Table 41

Too l

B 27610286

Start By:

a. Remove the fuel injection pump gear. Refer to

Disassembly and Assembly, “Fuel Pump Gear Remove”.

b. Remove the valve mechanism cover. Refer

to Disassembly and Assembly Manual, “Valve Mechanism Cover - Remove and Install”.

Part

Number

27610212

dure (Standard Idler

Required Tool

Camshaft Timing Pin 1

Crankshaft Timing Pin

Part Name

Qty

Illustration 170

Checking backlash

g00944084

11. Ensure that the backlash for the gears (1), (2) and (3) is within specified values. Refer to the Specifications Manual, “Gear Group (Front)” for further information.

12. Lubricate each gear with clean engine oil.

13. Adjust the engine valve lash. Refer to Testing

and Adjusting Manual, “Engine Valve Lash Inspect/Adjust”.

End By:

a. Install the front cover. Refer to 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.

Illustration 171

Alignment of timing marks

g01197578

Page 92

92 SENR9983 Disassembly and Assembly Section

1. Ensure that Tooling (A) is installed into hole (X) in the camshaft ge

ar. Use Tooling (A) in order to lock

the camshaft in the correct position.

Note: Ensure t

hat the gears are marked in order to

show alignment. Refer to Illustration 171.

Illustration 172

g01197252

2. EnsurethatTooling(B)isinstalledinhole(Y)in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position.

Illustration 173

g01197580

Illustration 174

g01197246

7. Remove the assembly of the idler gear (2) and the hub (7) from the recess in the front housing.

Note: The idler gear must be tilted during removal.

8. Remove the hub (7) from the idler gear (2).

Removal Procedure (Heavy-Duty Idler Gear)

Table 42

Required Tools

Tool

Part

Number

27610212

27610286

Part Name Qty

Camshaft Timing Pin 1

Crankshaft Timing Pin 1

3. Loosen the nuts (5) on all rocker arms (6). Unscrew the adjusters (4) on all rocker arms (6) until all valves are fully closed.

Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.

4. Mark the plate (3) in order to show orientation.

Note: Identification will ensure that the plate can be

installed in the original orientation.

5. Remove the three setscrews (1).

6. Remove the plate (3).

Start By:

a. Remove the fuel injection pump gear. Refer to

Disassembly and Assembly, “Fuel Pump Gear -

emovel”.

b. Remove the valve mechanism cover. Refer

o Disassembly and Assembly Manual, “Valve

t Mechanism Cover - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Page 93

SENR9983 93

Disassembly and Assembly Section

Note: The assembly of heavy-duty idler gear is not serviceable. D

o not disassemble the heavy-duty idler

gear.

Illustration 175

Alignment of timing marks

g01197287

1. Ensure that Tooling (A) is installed into hole (X) in the camshaft gear. Use Tooling (A) in order to lock the camshaft in the correct position.

Note: Ensure that the gears are marked in order to show alignment. Refer to Illustration 175.

Note: Failure to ensure that ALL adjusters are fully unscrewed can r

esult in contact between the valves

and pistons.

4. Remove the thr

ee setscrews (1) from the

assembly of heavy-duty idler gear (2).

Illustration 178

g01197288

5. Remove the assembly of the idler gear (2) from the recess in the front housing.

Note: The idler gear must be tilted during removal.

Illustration 176

g01197252

2. EnsurethatTooling(B)isinstalledinhole(Y)in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position.

Illustration 177

g01197581

3. Loosen the nuts (4) on all rocker arms (5). Unscrew the adjusters (3) on all rocker arms (5) until all valves are fully closed.

i02403284

Idler Gear - Install

Installat Idler Gear)

Table 43

Tool

B 27610286

Keep all parts clean from contaminants.

Contamin component life.

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

ion Procedure (Standard

Required T

Part

Number

27610212

Camshaft Timing Pin 1

Crankshaft Timing Pin

NOTICE

ants may cause rapid wear and shortened

ools

Part Name

Qty

Page 94

94 SENR9983 Disassembly and Assembly Section

6. Lubricate the hub (7) with clean engine oil. Slide the hub (7) into

the idler gear (2). Ensure that the

timing marks are toward the front of the idler gear.

Illustration 179

Alignment of timing marks

g01197578

2. Ensure that Tooling (A) is installed into the hole (X) in the camshaft gear (1).

Illustration 180

g01198121

3. EnsurethatTooling(B)isinstalledinhole(Y)in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position. Refer to Testing and Adjusting Manual, “Finding Top Centre Position for No.1 Piston”.

Illustration 182

g01198122

7. Align the timing mark on the idler gear (2) with the timing mark on the camshaft gear. Refer to the illustration 179. Install the assembly of the idler gear (2) and the hub (7) into the recess in the timing case. Ensure that the oil hole (Z) is t o the top of the hub.

Note: The idler gear must be tilted during installation. Ensure that the holes in the hub are aligned with the holes in the cylinder block.

8. Clean the plate (3) and inspect the plate for wear or damage. If necessary, replace the plate.

9. Lubricate the plate (3) with clean engine oil. Align the holes in the plate (3) with the holes in the hub (7). Install the plate in the original orientation.

10. Install the setscrews (1).

11. Remove Tooling (A) and (B). Install the plug (8) to

the cylinder block. Refer to Illustration 180.

Illustration 181

g01198127

4. Clean the idler gear (2) and inspect the idler gear for wear or damage. Refer to Specifications Manual, “Gear Group (Front)” for more information. If necessary, replace the idler gear.

5. Clean the hub (7) and inspect the hub for wear or damage. Refer to Specifications Manual, “Gear Group (Front)” for more information. If necessary, replace the hub.

12. Tighten the setscrews (1) to a torque of 44 N·m (32 lb ft).

Page 95

SENR9983 95

Disassembly and Assembly Section

Installation Procedure (Heavy-Duty Idler Gear)

Table 44

Required Tools

Part

Number

27610212

27610286

21825496

Part Name Qty

Camshaft Timing Pin 1

Crankshaft Timing Pin 1

Dial gauge 1

Magnetic Base 1

NOTICE

Illustration 183

Checking end play by using a set of feeler gauge’s

g00944081

13. Use a set of feeler gauge’s in order to check the end play for the idler gear. Refer to Specifications Manual, “Gear Group (Front)” for more information.

Tool

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

ion 184

Illustrat

Checking backlash

g00944084

14. Check the backlash between the idler gear and the camshaft gear. Refer to the Specifications Manual, “G

ear Group (Front)” for more information.

15. Check the backlash between the idler gear and the cranks

haft gear. Refer to the Specifications

Manual, “Gear Group (Front)” for more information.

16. Lightly l

ubricate all of the gears with clean engine

oil.

1. Ensure that number one piston is at top dead center on the compression stroke. Refer to the Te s ti ng an

d Adjusting Manual, “Finding Top Center

for No. 1 Piston”.

Illustration 185

Alignment of timing marks

g01197287

2. Ensure that Tooling (A) is installed into the hole (X) in the camshaft gear.

End By:

a. Install the fuel injection pump gear. Refer to

Disassem

bly and Assembly, “Fuel Pump Gear -

Install”.

Illustration 186

g01198126

3. Ensure that Tooling (B) is installed in hole (Y) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position. Refer to Testing and Adjusting Manual, “Finding Top Centre Position for No.1 Piston”.

Page 96

96 SENR9983 Disassembly and Assembly Section

4. Clean the assembly of the idler gear (2) and inspect the ass

embly of the idler gear for wear or damage. Refer to Specifications Manual, “Gear Group (Front)” for more information. If necessary, replace the as

sembly of the idler gear.

5. Lubricate the bearings in the assembly of the idler gear (2) with

Illustration 187

clean engine oil.

g01197288

6. Align the timing mark on the idler gear (2) with the timing mark on the camshaft gear. Refer to the illustration 185. Install the assembly of the idler gear (2) into the recess in the timing case. Ensure that the identification mark TOP is upward.

Note: The idler gear must be tilted during installation. Ensure that the holes in assembly of the idler gear are aligned with the holes in the cylinder block.

10. Use Tooling (C) in order to check the end play for the hea

vy-duty idler gear. Refer to Specifications Manual, “Gear Group (Front)” for more information.

Illustration 189

Checking backlash

g00944084

11. Check the backlash between the idler gear and the camshaft gear. Refer to the Specifications Manual, “Gear Group (Front)” for more information.

12. Check the backlash between the idler gear and the crankshaft gear. Refer to the Specifications Manual, “Gear Group (Front)” for more information.

13. Lightly lubricate all of the gears with clean engine oil.

End By:

7. Install the setscrews (1).

8. Remove Tooling (A) and (B). Install the plug (6) to

the cylinder block. Refer to Illustration 186.

9. Tighten the setscrews (1) to a torque of 44 N·m (32 lb ft).

Illustr

ation 188

g01198143

a. Install the fuel injection pump gear. Refer to

Disassembly and Assembly, “Fuel Pump Gear Install”.

i02296670

Housing (Front) - Remove

Removal Procedure

Start By:

a. Remove the fan. Refer to Disassembly and

Assembly Manual, “Fan - Remove and Install”.

b. If necessary, remove the alternator. Refer to

Disassembly and Assembly Manual, “Alternator Remove”.

c. Remove the front pulley. Refer to Disassembly

and Assembly Manual, “Vibration Damper and Pulley - Remove”.

Page 97

SENR9983 97

Disassembly and Assembly Section

d. Remove the engine oil pan. Refer to Disassembly

and Assembly Ma

nual, “Engine Oil Pan -

Remove”.

e. If the engine h

as an accessory drive, remove the accessory drive. Refer to Disassembly and Assembly Manual, “Accessory Drive - Remove and Install”

f. Remove the timing gears. Refer to Disassembly

and Assembly

Manual, “Gear Group (Front) -

Remove and Install”.

g. Remove the fu

el injection pump. Refer to Disassembly and Assembly Manual, “Fuel InjectionPump-Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminant

s 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, adjusti

ng and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component contai

ning fluids.

Illustration 191

g01176043

3. Remove the setscrews (7), (8) and (9) from the front housing (3).

Note: The setscrews are three different lengths. Note the positions of the different setscrews.

4. Remove the front housing (3) from the cylinder block.

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenan

ce Manual, “Cooling System Coolant -

Drain” for the correct procedure.

Illustration 190

g011805

2. Remove the two setscrews (1) that secure the bypass tube (2) to the front housing (3). Remove the bypa

ss tube (2) from the cylinder head. Remove the O-rings (4) and (5) from the bypass tube (2). Discard the O-rings.

5. Remove the joint (6). Discard the joint.

Illustration 192

g01175068

6. Remove the thrust washer (10) from the cylinder block.

Page 98

98 SENR9983 Disassembly and Assembly Section

i02296671

Housing (Front) - Install

Installation P

Table 45

Tool

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Number

27610216 Alignment Tool 1

21820221

rocedure

Required Tools

Part

Part Description Qty

3 Bond 1386D 1

Guide Stud (M8by70mm)

Setscrews (M10 by 50 mm)

Straight Edge 1

POWERPART Rubber Grease

NOTICE

4. Install the thrust washer (10) into the recess in the cylinder bl

ock. Refer to Disassembly and Assembly Manual, “Camshaft - Install” for more information.

Illustration 194

g01191265

5. Install Tooling (B) to the cylinder block. Refer to Illustration 194.

6. Align a new joint (6) with Tooling (B). Install the joint to the cylinder block.

1. Ensure tha

t the front housing is clean and free from damage. If necessary, replace the front housing.

Install blanking plugs to a new front housing. Use Tooling (A) to seal all D-plugs.

2. Check the condition of the crankshaft front seal. If the front seal is damaged, remove the front seal from the f

ront housing.

3. Clean all the mating surfaces of the cylinder block.

Note: Ensure that two circular tabs (X) on the joint

are engaged in the two holes (Y) in the cylinder block.

Illustration 195

Typical example

g01182264

7. Install Tooling (C) to the cylinder block.

8. Install the front housing over Tooling (B) and

Tooling (C) onto the cylinder block.

Illustration 193

g01175068

Page 99

SENR9983 99

Disassembly and Assembly Section

Illustration 196

(7)M8by20mm (8)M8by35mm (9)M8by25mm

g01203928

9. Install the four setscrews (9) to the front housing (3) finger tight.

10. Remove Tooling (B).

11. Loosely install the setscrews (7) and (8). Refer

to Illustration 196 for the correct position of the setscrews.

12. Align the bottom face of the front housing (3) to the lower machined face of the cylinder block. Use a Tooling (D) and a feeler gauge in order to check the alignment between the front housing and the cylinder block. Refer to Illustration 195. Refer to Specifications, “Front Housing and Covers” for further information.

Illustration 197

g01203927

13. Tighten the setscrews (6), (7) and (8) in the sequence that is shown in illustration 197 to a torque of 28 N·m (20 lb ft).

Note: Ensure that the housing and the cylinder block are correctly aligned.

14. Remove Tooling (C) from the cylinder block.

15. If necessary, install a new crankshaft front seal.

Refer to Disassembly and Assembly Manual, “Crankshaft Front Seal - Remove and Install”.

Illustration 198

Typical example

g01180542

16. Install two new O-ring seals (4) and (5) to the bypass tube (1). Use Tooling (E) in order to lubricate the O-ring seals. Install the bypass tube (2) to the cylinder head. Install the two setscrews (1). Tighten the setscrews to a torque of 22 N·m (16 lb ft).

17. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Fill” for the correct procedure.

Page 100

100 SENR9983 Disassembly and Assembly Section

End By:

a. Install the fuel injection pump. Refer to

Disassembly and Assembly Manual, “Fuel Injection Pum

p-Install”.

b. Install the timing gears. Refer to Disassembly and

Assembly Manu

al, “Gear Group (Front) - Install”.

c. If the engine has an accessory drive, install

the accessory

drive. Refer to Disassembly and Assembly Manual, “Accessory Drive - Remove and Install”.

d. Install the engine oil pan. Refer to Disassembly

and Assembly Manual, “Engine Oil Pan - Install”.

e. Install the front pulley. Refer to Disassembly and

Assembly Manual, “Vibration Damper and Pulley Install”.

f. If necessary, install the alternator. Refer to

Disassembl

y and Assembly Manual, “Alternator -

Install”.

g. Install the

fan. Refer to Disassembly and Assembly

Manual, “Fan - Remove and Install”.

i02296672

Accessory Drive - Rem ov e and Install

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminan component life.

ts may cause rapid wear and shortened

Illustration 199

g01212859

1. Remove the M10 Allen head screw (1) from the accessory drive housing (8). Remove the five M8 Allen head screws (6) from the accessory drive housing (8).

2. Remove the accessory drive housing (8) from the front housing.

3. If necessary, follow Steps 3.a through 3.c in order to disassemble the accessory drive.

a. R emove the circlip (2) from the accessory drive

housing (8).

b. Place the accessory drive housing (8) onto a

suitable support. Press the assembly of the gear (4) and the bearings (3) and (5) out of the accessory drive housing (8). Use a suitable puller in order to remove the bearings (3) and (5) from the gear (4).

c. Remove the O-ring seal (7) from the accessory

drive housing (8). Discard the O-ring seal.

Installation Procedure

Table 46

Required Tools

Tool

Part

Number

21820603

21820221

Part Description Qty

POWERPART Retainer

POWERPART Rubber Grease

3 Bond 1386D 1

Perkins Engine 1106D Disassembly and Assembly

Specifications and Main Features

Frequently Asked Questions

User Manual