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62

KENR6932

Disassembly and Assembly Section

3.

Remove joints (10).

i02654368

Engine Oil Cooler - Install

(Engine Oil Cooler with a Low

Mounted Filter Base)

 

Assembly Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01336430

Illustration 105

Typical example

1.

Ensure that cooler matrix (19) is clean and free

from damage. Ensure that spacer plate (17)

is clean and free from damage. Replace any

damaged components.

2.

Position a new joint (18) onto spacer plate (17).

Install cooler matrix (19) to the spacer plate.

3.

Install bolts (15)

fi

nger tight.

g01336427

Illustration 106
Typical example

4.

Position brackets (5), (10) and (14) onto the

assembly of oil cooler (6). Install bolts (7).

Note:

Ensure that brackets for the tube assemblies

are installed in the correct location and the correct

orientation. The bolts are different lengths. Ensure

that the different bolts are installed in the correct

location.

5.

Install new joint (16) to the assembly of oil cooler

(6). Push bolts (7) through the holes in the joint.

Note:

The holes in the joint have serrations that hold

the bolts captive.

Installation Procedure (Engine Oil
Cooler with a Low Mounted Filter
Base)

1.

Clean the mating surfaces of the cylinder block.

Summary of Contents for 1106C Series

Page 1: ...May 2007 Disassembly and Assembly 1106C Genset PK Engine KENR6932 00...

Page 2: ...ing 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 canno...

Page 3: ...ng Remove and Install Standard Housing 78 Flywheel Housing Remove and Install Wet Back End Housing 81 Vibration Damper and Pulley Remove Pulleys without Split Lock Rings 84 Vibration Damper and Pulley...

Page 4: ...ove and Install 170 Inlet Air Temperature Sensor Remove and Install 171 Glow Plugs Remove and Install 172 Alternator Belt Remove and Install 173 Fan Remove and Install 174 Fan Drive Remove and Install...

Page 5: ...c tube assemblies 1 in order to show the correct position of the tube assemblies 3 Place a suitable container below the fuel priming pump in order to catch any fuel that might be spilled Drain the pri...

Page 6: ...osition fuel priming pump 4 on the mounting bracket Install bolts 7 to the fuel priming pump Tighten the bolts to a torque of 44 N m 32 lb ft 4 Remove the plugs from the plastic tube assemblies Remove...

Page 7: ...Gen eral Hazard Information and High Pressure Fuel Lines for safety information Refer to System Operation Testing and Adjusting Cleanliness of Fuel System Components for de tailed information on the s...

Page 8: ...ht be spilled 4 Disconnect plastic tube assemblies 2 4 and 5 from fuel filter base 1 Plug the plastic tube assemblies with new plugs Cap the ports in the fuel filter base with new caps 5 Remove fuel f...

Page 9: ...n eral Hazard Information and High Pressure Fuel Lines for safety information Refer to System Operation Testing and Adjusting Cleanliness of Fuel System Components for de tailed information on the sta...

Page 10: ...carried out to the fuel system are performed by authorised personnel that have the correct train ing Before begining ANY work on the fuel system re fer to Operation and Maintenance Manual Gen eral Ha...

Page 11: ...ft 10 Connect plastic tube assembly 5 to the outlet of fuel transfer pump 2 11 Install plastic tube assembly 7 to fuel transfer pump 2 12 Restore the fuel supply 13 Remove the air from the fuel syste...

Page 12: ...dure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct train ing Before begining ANY work on the fuel s...

Page 13: ...24 Cap Kit 1 Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service...

Page 14: ...ve seal 5 from electronic unit injector 1 and the base of the valve mechanism cover 11 Plug the open port in electronic unit injector 1 immediately Use Tooling A in order to plug the open port in the...

Page 15: ...e Nut Tool 1 NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct train ing Before begining ANY work on th...

Page 16: ...tighten the nuts on fuel injection line 6 to a torque of 30 N m 22 lb ft 6 Install the bolts 11 for tube clips 12 that secure fuel injection line 6 Tighten bolts 11 to a torque of 22 N m 16 lb ft Tig...

Page 17: ...sassembly and Assembly Fuel Priming Pump Remove c Remove the front cover Refer to Disassembly and Assembly Front Cover Remove and Install Note Either Tooling A can be used Use the Tooling that is most...

Page 18: ...nsfer pump 8 10 Disconnect plastic tube assembly 10 from the outlet of fuel transfer pump 8 11 Disconnect plastic tube assembly 5 from fuel injection pump 1 12 Remove tube assembly 12 for the fuel ret...

Page 19: ...ssembly Fuel Transfer Pump Remove i02654503 Fuel Injection Pump Install Installation Procedure Table 4 Required Tools Tool Part Number Part Description Qty A 21825576 Crankshaft Turning Tool 1 2761029...

Page 20: ...ere should be no resistance when the locking pin is inserted 3 If the fuel injection pump timing has been lost follow Steps 3 a through 3 e in order to reset the fuel injection pump timing a If necess...

Page 21: ...r to Disassembly and Assembly Gear Group Front Remove for the correct procedure 10 Install the fuel injection pump gear to the fuel injection pump Refer to Disassembly and Assembly Fuel Injection Pump...

Page 22: ...transfer pump end to a torque of 21 N m 15 lb ft 20 Install plastic tube assembly 5 to fuel injection pump 1 21 Install plastic tube assembly 10 for the fuel outlet to fuel transfer pump 8 22 Install...

Page 23: ...number one piston is at top dead center on the compression stroke Refer to System Operation Testing and Adjusting Finding Top Centre Position for No 1 Piston g01335379 Illustration 32 2 Install Tooli...

Page 24: ...arts clean from contaminants Contaminants may cause rapid wear and shortened component life Note The fuel injection pump must remain locked until the procedure instructs you to unlock the fuel injecti...

Page 25: ...k the fuel injection pump 5 In order to unlock fuel injection pump 5 loosen the locking bolt 5 in the fuel injection pump Slide spacer 7 into position Z1 Tighten locking bolt 6 against the spacer to a...

Page 26: ...must be observed during ALL work on the fuel system NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the prod...

Page 27: ...e and remove seal 8 from the appropriate electronic unit injector 11 Refer to Disassembly and Assembly Fuel Injecton Lines Remove Note Cap all open ports immediately with new caps 7 Use a deep socket...

Page 28: ...d personnel that have the correct train ing Before begining ANY work on the fuel system re fer to Operation and Maintenance Manual Gen eral Hazard Information and High Pressure Fuel Lines for safety i...

Page 29: ...ation mark on the original electronic unit injector The electronic unit injector must be reinstalled in the original location in the cylinder head g01255700 Illustration 49 8 Use Tooling C to pry bene...

Page 30: ...enance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Dispose...

Page 31: ...ght 8 Remove the cap from electronic unit injector 11 Install a new seal 8 to electronic unit injector 11 and to the valve mechanism cover base Ensure that the flange on the seal is flush with the val...

Page 32: ...0028 Vacuum Pump 1 D GE50030 Tube 7 9 mm 0 31 inch Outside Diameter 1 E 27610294 Injector Pipe Nut Tool 1 F 27610296 Torque Wrench 1 Note This is an optional procedure to install the electronic unit i...

Page 33: ...e Note Do not lubricate the O ring seal 5 Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage Ensure that the sealing washer has been removed from...

Page 34: ...ssembly Refer to Disassembly and Assembly Rocker Shaft Install g01247489 Illustration 61 Typical example 15 Tighten banjo bolt 7 for tube assembly 6 Tighten the banjo bolt to a torque of 21 N m 15 lb...

Page 35: ...s 2 8 Loosen nuts 11 Refer to Illustration 63 9 Remove exhaust manifold 1 and the assembly of the turbocharger from the cylinder head Refer to Disassembly and Assembly Exhaust Manifold Remove and Inst...

Page 36: ...urbocharger inlet and for the turbocharger outlet 2 If the turbocharger has a remote wastegate solenoid disconnect the hose to the solenoid from the turbocharger 3 Disconnect the exhaust pipe 4 If the...

Page 37: ...and shortened component life g01335760 Illustration 66 1 Disconnect the pipe for boost sensor 7 at actuator 6 2 Remove circlip 1 that retains actuator rod 4 3 Remove actuator rod 4 from pin 2 4 Remov...

Page 38: ...to the actuator High pressures may damage the actuator 6 Install the pipe for boost pressure 7 to actuator 6 End By a To check the wastegate actuator for correct operation refer to System Operation Te...

Page 39: ...housing and the compressor housing a Loosen band clamps 21 sufficiently in order to allow the housings to rotate Note If the band clamps are damaged replace the band clamps b Carefully turn bearing h...

Page 40: ...13 N m 9 6 lb ft 19 Tighten banjo bolt 9 to a torque of 20 N m 14 lb ft Tighten bolt 5 and 8 to a torque of 22 N m 16 lb ft 20 Install the bolts for tube clips 2 to the cylinder block Tighten bolt 2 t...

Page 41: ...ifold Tighten the studs to a torque of 18 N m 13 lb ft 4 Install a new joint 14 to exhaust manifold 12 5 Position turbocharger 6 on the exhaust manifold Note Ensure that the turbocharger is correctly...

Page 42: ...nger tight Ensure that tube assembly 3 fits correctly 19 Tighten banjo bolt 1 to a torque of 20 N m 14 lb ft Tighten bolt 5 and 11 to a torque of 22 N m 16 lb ft 20 If the turbocharger has an exhaust...

Page 43: ...h tube clips tighten the bolts for the tube clips Tighten M8 bolts to a torque of 22 N m 16 lb ft Tighten bolts M10 to a torque of 44 N m 32 5 lb ft 7 Follow Steps 7 through 7 c in order to connect wi...

Page 44: ...ter bolts 2 from exhaust manifold 3 Remove outer bolts 5 and spacers 4 from exhaust manifold 3 Note Support the manifold as the bolts are removed 3 Remove exhaust manifold 3 4 Remove exhaust manifold...

Page 45: ...ad 6 If bolts 2 and 5 have been previously used the bolts should be thoroughly cleaned Tooling B should be applied to the first two threads of the bolts Note Do not apply Tooling B to new bolts 7 Inst...

Page 46: ...5 from exhaust manifold 3 Note Support the manifold as the bolts are removed 4 Remove the assembly of exhaust manifold 3 and turbocharger 5 Remove exhaust manifold gaskets 1 6 Remove the turbocharger...

Page 47: ...utward and upward 6 Align exhaust manifold 3 with Tooling A Install the exhaust manifold to the cylinder head 7 If bolts 4 and 6 have been previously used the bolts should be thoroughly cleaned Toolin...

Page 48: ...elbow finger tight 5 Install bolts 2 finger tight 6 Ensure that coupling 1 is fully engaged into the outlet of turbocharger 3 and into exhaust elbow 4 Ensure that the gap between the turbocharger and...

Page 49: ...y the inlet manifold 8 Remove inlet manifold seal 6 from the recess in inlet manifold 4 9 Do not remove two dowel pins 7 Installation Procedure Table 15 Required Tools Tool Part Number Part Name Qty A...

Page 50: ...s assembly 13 Connect the breather hose to the separator for the crankcase breather not shown Refer to Disassembly and Assembly Crankcase Breather Install 14 If the engine is equipped with a cover ove...

Page 51: ...or the push rods in the cylinder head in order to prevent the entry of loose parts into the engine g01335929 Illustration 89 1 Follow Steps 1 a through 1 h in order to remove the harness assemblies fo...

Page 52: ...ir of cylinders NOTICE Do not turn the crankshaft while the valve springs are removed 3 Apply sufficient pressure to Tooling B in order to allow removal of valve keepers 8 Note Do not compress the spr...

Page 53: ...Repeat steps 2 to 6 for the remaining valves 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 insta...

Page 54: ...Procedure Table 18 Required Tools Tool Part Number Part Description Qty 21825666 Valve Spring Compressor 1 27610235 Adapter 1 A 27610295 Head 1 Start By a Remove the cylinder head Refer to Disassembly...

Page 55: ...27610235 Adapter 1 A 27610295 Head 1 NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life 1 Clean all components of the cylinder head assembly...

Page 56: ...ocedure and use all recommended tooling to release the spring force g01335985 Illustration 96 6 Install Tooling A in the appropriate position on the cylinder head in order to compress valve spring 3 N...

Page 57: ...ccording to local regulations and mandates 1 Place a suitable container below engine oil filter base 3 in order to catch any oil that might be spilled g01336008 Illustration 97 Typical example 2 If th...

Page 58: ...e Start By a Remove the bracket for the Electronic Control Module Refer to Disassembly and Assembly ECM Mounting Bracket Remove and Install NOTICE Ensure that all adjustments and repairs that are carr...

Page 59: ...r to disconnect the engine wiring harness 4 a Disconnect engine wiring harness 4 from position sensor 2 for the fuel injection pump b Disconnect engine wiring harness 4 from solenoid 1 for the fuel in...

Page 60: ...l Lines for safety information Refer to System Operation Testing and Adjusting Cleanliness of Fuel System Components for de tailed information on the standards of cleanliness that must be observed dur...

Page 61: ...ne wiring harness 3 from oil pressure sensor 8 d Cut the cable straps that secure engine wiring harness 3 to the assembly of oil cooler 4 Position the harness away from the assembly of the oil cooler...

Page 62: ...7 Install cooler matrix 19 to the spacer plate 3 Install bolts 15 finger tight g01336427 Illustration 106 Typical example 4 Position brackets 5 10 and 14 onto the assembly of oil cooler 6 Install bolt...

Page 63: ...5 Remove the plugs from tube assembly 9 Remove the caps for the fuel return from the cylinder head and from transfer pump 8 Install tube assembly 9 to the cylinder head and to transfer pump 8 6 Follow...

Page 64: ...ion 110 5 Install bolts 7 to the assembly of oil cooler 4 Note The bolts are different lengths Ensure that the different bolts are installed in the correct location 6 Install a new joint 8 to assembly...

Page 65: ...nce Manual Cooling System Coolant Change for the correct procedure 8 Check level of engine lubricating oil Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure En...

Page 66: ...ling A to the threads of cap 1 Use an allen wrench to install cap 1 to engine oil pump 4 Tighten the cap to a torque of 21 N m 15 5 lb ft Note Ensure that the spring is properly located inside the plu...

Page 67: ...housing of the engine oil pump unless the dowels are damaged i02654486 Engine Oil Pump Install Installation Procedure NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear a...

Page 68: ...9 c a Install the components of the support bracket Ensure the correct location and orientation of the bracket and the retaining clip b Tighten the bolts finger tight in order to align the components...

Page 69: ...Pump Install Installation Procedure Table 22 Required Tools Tool Part Number Part Description Qty A Guide Stud M8 by 70 mm 2 NOTICE Keep all parts clean from contaminants Contaminants may cause rapid...

Page 70: ...ng surface of front cover 1 g01336660 Illustration 121 4 Install Tooling A in position X 5 Use Tooling A in order to align new joint 2 to front cover 1 Install the joint to the front cover 6 Align wat...

Page 71: ...during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling an...

Page 72: ...lator housing is installed position a new O ring seal 3 into the groove in water temperature regulator housing 2 A new water temperature regulator housing is supplied with a new O ring seal 3 Install...

Page 73: ...remaining bolts 4 6 Use the lifting device to remove the flywheel from the engine g01336669 Illustration 128 Typical example 7 Inspect flywheel 1 and ring gear 5 for wear or damage Replace any worn c...

Page 74: ...el 1 2 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 g01336668 Illustration 130 T...

Page 75: ...nent containing fluids Dispose of all fluids according to local regulations and mandates g01337506 Illustration 131 Typical example Note The assembly of the crankshaft rear seal is nonserviceable If t...

Page 76: ...ion 133 Typical example 4 Place the assembly of the crankshaft rear seal over crankshaft flange 1 Align dowel 5 with the slot in crankshaft rear seal 2 5 Ensure that plastic sleeve 3 is engaged on cra...

Page 77: ...g are manufactured as one assembly Note Do not lubricate the crankshaft rear seal or the crankshaft flange The crankshaft rear seal must be installed dry NOTICE Keep all parts clean from contaminants...

Page 78: ...e that the crankshaft rear seal is seated against the cylinder block During this process plastic sleeve 3 will be forced out of the crankshaft rear seal Discard the plastic sleeve Note Ensure that dow...

Page 79: ...using 1 3 Install a suitable lifting device to the flywheel housing in order to support the flywheel housing The flywheel housing can weigh 32 kg 70 5 lb g01337563 Illustration 138 Typical example 4 R...

Page 80: ...housing g01337569 Illustration 140 Engine with an aluminum oil pan g01337572 Illustration 141 Engine with a cast iron oil pan 2 Inspect crankshaft rear seal 8 for leaks If there are any oil leaks repl...

Page 81: ...stem Operation Testing and Adjusting Flywheel Housing Inspect End By a Install the flywheel Refer to Disassembly and Assembly Flywheel Install i02654369 Flywheel Housing Remove and Install Wet Back En...

Page 82: ...CE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life 1 Ensure that the flywheel housing is clean and free from damage If necessary replace the flywh...

Page 83: ...Install a suitable lifting device to the flywheel housing The flywheel housing can weigh 32 kg 70 5 lb g01337602 Illustration 149 Typical example 9 Use the lifting device to align flywheel housing 1...

Page 84: ...ove remaining bolts 4 3 Remove vibration damper 3 and crankshaft pulley 2 from crankshaft adapter 1 Remove Tooling A from crankshaft adapter 1 4 Use a suitable tool in order to prevent the crankshaft...

Page 85: ...pter 1 Remove O ring seal 7 from thrust block 6 Remove split lock rings 9 and spacer 8 from crankshaft adapter 1 Note the position and orientation of the split lock rings and the spacer i02654371 Vibr...

Page 86: ...ription Qty A Guide Stud M12 by 70 mm 1 B 27610299 E18 Torx socket 1 NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life g01337777 Illustration...

Page 87: ...l Remove and Install Removal Procedure Table 35 Required Tools Tool Part Number Part Description Qty A 27610301 Front Oil Seal Removal Tool 1 Start By a Remove the crankshaft pulley Refer to Disassemb...

Page 88: ...Assembly Crankshaft Pulley Remove and Install i02654495 Front Cover Remove and Install Removal Procedure Start By a If the engine has a fan remove the fan Refer to Disassembly and Assembly Fan Remove...

Page 89: ...a torque of 22 N m 16 lb ft End By a If the engine has a fan install the fan Refer to Disassembly and Assembly Fan Remove and Install i02654515 Gear Group Front Remove and Install Removal Procedure T...

Page 90: ...35380 Illustration 159 3 Remove plug 4 from the cylinder block Install Tooling C into hole Y in the cylinder block Use Tooling C in order to lock the crankshaft in the correct position Refer to System...

Page 91: ...n pump 1 Ensure that number one piston is at top dead center on the compression stroke Refer to System Operation Testing and Adjusting Finding Top Center for No 1 Piston g01335380 Illustration 162 2 I...

Page 92: ...t the timing marks on gears 2 and 3 are in alignment See Illustration 166 Ensure that the mesh of the gears is correct Refer to Disassembly and Assembly Fuel Injection Pump Gear Install for more infor...

Page 93: ...lock the camshaft in the correct position Note Ensure that the gears are marked in order to show alignment Refer to Illustration 168 g01337919 Illustration 169 2 Ensure that Tooling B is installed in...

Page 94: ...sembly of heavy duty idler gear is not serviceable Do not disassemble the heavy duty idler gear g01337924 Illustration 172 Alignment of timing marks 1 Ensure that Tooling A is installed into hole X in...

Page 95: ...B is installed in hole Y in the cylinder block Use Tooling B in order to lock the crankshaft in the correct position Refer to System Operation Testing and Adjusting Finding Top Centre Position for No...

Page 96: ...et of feeler gauge s in order to check the end play for the idler gear Refer to Specifications Gear Group Front for more information g01335426 Illustration 181 Checking backlash 15 Check the backlash...

Page 97: ...damage Refer to Specifications Gear Group Front for more information If necessary replace the assembly of the idler gear 5 Lubricate the bearings in the assembly of idler gear 2 with clean engine oil...

Page 98: ...pan Refer to Disassembly and Assembly Engine Oil Pan Remove e If the engine has an accessory drive remove the accessory drive Refer to Disassembly and Assembly Accessory Drive Remove and Install f Dra...

Page 99: ...Qty A 21820117 3 Bond 1386D 1 B Guide Stud M8 by 70 mm 2 27610216 Alignment Tool 1 C studs M10 by 50 mm 3 D Straight Edge 1 E 21820221 POWERPART Rubber Grease 1 NOTICE Keep all parts clean from conta...

Page 100: ...ypical example 7 Install Tooling C to the cylinder block 8 Install the front housing over Tooling B and Tooling C onto the cylinder block g01338002 Illustration 193 7 M8 by 20 mm 8 M8 by 35 mm 9 M8 by...

Page 101: ...Disassembly and Assembly Fuel Injection Pump Install b Install the timing gears Refer to Disassembly and Assembly Gear Group Front Install c If the engine has an accessory drive install the accessory...

Page 102: ...RPART Rubber Grease 1 C 21820117 3 Bond 1386D 1 NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life g01339559 Illustration 197 1 If necessary f...

Page 103: ...Housing Front Install 4 Lightly lubricate bearing 3 bearing 5 and gear 4 with clean engine lubricating oil Install the assembly of the accessory drive to the front housing 5 Apply Tooling C to Allen h...

Page 104: ...her body 4 Note Note the orientation of the outlet 4 Remove gauze 2 from breather body 4 5 Remove O ring seal 3 from breather body 4 6 Use Tooling A in order to unscrew breather body 4 from adapter pl...

Page 105: ...l 1 NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life g01339595 Illustration 201 Breather tool 1 To remove the breather body Tooling A must b...

Page 106: ...the orientation of the outlet 7 Remove gauze 2 from breather body 4 8 Remove O ring seal 3 from breather body 4 9 Use Tooling A in order to unscrew breather body 4 from adapter plate 8 10 Remove O rin...

Page 107: ...10 5 Install washers 7 and bolts 6 to adapter plate 8 Tighten the bolts to a torque of 4 4 N m 38 lb in 6 Lubricate a new O ring seal 5 with clean engine oil Install the O ring seal to the bottom of b...

Page 108: ...ing A must be used The tool should be fabricated from 3 1 mm 1 8 inch steel stock The dimensions for the tool are given in Illustration 207 All dimensions are shown in millimeters g01339597 Illustrati...

Page 109: ...ft 14 Install a new canister 20 to base 18 Refer to Operation and maintenance Manual Crankcase Breather Canister Replace 15 Install spring clamps 14 to hose 15 Install hose 15 to cover 1 and to base...

Page 110: ...base Position valve mechanism cover 2 onto valve mechanism cover base 5 Ensure that harness assemblies 6 are not trapped during the assembly procedure Install bolts 1 and 3 g01353909 Illustration 213...

Page 111: ...CE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life 1 Thoroughly clean all mating surfaces of the valve mechanism cover Clean the mating surfaces o...

Page 112: ...ection lines Refer to Disassembly and Assembly Fuel Injection Lines Remove NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life NOTICE Use a dee...

Page 113: ...d 7 Remove seal 9 from valve mechanism cover base 6 Installation Procedure Table 51 Required Tools Tool Part Number Part Description Qty A Circlip Pliers 1 B 21820221 POWERPART Rubber Grease 1 C 27610...

Page 114: ...r base 6 are clean and free from damage Replace any damaged components b Use Tooling B to lubricate a new O ring seal 8 Install O ring seal 8 onto harness assembly 4 c From the inside of valve mechani...

Page 115: ...remove harness assemblies 4 from valve mechanism cover base 7 a Cut cable strap 3 b Disconnect plug 6 from harness assembly 4 c Use Tooling A to remove circlip 5 d From the outside of valve mechanism...

Page 116: ...isolated screws 9 to valve mechanism cover base 6 g01342487 Illustration 228 4 Position valve mechanism cover base 7 on the cylinder head Tighten isolated screws 9 to a torque of 9 N m 79 lb in in th...

Page 117: ...use rapid wear and shortened component life g01340040 Illustration 230 g01340041 Illustration 231 1 Progressively loosen torx screws 1 Begin at the ends of the rocker shaft assembly and work toward th...

Page 118: ...pring force 1 Make an identification mark on each rocker arm assembly in order to show the location Note The components must be reinstalled in the original location Do not interchange components g0134...

Page 119: ...ts 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 Specifications Rocker Shaft for m...

Page 120: ...y To prevent possible injury follow the established assembly procedure and wear protective equip ment 7 Install spring 6 to rocker shaft 5 8 Repeat Steps 5 to 7 in order to assemble the remaining comp...

Page 121: ...mbly 2 onto the cylinder head The retaining clip 6 should face the front of the engine Note Ensure that adjustment screws 5 are properly seated in ends of pushrods 3 8 Gradually tighten torx screws 1...

Page 122: ...Dispose of all fluids according to local regulations and mandates 1 Drain the coolant from the cooling system into a suitable container for storage or for disposal Refer to Operation and Maintenance...

Page 123: ...e has a wastegate solenoid loosen the tube clips for tube assembly 9 Remove tube assembly 9 from the wastegate solenoid and from the cylinder head Plug the port in the wastegate solenoid with a new pl...

Page 124: ...sembly and Assembly Water Temperature Regulator Remove and Install 18 If necessary remove inlet manifold 2 from cylinder head 15 Refer to Disassembly and Assembly Inlet manifold Remove and Install i02...

Page 125: ...r bar must be used in order to distribute the weight of the cylinder head during the lifting operation 8 Use Tooling A to align the cylinder head with the cylinder block Install the cylinder head to t...

Page 126: ...s Install new O ring seals 12 and 13 to bypass tube 11 Install the bypass tube in the cylinder head Install bolts 10 Tighten the bolts to a torque of 22 N m 16 lb ft g01340077 Illustration 255 Typical...

Page 127: ...tem with coolant Refer to Operation and Maintenance Manual Cooling System Coolant Change for the correct filling procedure 28 If necessary fill the engine oil pan to the correct level that is indicate...

Page 128: ...n 3 Repeat Steps 1 and 2 in order to remove the remaining lifters Installation Procedure Table 57 Required Tools Tool Part Number Part Description Qty A 21825576 Crankshaft Turning Tool 1 27610291 Bar...

Page 129: ...move 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 1 Th...

Page 130: ...62 Typical example 4 If necessary install a new key 4 into camshaft 3 5 Lubricate the bearing surfaces of camshaft 3 and lubricate the lobes of the camshaft with clean engine oil NOTICE Do not damage...

Page 131: ...regulations and mandates 1 Use Tooling A in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke Refer to System Operation Testing and Adjusting Fi...

Page 132: ...Part Number Part Name Qty B 27610212 Camshaft Timing Pin 1 27610286 Crankshaft Timing Pin 1 C 27610287 Adapter 1 NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and sho...

Page 133: ...orque of 95 N m 70 lb ft g01335426 Illustration 273 9 Ensure that the backlash for gears 1 and 8 is within specified values Refer to Specifications Gear Group Front for further information 10 Ensure t...

Page 134: ...ontaminants Contaminants may cause rapid wear and shortened component life 1 Clean the bearing housing in the cylinder block Ensure that the oil hole in the bearing housing is free from debris g013405...

Page 135: ...be assembly Note Identify the position and orientation of the tube assembly g01340606 Illustration 277 Typical example 1 Place a suitable container below engine oil pan 7 Remove drain plug 5 and drain...

Page 136: ...during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any...

Page 137: ...Sealant D 21820117 POWERPART Threadlock and Nutlock E Straight Edge 1 Note In order to install a cast iron oil pan the engine must be removed from the application NOTICE Keep all parts clean from cont...

Page 138: ...ine oil pan can weigh 100 kg 220 lb 6 Use the lifting device to align the engine oil pan 7 with the studs Install the engine oil pan to the cylinder block 7 Install bolts 8 and 9 nuts 10 and the torx...

Page 139: ...82 g01340936 Illustration 283 10 Tighten the remaining bolts to a torque of 22 N m 16 lb ft Tighten the bolts in the sequence that is shown in Illustration 283 11 Use Tooling A to tighten the torx scr...

Page 140: ...uminum Oil Pan Installation Procedure Table 63 Required Tools Tool Part Number Part Description Qty A Guide Stud M8 by 100 mm 4 B 21820117 POWERPART Threadlock and Nutlock NOTICE Keep all parts clean...

Page 141: ...te The isolating screws must be replaced as a complete set in order to ensure the correct clamping of the engine oil pan 3 Position a new joint 4 onto the engine oil pan 7 4 Install the isolating scre...

Page 142: ...at is shown in Illustration 287 7 Remove Tooling A g01340725 Illustration 288 8 Install the four remaining isolating screws Tighten the isolating screws to a torque of 22 N m 16 lb ft Tighten the isol...

Page 143: ...ove the engine oil pan Refer to Disassembly and Assembly Engine Oil Pan Remove b Remove the flywheel housing Refer to Disassembly and Assembly Flywheel Housing Remove and Install NOTICE Keep all parts...

Page 144: ...llect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Dispose of all fluids according to local regulations and mandates g01342186 I...

Page 145: ...Housing Remove and Install i02654527 Piston Cooling Jets Remove and Install Removal Procedure Table 66 Required Tools Tool Part Number Part Description Qty A 21825576 Crankshaft Turning Tool 1 276102...

Page 146: ...ylinder block Install bolt 1 Tighten bolt 1 to a torque of 9 N m 80 lb in 4 Repeat steps 2 through 3 for the remaining piston cooling jets End By a Install the engine oil pump Refer to Disassembly and...

Page 147: ...necting rods should not be left without the connecting rod caps installed Temporarily install connecting rod cap 2 and bolts 3 to connecting rod 1 when the assembly is out of the engine Ensure that th...

Page 148: ...circlips 5 Note The forged marks X may be on the front of the connecting rod assembly or on the rear of the connecting rod assembly The forged marks should not be used for the purposes of orientation...

Page 149: ...central wire must be located inside the end of the spring g01341312 Illustration 300 b Use Tooling B to install oil control ring 3 over the spring Note Ensure that the central wire is 180 degrees from...

Page 150: ...the remaining piston and connecting rod assemblies Note Fracture split connecting rods should not be left without the connecting rod caps installed After the assembly procedure for the piston and conn...

Page 151: ...mage the finished surface of the crankshaft pin g01341300 Illustration 304 6 Install connecting rod cap 2 onto connecting rod 1 Note Ensure that etched number X on connecting rod cap 2 matches etched...

Page 152: ...arried out on the following pairs of cylinders 1 with 6 2 with 5 and 3 with 4 Ensure that both pairs of the connecting rod bearings are installed before changing from one pair of cylinders to another...

Page 153: ...sed Connecting Rod fasteners 1 Inspect the pins of the crankshaft for damage If the crankshaft is damaged replace the crankshaft Refer to Disassembly and Assembly Crankshaft Remove and Disassembly and...

Page 154: ...h 5 and 3 with 4 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 Connectin...

Page 155: ...rust washers 4 from the cylinder block In order to remove thrust washers 4 use Tooling A to rotate the crankshaft in the correct direction If necessary push the crankshaft toward the front of the engi...

Page 156: ...the crankshaft Inspect the journals of the crankshaft for damage If necessary replace the crankshaft or recondition the crankshaft g01341335 Illustration 313 3 Lubricate the crankshaft journal and up...

Page 157: ...re that the cap is correctly seated Note Do not tap the main bearing cap into position as the bearing shell may be dislodged 9 Tighten bolts 1 to a torque of 80 N m 59 lb ft Turn bolts 1 through an ad...

Page 158: ...rder to inspect the height of the piston above the cylinder block NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life 1 The engine should be mo...

Page 159: ...ants Contaminants may cause rapid wear and shortened component life NOTICE If the crankshaft has been reground or if the crankshaft has been replaced the height of the piston above the cylinder block...

Page 160: ...not damage the main bearing shells g01341402 Illustration 324 9 Lubricate thrust washers 6 with clean engine oil Install thrust washers 6 into number six main bearing in the cylinder block Note The g...

Page 161: ...e crankshaft end play is 0 10 mm 0 004 inch to 0 41 mm 0 016 inch 17 If the crankshaft has been replaced or the crankshaft has been reconditioned inspect the height of the piston above the cylinder bl...

Page 162: ...rapid wear and shortened component life 1 Ensure that the flange for the crankshaft timing ring on the crankshaft is clean and free from damage 2 Support crankshaft 1 on a suitable stand g01341462 Ill...

Page 163: ...the crankshaft or an interference fit on the crankshaft g01341481 Illustration 330 Typical example g01341488 Illustration 331 Typical example 1 If the crankshaft gear is a sliding fit on the cranksha...

Page 164: ...ired Tools Tool Part Number Part Description Qty Plastic Gauge Green 0 025 to 0 076 mm 0 001 to 0 003 inch 1 Plastic Gauge Red 0 051 to 0 152 mm 0 002 to 0 006 inch 1 Plastic Gauge Blue 0 102 to 0 229...

Page 165: ...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 are not the same width Measure the majo...

Page 166: ...tion i02654535 Position Sensor Fuel Injection Pump Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life g01...

Page 167: ...ned component life NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fl...

Page 168: ...Sensor 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 fluids...

Page 169: ...hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death NOTICE Ensure that all adjustment...

Page 170: ...el pressure sensor 3 to the fuel manifold Tighten the fuel pressure sensor to a torque of 34 N m 25 lb ft 4 Connect harness assembly 2 to fuel pressure sensor 3 5 Slide locking tab 1 into the locked p...

Page 171: ...Slide locking tab 1 into the locked position i02654521 Inlet Air Temperature Sensor Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wea...

Page 172: ...Plugs Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life 1 Isolate the electrical supply 2 Disconnect th...

Page 173: ...ly Crankcase Breather Install 7 Restore the electrical supply to the engine i02654452 Alternator Belt Remove and Install Removal Procedure Table 81 Required Tools Tool Part Number Part Description Qty...

Page 174: ...oner 1 From the front of the engine turn the tool in a clockwise direction 3 Insert Tooling A into hole Y Release the pressure on the square drive tool 4 Install alternator belt 1 Ensure that the alte...

Page 175: ...oriented 6 Inspect the condition of locking nuts 1 If necessary replace the locking nuts Install locking nuts 1 Tighten locking nuts 1 to a torque of 22 N m 16 lb ft End By a Install the Alternator B...

Page 176: ...e electrical supply to the engine 2 Isolate the fuel supply to the engine g01341877 Illustration 356 Typical example 3 Cut cable tie 3 Unscrew the fastener 6 that secures the OEM harness 2 to the elec...

Page 177: ...electronic control module is clean and free from damage If necessary replace the electronic control module g01341878 Illustration 358 Typical example 3 If necessary follow Steps 3 a through 3 d in ord...

Page 178: ...to the connector pins during installation of the harness 10 Use a new cable strap 3 in order to secure the harness assembly 11 Restore the fuel supply to the engine 12 Restore the electrical supply to...

Page 179: ...is clean and free from damage If the mounting bracket is damaged replace the bracket g01342051 Illustration 363 g01342046 Illustration 364 2 Position mounting bracket 8 against the cylinder block Ens...

Page 180: ...By a Install the electronic control module Refer to Disassembly and Assembly Electronic Control Module Remove and Install i02654421 Alternator Remove Alternators with Mounting Lugs Removal Procedure S...

Page 181: ...alternator bracket 2 5 If necessary follow Steps 5 a and 5 b in order to remove pulley 4 from alternator 1 a Hold the shaft of alternator 1 with an allen wrench Use a cranked ring spanner to loosen nu...

Page 182: ...r mounting bracket 2 Install bolts 3 into the alternator bracket Tighten the bolts to a torque of 44 N m 32 lb ft 3 Connect the wiring harness assembly to alternator 1 4 Install the alternator belt Re...

Page 183: ...8 lb ft Tighten M12 nuts to a torque of 78 19 5 N m 57 14 lb ft 5 Connect the harness assembly to the electric starting motor and the solenoid 6 Connect the battery i02654446 Air Compressor Remove an...

Page 184: ...quipped with a hydraulic pump on the rear of the air compressor remove the hydraulic pump 4 Use Tooling A in order to rotate the crankshaft so that number one piston is at the top center position on t...

Page 185: ...5 12 If necessary remove bolts 16 and remove plate 15 Remove O ring seal 12 from plate 15 Refer to Illustration 374 13 If necessary remove nut 18 and remove the spring washer Use Tooling C in order t...

Page 186: ...age b Install gear 17 and a new spring washer to the shaft of the air compressor c Apply Tooling D to the threads of the shaft Install nut 18 to the shaft of air compressor 5 Tighten the nut to a torq...

Page 187: ...mark X is aligned with the timing mark A6 Refer to Illustration 378 for air compressors with a SAE drive Refer to Illustration 379 for air compressors with a DIN drive 7 Install nuts 14 Tighten the nu...

Page 188: ...nder block Install plug 1 to the cylinder block Refer to Illustration 377 14 If the engine is equipped with a hydraulic pump on the rear of the air compressor install the hydraulic pump 15 Connect the...

Page 189: ...ion Procedure 108 Crankcase Breather Install Unfiltered Breather 106 Installation Procedure 106 Crankcase Breather Remove Filtered Breather 105 Removal Procedure 105 Crankcase Breather Remove Unfilter...

Page 190: ...move and Install Side Mounted Exhaust Manifold 43 Installation Procedure Side Mounted Exhaust Manifold 44 Removal Procedure 43 Exhaust Manifold Remove and Install Top Mounted Exhaust Manifold 45 Insta...

Page 191: ...Installation Procedure 150 Pistons and Connecting Rods Remove 146 Removal Procedure 146 Position Sensor Fuel Injection Pump Remove and Install 166 Installation Procedure 166 Removal Procedure 166 R Ro...

Page 192: ...ocedure 84 W Wastegate Solenoid Remove and Install 42 Installation Procedure 42 Removal Procedure 42 Water Pump Install 69 Installation Procedure 69 Water Pump Remove 68 Removal Procedure 68 Water Tem...

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