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KENR6932

Table of Contents

Table of Contents

Disassembly and Assembly Section

Fuel Priming Pump - Remove and Install (Mechanical

Priming Pump) ...................................................... 5

Fuel Priming Pump - Remove and Install (Electrical

Priming Pump) ...................................................... 6

Fuel Filter Base - Remove and Install (Secondary

Fuel Filter) ............................................................. 8

Fuel Transfer Pump - Remove ................................ 9

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

Fuel Manifold (Rail) - Remove and Install .............. 11

Fuel Injection Lines - Remove ............................. 13

Fuel Injection Lines - Install ................................. 15

Fuel Injection Pump - Remove ............................ 17

Fuel Injection Pump - Install ................................ 19

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

Fuel Injection Pump Gear - Install ........................ 24

Electronic Unit Injector - Remove ......................... 26

Electronic Unit Injector - Install ............................. 30

Turbocharger - Remove (Turbocharger Top Mounted

) ........................................................................... 34

Turbocharger - Remove (Side Mounted

Turbocharger) ..................................................... 36

Turbocharger - Disassemble ................................ 37

Turbocharger - Assemble .................................... 37

Turbocharger - Install (Turbocharger Top

Mounted) ............................................................. 38

Turbocharger - Install (Side Mounted

Turbocharger) ..................................................... 40

Wastegate Solenoid - Remove and Install ............ 42

Exhaust Manifold - Remove and Install (Side

Mounted Exhaust Manifold) ................................ 43

Exhaust Manifold - Remove and Install (Top Mounted

Exhaust Manifold) ............................................... 45

Exhaust Elbow - Remove and Install ................... 47

Inlet Manifold - Remove and Install ..................... 48

Inlet and Exhaust Valve Springs - Remove and

Install ................................................................... 50

Inlet and Exhaust Valves - Remove and Install .... 54

Engine Oil Filter Base - Remove and Install ........ 57

Engine Oil Cooler - Remove (Engine Oil Cooler with

a Low Mounted Filter Base) ................................ 58

Engine Oil Cooler - Remove (Engine Oil Cooler with

a High Mounted Filter Base) ............................... 60

Engine Oil Cooler - Install (Engine Oil Cooler with a

Low Mounted Filter Base) ................................... 62

Engine Oil Cooler - Install (Engine Oil Cooler with a

High Mounted Filter Base) .................................. 64

Engine Oil Relief Valve - Remove and Install ....... 65

Engine Oil Pump - Remove .................................. 66

Engine Oil Pump - Install ...................................... 67

Water Pump - Remove ......................................... 68

Water Pump - Install ............................................. 69

Water Temperature Regulator - Remove and Install

............................................................................. 71

Flywheel - Remove ............................................... 72

Flywheel - Install ................................................... 73

Crankshaft Rear Seal - Remove ........................... 75

Crankshaft Rear Seal - Install ............................... 75

Flywheel Housing - 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 - Remove (Pulley with

Split Lock Rings) ................................................. 84

Vibration Damper and Pulley - Install (Pulleys without

Split Lock Rings) ................................................. 85

Vibration Damper and Pulley - Install (Pulley with

Split Lock Rings) ................................................. 86

Crankshaft Front Seal - Remove and Install ......... 87

Front Cover - Remove and Install ......................... 88

Gear Group (Front) - Remove and Install ............. 89

Idler Gear - Remove ............................................. 92

Idler Gear - Install ................................................. 95

Housing (Front) - Remove .................................... 98

Housing (Front) - Install ........................................ 99

Accessory Drive - Remove and Install ............... 101

Crankcase Breather - Remove (Un

ltered

Breather) ........................................................... 103

Crankcase Breather - Remove (Filtered

Breather) ........................................................... 105

Crankcase Breather - Install (Un

ltered

Breather) ........................................................... 106

Crankcase Breather - Install (Filtered Breather) .. 108

Valve Mechanism Cover - Remove and Install

(Composite Valve Mechanism Cover) ............... 109

Valve Mechanism Cover - Remove and Install .... 110

Valve Mechanism Cover Base - Remove and Install

(Composite Valve Mechanism Cover Base) ...... 112

Valve Mechanism Cover Base - Remove and

Install .................................................................. 114

Rocker Shaft and Pushrod - Remove .................. 117

Rocker Shaft - Disassemble ............................... 118

Rocker Shaft - Assemble .................................... 119

Rocker Shaft and Pushrod - Install ..................... 120

Cylinder Head - Remove .................................... 121

Cylinder Head - Install ........................................ 124

Lifter Group - Remove and Install ....................... 128

Camshaft - Remove and Install ......................... 129

Camshaft Gear - Remove and Install ................ 130

Camshaft Bearings - Remove and Install .......... 133

Engine Oil Pan - Remove (Aluminum Oil Pan) ... 135

Engine Oil Pan - Remove (Cast Iron Oil Pan) .... 136

Engine Oil Pan - Install (Cast Iron Oil Pan) ........ 137

Engine Oil Pan - Install (Aluminum Oil Pan) ....... 140

Engine Oil Pan Plate - Remove and Install (Aluminum

Oil Pan) ............................................................. 143

Piston Cooling Jets - Remove and Install ........... 145

Pistons and Connecting Rods - Remove ............ 146

Pistons and Connecting Rods - Disassemble ..... 147

Pistons and Connecting Rods - Assemble ......... 149

Pistons and Connecting Rods - Install ................ 150

Connecting Rod Bearings - Remove (Connecting

rods in position) ................................................. 152

Connecting Rod Bearings - Install (Connecting rods

in position) ......................................................... 153

Crankshaft Main Bearings - Remove and Install

(Crankshaft in position) ..................................... 154

Crankshaft - Remove .......................................... 157

Crankshaft - Install .............................................. 159

Содержание 1106C Series

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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