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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GP GQ

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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

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 ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassembling any component containing ﬂuids.

Dispose of all ﬂuids according to local regulations and mandates.

a around a fuel system component that

3D-15, 403D-15T,

NOTICE

Illustration 1

Typical example

2. Loosen hose clamps (4) and disconnect hoses (5).

3. If necessary, remove fuel ﬁlter element (7)

from fuel ﬁlter base (1). Refer to Operation and Maintenance Manual, “Fuel System Filter Replace”.

4. Remove fasteners (2) and remove fuel ﬁlter base

(1) from the mounting bracket.

5. If necessary, remove plugs (6) and washers (not

shown) from fuel ﬁlter base (1). Remove tube assemblies (3) and rubber olives (not shown) from fuel ﬁlter base (1).

g01302737

NOTICE

Keep all parts clean from contaminants.

Contaminan component life.

Note: Place identiﬁcation marks on all hoses for installation purposes. Plug all hoses and all the ports in the fuel ﬁlter base. This helps prevent ﬂuid 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 ﬁlter base. The assembly of the fuel ﬁlter base and the hand priming pump is not serviceable.

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

from damage. If necessary, replace the fuel ﬁlter 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

Illustration 2

Typical example

2. If necessary, install new rubber olives (not shown) onto tube assemblies (3). Install tube assemblies (3) to fuel ﬁlter 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.

Dispose of all ﬂuids 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 ﬁlter base (1). Tighten the plugs to a torque of 23 N·m (17 lb ft).

4. Align fuel ﬁlter 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 ﬁlter element (7) to fuel ﬁlter 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.

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 ﬁlter element (5). Refer

to Operations and Maintenance Manual, “Fuel System Filter - Replace”.

4. Remove bolt (1) and remove fuel ﬁlter 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 ﬁlter base is clean and free from damage. If necessary, replace the fuel ﬁlter base.

Illustration 4

Typical example

g01303701

2. Align fuel ﬁlter 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 ﬁlter element (6) to fuel ﬁlter 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

Dispose of all ﬂuids according to local regulations and mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Place identiﬁcation marks on all hoses for installation purposes. Plug all hoses and all the ports in the fuel transfer pump. This helps prevent ﬂuid loss, and this helps to keep contaminants from entering the system.

rt to enter the fuel system. Thoroughly

stem component.

dure

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 ﬂange (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 ﬂuids are contained during perform ing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compar nent containing ﬂuids.

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 ﬂange (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 identiﬁcation marks on all hoses, on all hose assembl for installation purposes. Plug all hose assemblies and tube assemblies. This helps to prevent ﬂuid loss and this help the system.

1. Turn the fue

2. Turn the battery disconnect switch to the OFF

position.

ﬂuids 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 ﬂuids are contained during performance of inspection, maintenance, testing, adjusting collect the ﬂuid with suitable containers before opening any compartment or disassembling any component contain

Dispose of all ﬂuids according to local regulations and mandates.

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 ﬂuids.

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 identiﬁcation 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 ﬂexible fuel return hose.

For engines with a ﬂexible 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

Tool

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 ﬂ

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 ﬂexible 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) ﬁnger 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 ﬁrst.

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 ﬂuids are contained during perfo ing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compa nent containing ﬂuids.

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 ﬂuids 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 ﬂuids are contained during perfor ing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compa nent containing ﬂuids.

Dispose of al mandates.

nd Assembly, “Fuel Shutoff

NOTICE

mance of inspection, maintenance, test-

rtment or disassembling any compo-

l ﬂuids 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 ﬂexible fuel return hose.

For engines with a ﬂexible 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

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 Speciﬁcations, “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 Speciﬁcations, “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 ﬂexible fuel return hose.

For engines with a ﬂexible 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 ﬂuids are contained during performance of inspection, maintenance, testing, adjusti collect the ﬂuid with suitable containers before opening any compartment or disassembling any component contai

Dispose of all ﬂuids according to local regulations and mandates.

ng and repair of the product. Be prepared to

ning ﬂuids.

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

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

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 ﬁrst 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

Dispose of all ﬂuids according to local regulations and mandates.

Keep all parts clean from contaminants.

Contamina component life.

nts may cause rapid wear and shortened

cedure

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 speciﬁed 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 ﬁnger tight.

Position a new joint (7) on tube assembly (10). Align tube assembly (10) to the bottom of the turbocharge ﬁnger 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 ﬁnger

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 ﬁrst.

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

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 ﬁrst.

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

(1)

(2)

(3)

(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

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) ﬁnger 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 sufﬁcient 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

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

(1)

(2)

(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

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 sufﬁcient 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 Speciﬁcations, “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

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 Speciﬁcations, “Cylinder Head Val v e s ” for

the correct dimensions.

2. Place a temporary identiﬁcation 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

(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 Speciﬁcations, “Cylinder

Head Valves” for further information.

c. Inspect th

e valve guides for wear and for damage. Refer to Speciﬁcations, “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 Speciﬁcations, “Cylinder Head Valves”.

e. Inspect th

e valve springs for the correct length.

Refer to Speciﬁcations, “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 ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassembling any component containing ﬂuids.

Dispose of all ﬂuids according to local regulations and mandates.

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 ﬁnger 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 ﬂuids are contained during perform

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

tment or disassembling any compo-

nent containing ﬂuids.

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 ﬁnger 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

ﬂuids 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

Strap Wrench

Qty

Typical example

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

Dispose of all ﬂuids according to local regulations and mandates.

ay cause rapid wear and shortened

NOTICE

and repair of the product. Be prepared to

ing ﬂuids.

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 ﬁlter 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 ﬂuids are contained during performance of inspection, maintenance, testing, adjustin collect the ﬂuid with suitable containers before opening any compartment or disassembling any component containi

Dispose of all ﬂuids according to local regulations and mandates.

Keep all parts clean from contaminants.

g and repair of the p roduct. Be prepared to

ng ﬂuids.

ure

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

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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)

(2)

(3)

(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

mage to the engine may occur.

Multipurpose Grease 1

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.

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