Perkins Engine 402D, 403D, 404D Service Manual

Disassembly and
This document has been printed from SPI². Not for Resale
Assembly
KENR6226-01
April 2008
402D-403
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D-404D Industrial Engine
SAFETY.CAT.COM
Important Safety Information
This document has been printed from SPI². Not for Resale
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.
KENR6226-01 3
This document has been printed from SPI². Not for Resale
Table of Contents
Table of Contents
Disassembly and Assembly Section
Fuel Filter Base - Remove and Install (403D-11,
403D-15, 403D-15T, 403D-17, 404D-15, 404D-22,
404D-22T and 404D-22TA Engines) ..................... 4
Fuel Filter Base - Remove and Install (402D-05 and
403D-07 Engines) ................................................. 5
Fuel Transfer Pump - Remove and Install (Mechanical
Fuel Transfer Pump) ............................................. 7
Fuel Transfer Pump - Remove and Install (Electrical
Fuel Transfer Pump) ............................................. 8
Fuel Injection Lines - Remove and Install .............. 9
Fuel Shutoff Solenoid - Remove and Install ........ 12
Fuel Injection Pump - Remove and Install ........... 13
Fuel Injector - Remove and Install ....................... 15
Turbocharger - Remove and Install ..................... 16
Exhaust Manifold - Remove and Install ............... 18
Inlet and Exhaust Valve Springs - Remove and
Install ........................................... ........................ 19
Inlet and Exhaust Valves - Remove and Install .... 22
Engine Oil Line - Remove and Install ................... 24
Engine Oil Cooler - Remove and Install ............... 26
Engine Oil Relief Valve - Remove and Install ....... 27
Engine Oil Pump - Remove .................................. 28
Engine Oil Pump - Install ...................................... 30
Water Pump - Remove and Install (403D-11,
403D-15, 403D-15T, 403D-17, 404D-15, 404D-22,
404D-22T and 404D-22TA Engines) ................... 32
Water Pump - Remove and Install (402D-05 and
403D-07 Engines) ............................................... 33
Water Temperature Regulator Housing - Remove and
Install .................................................................. 35
Water Temperature Regulator - Remove and Install
(402D-05 and 404D-07 Engines) ........................ 36
Water Temperature Regulator - Remove and Install
(403D-11, 403D-15, 403D-15T, 403D-17, 404D-15,
404D-22, 404D-22T and 404D-22TA Engines) ... 38
Flywheel - Remove ............................................... 39
Flywheel - Install ................................................... 40
Crankshaft Rear Seal - Remove and Install ......... 41
Crankshaft Wear Sleeve (Rear) - Remove and
Install ........................................... ........................ 43
Flywheel Housing - Remove and Install .............. 44
Flywheel Housing - Remove and Install (Engines with
Flywheel Housing and Back Plate) ..................... 45
Crankshaft Pulley - Remove and Install ............... 47
Crankshaft Front Seal - Remove and Install ......... 48
Housing (Front) - Remove .................................... 49
Housing (Front) - Disassemble ............................. 50
Housing (Front) - Assemble .................................. 52
Housing (Front) - Install ........................................ 55
Crankcase Breather - Remove and Install
(Turbocharged Engines) ..................................... 56
Crankcase Breather - Remove and Install (Naturally
Aspirated Engines) .............................................. 58
Valve Mechanism Cover - Remove and Install ..... 60
Rocker Shaft and Pushrod - Remove ................... 62
Rocker Shaft - Disassemble (403D-15, 403D-15T,
403D-17, 404D-
Engines) .............................................................. 62
Rocker Shaft - Disassemble (402D-05, 403D-07,
403D-11 and 40
Rocker Shaft - Assemble (403D-15,
403D-15T,403D-17, 404D-22, 404D-22T and 404D-22TA Eng
Rocker Shaft - Assemble (402D-05, 403D-07,
403D-11 and 404D-15 Engines) ......................... 65
Rocker Shaft a
Cylinder Head - Remove ...................................... 67
Cylinder Head - Install .......................................... 69
Lifter Group - R
Camshaft - Remove .............................................. 72
Camshaft - Disassemble ....................................... 73
Camshaft - Asse
Camshaft - Install .................................................. 74
Engine Oil Pan - Remove and Install ................... 76
Pistons and Conn
Pistons and Connecting Rods - Disassemble ....... 78
Pistons and Connecting Rods - Assemble ........... 80
Pistons and Conn Connecting Rod Bearings - Remove (Connecting
rods in position) ................................................... 83
Connecting Rod B
in position) ........................................................... 83
Connecting Rod Bearings - Install ........................ 84
Crankshaft Main
Crankshaft Main Bearings - Install ........................ 86
Crankshaft - Remove ............................................ 88
Crankshaft - Inst
Bearing Clearance - Check ................................... 90
Coolant Temperature Switch - Remove and Install
(403D-11, 403D-1
404D-22, 404D-22T and 404D-22TA Engines) ... 91 Coolant Temperature Switch - Remove and Install
(402D-05 and 403 Engine Oil Pressure Switch - Remove and Install
............................................................................. 93
Glow Plugs - Remov
V-Belts - Remove and Install ................................ 96
Fan - Remove and Install ..................................... 96
Alternator-Remo
Alternators) ......................................................... 97
Alternator - Remove and Install (55 Amp
Alternator) ........................................................... 99
Alternator - Remove and Install (40 Amp
Alternator) ........................................................... 99
Alternator-Remo
Alternators) ....................................................... 101
Electric Starting Motor - Remove and Install ..... 102
22, 404D-22T and 404D-22TA
4D-15 Engines) ......................... 63
ines) ........................................... 64
nd Pushrod - Install ....................... 66
emove and Install ......................... 71
mble ........................................... 74
ecting Rods - Remove .............. 77
ecting Rods - Install .................. 81
earings - Install (Connecting rods
Bearings - Remove .................... 85
all ................................................ 89
5, 403D-15T, 403D-17, 404D-15,
D-07 Engines) ........................ 92
e and Install ......................... 95
veandInstall(65Ampand85Amp
veandInstall(14Ampand15Amp
Index Section
Index ............................... .................................... 103
4 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Disassembly an
d Assembly
Section
i02959949
Fuel Filter Base - Remove and Install (403D-11, 40 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines)
Removal Procedure
Do not allow dirt to enter the fuel system. Thoroughly clean the are will be disconnected. Fit a suitable cover over discon­nected fuel system component.
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent containing uids.
Dispose of all uids according to local regulations and mandates.
a around a fuel system component that
3D-15, 403D-15T,
NOTICE
NOTICE
Illustration 1
Typical example
2. Loosen hose clamps (4) and disconnect hoses (5).
3. If necessary, remove fuel lter element (7)
from fuel lter base (1). Refer to Operation and Maintenance Manual, “Fuel System Filter ­Replace”.
4. Remove fasteners (2) and remove fuel lter base
(1) from the mounting bracket.
5. If necessary, remove plugs (6) and washers (not
shown) from fuel lter base (1). Remove tube assemblies (3) and rubber olives (not shown) from fuel lter base (1).
g01302737
NOTICE
Keep all parts clean from contaminants.
Contaminan component life.
Note: Place identication marks on all hoses for installation purposes. Plug all hoses and all the ports in the fuel lter base. This helps prevent uid loss, and this helps to keep contaminants from entering the system.
1. Turn the fuel supply to the OFF position.
ts may cause rapid wear and shortened
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: If the engine is equipped with a hand priming pump, the hand priming pump is mounted on the fuel lter base. The assembly of the fuel lter base and the hand priming pump is not serviceable.
1. Ensure that the fuel lter base is clean and free
from damage. If necessary, replace the fuel lter base.
KENR6226-01 5
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645711
Fuel Filter B ase - Remove and Install
3D-07 Engines)
NOTICE
NOTICE
Illustration 2
Typical example
2. If necessary, install new rubber olives (not shown) onto tube assemblies (3). Install tube assemblies (3) to fuel lter base (1). Ensure the correct orientation of the tube assemblies. Tighten the nuts to a torque of 9 N·m (80 lb in).
g01302737
(402D-05 and 4 0
Removal Procedure
Do not allow dirt to enter the fuel system. Thoroughly clean the area a will be disconnected. Fit a suitable cover over discon­nected fuel system component.
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent containing uids.
Dispose of all uids according to local regulations and mandates.
round a fuel system component that
3. Install washers (not shown) onto plugs (6). Install plugs (6) to fuel lter base (1). Tighten the plugs to a torque of 23 N·m (17 lb ft).
4. Align fuel lter base (1) with the mounting bracket. Install fasteners (2). Tighten the fasteners to a torque of 50 N·m (37 lb ft).
5. If necessary, install a new fuel lter element (7) to fuel lter base (1). Refer to Operation and Maintenance Manual, “Fuel System Filter ­Replace”.
6. Connect hoses (5) and tighten hose clamps (4).
Note: Ensure that the hoses do not contact any other
engine components.
7. Turn the fuel supply to the ON position.
8. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime”.
NOTICE
Keep all parts clean from contaminants.
Contaminants component life.
Note: Place identication marks on all hoses for installation purposes. Plug all hoses and all the ports in the fuel lter base. This helps prevent uid loss, and this helps to keep contaminants from entering the system.
1. Turn the fuel supply to the OFF position.
may cause rapid wear and shortened
6 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Illustration 3
Typical example
g01303701
2. Loosen hose clamps (3) and disconnect hoses (4).
3. If necessary, remove fuel lter element (5). Refer
to Operations and Maintenance Manual, “Fuel System Filter - Replace”.
4. Remove bolt (1) and remove fuel lter base (2) from the mounting bracket.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that the fuel lter base is clean and free from damage. If necessary, replace the fuel lter base.
Illustration 4
Typical example
g01303701
2. Align fuel lter base (2) with the mounting bracket. Install bolt (1). Tighten the bolt to a torque of 25 N·m (18 lb ft).
3. If necessary, install a new fuel lter element (6) to fuel lter base (2). Refer to Operation and Maintenance Manual, “Fuel System Filter ­Replace”.
4. Connect hoses (4) and tighten hose clamps (3).
Note: Ensure that the hoses do not contact any other
engine components.
5. Turn the fuel supply to the ON position.
6. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime”.
KENR6226-01 7
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645722
Fuel Transfer Pump - Remove and Install (Mechanical Fu
el Transfer
Pump)
Removal Proce
Do not allow di clean the area around a fuel system component that will be disconnected. Fit a suitable cover over discon­nected fuel sy
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent containing uids.
Dispose of all uids according to local regulations and mandates.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Place identication marks on all hoses for installation purposes. Plug all hoses and all the ports in the fuel transfer pump. This helps prevent uid loss, and this helps to keep contaminants from entering the system.
rt to enter the fuel system. Thoroughly
stem component.
dure
NOTICE
NOTICE
NOTICE
Illustration 5
Typical example
Note: The fuel transfer pump can be oriented in two positions. Before removing the fuel transfer pump from the cylinder block, note the orientation of ange (5) on fuel transfer pump (1) for assembly.
2. Loosen the hose clamps and disconnect the hoses (not shown) from fuel transfer pump (1).
3. Evenly loosen bolts (4) and remove fuel transfer pump (1) from the cylinder block.
Note: In order to remove the fuel transfer pump, it may be necessary to rotate the crankshaft until the operating plunger of the fuel transfer pump is not under pressure.
4. Remove O-ring seal (3) from fuel transfer pump (1).
g01326306
1. Turn the fuel supply to the OFF position.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
8 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645719
Fuel Transfer Pump - Remove and Install (Electrical Fu
Removal Procedure
Care must be taken to ensure that uids are contained during perform ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compar nent containing uids.
ance of inspection, maintenance, test-
el Transfer Pump)
NOTICE
tment or disassembling any compo-
Illustration 6
Typical example
1. Clean the mating surfaces of the cylinder block and ange (5) on the fuel transfer pump.
Note: Ensure that the camshaft lobe for the fuel transfer pump is at minimum lift before the fuel transfer pump is installed. The fuel transfer pump canbeorientedintwopositions.Ensurethatthefuel transfer pump is oriented in the correct position.
2. Install a new O-ring seal (3) to fuel transfer pump (1).
3. Lubricate the operating plunger of fuel transfer pump (1) with clean engine oil.
4. Position fuel transfer pump (1) on the cylinder block. Ensure that the operating plunger is positioned correctly on the camshaft lobe. Install bolts (4). Tighten the bolts to a torque of 6 N·m (53lbin).
5. Connect the hoses (not shown) to fuel transfer pump (1). Tighten the hose clamps.
g01326306
Dispose of all mandates.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Put identication marks on all hoses, on all hose assembl for installation purposes. Plug all hose assemblies and tube assemblies. This helps to prevent uid loss and this help the system.
1. Turn the fue
2. Turn the battery disconnect switch to the OFF
position.
uids according to local regulations and
NOTICE
ies, on wires and on all tube assemblies
s to keep contaminants from entering
l supply to the OFF position.
Note: The inlet for the fuel transfer pump can be rotated 360 degrees by loosening bolt (2). The fuel inlet is adjustable in 15 degree increments. If adjustment is made to the position of the fuel inlet, tighten bolt (2) to a torque of 2.5 N·m (22 lb in).
6. Turn the fuel supply to the ON position.
7. Prime the fuel system. Refer to Systems
Operation, Testing and Adjusting, “Fuel System ­Prime” for additional information.
Illustration 7
Typical ex
3. Disconnect harness assembly (1).
ample
g01304057
KENR6226-01 9
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
4. Loosen hose clamps (4) and (5). Disconnect hoses (6) and (7
5. Remove bolts (2) and remove electric transfer pump (3).
Installation
1. Ensure that the electric transfer pump is clean
and free from d electric transfer pump.
Illustration 8
Typical example
2. Position el and install bolts (2).
).
Procedure
amage. If necessary, replace the
g01304057
ectric transfer pump (3) on the mounting
i02959953
Fuel Injection Lines - Remove and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants m component life.
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent contain
Dispose of all uids according to local regulations and mandates.
Do not let the tops of fuel injectors turn when the fuel line nuts are loosened or tightened.
ay cause rapid wear and shortened
NOTICE
and repair of the product. Be prepared to
ing uids.
NOTICE
3. Tighten bol
4. Connect hoses (6) and (7). Tighten hose clamps
(4) and (5)
5. Connect harness assembly (1).
6. Turn the fuel supply to the ON position.
7. Turn the ba
position.
8. Remove the Operation and Maintenance Manual, “Fuel System
- Prime”.
ts (2) to a torque of 9 N·m (79 lb in).
.
ttery disconnect switch to the ON
air from the fuel system. Refer to
The fuel injectors will be damaged if the top of the injector turns in the body.
The engine will be damaged if a defective fuel injector is used because the shape of fuel (spray pattern) that comes out of the nozzle will not be correct.
Note: Place identication marks on all tube assemblies for installation. Plug all lines and tube assemblies in order to prevent contamination.
1. Turn the fuel supply to the OFF position.
10 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Illustration 9
Typical example
g01326550
2. Disconnect nuts (1) for fuel injection lines (2) from the fuel injectors.
3. Disconnect nuts (1) for fuel injection lines (2) from the fuel injection pump.
4. Remove fuel injection lines (2) from the engine as a unit.
5. Use suitable caps in order to plug the open ports of the fuel injection pump immediately.
6. The 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines have a rigid fuel return line.
For engines with a rigid fuel return line, remove banjo bolt (4) from fuel return line (3). Rem ove washers (8).
The 402D-05, 403D-07, 403D-11 and 404D-15 engines have a exible fuel return hose.
For engines with a exible fuel return hose, disconnect the hose from the fuel injection pump.
ion 10
Illustrat
Typical example
g01326555
7. Remove nuts (5) from fuel injectors (7).
Note: For e
ngines with a rigid fuel return line, ensure that the fuel return line is not distorted when the nuts are loosened.
8. Remove fuel return line (3) and washers (6) from
fuel injectors (7).
9. Use suitable caps in order to plug the fuel injectors
immediately.
Installation Procedure
Table 1
Tools
Part Name Qty
Pipe Nut Tool
1
Tool
A
Part
Number
27610294
Required
Injector
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
KENR6226-01 11
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
The 402D-05, 403D-07, 403D-11 and 404D-15
NOTICE
engines have a
exible fuel return hose.
Do not let the tops of fuel injectors turn when the fuel line nuts are lo
osened or tightened.
The fuel injectors will be damaged if the top of the injector turns
in the body.
For engines with a exible fuel return hose, connect the fu
el return hose to the fuel injection
pump.
4. Tighten nuts (
5)toatorqueof27N·m(20lbft).
The engine will be damaged if a defective fuel injector is used becaus
e the shape of fuel (spray pattern) that
comes out of the nozzle will not be correct.
Note: The installation procedure is similar for the two cylinder,
the three cylinder and the four cylinder
engines.
Illustration 11
Typical e
xample
g01326555
1. Remove the caps from fuel injectors (7). Install new washe
rs (6) and fuel return line (3) to fuel
injectors (7).
Note: Th
e washers (6) have two small holes.
2. Install nuts (5) to fuel injectors (7).
3. The 403D-15, 403D-15T, 403D-17, 404D-22,
404D-22TA and 404D-22TA engines have a rigid fuel ret
urn line.
For engines with a rigid fuel return line, install new washers
(8) to fuel return line (3) and install banjo bolt (4) to the fuel injection pump. Tighten banjo bolt (4) to a torque of 7 N·m (62 lb in).
Illustration 12
Typical example
g01326550
5. Remove the caps from the outlet connections of the fuel injection pump. Install the fuel injection lines to the engine as a unit.
6. Connect fuel injection lines (2) to fuel injectors (7). Tighten the union nuts (1) nger tight.
7. Use Tooling (A) to tighten union nuts (1) at the fuel injection pump.
For 402D-05 and 403D-07 engines, tighten union nuts (1) to a torque of 20 N·m (15 lb ft).
For 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines, tighten the union nuts (1) to a torque of 23 N·m (17 lb ft).
Note: For the three cylinder and the four cylinder engines, tighten the center union nuts rst.
8. Use Tooling (A) to tighten union nuts (1) at the fuel injections.
For 402D-05 and 403D-07 engines, tighten union nuts (1) to a torque of 20 N·m (15 lb ft).
12 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
For 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D­engines, tighten the union nuts (1) to a torque of 23 N·m (17 lb ft).
9. Turn the fuel supply to the ON position.
10. Prime the fuel
Maintenance Manual, “Fuel System - Prime” for more information.
22, 404D-22T and 404D-22TA
system. Refer to Operation and
i02645718
Fuel Shutof f Solenoid ­Remove an d In
Removal Procedure
Care must be taken to ensure that uids are contained during perfo ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compa nent containing uids.
rmance of inspection, maintenance, test-
rtment or disassembling any compo-
stall
NOTICE
2. Disconnect electrical connection (3) from the harness ass connections for installation.
3. Remove fuel sh injection pump housing by rotating the fuel shutoff solenoid in a counterclockwise direction.
4. Remove sealing washer (2) from fuel shutoff solenoid (1).
embly (not shown). Mark all
utoff solenoid (1) from the fuel
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Dispose of a mandates.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Turn the battery disconnect switch to the OFF position.
ll uids according to local regulations and
NOTICE
Illustration 14
Typical example
1. Install sealing washer (2) to fuel shutoff solenoid (1).
2. Install fuel shutoff solenoid (1) into the fuel injection pump housing by rotating the fuel shutoff solenoid in a clockwise direction. Tighten the fuel shutoff solenoid to a torque of 17 N·m (12 lb ft).
3. Connect electrical connection (3) to the harness assembly (not shown).
4. Turn the battery disconnect switch to the ON position.
g01326564
Illustration 13
Typical e
xample
g01326564
KENR6226-01 13
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02959957
Fuel Injection Pump - Remove and Install
Removal Procedure
Start By:
a. Remove the fuel shutoff solenoid. Refer to
Disassembly a Solenoid - Remove and Install”.
Care must be taken to ensure that uids are contained during perfor ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compa nent containing uids.
Dispose of al mandates.
nd Assembly, “Fuel Shutoff
NOTICE
mance of inspection, maintenance, test-
rtment or disassembling any compo-
l uids according to local regulations and
Illustration 15
Typical example
g01327005
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: The removal procedure is similar for the two cylinder, t engines. The Illustrations show a four cylinder engine.
1. Remove the f
he three cylinder and the four cylinder
uel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection Lines
- Remove and Install” for more information.
The 402D-05, 403D-07, 403D-11 and 404D-15 engines have a exible fuel return hose.
For engines with a exible fuel return hose, disconnect the fuel hose from the inlet connection of the fuel
injection pump.
Illustration 16
Typical example
2. Gradual the fuel injection pump to the cylinder block.
3. Careful cylinder block and remove clip (7) that connects link (6) to fuel rack control (5).
ly loosen bolts (4) and nuts (2) that fasten
ly raise fuel injection pump (1) from the
g013270
06
4. Remove fuel injection pump (1) from the cylinder block.
5. Remove shims (3) from the mounting face of the cylinder block.
14 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Note: Record the thickness of each shim and the number of shims
for reassembly. The fuel injection timing is determined by the thickness of the shim pack that is between the fuel injection pump and the mounting f
ace on the cylinder block. Refer to Specications, “Fuel Injection Pump” for more information.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: The installation procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The Illustrations show a four cylinder engine.
1. Clean the mating surfaces of the cylinder block
and the fuel injection pump.
Illustration 17
Typical example
g01327005
2. New shims (3) must be used during assembly.
Install the correct thickness and the correct number of shims on the mounting face of the cylinder block. Refer to Specications, “Fuel Injection Pump” for more information.
Illustration 18
Typical example
g01327006
3. Positionfuelinjectionpump(1)closetothe mounting face of the cylinder block, and connect link (6) and fuel rack control (5) with clip (7).
4. Align fuel injection pump (1) with the studs on the cylinder block. Install the fuel injection pump to the cylinder block.
5. Install bolts (4) and nuts (2). Ensure that the tube clip for the engine oil line is secured by the appropriate fastener.
For 402D-05, 403D-07, 403D-11 and 404D-15 engines, evenly tighten bolts (4) and nuts (2) to a torqueof6N·m(53lbin).
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, evenly tighten bolts (4) and nuts (2) to a torque of 15 N·m (11 lb ft).
6. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.
The 402D-05, 403D-07, 403D-11 and 404D-15 engines have a exible fuel return hose.
For engines with a exible fuel return hose, connect the fuel hose to the inlet connection of the fuel injection pump.
KENR6226-01 15
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
End By:
a. Install the fuel shutoff solenoid. Refer to
Disassembly and Assembly, “Fuel Shutoff Solenoid - Rem
Fuel Injector
ove and Install”.
i02959963
- Remove and
Install
Removal Proce
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection Lines
- Remove and I
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusti collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent contai
Dispose of all uids according to local regulations and mandates.
ng and repair of the product. Be prepared to
ning uids.
dure
nstall”.
NOTICE
1. Use a deep socket to remove fuel injector (1) from the cylinder he
2. Remove seat washers (2) from the cylinder head.
Note: 402D-05 and 403D-07 engines have two seat
washers. The seat washers are different diameters. The 403D-11, 4 404D-15, 404D-22, 404D-22T and 404D-22TA engines have one seat washer.
3. Cap all openings or plug all openings immediately.
ad.
03D-15, 403D-15T, 403D-17,
Installation Procedure
Table 2
Required Tools
Too l
A
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Part
Number
1861117
Part Description Qty
POWERPART Universal Jointing Compound
NOTICE
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Illustration 19
Typical example
g01320610
Illustration 20
Typical ex
1. Clean the bore for the fuel injector in the cylinder
2. Install n
ample
head. Ensu Clean the threads on the body of the fuel injector.
fuel injector in the cylinder head.
re that no debris enters the cylinder.
ew seat washers (2) into the bore for the
g01304054
16 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Note: 402D-05 and 403D-07 engines have two seat washers. The se The 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines have o
3. Apply a bead of Tooling (A) to the rst two threads of the fuel in head. The bead should have a diameter of 2 mm (0.08inch)andalengthof6mm(0.25inch).
Note: Ensure that Tooling (A) does not cover the body of the fuel injector below the threads.
4. Install fuel injector (1) into the cylinder head. Use a deep socket to tighten the fuel injector to a torque of 64 N·m (47 l
End By:
a. Install the fuel injection lines. Refer to Disassembly
and Assembly, “Fuel Injection Lines - Remove and Install
at washers are different diameters.
ne seat washer.
jector that engage into the cylinder
b ft).
”.
i02645771
Turbocharg
er - Remove and
Install
Removal pro
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent containing uids.
Dispose of all uids according to local regulations and mandates.
Keep all parts clean from contaminants.
Contamina component life.
nts may cause rapid wear and shortened
cedure
NOTICE
NOTICE
ion 21
Illustrat
Illustration 22
g01304121
g01304528
1. Loosen hose clamps (5) and remove air inlet hose
Note: Plug and cap all open ports and tube
assemblies.
(1).
2. Remove allen head screws (21) and remove exhaust elbow (19) from turbocharger (4). Remove gasket (18) from the turbocharger.
KENR6226-01 17
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
3. Remove banjo bolt (2) and washers (3). Remove the fasteners a tube clips (6). Remove bolts (14) and remove tube assembly (13) from the cylinder block. Remove O-ring seal (1
4. Remove bolts (8) and disconnect tube assembly (10) from the
If necessary, remove bolts (9) and remove tube assembly (10 joint (11).
nd the spacers (not shown) for
2).
turbocharger. Remove joint (7).
) from the cylinder block. Remove
5. Remove nuts ( from the exhaust manifold. Remove gasket (20) from the exhaust manifold. If necessary, remove studs (15) fr
Note: Do not use the actuator rod of the wastegate to lift the t
urbocharger.
Installati
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear.Ifthe turbocharger must be replaced.
2. Te st t he a c to Systems Operation, Testing and Adjusting, “Wastegate - Test” for more information. If the actuator i operate within the specied limits, the complete turbocharger must be replaced.
17) and remove turbocharger (4)
om the exhaust manifold.
on procedure
NOTICE
turbocharger is worn, the complete
tuator for correct operation. Refer
s damaged or the actuator does not
Illustrat
ion 23
g01304121
Illustration 24
3. Clean the mating surfaces of the exhaust manifold. If necessary, install studs (15) to the exhaust manifold. Tighten the studs to a torque of 18 N·m (13 lb ft). Install a new gasket (20) over the studs.
4. Position turbocharger (4) onto the exhaust manifold. Install nuts (17) and tighten to a torque of 25 N·m (18 lb ft).
Note: Do not use the actuator rod of the wastegate to lift the turbocharger .
g01304528
18 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
5. Ensure that tube assemblies (10) and (13) are clean and free f the tube assemblies.
6. If necessary, assembly (10) onto the cylinder block. Install bolts (9). Tighten the bolts nger tight.
Position a new joint (7) on tube assembly (10). Align tube assembly (10) to the bottom of the turbocharge nger tight.
Tighten bolt (89lbin).
7. Lubricate th clean engine oil through oil inlet port (16). Rotate the shaft of the turbocharger in order to distribute the lubrica
8. Install a new O-ring seal (12) to tube assembly (13). Posit cylinder block. Install bolts (14). Tighten the bolts toatorqueof10N·m(89lbin).
9. Install new washers (3) and banjo bolt (2) to tube assembly (13). Position tube assembly (13) onto turbochar tight.
rom damage. If necessary, replace
position a new joint (11) and tube
r. Install bolts (8). Tighten the bolts
s (8) and (9) to a torque of 10 N·m
e bearings of turbocharger (4) with
nt.
ion tube assembly (13) against the
ger (4). Tighten the banjo bolt nger
i02959965
Exhaust Manifold - Remove and Install
Removal Procedure
Start By:
a. If the engine is equipped with a turbocharger,
remove the tur and Assembly, “ Turbocharger, Remove and Install”.
Keep all parts
Contaminants may cause rapid wear and shortened component li
Note: The two cylinder, the three cylinder and the four cylinder engines have different exhaust manifolds. The removal procedure is similar for all models.
bocharger. Refer to Disassembly
NOTICE
clean from contaminants.
fe.
10. If necessa fasteners (not shown) to tube clips (6). Torque the fasteners to 10 N·m (89 lb in).
11. Tighten banjo bolt (2) to a torque of 18 N·m (13 lb ft).
Note: Ensure that the tube assembly does not come into contact with any other components.
12. Clean the mating surfaces of exhaust elbow (19). Position a new gasket (18) and exhaust elbow (19) on turboc Tighten the bolts to a torque of 32 N·m (24 lb ft).
13. Ensure th defects or restrictions. Loosely install hose clamps (5) to air inlet hose (1). Install the air inlet hose to the conn and to the turbocharger. Tighten the hose clamps.
ry, install the spacer and install the
harger (4). Install allen head screws (21).
at inlet hose (1) is clean and free from
ection of the inlet manifold (not shown)
Illustration 25
Typical example
1. Loosen nuts (5) and bolts (6).
Note: In order to prevent distortion of the exhaust
manifold, loosen the outer fasteners rst.
2. Remove nuts (5) and bolts (6).
Note: Identify bolts of different lengths so that the
bolts can be installed in the correct positions.
3. Remove exhaust manifold (4) from cylinder head (1). Note the orientation of the exhaust manifold for installation.
g01326567
4. Remove gasket (3) from cylinder head (1).
KENR6226-01 19
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
5. If necessary, remove exhaust manifold studs (2) from cylinder h
Installation P
ead (1).
rocedure
NOTICE
Keep all parts c
lean from contaminants.
Contaminants may cause rapid wear and shortened component lif
e.
Note: The two cylinder, the three cylinder and the four cylinder engines have different exhaust manifolds. The installation procedure is similar for all models.
1. Ensure that the mating surfaces of the cylinder head and the exhaust manifold are clean and free from damage.
Note: On three cylinder engines and four cylinder engines, tight
en the inner bolts rst.
End By:
a. If the engine is equipped with a turbocharger,
install the turbocharger. Refer to Disassembly and Assembly, “ Tu
rbocharger, Remove and Install”.
i02959972
Inlet and Exhaust Valve Springs - Remove an d Install
Removal Procedure
Table 3
Required Tools
Tool Part Number Part Description Qty
21825739
A
(1)
B
(2)
B
(3)
B
(1)
402D-05 and 4
(2)
403D-11 and 404D-15 engines
(3)
403D-15, 403 D-15T, 403D-17, 404D-22, 404D-22T and
404D-22TA engines
-
27610235
21825934
03D-07 engines
Val ve Sp r ing
Adapter 1
Adapter 1
Adapter 1
Compressor 1
on 26
Illustrati
Typical example
g01326567
2. If necessary, install exhaust manifold studs (2) to cylinder head (1).
3. Install a new exhaust manifold gasket (3) to cylinder head (1).
4. Align exhaust manifold (4) with studs (2) and install the exhaust manifold to cylinder head (1).
Note: Ensure that the exhaust manifold is installed in the correct orientation.
5. Install nuts (5) and bolts (6) nger tight.
Note: Ensu
re that bolts of different lengths are
installed in the correct positions.
6. For 402D-0
5, 403D-07, 403D-11, 403D-15, 403D-15T, 403D-17, and 404D-15 engines, tighten nuts (5) and bolts (6) to a torque of 10 N·m (89lbin)
.
For 404D-22, 404D-22T and 404D-22TA engines, tighten n
uts (5) and bolts (6) to a torque of 25 N·m
(18 lb ft).
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly
and Assembly, “Rocker Shaft and
Pushrod - Remove”.
Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equip­ment.
Follow t he recommended procedure and use all recommended tooling to release the spring force.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
20 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Note: Do not use excessive force to turn the
NOTICE Install suitable plugs to the inlet ports of the cylinder head in order to
prevent the entry of loose parts into
the engine.
crankshaft. Th stems.
d. Continue to ro
e use of force can result in bent valve
tate the crankshaft and gradually release the pressure on Tooling (A) until the piston is at the top center position. The valve
NOTICE
Plug the apertures for the push rods in the cylinder
is now held in spring to be safely removed.
a position that allows the valve
head in order to prevent the entry of loose parts into the engine.
Note: The removal procedure is similar for the two
Ensure that th
e valve spring is compressed squarely
or damage to the valve stem may occur.
NOTICE
cylinder, the three cylinder and the four cylinder engines. The following procedure should be adopted in order to remove the valve springs when the cylinder head is installed to the engine. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install” for the procedure to remove the valve springs from a cylinder head that has been removed from the engine.
Note: Ensure that the appropriate piston is at the top center position before the valve spring is removed. Failure to ensure that the piston is at the top center
2. Use tool (A) i Remove valve keepers (1).
Note: For fou require replacement the procedure can be carried out on two cylinders at the same time. The procedure canbecarri 1with4and2with3.Ensurethatallofthevalve springs are installed before changing from one pair of cylinder
n order to compress valve spring (3).
r cylinder engines, if all valve springs
ed out on the following pairs of cylinders.
s to another pair of cylinders.
position may allow the valve to drop into the cylinder bore.
NOTICE Do not turn the crankshaft while the valve springs are removed.
Illustration 27
Typical example
1. Follow Ste
ps 1.a through 1.d in order to position
g0130458
the appropriate piston at top center.
a. Install To
oling (A) and (B) in position on the cylinder head in order to compress a valve spring for the appropriate piston.
b. Use Tooling (A) in order to compress valve
spring (3) and open the valve slightly.
Note: Do not compress the spring so that the valve spring retainer (2) touches the valve stem seal.
3. Apply sufcient pressure to Tooling (A) in order to allow removal of the valve keepers (1).
Note: Do not compress the spring so that the valve spring retainer (2) touches the valve stem seal.
Remove valve keepers (1).
4. Slowly rel
easethepressureonTooling(A).
5. Remove valve spring retainer (2) and remove
3
valve spri
ng (3).
6. RemoveTooling(A)and(B).
c. Carefully rotate the crankshaft until the piston
touches the valve.
KENR6226-01 21
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Installation P
Table 4
Tool Part Number Part Description Qty
21825739
A
(1)
B
(2)
B
B
(1)
(2)
(3)
404D-22TA engines
27610235
(3)
21825934 Adapter 1
402D-05 and 403D-07 engines 403D-11 and 404D-15 engines 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and
rocedure
Required Tools
-
Valve Spring Compressor 1
Adapter 1
Adapter 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE Do not turn the crankshaft while the valve springs are removed.
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.
NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
3. Install Tooling (A) and (B) in the appropriate
position on the cylinder head in order to compress the valve spri
ng.
4. Apply sufcient pressure to Tooling (A) in order to
install valve
keepers (1).
Note: Do not compress the spring so that valve spring retai
ner (2) touches the valve stem seal.
Install the valve spring keepers.
5. Carefully release the pressure on Tooling (A).
NOTICE Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine.
NOTICE Install suitable plugs to the inlet ports of the cylinder head in order to
prevent the entry of loose parts into
the engine.
1. Inspect the val
ve springs for the correct length.
Refer to Specications, “Cylinder Head Valves ”.
Note: Ensure
that the valve keepers are correctly
seated.
The valve spring keepers can be thrown from the valve when the valve spring compressor is released. E
nsure that the valve spring keepers are properly installed on the valve s tem. To help prevent personal injury, keep away from the front of the valve
spring keepers and valve springs
during the installation of the valves.
6. Remove Tool
ing (A). Ensure that all of the valves are secured in place by a valve spring and valve keepers. Rotate the crankshaft through about 45 degrees
inordertoclearthepistonfromthe valve. Lightly strike the top of the valve with a soft hammer in order to ensure that the valve keepers are proper
ly installed.
End By:
a. Install the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and Pushrod -
Install”.
Illustration 28
Typical example
g01304583
2. Install valve spring (3) onto the cylinder head. Position valve spring retainer (2) onto valve spring (3).
22 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02959973
Inlet and Exhaust Valves ­Remove an d Install
Ensure that the valve spring is compressed squarely or damage to the
NOTICE
valve stem may occur.
Removal Procedure
Table 5
Required Tools
Tool Part Number Part Description Qty
A 21825663
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”.
Valve Spring Compressor
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: The removal procedure is identical for the two cylinder, the three cylinder and the four cylinder engines. The
Illustrations show a four cylinder engine.
1. Clean the bottom face of the cylinder head. Check the dep
th of the valves below the face of the cylinder h ead before the valve springs are removed. Refer to Specications, “Cylinder Head Val v e s ” for
the correct dimensions.
2. Place a temporary identication mark on the heads of the
valves in order to identify the correct
position.
Note: Do not
stamp the heads of the valves. Stamping or punching the heads of the valves could cause the valves to fracture.
Illustration 29
Typical example
g01315963
Personal injury can result from being struck by parts prop
elled by a released spring force.
Make sure to wear all necessary protective equip­ment.
Illustration 30
Typical example
3. Use Tooling (A) in order to compress the appropriate valve spring (3). Remove valve keepers (1).
Follow the recommended procedure and use all recommen
ded tooling to release the spring force.
Note: Do not compress the valve spring so that valve
spring retainer (2) touches valve stem seal (4).
4. Remove Tooling (A).
g01325840
KENR6226-01 23
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
5. Remove valve spring retainer (2). Remove valve spring (3).
6. Remove valve (5).
7. Remove valve stem seal (4).
8. Repeat Steps 3
Installation
Table 6
Tool Part Number Part Description Qty
21825663
A
(1)
B
B
(1)
(2)
404D-22T and 404D-22TA engines
21825622
(2)
21825623
402D-05 and 40 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D -22,
to 7 for the remaining valves.
Procedure
Required Tools
Valve Spring Compressor 1
Valve Stem Seal Replacer 1
Val v e St e m Se a
3D-07 engines
l Replacer 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: The installation procedure is identical for the two cylinder, the three cylinder and the four cylinder engines. The I
llustrations show a four cylinder engine.
Illustration 31
Typical example
g01315893
2. Use Tooling (B) to install new valve stem seals (4) onto each of the valve guides.
Note: The outer face of the valve guides must be clean and dry before installing the valve stem seals.
1. Clean all components of the cylinder head assembly. En
sure that all ports, all coolant passages and all lubrication passages in the cylinder head are free from debris. Follow Steps
1.a through
1.e in order to inspect the components of the cylinder head assembly. Replace any components that are worn or damaged.
a. Inspect the cylinder head for wear and for
damage. Refer to Systems Operation, Testing and Adjusti
ng, “Cylinder Head Inspect”.
b. Inspect the valve seats for wear and for
damage. Ref
er to Specications, “Cylinder
Head Valves” for further information.
c. Inspect th
e valve guides for wear and for damage. Refer to Specications, “Cylinder Head Valves” and Systems Operation, Testing and Adjust
ing, “Valve Guide - Inspect” for
further information.
d. Inspect th
e valves for wear and for damage. Refer to Specications, “Cylinder Head Valves”.
e. Inspect th
e valve springs for the correct length.
Refer to Specications, “Cylinder Head Valves”.
Illustration 32
Typical example
g01325840
3. Lubricate the stem of valve (5) with clean engine oil. Install valve (5) in the appropriate position in the cylinder head. Check the depth of the valve below the face of the cylinder head. Refer to Systems Operation, Testing and Adjusting, “Valve Depth - Inspect” for more information.
24 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
4. Install valve spring (3) to the cylinder head. Position valve (3).
Personal injury can result from being struck by parts propel
Make sure to wear all necessary protective equip­ment.
Follow the recommended procedure and use all recommended
Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
spring retainer (2) onto valve spring
led by a released spring force.
tooling to release the spring force.
NOTICE
6. Remove Tooling (A).
7. Repeat Steps 4 to 6 for the remaining valves.
8. Place the cylin
Ensure that the heads of the valves are not obstructed. Gently strike the top of the valves with a soft ham keepers (1) are properly installed.
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly
der head on a suitable support.
mer in order to ensure that valve
, “Cylinder Head - Install”.
i02959976
Engine Oil Line - Remove and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 33
Typical example
5. Use Tooling (A) in order to compress valve spring (3). Install valve keepers (1).
Note: Donotcompressthespringsothatvalve spring retainer (2) touches valve stem seal (4).
The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves.
g01315963
Contaminants may cause rapid wear and shortened component life.
NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent containing uids.
Dispose of all uids according to local regulations and mandates.
KENR6226-01 25
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
4. Remove oil line (1) from the engine.
Installation Procedure
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
ion 34
Illustrat
Typical example
g01304820
1. Loosen nut (2) that attaches the clip on oil line (1) to the fuel injection pump.
2. Remove banjo bolt (3) and remove washers (4) from the cylinder block.
ion 36
Illustrat
Typical example
g01304820
1. Place oil line (1) on the engine. Ensure that the clip on the oil line is located below nut (2).
2. Position banjo bolt (3) and new washers (4) onto oil line (1). Install the banjo bolt and oil line to the cylinder
block nger tight.
Illustration 35
Typical example
g01307372
3. Remove banjo bolt (5) and remove washers (6) from the cylinder head.
26 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
NOTICE Care must be taken to ensure that uids are contained during perform
ance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compar
tment or disassembling any compo-
nent containing uids.
Illustration 37
Typical example
g01307372
3. Position banjo bolt (5) and new washers (6) onto oil line (1). Install the banjo bolt and the oil line to the cylinder head nger tight.
4. Tighten nut (2) that attaches the clip on oil line (1) to the fuel injection pump.
For 402D-05, 403D-07, 403D-11 and 404D-15 engines, tighten nut (2) to a torque of 6 N·m (53lbin).
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten nut (2) toatorqueof15N·m(133lbin).
Dispose of all
uids according to local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Drain the coolant from the cooling system into a suitable con
tainer. Refer to Operation and Maintenance Manual, “Cooling System Coolant ­Drain” for the correct procedure.
2. Drain the engine lubricating oil into a suitable container. Refer to Operation and Maintenance Manual, “Eng
ine Oil and Filter - Change” for the
correct procedure.
5. Tighten banjo bolts (3) and (5) to a torque of 12N·m(106lbin).
i02645673
Engine Oil Cooler - Remo ve and Install
Illustration 38
Removal Procedure
Table 7
Required Tools
Tool Part Number Part Description
A
-
Strap Wrench
Qty
1
Typical example
3. Use Tooling (A) to remove oil lter element (5).
4. Loosen hose clamps (2) and disconnect hoses
(1). Note the positions of the coolant inlet and the coolant outlet for installation.
5. Remove adapter (4) and remove oil cooler (3) from the cylinder block.
g01304837
KENR6226-01 27
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Note: Make a temporary mark in order to show the orientation of
6. Remove O-ring seal (6) from oil cooler (3).
the oil cooler for installation.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that the oil cooler is clean and free from damage. Clean the mating surfaces of the cylinder block.
i02645679
Engine Oil Relief Valve ­Remove and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants m component life.
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent contain
Dispose of all uids according to local regulations and mandates.
ay cause rapid wear and shortened
NOTICE
and repair of the product. Be prepared to
ing uids.
Illustration 39
Typical example
2. Install a new O-ring seal (6) to oil cooler (3). Position oil cooler (3) on the cylinder block and install adapter (4). Tighten adapter (4) to a torque of 34 N·m (25 lb ft).
Note: Ensure that the oil cooler is correctly oriented.
3. Connect hoses (1) to the coolant inlet and the
coolant outlet on oil cooler (3). Tighten hose clamps (2).
4. Install a new oil lter element (5).
5. Fill the cooling system to the correct level. Refer
to Operation and Maintenance Manual, “Cooling System Coolant - Fill” for the correct procedure.
6. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil Filter - Change” for the correct procedure.
g01304837
Illustration 40
Typical example
1. Remove engine oil relief valve (2) from the cylinder block.
2. Remove O-ring seal (1) from engine oil relief valve (2).
g01316066
28 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Installation P
Keep all parts c
Contaminants may cause rapid wear and shortened component life
rocedure
NOTICE
lean from contaminants.
.
i02645678
Engine Oil Pump - Remove
Removal Proced
Start By:
a. Remove the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Remove”.
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjustin collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent containi
Dispose of all uids according to local regulations and mandates.
Keep all parts clean from contaminants.
g and repair of the p roduct. Be prepared to
ng uids.
ure
NOTICE
NOTICE
Illustration 41
Typical ex
1. Install a new O-ring seal (1) to engine oil relief
2. Lubricate engine oil relief valve (2) with clean
3. Install engine oil relief valve (2) into the cylinder
ample
valve (2).
engine oil
block. Ti torque of 64 N·m (47 lb ft).
.
ghten the engine oil relief valve to a
g01316066
Contaminants may cause rapid wear and shortened component life.
NOTICE If the front housing is not installed, do not turn the crankshaft. Damage to the engine may occur.
Engine Oil Pump
Illustration 42
g01304840
KENR6226-01 29
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Idler Hub
Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equip­ment.
Follow the recommended procedure and use all recommended tooling to release the spring force.
1. Remove C-clip (9) that retains idler gear (3) on
idler hub (1).
2. Remove the following items from idler hub (1):
Collar (8 )
Spring (7)
Shim (6)
Oil pump cover (5)
3. Remove idler gear (3) from idler hub (1).
4. Remove inner rotor (4) from idler hub (1).
5. Remove thrust washer (2) from idler hub (1).
6. In order to remove the suction pipe, follow Steps
6.a through 6.d .
Illustration 44
Typical example
1. Remove camsh
aft (16). Refer to Disassembly and
Assembly, “Camshaft - Remove”.
2. Remove bolts
(17) and plate (14) from the cylinder
block. Remove joint (15).
3. Remove crank
shaft (18). Refer to Disassembly
and Assembly, “Crankshaft - Remove”.
g01320621
Illustration 45
Typical example
4. Use a hammer and use a suitable drift to remove
idler hub (1) from the cylinder block. Align the drift to the rear face of the hub and drive the hub from the inside of the cylinder block outward.
Illustration 43
g01327023
a. Removetheengineoilpan.Referto
Disassembly and Assembly, “Engine Oil Pan ­Remove and
Install”.
b. Remove bolts (12) and oil strainer (13) from
the cylind
er block. Inspect the oil strainer for damage. If the oil strainer is damaged, use a new part for replacement.
c. Remove suction pipe (11) from the cylinder
block.
d. Remove O-ring seal (10) from the suction pipe.
g01311490
30 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02960005
Engine Oil Pump - Install
Installation P
Table 8
Tool Part Number Part Description Qty
(1)
A
(2)
A
(3)
A
B
(1)
402D-05 and 403D-07 engines
(2)
403D-11 and 404D-15 engines
(3)
403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and
404D-22TA engines
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
If the front housing is not installed, do not turn the crankshaft. Da
21825624
21825625
27610324 Alignment Tool 1
rocedure
Required Tools
Alignment Tool 1
Alignment Tool 1
-
mage to the engine may occur.
Multipurpose Grease 1
NOTICE
NOTICE
3. Use a hammer in order to strike the guide plate of To o li ng ( A) . D r
ive idler hub (1) into the cylinder block until the guide plate contacts the front of the cylinder block.
4. Remove Tooling (A).
Illustration 47
g01320621
5. Install crankshaft (18). Refer to Disassembly and Assembly, “Crankshaft - Install”.
6. Position a new joint (15) on the cylinder block. Align plate (14) with the dowels in the cylinder block and install the plate. Install bolts (17) and tightentoatorqueof10N·m(89lbin).
7. Install camshaft (18). Refer to Disassembly and Assembly, “Camshaft - Install”.
Idler Hub
Illustration 46
Typical example
1. Install the p
in of Tooling (A) to the cylinder block.
2. Install idler hub (1) into the guide plate of Tooling (A). Align th
e guide plate of Tooling (A) with pin
of Tooling (A).
g01305803
Engine Oil Pump
Illustration 48
Typical example
1. Install thrust washer (2). Lubricate the thrust washer with clean engine oil.
g01304840
KENR6226-01 31
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Collar (8)
Refer to Illustration 48.
Illustration 49
Typical example
g01305805
Improper assembly of parts that a re spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equip­ment.
6. Install retain
Illustration 50
Checking end play by using a feeler gauge
ing ring (9) on idler hub (1).
g01320625
7. Use a feeler gauge in order to measure the end play of the engine oil pump. Refer to Specications, “Engine Oil Pump”.
8. If the oil strainer was removed, follow Steps 8.a through 8.c in order to install the oil strainer.
2. Apply Tooling (B) to the faces of inner rotor (4) and to the vanes of idler gear (3).
3. Align timing marks (X) on idler gear (3) with the respective timing marks on gears (19) and (20). Install idler gear (3) onto idler hub (1).
4. Install inner rotor (4) to idler gear (3).
Personal injury can result from the release of the spring force.
The drive shaft, the piston, and the drive gear are under spring force.
Use a press to slowly release the spring force be­fore the components are removed.
5. Install the following items to idler hub (1):
Oil pump cover (5)
Shim (6)
Spring (7)
Illustrat
ion 51
g01327023
a. Install a new O-ring seal (10) on oil tube
assembly (
11).
b. Install oil suction pipe (11) in the cylinder block.
c. Install oil strainer (13) to the cylinder block
and tighten bolts (12) to a torque of 11 N·m (97lbin)
.
End By:
a. Install the front housing. Refer to Disassembly and
Assembly, “Housing (Front) - Install”.
b. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
.
Install”
32 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02960013
Water Pump - Remove and Install (403D-11, 403D
-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines)
Removal Procedure
Start By:
a. Remove the fa
Assembly, “Fan - Remove and Install”.
b. Remove the al
Assembly, “Alternator - Remove and Install”.
Keep all part
Contaminants may cause rapid wear and shortened component li
Care must be t during performance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect the ing any compartment or disassembling any compo­nent containing uids.
Dispose of all uids according to local regulations and mandates.
1. Drain the co
suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coo
uid with suitable containers before open-
n. Refer to Disassembly and
ternator. Refer to Disassembly and
NOTICE
s clean from contaminants.
fe.
NOTICE
aken to ensure that uids are contained
olant from the cooling system into a
lant - Drain” for more information.
Illustration 52
Typical example
Illustration 53
Typical example
3. Loosen hose clamps (5) and remove hose (6) from water pump (1).
4. Remove bolt (3) and alternator bracket (2) from water pump (1).
g01304930
g01305206
2. Loosen the hose clamp and disconnect the hose (not shown
)fromthewaterpumpinlet.
Note: The alternator bracket on some engines is secured by two bolts.
5. Remove fasteners (7) and remove water pump (1).
Note: If necessary, gently tap the water pump with a
soft faced hammer in order to loosen the water pump.
6. Remove joint (4) from the cylinder block.
KENR6226-01 33
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Installation P
Keep all parts c
Contaminants may cause rapid wear and shortened component life
1. Ensure that the mating surfaces of the water pump and the cylinder block are clean and free from damage.
Illustration 54
Typical example
rocedure
NOTICE
lean from contaminants.
.
g01304930
Note: The alternator bracket on some engines is secured by two b
5. For engines that have an alternator bracket that is secured by o torque of 10 N·m (89 lb in).
For engines th secured by two bolts, tighten fasteners (3) and (7) toatorqueof10N·m(89lbin).
6. Connect the hose (not shown) to the water pump inlet and tighten the hose clamp. Install hose (6) on the water p
7. Fill the cooling system with coolant. Refer to Operation an System Coolant - Fill” for the correct procedure.
End By:
a. Install the alternator. Refer to Disassembly and
Assembly, “
b. Install the fan. Refer to Disassembly and
Assembly, “
olts.
ne bolt, tighten fasteners (7) to a
at have an alternator bracket that is
ump and tighten hose clamps (5).
d Maintenance Manual, “Cooling
Alternator - Remove and Install”.
Fan - Remove and Install”.
i02645778
Water Pump - Remove and Install
Illustration 55
Typical example
2. Install a new joint (4) to the cylinder block.
3. Place water pump (1) in position and install
fasteners (7) nger tight.
4. Position alternator bracket (2) on the water pump. Install bolt (3) nger tight.
g01305206
(402D-05 and 403D-07 Engines)
Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install”.
b. Remove the alternator. Refer to Disassembly and
Assembly, “Alternator - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
34 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
3. Remove bolt (3) and remove adjusting link (2) for
NOTICE
the alternator
from water pump (1).
Care must be taken to ensure that uids are contained during perform
ance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
Note: On some engines, the adjusting link for the alternator is
secured by two bolts.
collect the uid with suitable containers before open­ing any compar
tment or disassembling any compo-
4. Remove fasteners (7) and remove water pump (1).
nent containing uids.
Note: If necessary, gently tap the water pump with a
Dispose of all
uids according to local regulations and
soft faced hammer in order to loosen the water pump.
mandates.
5. Remove joint (6) from the cylinder head.
1. Drain the coolant from the cooling system into a
suitable cont
ainer for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Drain” for more information.
2. Loosen the hose clamp and disconnect the hose (not shown) from the water pump inlet.
Illustration 56
Typical example
g01304930
If the water pu
mp has a spacer, remove spacer
(5), and remove joint (4).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants component life.
1. Ensure that the mating surfaces of the water pump and the cylinder block are clean and free from damage. If the water pump has a spacer, ensure that the mating surfaces of the spacer are clean and free from damage.
may cause rapid wear and shortened
Illustration 58
Typical example
Illustration 57
Typical example
g01308309
g01304930
KENR6226-01 35
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645789
Water Temperature Regulator Housing - Remo ve and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Illustration 59
Typical example
2. Install a new joint (6) to the cylinder head.
If the water pump has a spacer, install spacer (5) and install a new joint (4) to the cylinder head.
3. Place water pump (1) in position and install fasteners (7). Tighten the fasteners nger tight.
4. Position adjusting link (2) for the alternator on the water pump. Install bolt (3) nger tight.
Note: On some engines, the adjusting link for the alternator is secured by two bolts.
5. If the adjusting link for the alternator is secured by one bolt, tighten fasteners (7) to a torque of 10 N·m (89 lb in).
g01308309
Contaminants m component life.
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent contain
Dispose of all uids 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 System Coolant - Drain” for more information.
ay cause rapid wear and shortened
NOTICE
and repair of the product. Be prepared to
ing uids.
and Maintenance Manual, “Cooling
If the adjusting link for the alternator is secured by two bolts, tighten fasteners (3) and (7) to a torque of 10 N·m (89 lb in).
6. Connect the hose (not shown) to the water pump inlet and tighten the hose clamp.
7. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Fill” for the correct procedure.
End By:
a. Install the alternator. Refer to Disassembly and
Assembly, “Alternator - Remove and Install”.
b. Install the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install”.
Illustration 60
Typical example
2. Loosen hose clamps (5) and disconnect hose (6) from water temperature regulator housing (2).
3. Remove bolts (4) and nuts (3).
4. Remove water temperature regulator housing (2)
from the cylinder head.
5. Remove joint (1) from the cylinder head.
g01307377
36 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
6. If necessary, remove the water temperature regulator. Ref “ Water Temperature Regulator - Remove and Install”.
er to Disassembly and Assembly ,
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that the mating surfaces of the cylinder head and the water temperature regulator housing are clean and free from damage.
i02645783
Water Temperature Regulator ­Remove and Install (402D-05 and 4 0
Removal Procedure
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that uids are contained during perform ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compar nent containing uids.
Dispose of all mandates.
ance of inspection, maintenance, test-
tment or disassembling any compo-
uids according to local regulations and
4D-07 Engines)
NOTICE
NOTICE
Illustration 61
Typical exa
2. Install a new joint (1) to the cylinder head.
3. Install water temperature regulator housing (2) to
4. Install bolts (4) and nuts (3). Tighten the fasteners
5. Connect hose (6) to water temperature regulator
6. If necessary, install the water temperature
7. Fill the co
mple
the cylinder head.
toatorqueof10N·m(89lbin).
housing (2). Tighten hose clamps (5).
regulator. Refer to Disassembly and Assembly , “WaterTem Install”.
Operation and Maintenance Manual, “Cooling System Coolant - Fill” for the correct procedure.
perature Regulator - Remove and
oling system with coolant. Refer to
g01307377
1. Drain the coolant from the cooling system into a suitable con to Operation and Maintenance Manual, “Cooling System Coolant - Drain” for more information.
Illustration 62
Typical example
tainer for storage or disposal. Refer
g01327025
KENR6226-01 37
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Personal injury can result from parts and/or cov­ers under spring pressure.
Spring force will be released when covers are re­moved.
Be prepared to hold spring loaded covers as the bolts are loosened.
2. Remove bolts (6) and nuts (5).
3. Remove outlet connection (4).
4. Remove joint (3).
5. Remove water temperature regulator (2) and
spring (1).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Inspect the water temperature regulator for wear, damage and correct operation. Refer to Systems Op “Water Temperature Regulator - Test” for more information. If necessary, replace the water temperatur
2. Ensure that the mating surfaces of the outlet connection free from damage.
eration,Testing and Adjusting,
e regulator.
and the cylinder head are clean and
Illustration 63
Typical example
Personal injury can result from parts and/or cov­ers under spring pressure.
Spring force will be released when covers are re­moved.
Be prepared to hold spring loaded covers as the bolts are loosened.
3. Install spring (1) and water temperature regulator
(2) to the cylinder head. Ensure that jiggle pin (7) on water temperature regulator (2) is in the vertically upward position.
4. Install a new joint (3) to the cylinder head.
5. Position outlet connection (4) onto the cylinder
head. Install nut (5) and bolts (6) to outlet connection (4). Tighten the fasteners to a torque of8N·m(71lbin).
g01326174
6. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Fill” for more information.
38 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02960059
Water Temperature Regula tor ­Remove an d Install (403D-11, 403D
-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines)
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE Care must be taken to ensure that uids are contained during perfo ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compa nent containing uids.
Dispose of al mandates.
1. Drain the coolant from the cooling system into a
suitable co to Operation and Maintenance Manual, “Cooling System Coolant - Drain” for more information.
rmance of inspection, maintenance, test-
rtment or disassembling any compo-
l uids according to local regulations and
ntainer for storage or disposal. Refer
Illustration 64
Typical example
2. Remove fasteners (1).
3. Remove outlet connection (2).
Note: Identify the orientation of the outlet connection
for installation.
4. Remove joint (3).
5. Remove water temperature regulator (4) from
water temperature regulator housing (5).
Installation Procedure
g01327027
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Inspect the water temperature regulator for wear, damage and correct operation. Refer to Systems Operation,Testing and Adjusting, “Water Temperature Regulator - Test” for more information. If necessary, replace the water temperature regulator.
2. Ensure that the mating surfaces of the outlet connection and the water temperature regulator housing are clean and free from damage.
KENR6226-01 39
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645699
Flywheel - Remove
Illustration 65
Typical example
g01327027
3. Install water temperature regulator (4) to water temperature regulator housing (5). Refer to Specications, “Water Temperature Regulator Housing for 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines” for the correct orientation of the water temperature regulator.
4. Install a new joint (3).
5. Install outlet connection (2) to water temperature
regulator housing (5).
Removal Proced
Table 9
Too l
A
B
Part
Number
-
-
ure
Required Tools
Part Description
Lifting Bracket
Guide Stud (M10 x 1.25 mm by 80mm)
Qty
1
2
Start By:
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting Motor - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: The two
cylinder, the three cylinder and the four cylinder engines have different ywheels. The removal procedure is similar for all models.
Note: Ensure the correct orientation of the outlet connection.
6. Install fasteners (1).
For 403D-11 and 404D-15 engines, tighten the fasteners to a torque of 6 N·m (53 lb in).
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten the fasteners to a torque of 14 N·m (124 lb in).
7. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant -Fill” for more information.
Illustration 66
Typical example
g01305297
1. Install Tooling (A) and a suitable lifting device to ywheel (2). The weight of the ywheel is approximately 42 kg (93 lb).
40 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
2. Remove two bolts (1) from positions (X) on the ywheel.
3. Install Tooling (B) in positions (X) on the ywheel.
4. Remove the remaining bolts (1) and remove
ywheel (2).
Note: On some three cylinder engines, a roll pin is located between the crankshaft and the ywheel.
5. Inspect ring gear (3) and ywheel (2) for wear or damage. If the ring gear or the ywheel is worn or damaged, use
new parts for replacement.
Flywheel - Install
Installation P
Table 10
Too l
A
B
Keep all parts clean from contaminants.
Contaminants component life.
Part
Number
rocedure
Required Tools
Part Description
-
-
may cause rapid wear and shortened
Lifting Bracket
Guide Stud (M10 x 1 .25 mm by 80mm)
NOTICE
i02645696
Qty
1
2
Illustration 67
Typical example
g00825639
6. To remove ring gear (3) from ywheel (2), place the ywheel on a suitable support. Use a hammer (not shown) and a punch (4) in order to remove the ring gear from the ywheel.
Always wear pr
otective gloves when handling
parts that have been heated.
Illustration 68
Typical exam
ple
g01305341
1. If the ring gear was removed, follow Steps 1.a through 1.c
in order to install ring gear (3) to
ywheel (2).
a. Identify th
e orientation of the new ring gear in order to install the ring gear correctly onto the ywheel.
Note: The chamfered side of gear teeth (Y) must face toward the starting motor when the ywheel is installed.
This will ensure the correct engagement of
the starting motor.
KENR6226-01 41
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
b. Heat ring gear (3) in an oven to a maximum
temperature of installation.
Note: Do not us
c. Ensure that the orientation of ring gear (3) is
correct and qu ywheel (2).
150°C (302°F) prior to
e a torch to heat the ring gear.
ickly install the ring gear onto
9. Remove Tooling (A) and the lifting device from the ywheel.
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting Motor-Remove
Crankshaft Re
and Install”.
i02960085
ar Seal - Remove
and Install
Removal Proc
Start By:
a. Remove the ywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove”.
Keep all parts clean from contaminants.
edure
NOTICE
Illustration 69
Typical example
2. Thoroughly clean the ywheel housing. Inspect the crankshaft rear seal for leaks. If there are any oil leaks replace the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”.
3. Install Tooling (B) to positions (X) in the crankshaft.
4. Install Tooling (A) and a suitable lifting device
to ywheel (2). The weight of the ywheel is approximately 42 kg (93 lb).
5. Position ywheel (2) onto Tooling (B).
On three cylinder engines that have a roll pin, ensure that the roll pin is installed to the crankshaft and that the roll pin is free from d amage. Align theholeintheywheel with the roll pin in the crankshaft.
6. Install bolts (1) nger tight.
g01305297
Contaminant component life.
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusti collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent contai
Dispose of all uids according to local regulations and mandates.
Note: The two cylinder, the three cylinder and the four cylinder engines have different congurations for the ywheel process is similar for all models.
s may cause rapid wear and shortened
NOTICE
ng and repair of the product. Be prepared to
ning uids.
housing and the back plate. The removal
7. Remove Tooling (B) and install the two remaining bolts (1).
8. Use a suitable tool to prevent ywheel (2) from rotating. Tighten bolts (1) to a torque of 74 N·m (54 lb ft).
42 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Illustration 70
Typical example
g01305376
1. Remove bolts (3) and remove the ywheel housing or back plate (2) from the cylinder block. Refer to Disassembly and Assembly, “Flywheel Housing ­Remove and Install” for more information.
2. Remove crankshaft rear seal (1) from the cylinder block. Discard the crankshaft oil seal.
Installation Procedure
Table 11
Required Tools
Tool Part Number Part Description
A
21826038
POWERPART Silicone Adhesive
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Qty
1
Illustration 71
Typical example
g01305365
1. Ensure that the mating surface of cylinder block (5) and the ywheel housing or back plate (2) are clean and free from damage. Inspect dowels (4). If the dowels are damaged, use new parts for replacement.
2. Ensure that crankshaft ange (6) is clean and free from damage. It is possible to reclaim a crankshaft ange that has a worn seal surface, or a damaged seal surface by installing a wear sleeve. Refer to Disassembly and Assembly, “Crankshaft Wear Sleeve (Rear) - Remove and Install” for more information.
3. Apply clean engine lubricating oil to the ange of crankshaft (6) around the running surface of crankshaft rear seal.
4. Align a new crankshaft rear seal (1) with the ange of crankshaft (6). Carefully install crankshaft rear seal (1) onto the crankshaft ange.
5. Apply a continuous bead of Tooling (A) to the rear face of the cylinder block around the edge of crankshaft rear seal (1). Apply a continuous bead of Tooling (A) around plug (X).
6. Align the ywheel housing or back plate (2) to dowels (4). Install the ywheel housing or back plate (2) and install bolts (3) to cylinder block (5). Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install” for more information.
7. Tighten bolts (3).
KENR6226-01 43
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
For 402D-05 and 403D-07 engines, tighten the bolts to a torqu
For 403D-11 and 404D-15 engines, tighten the boltstoatorq
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 4 boltstoatorqueof25N·m(19lbft).
End By:
a. Install the ywheel. Refer to Disassembly and
Assembly, “F
eof15N·m(11lbft).
ue of 50 N·m (37 lb ft).
04D-22TA engines, tighten the
lywheel - Install”.
i02645791
Crankshaft Wear Sleeve (Rear)
- Rem ove and Install
Removal Procedure
Start By:
a. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”.
2. Insert a thin blade between crankshaft wear sleeve (1) and c line. The crankshaft wear sleeve will separate along the line.
3. Remove crankshaft wear sleeve (1) from crankshaft (2). Discard the crankshaft wear sleeve.
Installatio
Table 12
Tool Part Number Part Descript
A
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. Remove any areas of raised damage.
21820518
rankshaft (2) below the scored
n Procedure
Required Tools
ion
POWERPART Liquid Gasket
NOTICE
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Wear sleeves are used to reclaim worn seal surfaces or are not original equipment.
Illustration 72
Sectional view of the crankshaft and of the wear sleeve
damaged seal surfaces. Wear sleeves
g01266598
Illustration 73
Sectional view of the wear sleeve
2. Apply a small continuous bead of Tooling (A) to the inner surface of crankshaft wear sleeve (1) at positionX.ApplythebeadofTooling(A)5.00mm (0.2 inch) from the ange end of the crankshaft wear sleeve.
g01269521
1. Useasharptooltoscoreadeeplineacross crankshaft wear sleeve (1).
Note: Take care to avoid damaging the crankshaft.
44 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: The two cylinder, the three cylinder and the four cylinder engines have different ywheel housings. The removal procedure is similar for all models.
1. Support the engine.
Illustration 74
Sectional view of the crankshaft, the wear sleeve and the installation tool
3. Align crankshaft wear sleeve (1) with crankshaft (2). Position installation tool (3) that is provided with the crankshaft wear sleeve over the crankshaft. Use a hammer to drive the crankshaft wear sleeve onto the crankshaft. Ensure that dimension (Y) is 2.5 ± 0.1 mm (0.098 ± 0.004 inch).
Note: Dimension (Y) is the distance from the edge of the crankshaft wear sleeve from the rear face of the crankshaft.
4. Remove installation tool (3).
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, “Crankshaft Rear Seal - Remove and Install”.
g01318215
i02960993
Flywheel Housing - Remove and Install
2. Install a suitable lifting device to the ywheel
housing. Support the weight of the housing. The weight of the ywheel housing is approximately 30 kg (66 lb).
Illustration 75
Typical example
3. Remove bolts (1) that fasten ywheel housing (2) to the cylinder block.
4. Use the lifting device to remove ywheel housing (2) from the engine.
g01305734
Removal Procedure
Start By:
a. Remove the ywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove”.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
KENR6226-01 45
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645702
Flywheel Housing - Remove and Install (Engines with F
lywheel
Housing and Back Plate)
Illustration 76
Typical example
1. Ensure that the mating surfaces of ywheel housing (2) are clean and free from damage. Inspect the crankshaft rear seal (3) for leaks. If necessary, replace the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install” for the correct procedure. Inspect dowels (4) for damage. If the dowels are damaged, use new parts for replacement.
2. Use a suitable lifting device to align ywheel housing (2) to dowels (5) and install the ywheel housing. The weight of the ywheel housing is approximately 30 kg (66 lb).
g01326595
Removal Proce
Start By:
a. Remove the ywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove”.
Keep all parts clean from contaminants.
Contaminants component life.
1. Support the engine.
2. Install a suitable lifting device to the ywheel
housing. Support the weight of the housing. The weight of the ywheel housing is approximately 30 kg (66 lb).
may cause rapid wear and shortened
dure
NOTICE
3. Install bolts (1).
For 402D-05 and 403D-07 engines, tighten the boltstoatorqueof15N·m(11lbft).
For 403D-11 and 404D-15 engines, tighten the boltstoatorqueof50N·m(37lbft).
For 403D-15, 403D-15T and 403D-17 engines, tighten the bolts to a torque of 25 N·m (19 lb ft).
4. Remove the lifting device from the ywheel housing.
Illustration 77
End By:
a. Install the ywheel. Refer to Disassembly and
Assembly, “Flywheel - Install”.
g01326591
46 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Illustration 78
Typical example
g01305649
3. Remove bolts (3) and (4) that fasten ywheel housing (8) to the cylinder block.
4. Remove bolts (6) on each side of the cylinder block. These bolts fasten ywheel housing (8) to the cylinder block.
5. Remove bolts (1) that fasten back plate (2) to ywheel housing (8).
6. Remove nuts (5) and the bolts (not shown) that fasten back plate (2) to ywheel housing (8).
7. Carefully remove ywheel housing (8) from back plate (2) and dowels (7). Use a suitable lifting device to remove the ywheel housing.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that the mating surfaces of back plate (2) and ywheel housing (8) are clean and free from damage. Inspect the crankshaft rear seal (not shown) for leaks. If necessary, replace the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install” for the correct procedure. Inspect dowels (7) for damage. If the dowels are damaged, use new parts for replacement.
Illustration 79
Illustration 80
example
Typical
g01305649
g01326591
2. Use a suitable lifting device to align ywheel housing
(8) to dowels (7). The weight of the ywheel housing is approximately 30 kg (66 lb). Install the ywheel housing to the back plate.
3. Install nuts (5) and the bolts (not shown) that fasten back plate (2) to ywheel housing (8).
4. Install bolts (1) that fasten back plate (2) to ywheel housing (8).
5. Install bolts (6) on each side of the cylinder block. These bolts fasten ywheel housing (8) to the
er block.
cylind
KENR6226-01 47
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
6. Remove the lifting device from the ywheel housing.
7. Install bolts (3) and (4) that fasten ywheel housing (8) to
the cylinder block.
8. Tighten the fasteners to a torque of 25 N·m (19 lb ft).
End By:
a. Install the ywheel. Refer to Disassembly and
Assembly, “Flywheel - Install”.
i02961010
Crankshaft Pulley - Remove and Install
Removal Procedure
Start By:
a. Remove the V-belt. Refer to Disassembly and
Assembly, “V Belts Remove and Install” for more information.
Table 13
Required Tools
Tool
A
Part
Number
21825619
-
Description Qty
Puller 1
Bolt 3
Illustration 82
g01305772
2. Install Tooling (A) to crankshaft pulley (2). Use Tooling (A) in order to remove crankshaft pulley (2) from crankshaft (4). Remove Tooling (A).
3. Remove nut (3).
4. Remove pulley (2) from crankshaft (4).
5. Remove woodruff key (1) from crankshaft (4).
Installation Procedure
1. Ensure that the following components are
clean and free from damage: the taper of the crankshaft, the woodruff key, and the bore of the crankshaft pulley. Replace any components that are damaged. Ensure that the taper of the crankshaft and the bore of the crankshaft pulley are clean and dry before assembly.
ation 83
Illustr
Typical example
2. Install woodruff key (1) to crankshaft (4).
3. Install c
rankshaft pulley (2) to crankshaft (4).
4. Lubricate nut (3) with clean engine oil and install
Illustration 81
Typical example
1. Loosen nut (3).
Note: Do not remove the nut at this time.
g01326646
the nut.
For 402D-05 and 403D-07 engines, tighten nut (5) to a torq
ue of 93 N·m (69 lb ft).
g01326646
48 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
For 403D-11 and 404D-15 engines, tighten nut (5) to a torque of 12
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 4 toatorqueof304N·m(224lbft).
End By:
a. Install the V-belt to the engine. Refer to
Disassembly a Install”.
3 N·m (91 lb ft).
04D-22TA engines, tighten nut (5)
nd Assembly, “V Belts Remove and
i02645666
Crankshaft Front Seal ­Remove an d Install
Removal Procedure
Table 14
Required Tools
Part
Tool
A
Start By:
a. Remove the crankshaft pulley. Refer to
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Number Part Descrip
27610311
Disassembly and Assembly, “Crankshaft Pulley
- Remove and Install”.
Slide Hammer Puller
NOTICE
tion
Qty
1
Illustration 84
Typical example
1. Use a 4 mm (0.158 inch) drill in order to make three holes in crankshaft front seal (2).
NOTICE Ensure that the main lip is used in order to remove the crankshaft front seal. Do not damage the edge of the housing for the crankshaft front seal.
Note: Do not damage the crankshaft during the removal process of the crankshaft front seal.
2. Use Tooling (A) to carefully remove crankshaft
front seal (2). Alternate the position of Tooling (A) from one hole to another hole. This will allow you to evenly remove the crankshaft front seal from front housing (1).
g01310976
Alternative Removal Procedure
Start By:
a. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft Pulley
- Remove and Install”.
b. Remove the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Remove”.
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
KENR6226-01 49
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Note: This is an alternative procedure to remove the crankshaft used if the front housing has been removed from the engine.
1. Use a suitable mandrel and a press in order to remove the oil seal from the front cover. Ensure that the fron damage to the cover while the oil seal is being removed.
front oil seal. This procedure may be
t cover is supported in order to prevent
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
i02645726
Housing (Front) - Remove
Removal Proced
Start By:
a. Remove the fuel injection pump. Refer to
Disassembly and Assembly, “Fuel Injection Pump
- Remove”.
b. Remove the crankshaft pulley. Refer to
Disassembly a
- Remove and Install”.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that uids are contained during perfor ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compa nent containing uids.
nd Assembly, “Crankshaft Pulley
mance of inspection, maintenance, test-
rtment or disassembling any compo-
ure
NOTICE
NOTICE
Illustration 85
Typical example
1. Ensurethattheboreinfronthousing(1)andthe nose of the crankshaft are clean and free from damage.
2. Lubricate the lip of a new crankshaft front seal (2) with clean engine oil.
3. Position crankshaft front seal (2) in the bore of front housing (1).
NOTICE Ensure that the lip of the crankshaft front seal that is spring loaded is facing toward the inside of the front housing and that it is square with the bore of the hous­ing for the crankshaft front seal.
4. Use a suitable tool to install crankshaft front seal
(2) to front housing (1).
End By:
a. Install the crankshaft pulley. Refer to Disassembly
and Assembly, “Crankshaft Pulley - Remove and Install”.
g01311777
Dispose of al mandates.
l uids according to local regulations and
50 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02902054
Housing (Front) - Disassemble
ion 86
Illustrat
Typical example
1. If the engine is equipped with a turbocharger,
disconnect the hose from connection (1).
2. Remove nuts (4) and bolts (9).
g01357158
Disassembly Pr
Start By:
a. Record the governor settings. Refer to Systems
Operation, Testing and Adjusting, “Govener ­Adjust”
b. Remove the engine front housing. Refer to
Disassembly a Remove”.
Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equip­ment.
Follow t he recommended procedure and use all recommended tooling to release the spring force.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
ocedure
nd Assembly, “Housing (Front) -
NOTICE
3. Remove co
4. Remove fasteners (3). Identify the position of the
differen
5. Carefully remove front housing (6) from plate (5).
Ensure th
Note: The front housing is aligned to the plate and to the cyl
6. Remove the joint (not shown).
ver (8) and O-ring seal (7).
t fasteners for installation.
at pin (2) remains in the front housing.
inder block with dowels.
Illustration 87
Typical example
1. Remove spr of throttle control (1).
ing (4) from arm (2) on the assembly
g01357675
KENR6226-01 51
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Illustration 88
Typical example
g01354631
2. Remove bolts (5) and remove the assembly of throttle control (1) from front housing (3).
3. Remove joint (6).
Illustration 90
g01357689
7. Iftheengineisequippedwithanangleichunit, remove angleich unit (10) from lever assembly (7).
Illustration 91
Typical example
g01357693
Illustration 89
Typical example
g01357717
4. Remove shaft (9) from front housing (3).
5. Remove lever assembly (7) from front housing (3).
6. Remove sealing washer (8) from shaft (9).
52 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Note: The position of fuel screw (16) controls the emissions o
f the engine. Do not remove the fuel screw unless a different front housing will be installed. Do not adjust the fuel screw. Refer to Systems Ope
ration, Testing and Adjusting, “Governor” for further information.
Illustration 92
Typical example
g01357727
8. Disconnect spring (12) from front housing (3).
9. Remove nut (14) and remove sealing washer (13)
from front housing (3).
10. Remove shaft (15) and remove lever assembly (1 1) from front housing (3).
12. If necessary
, remove cap (21), locknut (20) and sealing washer (19) from front housing (3). Remove fuel screw (16).
i02706594
Housing (Front) - Assemble
Assembly Procedure
Table 15
Required Tools
Too l
A
Improper assembly of parts that are spring loaded can cause bodily injury.
Part
Number
21820117
Part Description Qty
POWERPART Thread Lock
1
Illustration 93
Typical example
11. Remove spring assembly (17) and remove sealing washer (18) from front housing (3).
T o prevent possible injury, follow the established assembly procedure and wear protective equip­ment.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
g01358077
KENR6226-01 53
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
d. Install a new emissions label to front housing
(3).
2. Install a new sealing washer (18) to spring assembly (17)
. Loosely install spring assembly
(17) to front housing (3).
Illustration 94
Typical example
Illustration 95
Typical example
g01358537
g013580
Illustration 96
Typical example
g01357727
3. Place lever assembly (11) in position in front housing (3) and install shaft (15).
Note: Ensure the correct orientation of the lever assembly.
77
Note: Th
e position of stop (16) controls the emissions of the engine. Ensure correct adjustment of the stop.
1. If the original front housing has been replaced by
a different item, follow Steps 1.a through 1.d.
a. Install stop (16) to front housing (3).
b. Install
a new sealing washer (19) to stop (16).
Illustration 97
Typical example
c. Loosely install locknut (20) to stop (16). The
procedu the stop is described in Systems Operation, Testing and Adjusting, “Govenor”.
re that is used to set the position of
4. Install a new sealing washer (13) and nut (14) to front housing (3). Tighten the nut to a torque of 6N·m(53lbin).
g01357693
54 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
5. Connect spring (12) to front housing (3). Refer to Illustration 9
Illustration 98
6.
g01357689
6. If the engine is equipped with an angleich unit, follow Steps 6.a and 6.b in order to install the angleich unit.
a. Apply Tooling (A) to the rst two threads of
angleich unit (10).
b. Install angleich unit (10) to lever assembly (7).
Tighten the angleich unit to a torque of 6 N·m (53lbin).
Note: Ensure that Tooling (A) is not allowed to contaminate the plunger assembly of the angleich unit. Contamination of the plunger assembly will render the angleich unit inoperative.
8. Placeleverassembly(7)inpositioninfront housing (3) and
install shaft (9). Tighten the shaft
to a torque of 16 N·m (142 lb in).
Note: Ensure t
he correct orientation of the lever
assembly.
Illustration 100
Typical example
g01354631
9. Position a new joint (6) and position the assembly of throttle control (1) onto front housing (3).
10. Install bolts (5). Tighten the bolts to a torque of 11 N · m (97 lb in).
Illustration 99
Typical example
7. Install a new sealing washer (8) to shaft (9).
g01357717
Illustration 101
Typical example
11. Install spring (4).
g01354629
KENR6226-01 55
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
12. If the position of stop (16) has been altered, the stop must be res
et. Refer to Systems Operation, Testing and Adjusting, “Governor” for the correct procedure.
13. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) Install” for more information
.
14. Set the position of the spring assembly (17). Refer to Illu
stration 95. The procedure that is used to set the position of the spring assembly is described in Systems Operation, Testing and Adjusting, “
Govenor”. Tighten the spring assembly
to a torque of 34 N·m (25 lb ft).
15. Install a new
new cap (21) to nut (20). Refer to
Illustration 95.
Housing (Front) - Install
Installati
Table 16
Tool
(1)
A
(2)
A
(1)
402D-05, 403D-07, 40 3D-11 and 404D-16 engines
(2)
403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and
404D-22TA engines
Keep all parts clean from contaminants.
on Procedure
Required Tools
Part
Number
21825620
21825621
Seal Protector 1
Seal Protector 1
NOTICE
Part Description
i02965670
Qty
ion 102
Illustrat
Typical example
g01494813
Contaminan
ts may cause rapid wear and shortened
component life.
Illustration 103
Typical example
g014955
33
56 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
10. If the engine is equipped with a turbocharger, connect the hos
End By:
a. Install the crankshaft pulley. Refer to Disassembly
and Assembly, “Crankshaft Pulley - Remove and Install”.
b. Install the fuel injection pump. Refer to
Disassembly a
-Install”.
e to connection (1).
nd Assembly, “Fuel Injection Pump
i02970280
Crankcase Breather - Remove and Install (Turbocharg
ed Engines)
ion 104
Illustrat
Typical example
1. Ensure that the assembly of front housing (5) and the nose of the crankshaft are clean and free from damage. C
2. Install Tooling (A) on the nose of the crankshaft.
3. Align pin (11) with Hole (X) in oil pump cover (9).
Ensure that the oil pump cover is concentric to idler gea
4. Install a new joint to plate (4).
5. Guide the linkage for the fuel injection pump into
position so that the link is free to move inside the aperture pump. Align front housing (5) to the dowels in plate (4). Install front housing (5) to plate (4).
6. Install fasteners (2) and tighten to a torque of 10 N·m (89 lb in).
lean the mating surface of plate (4).
r assembly (10).
on the cylinder block for the fuel injection
g01495653
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE Care must be taken to ensure that uids are contained during perfo ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any comp nent containing uids.
Dispose of a mandates.
rmance of inspection, maintenance, test-
artment or disassembling any compo-
ll uids according to local regulations and
7. RemoveTooling(A)fromthenoseofthe crankshaft.
8. Install a new O-ring seal (6) to front housing (5). Position cover (7) on front housing (5) and install nuts (3
9. Tighten nuts (3) to a torque of 50 N·m (37 lb ft).
) and bolts (8).
KENR6226-01 57
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
b. Remove screws (9) and carefully remove plate
(10).
c. Remove gauze (8) from valve mechanism
cover (7).
ion 105
Illustrat
Typical example
g01310618
Installation
Table 17
Tool Part Number Part Description Qty
27610296
A
Procedure
Required Tools
Torque Wrench 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE Make sure that the components of the breather as­sembly are installed correctly. Engine damage may occur if the breather assembly is not working properly.
Personal injury can result from parts and/or cov­ers under spring pressure.
Spring force will be released when covers are re­moved.
Be prepared to hold spring loaded covers as the bolts are loosened.
1. Remove bolts (1) and remove the assembly of
cover (2), spring (3) and diaphragm (4). Note the orientation of cover (2).
2. Remove spring (3) and diaphragm (4) from cover (2).
3. Remove adapter (5) and joint (6) from valve mechanism cover (7).
Note: Make a temporary mark in order to show the orientation of the adapter for installation.
4. If necessary, follow Steps 4.a through 4.c in order to remove the gauze for the breather.
a. Remove valve mechanism cover (7). Refer to
Disassembly and Assembly, “V alve Mechanism Cover - Remove and Install” for the correct procedure.
Illustration 106
Typical example
g01310618
58 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
1. Clean all parts and inspect all parts. Replace any parts that are w cavity for the breather in the valve mechanism cover is clean. Ensure that vent hole in adapter (5) and the ven restriction.
2. If necessary to install the gauze for the breather.
a. Install gauz
b. Position plate (10) on valve mechanism cover
(7) and insta
c. Tighten screws (9) to a torque of 1.5 N·m
(13lbin).
d. Install valve mechanism cover (7). Refer to
Disassembly Cover - Remove and Install” for the correct procedure.
3. Position a new joint (6) on the valve mechanism cover and install adapter (5).
Note: Ensure the correct orientation of the adapter. The vent hole should face upward.
orn or damaged. Ensure that the
t hole in cover (2) are free from
, follow Steps 2.a through 2.d in order
e (8) to valve mechanism cover (7).
ll screws (9).
and Assembly, “Valve Mechanism
i02970301
Crankcase Breather - Remove and Install (Naturally Asp
Removal Procedure
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that uids are contained during perform ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compar nent containing uids.
Dispose of all mandates.
ance of inspection, maintenance, test-
tment or disassembling any compo-
uids according to local regulations and
irated Engines)
NOTICE
NOTICE
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.
4. Install diaphragm (4) and spring (3) to cover (2).
5. Position the assembly of cover (2), spring (3) and
diaphragm (4) onto valve mechanism cover (7).
Note: Ensure the correct orientation of the cover.
6. Install bolts (1). Use Tooling (A) in order to tighten
boltstoatorqueof3N·m(27lbin).
The two cylinder, the three cylinder and the four cylinder eng The removal procedure is similar for all models.
ines have different crankcase breathers.
KENR6226-01 59
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Installation P
Table 18
Tool
A
Part
Number
27610296
rocedure
Required Tools
Part Description
Torque Wrench 1
Qty
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE Make sure that the components of the breather as­sembly are installed correctly. Engine damage may occur if the breather assembly is not working properly.
The two cylinder, the three cylinder and the four cylinder engines have different crankcase breathers. The installation procedure is similar for all models.
ion 107
Illustrat
Typical example
g01307795
Personal injury can result from parts and/or cov­ers under spring pressure.
Spring force will be released when covers are re­moved.
Be prepared to hold spring loaded covers as the bolts are loosened.
1. Remove bolts (1) and remove the assembly of
cover (2), spring (3) and diaphragm (4). Note the orientation of cover (2).
2. Remove spring (3) and diaphragm (4) from cover (2).
3. If necessary, follow Steps 3.a through 3.c in order to remove the gauze for the breather.
a. Remove valve mechanism cover (7). Refer to
Disassembly and Assembly, “V alve Mechanism Cover - Remove and Install” for the correct procedure.
b. Remove screws (8) and carefully remove plate
(9).
c. Remove gauze (6) from valve mechanism
cover (7).
Illustration 108
Typical example
1. Clean all p
arts and inspect all parts. Replace any parts that are worn or damaged. Ensure that the cavity for the breather in the valve mechanism cover is c
lean. Ensure that vent hole (5) and the
vent hole in cover (2) are free from restriction.
g0130779
5
60 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
2. If necessary, follow Steps 2.a through 2.d in order to install the g
a. Install gauze (6) to valve mechanism cover (7).
b. Position plate (9) on valve mechanism cover
(7) and install screws (8).
c. Tighten screws (8) to a torque of 1.5 N·m
(13lbin).
d. Install valve mechanism cover (7). Refer to
Disassembly and Assembly, “V alve Mechanism Cover - Remov procedure.
Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equip­ment.
auze for the breather.
e and Install” for the correct
NOTICE Care must be taken to ensure that uids are contained during perform ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compar nent containing uids.
Dispose of all mandates.
Note: The removal procedure is similar for the two cylinder, the engines. The illustrations show the four cylinder engine.
ance of inspection, maintenance, test-
tment or disassembling any compo-
uids according to local regulations and
three cylinder and the four cylinder
Follow the recommended procedure and use all recommended tooling to release the spring force.
3. Install diaphragm (4) and spring (3) to cover (2).
4. Position the assembly of cover (2), spring (3) and
diaphragm (4) onto valve mechanism cover (7).
Note: Ensure the correct orientation of the cover.
5. Install bolts (1). Use Tooling (A) in order to tighten
boltstoatorqueof3N·m(27lbin).
i02961022
Valve Mech
anism Cover -
Remove an d Install
Removal Pr
Keep all pa
ocedure
NOTICE
rts clean from contaminants.
Illustration 109
Typical example
1. Loosen the hose clamps and disconnect the hose
(not shown) from connection (2).
g01316539
Contaminants may cause rapid wear and shortened component
life.
Illustration 110
Typical example
g01316551
KENR6226-01 61
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
2. Remove nuts (5) and washers (6) from valve mechanism cove
r(7).
3. Remove bolts (4) from valve mechanism cover (7).
Note: Loosen the bolts evenly in order to avoid
distortion of the valve mechanism cover.
4. Remove valve mechanism cover (7) from base (8). Remove joint (9) from valve mechanism cover (7).
5. If necessary, remove bolts (1) and remove connection (2) from valve mechanism cover (7). Remove gaske
t(2).
6. If necessary, remove the crankcase breather. Refer to Disa
ssembly and Assembly, “Crankcase Breather - Remove and Install” for more information.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
2. If necessary, install the crankcase breather. Refer to Disass
embly and Assembly, “Crankcase Breather - Remove and Install” for more information.
3. Install a new joint (9) to valve mechanism cover (7).
4. Position valve mechanism cover (7) onto housing (8) and install bolts (4) nger tight.
5. Install new washers (6) and nuts (5) nger tight.
6. For 402D-05,
403D-07, 403D-11 and 404D-15 engines, evenly tighten bolts (4) to a torque of 10 N·m (89 lb in). Tighten nuts (5) to a torque of 10 N·m (89 lb i
n).
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and
404D-22TA engines, evenly tighten bolts (4) to a torque of 10 N·m (89 lb in). Tighten nuts (5) to a torque of 14 N·m (124 lb in).
Note: The installation procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The illustrations show the four cylinder engine.
Illustration 111
Typical example
g01316551
Illustration 112
Typical example
g01316539
7. If necessary, position a new gasket (3) onto valve mechanism cover (7) and install connection (2). Install bolts (1) and tighten to a torque of 14 N·m (124 lb in).
8. Connect the hose (not shown) to connection (2) and tighten the hose clamps.
1. Ensure that the valve mechanism cover is clean and free from damage. Clean the mating surface of base (8).
62 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645767
Rocker Shaft and Pushrod ­Remove
Removal Procedure
Start By:
a. Remove the engine oil line. Refer to Disassembly
and Assembly, Install”.
b. Remove the val
Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.
Keep all part
Contaminants may cause rapid wear and shortened component li
“Engine Oil Line - Remove and
ve mechanism cover. Refer to
NOTICE
s clean from contaminants.
fe.
Note: Identication will ensure that the pushrods and the caps can be r Do not interchange the positions of used pushrods or caps.
5. Remove pushrods (6) from the cylinder head. Remove caps (5) from the valve stems.
Illustration 114
Typical example
6. Remove joint (7) from the base of rocker shaft assembly (3).
einstalled in the original positions.
g01317309
Illustration 113
Typical example
1. Loosen the nuts and adjustment screws (4) on all rocker arms.
2. Remove bolts (1) and nuts (2) from rocker shaft assembly (3).
3. Remove rocker shaft assembly (3) from the cylinder head.
4. Place temporary identicationmarksoncaps(5) and pushrods (6).
g01316901
i02961061
Rocker Shaft - Disassemble (403D-15, 4
03D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA Engine s)
Disassembly Procedure
Start By:
a. Remove the rocker shaft and the pushrods. Refer
to Disasse Pushrod - Remove”.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Make a temporary identication mark on each
rocker arm assembly in order to show the location.
Note: Used components must be reinstalled in the original location. Do not interchange components.
mbly and Assembly, “Rocker Shaft and
NOTICE
KENR6226-01 63
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645756
Rocker Shaft - Disassemble (402D-05, 403D-07, 403D-11 and 404D-15 Eng
Disassembly Procedure
Start By:
ines)
Illustration 115
Typical example
2. In order to remove rocker shaft (6), install a suitable bolt into the end of the rocker shaft. Use the bolt to pull the rocker shaft from base (8).
g01317304
a. Remove the roc
to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”.
Keep all parts
Contaminants may cause rapid wear and shortened component lif
1. Make a temporary identication mark on each rocker arm assembly in order to show the location.
Note: Used components must be reinstalled in the original location. Do not interchange components.
ker shaft and the pushrods. Refer
NOTICE
clean from contaminants.
e.
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.
3. Remove rocker arms (3), washers (5), and springs
(4).
4. Remove O-ring seal (7) from rocker shaft (6).
5. Remove adjustment screws (1) and nuts (2) from
rocker arms (3).
Illustration 116
Typical example
1. Remove plug (6) from base (10).
2. Remove O-ring seal (7) from plug (6).
g01316925
64 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
3. On 403D-07, 403D-11 and 404D-15 engines, remove screw (9
Note: Screw (9) is not used on 402D-05 engines.
4. In order to remove rocker shaft (8), install a
suitable bolt into the end of the rocker shaft. Use the bolt to pul
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.
5. Remove rocker arms (3), washers (5), and springs
(4).
6. Remove adjustment screws (1) and nuts (2) from rocker arms (3).
).
l the rocker shaft from base (10).
i02961065
Rocker Shaft - Assemble (403D-15, 403D-15T,403D -17, 404D-22, 404D-
22T and
404D-22TA Engine s)
Assembly Procedure
Personal inju parts propelled by a released spring force.
Make sure to w ment.
Follow t he re recommended tooling to release the spring force.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that a from wear or damage. Refer to Specications, “Rocker Shaft” for more information. If necessary, replace any damaged.
ry can result from being struck by
ear all necessary protective equip-
commended procedure and use all
NOTICE
ll components are clean and free
components that are worn or
KENR6226-01 65
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Rocker arm (3)
7. Repeat Steps 5 and 6 in order to install the remaining components.
8. Ensure that rocker shaft (6) is fully engaged into base (8). Check that recesses (X) on the rocker shaft are alig
End By:
a. Install the rocker shaft and the pushrods. Refer to
Disassembly and Assembly, “Rocker Shaft and Pushrod - Ins
ned with holes (Y) in the base.
tall”.
i02645751
Illustration 117
Typical example
2. Lubricate adjustment screw (1) with clean engine oil. Install adjustment screw (1) and nut (2) to rocker arm (3). Repeat the process for the remaining rocker arms.
3. Install a new O-ring seal (7) onto rocker shaft (6). Lubricate the rocker shaft with clean engine oil.
4. Position the end of rocker shaft (6) into the bore in base (8). Align recesses (X) on the rocker shaft with holes (Y) in the base.
5. Gradually insert rocker shaft (6) into the b ase (8). Install rocker arm (3).
6. Continue to insert rocker shaft (6) and install the following components to the rocker shaft:
Rocker arm (3)
Washer (5)
Spring (4)
g01317298
Rocker Shaft
- Assemble (402D-05, 403D-07, 403D-11 and 404D-15 Engines)
Assembly Procedure
Table 19
Required Tools
Tool Part Number
A 21820117
Personal inj parts propelled by a released spring force.
Make sure to ment.
Follow t he r recommended tooling to release the spring force.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that
from wear or damage. Refer to Specications, “Rocker Shaft” for more information. If necessary, replace any damaged.
ury can result from being struck by
wear all necessary protective equip-
ecommended procedure and use all
all components are clean and free
components that are worn or
Part Description
POWERPART Threadlock and Nutlock
NOTICE
Qty
1
Washer (5)
66 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Rocker arm (3)
6. Repeat Steps 5 and 4 in order to install the
remaining components.
7. For 403D-07, 403D-1 1 and 404D-15 engines,
Apply Tooling (A) to the rst two threads of screw (9). Install s
Note: Ensure that Tooling (A) is allowed to contaminate t
8. Install a new O-ring seal (7) to plug (6).
9. Install plug (6) to base (10). Tighten the plug to a
torque of 15 N·m (11 lb ft).
End By:
crew (9) in hole (Y) in the base.
he oil gallery in the rocker shaft.
ion 118
Illustrat
Typical example
2. Lubricate adjustment screw (1) with clean engine oil. Install adjustment screw (1) and nut (2) to rocker remaining rocker arms.
3. Lubricat Position the end of the rocker shaft into the bore of base (10).
For 402D-05 engines, align the two recesses (not shown) on the rocker shaft with the holes in base (10).
For 403D-07, 403D-11 and 404D-15 engines, align ho base (10).
arm (3). Repeat the process for the
e rocker shaft (8) with clean engine oil.
le (X) in the rocker shaft with hole (Y) in
g01316988
a. Install the ro
Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”.
cker shaft and the pushrods. Refer to
i02961082
Rocker Shaft and Pushrod ­Install
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that all components are clean and free from wear or damage. Refer to Specications, “Rocker Shaft” for more information. Replace any components that are worn or damaged.
4. Gradual Install rocker arm (3).
5. Continu following components to the rocker shaft:
ly insert rocker shaft (8) into base (10).
e to insert rocker shaft (8) and install the
Rocker a
Washer (5)
Spring (4)
Washer (
rm (3)
5)
Illustration 119
Typical example
g0131730
9
KENR6226-01 67
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
2. Install a new joint (7) to the base of rocker shaft assembly (3).
Illustration 120
Typical example
3. Apply clean engine lubricating oil to both ends of pushrods (6). Install the pushrods to the engine with the cup upward. Ensure that the pushrods are installed correctly in the socket o f the valve lifters.
Note: If the pushrods have been used, ensure that the pushrods are installed in original positions.
4. Lubricate the top of the valve stems with clean engine oil. Install caps (5) to the valve stems.
Note: If the caps have been used, ensure that the caps are installed in original positions.
5. Install rocker shaft assembly (3) to the cylinder head.
Note: Ensure that the ends of adjustment screws (4) are correctly seated in ends of pushrods (6).
g01316901
8. Adjust the valve lash. Refer to Systems Operation, Te s ti ng an d Ad j Inspect/Adjust” for the correct procedure.
End By:
a. Install the valve mechanism cover. Refer to
Disassembly a Cover - Remove and Install”.
b. Install the en
and Assembly, “Engine Oil Line- Remove and Install”.
usting, “Engine Valve Lash -
nd Assembly, “Valve Mechanism
gine oil line. Refer to Disassembly
i02961089
Cylinder Head - Remove
Removal Procedure
Start By:
a. Remove the exhaust manifold. Refer to
Disassembly
- Remove and Install”.
b. Remove the fu
and Assembly, “Fuel lter Base - Remove and Install”.
c. Remove the fuel injectors. Refer to Disassembly
and Assembly, “Fuel Injector - Remove”.
d. Remove the glow plugs. Refer to Disassembly
and Assembly, “Glow Plugs- Remove and Install”.
e. Remove the rocker shaft and the pushrods. Refer
to Disassembly and Assembly, “Rocker Shaft and Pushrod - R
f. Remove the water pump. Refer to Disassembly
and Assemb Install”.
and Assembly, “Exhaust Manifold
el lter base. Refer to Disassembly
emove”.
ly, “Water Pump - Remove and
6. Install nuts (2). Use a deep socket to evenly tighten the nuts. Begin at the center of the rocker shaft and work outward.
For 402D-05 and 403D-07 engines, tighten nuts (2)toatorqueof10N·m(88lbin).
For 403D-11 and 404D-15 engines, tighten nuts (2)toatorqueof23N·m(17lbft).
For 403D-15, 403D-15T, 403D-17, 404D-22,404D-22T and 404D-22TA engines, tightennuts(2)toatorqueof33N·m(24lbft).
7. Install bolts (1) and tighten to a torque of 10 N·m (88lbin).
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
68 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
NOTICE Care must be taken to ensure that uids are contained during perform
ance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compar
tment or disassembling any compo-
nent containing uids.
Dispose of all
uids according to local regulations and
mandates.
1. Drain the coolant from the cooling system into
asuitablecon
tainer for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Drain” for the correct draining pro
cedure.
Illustration 123
The cylinder head tightening sequence for three cylinder engine
Illustration 124
The cylinder head tightening sequence for four cylinder engine
g01317351
g01309552
2. Gradually loosen bolts (1) in reverse numerical order. This will prevent distortion of the cylinder head.
Illustration 121
Typical example
g01309672
For 402D-05 engines, loosen the cylinder head bolts in the reverse order to the sequence that is shown in Illustration 122.
For 403D-07, 403D-11, 403D-15, 403D-15T and 403D-17 engines, loosen the cylinder head bolts in the reverse order to the sequence that is shown in Illustration 123.
For 404D-15, 404D-22, 404D-22T and 404D-22TA engines, loosen the cylinder head bolts in the reverse order to the sequence that is shown in Illustration 124.
3. Remove bolts (1) from cylinder head (2).
4. Attach a suitable lifting device to cylinder head (2).
Illustration 122
The cylinder head tightening sequence f or two cylinder engine
g01317344
The weight of the cylinder head is approximately 30 kg (66 lb). Carefully lift the cylinder head off the cylinder block.
KENR6226-01 69
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Note: Do not use a lever to separate the cylinder head from the cy
linder block. T ake care not to damage the machined surfaces of the cylinder head during the removal procedure. Avoid contamination of the cylinde
r bores with coolant or with debris.
NOTICE Place the cylinder head on a surface that will not scratch the fa
ce of the cylinder head.
5. Remove the cylinder head gasket.
Note: The old gasket for the cylinder head should
be retained for the purpose of identication. Gaskets of di
fferent thickness are available. Refer to
Specications, “Cylinder Head”.
Table 20
Required Tools
Tool Part Number Part Description Qty
(1)
A
(2)
A
(3)
A
(1)
402D-05 and 403D-07 engines
(2)
403D-11 and 40
(3)
403D-15, 403D-1 5T, 403D-17, 404D-22 , 404D-22T and
404D-22TA engines
-
-
-
Guide Bolt (M8 by 60 mm)
Guide Bolt (M9 by 95 mm)
Guide Bolt (M11 by 100 m m)
4D-15 engines
1. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Do not damage the mat
ing surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant pa
ssages.
2. Inspect the mating surface of the cylinder head for distorti
on. Refer to Specications, “Cylinder Head” for more information. If the mating surface of the cylinder head is distorted beyond maximum permitted l
imits, replace the cylinder head.
2
2
2
Illustration 125
Typical example
g01317405
6. Note the position of dowels (3) in the cylinder block. Do not remove the dowels unless the dowels are damaged.
7. If necessary, remove the water temperature regulator from the cylinder head. Refer to Disassembly and Assembly, “Water Temperature Regulator - Remove and Install”.
i02961101
Cylinder Head - Install
Installa
Keep all p
Contaminants may cause rapid wear and shortened componen
tion Procedure
NOTICE
arts clean from contaminants.
tlife.
Illustration 126
Typical example
g01317467
3. Inspect dowels (3) for damage. If necessary, replace the dowels in the cylinder block.
4. Install Tooling (A) to the cylinder block. Refer to Illustration 126.
70 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Note: Ensure that the cylinder head is correctly positioned ont
o dowels (3).
9. Remove Tooling (A).
10. Install bolts (1) to cylinder head (2).
Illustration 127
Typical example
g01317471
5. Ensure that the new cylinder head gasket (4) is the same thickness as the cylinder head gasket that was previously removed. The thickness of the cylinder head gasket is indicated by the number that is shown at position (X). Refer to Specications, “Cylinder Head” for more information.
6. Align cylinder head gasket (4) with Tooling (A) and with dowels (3). Install the cylinder head gasket onto the cylinder block.
7. Use a suitable lifting device to lift the cylinder head. The weight of the cylinder head is approximately 30 kg (66 lb).
Illustration 129
The tightening sequence for a two cylinder engine
Illustration 130
The tightening sequence for a three c ylinder engine
g01317344
g01317351
Illustration 128
Typical example
8. Use Tooling (A) to align cylinder head (2) with the cylinder block. Install the cylinder head to the cylinder block.
g01309672
Illustration 131
The tightening sequence for a four cylinder engine
11. For 402D-05 engines, tighten bolts (1) to a torque of 37 N·m (27 lb ft). Use the numerical sequence that is shown in Illustration 129.
g01309552
KENR6226-01 71
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
For 403D-07 engines, tighten bolts (1) to a torque of 37 N·m (27 lb f thatisshowninIllustration130.
For 403D-11 en of 51 N·m (38 lb ft). Use the numerical sequence thatisshowninIllustration130.
For 403D-15, 403D-15T and 403D-17 engines, tighten bolts (1) to a torque of 101 N·m (75 lb ft). Use the numer Illustration 130.
For 404D-15 e of 51 N·m (38 lb ft). Use the numerical sequence thatisshowninIllustration131.
For 404D-22, 404D-22T and 404D-22TA engines, tighten bolts (1) to a torque of 101 N·m (75 lb ft). Use the nume Illustration 131.
12. If necessar regulator to the cylinder head. Refer to Disassembly and Assembly, “Water Temperature Regulator
End By:
- Remove and Install”.
t). Use the numerical sequence
gines, tighten bolts (1) to a torque
ical sequence that is shown in
ngines, tighten bolts (1) to a torque
rical sequence that is shown in
y, install the water temperature
i02645737
Lifter Group - Remove and Install
Removal Procedure
Table 21
Required Tools
Too l
A
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”.
Keep all parts clean from contaminants.
Contaminants component life.
Part
Number
-
may cause rapid wear and shortened
Part Description Qty
Telescopic Magnet 1
NOTICE
a. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
b. Install the rocker shaft and the pushrods. Refer to
Disassembly and Assembly, “Rocker Shaft and Pushrod - I
c. Install the glow plugs. Refer to Disassembly and
Assembly
d. Install the fuel injectors. Refer to Disassembly and
Assembly
e. Install the fuel lter base. Refer to Disassembly
and Assem Install”.
f. Install t
and Assembly, “Exhaust Manifold - Remove and Install”.
nstall”.
, “Glow Plugs - Remove and Install”.
, “Fuel Injector - Install”.
bly, “Fuel lter Base - Remove and
he exhaust manifold. Refer to Disassembly
NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjustin collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent contain
Dispose of all uids according to local regulations and mandates.
Illustration 132
g and repair of the p roduct. Be prepared to
ing uids.
g00828101
1. Use Tooling (A) to remove lifter (1) from the
cylinder block.
Note: Make a temporary identication mark on each lifter in order to identify the correct location.
72 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
2. Repeat Step 1 for the remaining lifters.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE It is strongly recommended that all lifters should be replaced when a
Illustration 133
new camshaft is installed.
g00692979
i02963920
Camshaft - Remove
Removal Proced
Start By:
a. Remove the lifters. Refer to Disassembly and
Assembly, “Lifter Group - Remove and Install”.
b. Remove the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Remove”.
Keep all parts clean from contaminants.
Contaminants component life.
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjustin collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent contain
may cause rapid wear and shortened
g and repair of the p roduct. Be prepared to
ing uids.
ure
NOTICE
NOTICE
1. Clean lifters (1). Follow Steps 1.a through 1.c in
order to inspect the lifters. Replace lifters that are worn or damaged.
a. Inspect the seat of the pushrod in the lifter for
visual wear or damage. Ensure that oil holes in the lifter are not restricted.
b. Inspect the shank of the lifter for wear or
damage. Refer to Specications, “Lifter Group” for more information.
c. Inspect the face of the lifter that runs on the
camshaft for visual wear or damage.
2. Lubricate lifters (1) with clean engine oil.
3. Install lifters (1) into the cylinder block.
Note: Theliftersshouldbefreetorotate.Ifthelifters
have been used, ensure that the lifters are installed in the original positions.
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install”.
Dispose of all uids according to local regulations and mandates.
1. If the engine is equipped with a mechanical fuel transfer pump, remove the fuel transfer pump. Refer to Dis Transfer Pump - Remove and Install”.
assembly and Assembly, “Fuel
KENR6226-01 73
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 40
4D-22TA engines, remove bolt (2). Rotate camshaft gear (4) in order to align the access hole in the camshaft gear with bolt (1). Remove bolt (1
).
4. Remove camshaft retainer (5).
5. Rotate the crankshaft until timing marks (X) are
aligned on the following gears:
Crankshaft gear (7)
Illustration 134
Typical example
g01311407
Camshaft gea
Idlergear(6)
Illustration 136
Typical example
r(4)
g01311416
6. Carefully remove camshaft assembly (8) from the cylinder block.
Note: Ensure that the lobes of the camshaft and the camshaft bearings are not damaged.
Camshaft - D isassemble
Illustration 135
Typical example
2. Remove s
lider (3) from camshaft gear (4).
g013114
Note: 402D-05, 403D-07, 403D-11, and 404D-15 engines
have a different camshaft retainer and different fasteners to 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines. The removal
procedure is similar for all models.
3. Rotate camshaft gear (4) in order to align the
access
hole in the camshaft gear with fastener (2).
For 402D-05, 403D-07, 403D-11, and 404D-15
s, remove allen head screw (2) and remove
engine bolt (1).
11
Disassembly Procedure
Table 22
Required Tools
Too l
A
Start By:
a. Remove the camshaft assembly. Refer to
Disassembly and Assembly, “Camshaft ­Remove”.
Part
Number
-
Part Name Qty
Combination Puller
i02645655
1
74 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Illustration 137
Typical example
1. Use Tooling (A) to remove gear (5) from camshaft
(1).
Note: The gear should be positioned on a suitable support in order to prevent damage to the governor yweights during disassembly.
2. Remove spacer (4) and woodruff key (2) from
camshaft (1).
3. Use Tooling (A) to remove bearing (3) from
camshaft (1).
Note: Identify the orientation of the bearing for installation.
g01326129
Illustration 138
Typical example
2. Lubricate the nose of camshaft (1) with clean engine oil. Use a suitable press to install bearing (3) to the camshaft.
Note: E nsure that the bearing is installed in the correct orientation. The camshaft bearing should be pressed squarely onto the camshaft or damage to the bearing may occur. Do not press on the outer race of the bearing.
3. Install spacer (4) and woodruff key (2) to camshaft (1).
4. Align gear (5) with woodruff key (2). Use a suitable press to install the gear to the nose of camshaft (1).
Note: The gear should be positioned on a suitable support in order to prevent damage to the governor yweights during installation.
End By:
g01326129
i02645654
a. Install the camshaft assembly. Refer to
Disassembly and Assembly, “Camshaft - Install”.
Camshaft - Assemble
Camshaft - Install
Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that all components of the camshaft assembly are clean and free from damage.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contamin component life.
ants may cause rapid wear and shortened
i0296392
6
KENR6226-01 75
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Disassembly and Assembly Section
1. Ensure that the assembly of the camshaft is clean and free from da
mage.
2. Lubricate the bearings of the camshaft with clean engine oil.
Illustration 139
Typical example
Illustration 140
Typical example
g01311416
g01311407
3. Carefully install camshaft assembly (8) into the cylinder block. Ensure that timing marks (X) are aligned on the following gears:
Crankshaft gear (7)
Camshaft gear (4)
Idler gear (6)
Note: Do not damage the lobes of the camshaft or the camshaft bearings.
Illustration 141
Typical example
g01311411
Note: 402D-05, 403D-07, 403D-11, and 404D-15 engines have a different camshaft retainer and different fasteners to 403D-15, 403D-15T, 403D-17, 404D-22,404D-22T and 404D-22TA engines. The installation procedure is similar for all models.
4. Place camshaft retainer (5) in position. Align the holes in the retainer with the holes in the cylinder block.
5. Rotate camshaft gear (4) in order to align the access hole in the camshaft gear with the hole for fastener (2).
For 402D-05, 403D-07, 403D-11, and 404D-15 engines, install allen head screw (2) and bolt (1). Tightenfasteners(1)and(2)toatorqueof10N·m (89 lb in).
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, install bolt (2) and tighten to a torque of 10 N·m (89 lb in). Rotate camshaft gear (4) in order to align the access hole in the camshaft gear with the hole for bolt (1). Install bolt (1) and tighten to a torque of 10 N·m (89 lb in).
6. Install slider (3) to camshaft gear (4).
7. If the engine is equipped with a mechanical fuel
transfer pump, install the fuel transfer pump. Refer to Disassembly and Assembly, “Fuel Transfer Pump - Remove and Install”.
End By:
a. Install the lifters. Refer to Disassembly and
Assembly, “Lifter Group- Remove and Install”.
76 KENR6226-01
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Disassembly and Assembly Section
b. Install the front housing. Refer to Disassembly and
Assembly, “Hou
sing (Front) - Install”.
i02645675
Engine O il Pan - Remove and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent containing uids.
1. Remove drain plugs (5) from engine oil pan (2). Drain the engin for storage or disposal. Refer to Operation and Maintenance Manual, “Oil Filter Change” for the correct proce
2. Remove sealing washers (3) from drain plugs (5).
3. Remove bolts (4) from engine oil pan (2).
4. Remove engine
5. Remove joint (1).
eoilintoasuitablecontainer
dure.
oil pan (2) from the engine.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: The two cylinder, the three cylinder and the four cylinder engines have different engine oil pans. The installation procedure is similar for all models.
Dispose of all uids according to local regulations and mandates.
Note: The two cylinder, the three cylinder and the four cylinder engines have different engine oil pans. The removal procedure is similar for all models.
Illustration 142
Typical example
g01326659
Illustration 143
1. Ensure that the engine oil pan is clean and free from damage. Clean the mating surface of the cylinder block.
2. Install a new joint (1) and engine oil pan (2) to the engine.
3. Installbolts(4)andtightentoatorqueof11N·m (97 lb in).
g01326659
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Disassembly and Assembly Section
4. Install drain plugs (5) and sealing washers (3) to oil pan (2). Tig 34 N·m (25 lb ft).
hten the drain plugs to a torque of
5. Fill the engin Operation and Maintenance Manual, “Engine Oil Filter Change” for the correct procedure.
e oil pan to the correct level. Refer to
i02645749
Pistons and Connecting Rods
-Remove
Removal Procedure
Table 23
Required Tools
Tool Part Number Part Description Qty
27610274
A
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”.
b. Remove the suction pipe. Refer to Disassembly
and Assembly, “Engine Oil Pump - Remove”.
Ridge Reamer 1
Illustration 144
3. The connecting rod and the connecting rod cap should have an etched number (X) on the side. The number on the connecting rod and the connecting rod cap must match. Ensure that connecting rod (4) and connecting rod cap (2) are marked for the correct location. If necessary, make a temporary mark on the connecting rod and the connecting rod cap in order to identify the cylinder number.
g01317717
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Positionthepistonthatisbeingremovedinthe bottom center position.
2. Use Tooling (A) in order to remove the carbon from the inner surface of the cylinder bore.
Note: Do not stamp the connecting rod assembly.
4. Remove nuts (1) and remove connecting rod cap
(2) from connecting rod (4).
Note: Use tape or rubber tubing on the threads of the connecting rod bolts in order to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals.
Illustration 145
Typical example
g01317733
5. Carefully push piston (5) and the connecting rod assembly out of the cylinder bore. Lift the piston out of the top of the cylinder block.
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Disassembly and Assembly Section
Note: Make an identication mark underneath the piston on the pi
n boss in order to identify the position on the piston for installation. Always mark the front pin boss.
6. Keep connecting rod bearings (3) with the
respective connecting rod (4) and cap (2).
7. Repeat Steps 1 through 6 in order to remove the
remaining pistons and connecting rods.
i02645741
Pistons and Connecting Rods
- Disassemble
Disassembly Procedure
Table 24
Required Tools
Tool
A
B
Start By:
a. Remove the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and Connecting Ro ds - Remove”.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Part
Number Part Description Qty
-
-
Retaining Ring Pliers 1
Ring Expander 1
NOTICE
ion 146
Illustrat
Typical example
g01311807
2. Place the piston and connecting rod assembly on a suitable surface with the connecting rod upward. Use Tooli
ng (A) in order to remove retaining rings
(4).
3. Remove pi
ston pin (3) and connecting rod (1) from
piston (2).
Note: If t
he piston pin cannot be removed by hand, heat the piston to a temperature of 45 ± 5 °C (113 ± 9 °F). Do not use a torch to heat the piston.
1. Make a tempo
rary mark on the components of the piston and connecting rod assembly. This will ensure that the components of each piston and connectin
grodassemblycanbereinstalledinthe original cylinder. Mark the front of the piston and the front of the connecting rod. Do not interchange componen
ts.
Illustration 147
Typical example
g00829406
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Disassembly and Assembly Section
Illustrat
ion 148
g01311809
4. Place the piston on a suitable surface with the crown upw
ard. Use Tooling (B) in order to remove compression rings (5) and (6), and oil control ring (7) from piston (2).
Note: Identify the orientation of the piston rings for installation.
ion 149
Illustrat
Typical example
g01311837
5. Remove nuts (11) and connecting rod cap (10) from connecting rod (1).
6. Remove the lower half of connecting rod bearing (9) from connecting rod cap (10). Remove the upper hal
f of connecting rod bearing (8) from connecting rod (1). Keep the bearing shells together.
NOTICE Removal of the piston pin bushing in the connecting rod must be carried out by personnel with the correct training information refer to your authorized
7. Inspect
. Also special machinery is required. For more
Perkins dealer.
the connecting rod for wear or damage. If necessary, replace the connecting rod or replace the bush for the piston pin.
80 KENR6226-01
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Disassembly and Assembly Section
i02645739
Pistons and Connecting Rods
- Assemble
Assembly Procedure
Table 25
Required Tools
Tool
A
B
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that all components are clean and free from wear or damage. If necessary, replace any components th
2. Follow Steps 2.a through 2.e in order to install the piston rings t
Part
Number
-
-
Part Description Qty
Retaining Ring Pliers 1
Ring Expander 1
NOTICE
at are worn or damaged.
o the piston.
Illustration 151
Typical example
g00829406
b. Use Tooling (B) to install oil control ring (7) over
the spring.
Note: Ensure that the central wire is 180 degrees from the ring gap.
c. Use Tooling (B) to install intermediate
compression ring (6) into the second groove in the piston. The letter “T” and the chamfer (Y) on the inner face of the ring must be upward.
d. Use Tooling (B) to install top compression ring
(5)intothetopgrooveinthepiston.Theletter “T” must be upward.
Illustration 150
g01038129
a. Position the spring for oil control ring (7) into the
oil ring groove in the piston. The central wire must be located inside the end of the spring.
e. Position the piston ring gaps at 120 degrees
away from each other.
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Disassembly and Assembly Section
ion 152
Illustrat
Typical example
g01311807
3. Lubricate the bush in connecting rod (1) and lubricate the bore for the piston pin in piston (2) with clea
nengineoil.
4. Place the piston on a suitable surface with the crown dow
nward. Install connecting rod (1) and piston pin (3) to piston (2). The name Shibaura inside the piston must align with the stamped number o
n the connecting rod. Ensure the correct
orientation of the connecting rod in the piston.
Note: If
the piston pin cannot be installed by hand, heat the piston to a temperature of 45 ± 5 °C (1 13 ± 9 °F). Do not use a torch to heat the piston.
5. Use Tooling (A) in order to install retaining rings
(4) to the piston pin bore in piston (2).
Note: Ensure that the retaining rings are seated in the grooves in the piston.
ion 153
Illustrat
Typical example
g01311837
6. Install the upper half of connecting rod bearing (8) to connecting rod (1).
7. Install the lower half of connecting rod bearing (9) to connecting rod cap (10).
End By:
a. Install t
he pistons and the connecting rods. Refer to Disassembly and Assembly, “Piston and Connecting Rods - Install”.
i02961862
Pistons and Connecting Rods
-Install
Installation Procedure
Table 26
Required Tools
Tool Part
A
Number
21825491
Part Description
Piston Ring Compressor 1
Qty
82 KENR6226-01
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Disassembly and Assembly Section
4. Ensure that the gaps for the piston rings are at
NOTICE
Keep all parts clean from contaminants.
120 degrees awa (A) onto piston (5). Use tape or rubber tubing on
y from each other. Install Tooling
the connecting rod bolts to protect the crankshaft
Contaminants may cause rapid wear and shortened
journals.
component life.
Note: Ensure that Tooling (A) is installed correctly
1. If the connecting rod caps were temporarily
installed, remove the connecting rod caps. If necessary, thoroughly clean all of the components.
and that the p Ensure that the piston and the connecting rod assembly are installed in the correct cylinder. Align number (X) on
iston can easily slide from the tool.
thesideoftheconnectingrodtothe
right side of the cylinder block. The right hand side is
2. Apply clean engine oil to the cylinder bore, to the
determined from the ywheel end of the engine.
piston rings, to the outer surface of the piston and to the connecting rod bearings.
5. Carefully push the piston and the connecting rod assembly into the cylinder bore and onto the
Note: Install the connecting rod bearings dry
crankshaft
pin.
when clearance checks are performed. Refer to Disassembly and Assembly, “Bearing Clearance ­Check”. Apply clean engine oil to the connecting rod
Note: Do not damage the nished surface of the crankshaft
pin.
bearings during nal assembly.
6. Install connecting rod cap (2) onto connecting rod
3. Rotate the crankshaft until the crankshaft pin
is at the bottom center position. Lubricate the crankshaft pin with clean engine oil.
(4). Ensur cap matches number (X) on the connecting rod. Install nuts (1).
e that number (X) on the connecting rod
ion 154
Illustrat
Typical example
g01311916
For 402D-05 and 403D-07 engines, tighten nuts (1) to a torque of 23 N·m (16 lb ft).
For 403D-11 and 404D-15 engines, tighten nuts (1) to a torque of 32 N·m (24 lb ft).
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten nuts (1) to a tor
queof52N·m(38lbft).
7. Repeat Steps 1 through 6 for the remaining pistons a
nd connecting rods.
8. Ensure that the installed connecting rod assembly has tacti
le side play. Carefully rotate the crankshaft
in order to ensure that there is no binding.
End By:
a. Install the suction pipe. Refer to Disassembly and
Assembly
, “Engine Oil Pump - Install”.
b. Install the cylinder head. Refer to Disassembly
and Assem
bly, “Cylinder Head - Install”.
24
Illustration 155
Typical example
g013119
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Disassembly and Assembly Section
i02645659
Connecting Rod Bearings ­Remove (Connecting ro
Removal Procedure
Start By:
a. Remove the suc
and Assembly, “Engine Oil Pump - Remove”.
Keep all parts
Contaminants may cause rapid wear and shortened component lif
Note: If all connecting rod bearings require replacement on a four cylinder engine, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairsofcylinders.1with4and2with3.Ensure
that both pairs of the connecting rod bearings are installed before changing from one pair of cylinders to another pair of cylinders..Refer
to Disassembly and Assembly, “Connecting Rod Bearings - Install”.
clean from contaminants.
e.
ds in position )
tion pipe. Refer to Disassembly
NOTICE
1. Rotate the crankshaft until the piston is at the bottom center p remove connecting rod cap (5) from connecting rod (1).
2. Remove lower connecting rod bearing (4) from connecting rod cap (5).
3. Carefully push connecting rod (1) into the cylinder bore. Remove upper connecting rod bearing (3) from the conn
Note: Use tape or rubber tubing on connecting rod bolts (2) in o The sharp edges of the connecting rod bolts could damage the crankshaft journals.
osition. Remove nuts (6) and
ecting rod.
rder to protect the crankshaft journals.
i02961864
Connecting Rod Bearings ­Install (Connecting rods in position)
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Illustration 156
Typical example
Note: The connecting rod and the connecting rod cap should have matching numbers at position (X). If necessary, make a temporary mark on connecting rod (1) and on connecting rod cap (5).
g01317759
1. Inspect the pins of the crankshaft for damage. If the crankshaft is damaged, replace the crankshaf to Disassembly and Assembly, “Crankshaft
- Remove” and Disassembly and Assembly, “Cranksha rod bearings are clean and free from wear or damage. If necessary, replace the connecting rod bearings
t or recondition the crankshaft. Refer
ft - Install”. Ensure that the connecting
.
84 KENR6226-01
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Disassembly and Assembly Section
For 403D-11 and 404D-15 engines, tighten nuts (4) to a torque o
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 4 (4) to a torque of 52 N·m (38 lb ft).
f32N·m(24lbft).
04D-22TA engines, tighten nuts
Illustration 157
Typical example
2. Clean the bearing surface of connecting rod (1) and connecting rod cap (5). Ensure that number (X) on connecting rod cap (5) aligns with number (X) on connecting rod (1).
3. Install upper connecting rod bearing (3) to connecting rod (1). Lubricate the bearing surface of the connecting rod bearing with clean engine oil.
4. Carefully pull connecting rod (1) against the crankshaft pin.
g01317759
9. Ensure that th has tactile side play. Carefully rotate the crankshaft in order to ensure that there is no binding.
Note: If all connecting rod bearings require replacement on a four cylinder engine, the procedure canbecarrie Theprocedurecanbecarriedoutonthefollowing pairs of cylinders. 1 with 4 and 2 with 3. Ensure
that both pai are installed before changing from one pair of cylinders to another pair of cylinders. Refer
to Disassem Bearings - Remove” for more information.
End By:
a. Install the suction pipe. Refer to Disassembly and
Assembly,
e installed connecting rod assembly
d out on two cylinders at the same time.
rs of the connecting rod bearings
bly and Assembly, “Connecting Rod
“Engine Oil Pump - Install”.
i02186171
Connecting Rod Bearings ­Install
Note: Use tape or rubber tubing on connecting rod
bolts (2) in order to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals.
5. Clean the connecting rod cap. Install lower connecting rod bearing (4) to connecting rod cap (5).
6. Lubricate the pin of the crankshaft and lubricate lower connecting rod bearing (3) with clean engine oil.
NOTICE When the connecting rod caps are installed, ensure that the identication marks are aligned.
7. Install connecting rod cap (5).
8. Install nuts (4).
For 402D-05 and 403D-07 engines, tighten nuts (4)toatorqueof23N·m(16lbft).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE When the connecting rod caps are installed, ensure that the identication marks are aligned.
KENR6226-01 85
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Disassembly and Assembly Section
Note: The identication marks must face the right hand side of the
9. Repeat Steps 2 through 8 for the installation of the
remaining con
End By:
a. Install the oil supply tube. Refer to Disassembly
and Assembly, “Crankshaft - Install”.
b. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and Install”.
engine for the correct installation.
necting rod bearings.
i02645668
Illustration 158
Typical example
1. Check the clearance between the connecting rod bearing and the connecting rod bearing journal of the crankshaft. Install the connecting rod bearings dry when the clearance checks are made. Refer to Disassembly and Assembly, “Bearing Clearance
- Check” for information on bearing clearance checks.
2. Clean the bearing surface of the connecting rod (1) and the connecting rod cap (5). Ensure that the number (6) on the connecting rod cap (5) aligns with the number (6) on the connecting rod (1).
3. Clean the upper connecting rod bearing (3) and lubricate the bearing face with clean engine oil.
4. Clean the lower connecting rod bearing (3) and lubricate the bearing face with clean engine oil.
Note: Align the tabs on the back of the connecting rod bearings (3) with the tab grooves in the connecting rod (1) and the tab grooves on the connecting rod cap (5).
g0 1111 763
Crankshaft M
ain Bearings -
Remove
Removal Proc
Start By:
a. Remove the crankshaft assembly. Refer to
Disassembly and Assembly, “Crankshaft ­Remove”.
Keep all parts clean from contaminants.
Contaminant component life.
Crankshaft Main Bearings
1. Ensure that the bearing caps are marked for
orientation and the correct position.
s may cause rapid wear and shortened
edure
NOTICE
5. Install the upper connecting rod bearing (3) to the connecting rod (1).
6. Position the connecting rod (1) against the crankshaft.
7. Install the lower connecting rod bearing (3) in the connecting rod cap (5).
8. Install the connecting rod cap (5) in position on the connecting rod (1) and install the nuts (4) to the connecting rod bolts (2). Refer to Disassembly and Assembly, “Pistons and Connecting Rods ­Install” for the correct torque of the connecting rod nuts (4).
86 KENR6226-01
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Disassembly and Assembly Section
4. Remove main bearings (4) and (5) from the main bearing caps. K
eep the main bearings with the
respective bearing caps.
Illustration 159
g01327056
5. Do not remove d caps.
Crankshaft Be
Table 27
Too l
A
Illustration 161
Part
Number
27610275
owels (8) from the main bearing
aring (Front)
Required Tools
Part Description
Driver 1
g01327066
Qty
Illustration 160
Typical example
g01327033
2. Remove bolts (1) and upper main bearing cap (2) from lower main bearing cap (6).
3. For C1.5 engines, remove thrust washers (7).
For C2.2 engines, remove thrust washers (3) and (7).
1. Use Tooling (A) to remove crankshaft bearing (9) from the cylinder block.
i02963756
Crankshaft Main Bearings ­Install
Installation Procedure
Crankshaft Main Bearings
1. Clean the crankshaft and inspect the crankshaft
for wear or damage. Refer to Specications, “Crankshaft” for more information.
2. Clean the main bearings and the main bearing caps. For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, clean the thrust washers. Inspect all components for wear or damage.
KENR6226-01 87
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Disassembly and Assembly Section
4. Install lower main bearing (5) to lower main bearing cap (6)
. Ensure that the locating tab for the main bearing is seated in the slot in the main bearing cap.
Note: The lower bearing is a plain bearing that has oil holes.
5. Lubricate main bearings (4) and (5) with clean engine oil.
6. Position the upper half of main bearing cap (2) in position on the crankshaft. Position the lower half of
main bearing cap (6) in position on the crankshaft. Ensure the correct location and orientation of the bearing caps. The locating tabs for the upper
and the lower bearings should be on the same side of the engine. Ensure that dowels (8) are in the correct position. This will ensure that the two
halves of the main bearing caps are
aligned.
ion 162
Illustrat
Typical example
g01327033
For 403D-1
5, 403D-15T and 403D-17 engines,
install thrust washers (7).
For 404D-2
2, 404D-22T and 404D-22TA engines,
install thrust washers (3) and (7).
Note: Ensu
re that the thrust washers are aligned correctly and that the oil grooves are facing the crankshaft.
7. Install bolts (1).
For 402D-0
5, 403D-07, 403D-11, and 404D-15 engines, tighten the bolts to a torque of 23 N·m (17 lb ft).
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten the bolts to a
torque of 52 N·m (38 lb ft).
Crankshaft Bearing (Front)
Table 28
Tools
Part Desc
Driver 1
ription
Too l
A
Required
Part
Number
27610275
Qty
Illustration 163
Typical example
g01485913
3. Install upper main bearing (4) to upper main bearing cap (2). Ensure that the locating tab for the main bearing is seated in the slot in the main bearing cap.
Note: The upper bearing has a groove.
88 KENR6226-01
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Disassembly and Assembly Section
c. Remove the engine oil pump and the suction pipe.
Refer to Disass Pump - Remove”.
embly and Assembly, “Engine Oil
Illustration 164
1. Use Tooling (A) to install crankshaft bearing (9) to the cylinder block. Follow Steps 1.a through 1.c in order to install the crankshaft bearing.
a. Ensure that oil supply hole (12) is aligned with
the oil gallery in the cylinder block.
b. Ensure that joint (10) is upward.
g01485933
d. Remove the pis
Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove”.
Keep all parts clean from contaminants.
Contaminants component life.
1. The engine should be mounted in a suitable stand with the rear end upward.
tons and the connecting rods.
NOTICE
may cause rapid wear and shortened
c. Ensure that chamfer (11) faces toward the
cylinder block.
End By:
a. Install the crankshaft assembly. Refer to
Disassembly and Assembly, “Crankshaft - Install”.
Crankshaft - Remove
Removal Procedure
Start By:
a. Remove the engine oil relief valve. Refer to
Disassembly and Assembly, “Engine Oil Relief Valve - Remove and Install”.
b. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install”.
i02645665
Illustration 165
Typical example
2. Remove bolts (2) from the cylinder block.
3. Remove allen head screws (1) from the cylinder
block.
g01311526
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Disassembly and Assembly Section
Illustration 166
Typical example
g01311527
4. Attach a suitable lifting device (3) to crankshaft assembly (4).
5. Carefully lift crankshaft assembly (4) from the cylinder block. If necessary, gently tap the nose of the crankshaft with a soft faced hammer.
Note: Install the nut for the crankshaft pulley in order to protect the nose of the crankshaft. Do not scratch any of the nished surfaces on the crankshaft.
i02961985
Crankshaft - Install
Installation Procedure
Table 29
Required Tools
Too l
A 21825617
Part
Number
Part Description Qty
Dial Indicator Group
1
Illustration 167
Typical example
g01311527
3. Attach a suitable lifting device (3) to crankshaft assembly (4). Lubricate the front journal of the crankshaft with clean engine oil.
Illustration 168
Typical example
g01311526
1. The engine should be mounted in a suitable stand with the r
ear end upward.
2. Ensure that the crankshaft assembly is clean and free from
damage.
Ensure that the oil passages in the main bearings align with the oil passages in the cylinder block.
NOTICE
90 KENR6226-01
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Disassembly and Assembly Section
4. Align the holes in the crankshaft assembly for bolts (2) with t
he holes in the cylinder block. Align the holes in the crankshaft assembly for allen head screws (1) with the holes in the cylinder block. Carefu
lly lower the crankshaft assembly (4) into the cylinder block. If necessary, gently tap the rear of the crankshaft with a soft faced hammer.
5. Remove lifting device (3) from crankshaft assembly (4).
6. Install allen head screws (1) nger tight.
7. Install bolt
s(2).
For 402D-05, 403D-07, 403D-11 and 404D-15 engines, tig
hten bolts (2) to a torque of 27 N·m
(20 lb ft).
For 403D-15,
403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten bolts (4)toatorqueof52N·m(38lbft).
8. Tighten allen head screws (1) to a torque of 27 N·m (20 lb ft).
9. Rotate the crankshaft in order to ensure that there is no binding.
10. Check the crankshaft end play. Push the crankshaft toward the front of the engine. Install Too li ng ( A
) to the cylinder block and the rear face of the crankshaft. Push the crankshaft toward the rear of the engine. Use Tooling (A) to measure the cranks
haft end play. Refer to Specications, “Crankshaft” for the maximum permissible crankshaft end play.
End By:
a. Install t
he pistons and the connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install”.
b. Install the engine oil pump and the suction pipe.
Refer to Disassembly and Assembly, “Engine Oil Pump - Ins
tall”.
c. Install the crankshaft rear seal. Refer to
Disassem
bly and Assembly, “Crankshaft Rear
Seal - Remove and Install”.
d. Install
the engine oil relief valve. Refer to Disassembly and Assembly, “Engine Oil Relief Valve - Remove and Install”.
i02748526
Bearing Clearance - Check
Measurement Pr
Table 30
Tool
A
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Perkins does not recommend the checking of the actual c on small engines. This is because of the possibility of obtaining inaccurate results and of damaging the bearing she bearing shell is quality checked for specicwall thickness.
Note: The measurements should be within specications and the correct bearings should be used. If for the block and the rods were measured during disassembly, no further checks are necessary. However, i bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small dia (0.004 inch).
Lead wire age the bearing surfaces.
Part
Number Part Description Qty
-
-
-
-
learances of the bearing shells particularly
ll or the journal surfaces. Each Perkins
the crankshaft journals and the bores
f the technician still wants to measure the
meters if clearances are less than 0.10 mm
, shim stock or a dial bore gauge can dam-
ocedure
Required Tools
Plastic Gauge (Green)
0.025 to 0.076 mm (0.001 to 0.003 inch)
Plastic Gauge (Red)
0.051 to 0.152 mm (0.002 to 0.006 inch)
Plastic Gauge (Blue)
0.102 to 0.229 mm (0.004 to 0.009 inch)
Plastic Gauge (Yellow)
0.230to0.5 (0.009 to 0.020 inch)
NOTICE
NOTICE
10 mm
1
1
1
1
The techn
ician must be very careful to use Tooling (A)
correctly. The following points must be remembered:
KENR6226-01 91
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Ensure that the backs of the bearings and the
bores are clean
Ensure that the bearing locking tabs are properly
seated in the t
The crankshaft must be free of oil at the contact
points of Tool
1. Put a piece of Tooling (A) on the crown of the bearing that i
Note: Do not allow Tooling (A) to extend over the edge of the be
2. Use the correct torque-turn specications in order to install th wrench. Be careful not to dislodge the bearing when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A) is installed.
3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooli crankshaft journal. Refer to Illustration 169.
and dry.
ab grooves.
ing (A).
sinthecap.
aring.
e bearing cap. Do not use an impact
ng (A) is in the bearing cap or on the
i02962020
Coolant Temperature Switch ­Remove and Install (403D-11, 403D
-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines)
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE Care must be taken to ensure that uids are contained during perfo ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compa nent containing uids.
rmance of inspection, maintenance, test-
rtment or disassembling any compo-
Illustration 169
Typical Exam p le
4. Remove all of Tooling (A) before you install the bearing cap.
Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling(A)arenotthesamewidth.Measurethe major width in order to ensure that the parts are within the specication range. Refer to Specications Manual, “Connecting Rod Bearing Journal” and Specications Manual, “Main Bearing Journal” for the correct clearances.
g01152855
Dispose of al mandates.
1. Drain the coolant from the cooling system into a suitable co to Operation and Maintenance Manual, “Cooling System Coolant - Drain” for more information.
Illustration 170
Typical example
2. Disconnect the harness assembly (not shown) from coolant temperature switch (2).
3. Remove coolant temperature switch (2) from water temperature regulator housing (1).
l uids according to local regulations and
ntainer for storage or disposal. Refer
g01326627
92 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Installation P
Table 31
Tool Part Number Part Descripti
21820122
A
Keep all parts clean from contaminants.
Contaminants m component life.
1. Inspect the coolant temperature switch for damage and correct operation. Refer to Systems Operation, Testing and Adjusting, “Coolant Temperature Switch - Test” for more information. If necessary, replace the coolant temperature switch.
rocedure
Required Tools
on
POWERPART Pipe Sealant
NOTICE
ay cause rapid wear and shortened
Qty
1
i02645660
Coolant Temperature Switch ­Remove and Install (402D-05 and 4 0
Removal Procedure
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that uids are contained during perform ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open­ing any compar nent containing uids.
Dispose of all mandates.
ance of inspection, maintenance, test-
tment or disassembling any compo-
uids according to local regulations and
3D-07 Engines)
NOTICE
NOTICE
Illustration 171
Typical example
2. Install coo temperature regulator housing (1). Use a deep socket to tighten the coolant temperature switch to a torque o
Note: Ifausedcoolanttemperatureswitchis installed threads of the coolant temperature switch.
3. Connect th coolant temperature switch (2).
4. Fill the co level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Fill” for more informat
lant temperature switch (2) to water
f27N·m(20lbft).
, apply a thin layer of Tooling (A) to the
e harness assembly (not shown) to
oling system with coolant to the correct
ion.
g01326627
1. Drain the coolant from the cooling system into a suitable con to Operation and Maintenance Manual, “Cooling System Coolant - Drain” for more information.
Illustration 172
Typical example
2. Disconnect the harness assembly (not shown) from coolant temperature switch (1).
3. Remove coolant temperature switch (1) from water pump (2).
tainer for storage or disposal. Refer
g01325724
KENR6226-01 93
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Installation P
Table 32
Tool Part Number Part Descripti
21820122
A
Keep all parts clean from contaminants.
Contaminants m component life.
1. Inspect the coolant temperature switch for damage and correct operation. Refer to Systems Operation, Testing and Adjusting, “Coolant Temperature Switch - Test” for more information. If necessary, replace the coolant temperature switch.
rocedure
Required Tools
on
POWERPART Pipe Sealant
NOTICE
ay cause rapid wear and shortened
Qty
1
i02645676
Engine Oil Pressure Switch ­Remove and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants m component life.
Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test­ing, adjusting collect the uid with suitable containers before open­ing any compartment or disassembling any compo­nent contain
Dispose of all uids according to local regulations and mandates.
ay cause rapid wear and shortened
NOTICE
and repair of the product. Be prepared to
ing uids.
Illustration 173
Typical example
2. Install coo pump (2). Use a deep socket to tighten the coolant temperature switch to a torque of 27 N·m (20 lb ft).
Note: Ifausedcoolanttemperatureswitchis installed, apply a thin layer of Tooling (A) to the threads of
3. Connect the harness assembly (not shown) to coolant te
4. Fill the cooling system with coolant to the correct level. Ref Manual, “Cooling System Coolant - Fill” for more information.
lant temperature switch (1) to water
the coolant temperature switch.
mperature switch (1).
er to Operation and Maintenance
g01325724
Note: The engine oil pressure switch may be located in the valve mechanism cover or in the cylinder block. Refer to Spec for the correct location.
ications, “Engine Oil Pressure Switch”
ation 174
Illustr
Typical example
g01307413
94 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
1. Disconnect the harness assembly (not shown) from engine oil
pressure switch (1).
2. If engine oil pressure switch (1) is located in the valve mechani
sm cover, remove the engine oil
pressure switch from the valve mechanism cover.
Illustration 175
Typical example
3. If engine oi
l pressure switch (1) is located in the
g01307450
cylinder block follow Steps 3.a through 3.c in order to remove the engine oil pressure switch.
a. Remove engine oil pressure switch (1) and
adapter (4) as an assembly from oil line (2).
b. Remove wa shers (3).
c. Remove engi
ne oil pressure switch (1) from
adapter (4).
Installation Procedure
Table 33
Required Tools
Tool Part Number Part Description
A 21820122
POWERPART Pipe Sealant
Note: The engine oil pressure switch may be located in the valve mechanism cover or in the cylinder block. Refer to Specications, “Engine Oil Pressure Switch” for the correct location.
Qty
1
ion 176
Illustrat
Typical example
g01307413
Note: If a used engine oil pressure switch is installed, apply a thin layer of Tooling (A) to the threads of the engine oi
l pressure switch.
1. If engine oil pressure switch (1) is located in the valve mec
hanism cover, install the engine oil pressure switch and tighten to a torque of 11 N·m (97 lb in).
Illustration 177
Typical example
2. If engine oil pressure switch (1) is located in the cylinder block follow Steps 2.a through 2.c in order to install the engine oil pressure switch.
g01307450
KENR6226-01 95
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
a. Install engine oil pressure switch (1) to adapter
(4). Tighten th torque of 23 N·m (17 lb ft).
Note: If a used apply a thin layer of Tooling (A) to the threads of the engine oil pressure switch.
b. Position new washers (3) onto oil line (2) and
install the assembly of engine oil pressure switch (1) an
c. Tighten adapter (4) to a torque of 11 N·m
(97lbin).
3. Connect the harness assembly (not shown) to engine oil pr
eengineoilpressureswitchtoa
engine oil pressure switch is installed,
d adapter (4) to the cylinder block.
essure switch (1).
i02962102
Glow Plugs - Remove and Install
Installation P
Table 34
Tool
A
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that the threads of the glow plugs are clean and free from damage. Replace any damaged glow plugs.
Part
Number
27610296
rocedure
Required Tools
Part Name
Torque Wrench 1
NOTICE
Qty
Removal Procedure
1. Turn the battery disconnect switch to the OFF
position.
NOTICE
Keep all parts clean from contaminants.
Contaminan component life.
Illustration 178
Typical example
2. Remove nuts (1) and washers (2) from bus bar (3).
ts may cause rapid wear and shortened
g01326605
Illustration 179
Typical example
2. Install glow plugs (4) into the cylinder head.
For 402D-05,403D-07,403D-11 and 404D-15 engines, tighten the glow plugs to a torque of 12 N·m (106 lb in).
For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten the glow plugs to a torque of 18 N·m (159 lb in).
3. Position bus bar (3) onto glow plugs (4).
4. Install washers (2) and nuts (1) to glow plugs (4).
Use Tooling (A) to tighten the nuts to a torque of
1.2N·m(10.6lbin).
5. Turn the battery disconnect switch to the ON position.
g01326605
3. Remove bus bar (3) from glow plugs (4).
4. Remove glow plugs (4) from the cylinder head.
96 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645773
V-Belts - Remove an d Install
Removal Proced
Keep all parts c
Contaminants may cause rapid wear and shortened component life
1. Iftheengineisequippedwithfanguards,remove the fan guards.
lean from contaminants.
.
ure
NOTICE
Illustration 181
Typical example
1. Check the condition of the V-belt . If the V-belt is worn or damaged, use a new V-belt for replacement.
2. Install V-belt (5) in position on the engine.
Note: A used V-belt should be installed in the original
direction of rotation.
g01325726
Illustration 180
Typical example
2. Loosen bolts (1), (2) and (4).
3. Push alternator (3) toward the engine and remove
V-belt (5).
Note: Mark the direction of rotation if the V-belt will be reused.
g01325726
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
3. Slide alternator (3) away from the engine. Refer to Systems Operation, Testing and Adjusting, “Belt Tension Chart” for information on the correct belt tension. Tighten bolts (1), (2) and (4) to a torque of 25 N·m (18 lb ft).
4. If the engine is equipped with fan guards, install the fan guards.
i02645681
Fan - Remove and Install
Removal Procedure
Start By:
a. Remove the V-Belt. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install”.
KENR6226-01 97
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
2. Position pulley (4) and spacer (3) on water pump (5). Ensure tha
3. Install fan (2).
Note: Ensure the correct orientation of the fan.
t the bolt holes are aligned.
Illustration 182
Typical example
1. Remove bolts (1) and remove fan (2).
Note: Mark the orientation of the fan for installation.
2. Remove spacer (3) and pulley (4) from water
pump (5).
g01318055
Installation Procedure
1. Ensure that all components are clean and free
from damage. Replace any components that are worn or damaged.
4. Install bolts (97 lb in).
End By:
a. Install the V-Belt. Refer to Disassembly and
Assembly, “V-
(1)andtightentoatorqueof11N·m
Belts - Remove and Install” .
i02645653
Alternator - Remove and Install (65 Amp and 85 A mp Alternators)
Removal Procedure
Start By:
a. Remove the V-Belt. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
tery disconnect switch to the OFF
ary identication marks on the
Illustration 183
Typical example
1. Turn the bat position.
2. Make tempor connections of the harness assembly.
g01318055
98 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
Installation P
rocedure
ion 184
Illustrat
Typical example
g01308285
3. Disconnect the harness assembly (not shown) from alternator (5).
4. Remove bolt (4) and washer (3) from alternator (5).
5. Remove washer (7) and nut (6). Remove bolt (8) and alternator (5) from the mounting bracket.
6. If necessary, remove bolt (1) and remove adjusting link (2).
Illustration 185
Typical ex
ample
g01308285
1. If necessary, install adjusting link (2) and install bolt (1) fin
ger tight.
2. Position alternator (5) on the mounting bracket.
3. Install bolt (8), washer (7) and nut (6) nger tight.
4. Install b
olt (4) and washer (3) nger tight.
5. Install the V-Belt. Refer to Disassembly and Assembly
,“V-Belts-RemoveandInstall”.
Note: Ensure that the alternator pulley is in alignment with the c
rankshaft pulley. Ensure that all fasteners
are tightened.
6. Connect t
he harness assembly (not shown) to the
alternator.
7. Turn the b
attery disconnect switch to the ON
position.
KENR6226-01 99
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
i02645652
Alternator - R emove and Insta ll (55 Amp Alternator)
Removal Procedure
Start By:
a. Remove the V-Belt. Refer to Disassembly and
Assembly, “V-
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Turn the battery disconnect switch to the OFF position.
2. Make temporary identication marks on the connections of the harness assembly.
Belts - Remove and Install”.
NOTICE
Installation P
Illustration 187
Typical example
1. If necessary, install adjusting link (4) and install bolt (1) nger tight.
rocedure
g01308282
Illustration 186
Typical example
3. Disconnect the harness assembly (not shown) from alternator (5).
4. Remove bolt (2) and washer (3) from alternator (5).
5. Remove fasteners (6) and (7) and remove alternator (5) from the mounting bracket.
6. If necessary, remove bolt (2) and remove adjusting link (4).
g01308282
2. Position alternator (5) on the mounting bracket.
3. Install fasteners (6) and (7) nger tight.
4. Install bolt (2) and washer (3) nger tight.
5. Install the V-Belt. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install”.
Note: Ensure that the alternator pulley is in alignment with the crankshaft pulley. Ensure that all fasteners are tightened.
6. Connect the harness assembly (not shown) to the alternator.
7. Turn the battery disconnect switch to the ON position.
i02645651
Alternator - Remove and Install (40 Amp Alternator)
Removal Procedure
Start By:
a. Remove the V-Belt. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install”.
100 KENR6226-01
This document has been printed from SPI². Not for Resale
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Turn the battery disconnect switch to the OFF position.
2. Make temporary identication marks on the connections of the harness assembly.
Installation P
Illustration 189
Typical example
1. If necessary, install adjusting link (2) and install bolts (1). Tighten bolts (1) to a torque of 10 N·m (89 lb in).
rocedure
g01308278
Illustration 188
Typical example
3. Disconnect the harness assembly (not shown) from alternator (4).
4. Remove bolt (5), washer (6) and spacer (3) from alternator (4).
5. Remove bolt (8) and washer (7). Remove the alternator (4) from the mounting bracket.
6. If necessary, remove bolts (1) and remove adjusting link (2).
g01308278
2. Position alternator (4) on the mounting bracket and install bolt (8) and washer (7) nger tight.
3. Install bolt (5), washer (6) and spacer (3) nger tight.
4. Install the V-Belt. Refer to Disassembly and Assembly, “V-Belts - Remove and Install”.
Note: Ensure that the alternator pulley is in alignment with the crankshaft pulley. Ensure that all fasteners are tightened.
5. Connect the harness assembly (not shown) to the alternator.
6. Turn the battery disconnect switch to the ON position.
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