Perkins Engine 1106D Disassembly and Assembly
Disassembly and
Assembly
SENR9983
October 2005
1106D Ind
PJ (Engine )
ustrial Engine
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.
SENR9983 3
Table of Contents
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
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.
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
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”.
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
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”.
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).
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.
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
A
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.
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
A
Part
Number
27610294
Required
Injector Pipe Nut Tool 1
Qty
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
9
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).
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
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.
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
A
A
B
C
D
Part
Number
21825576
27610289
27610290
27610212
27610286
-
Part Name Qty
Crankshaft Turning Tool 1
Crankshaft Turning Tool 1
Gear 1
Camshaft Timing Pin 1
Crankshaft Timing Pin 1
Cap
2
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.
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.
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.
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.
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
A
A
B 27610212
C
E 27610302
F 21820221
Part
Number
21825576
27610289
27610290
27610286
Crankshaft Turning Tool
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
1
1
1
1
1
1
-
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.
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”.
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.
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
22 SENR9983
Disassembly and Assembly Section
i02296762
Fuel Injection Pump Gear Remove
Removal Procedure
Table 5
Required Tools
Too l
A
A
B
C
D
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
Crankshaft Turning Tool 1
Gear 1
Camshaft Timing Pin 1
Crankshaft Timing Pin 1
Puller (Two Leg)
1
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.
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
B
C
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”.
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.
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
A
B
C
-
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
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).
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
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
B
C
-
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”.
1
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”.
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.
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.
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
B
D
E
F 2761029
Number
-
-
-
27610294
6
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
1
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.
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
B
D
E
F
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
1
1
Loading...