100% found this document useful (2 votes)

935 views

854F-Disassembly and Assembly

PERKINS 854F-Disassembly and Assembly

Uploaded by

ZIBA KHADIBI

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

100% found this document useful (2 votes)

935 views

854F-Disassembly and Assembly

PERKINS 854F-Disassembly and Assembly

Uploaded by

ZIBA KHADIBI

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 204

UENR0624-03 (en-us)

January 2017

Disassembly and Assembly

854E-E34TA, 854F-E34T and 854F-
E34TA Industrial Engines
JR (Engine)
JS (Engine)
JT (Engine)
JV (Engine)

This document has been printed from SPI2. NOT FOR RESALE
i06558969

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 3
Table of Contents

Table of Contents Water Pump - Remove ........................................94

Water Pump - Install ............................................95
Water Temperature Regulator - Remove and
Disassembly and Assembly Section Install ...............................................................96
Engine Lifting Bracket - Remove ..........................98
Inspection of Parts ................................................5 Engine Lifting Bracket - Install ..............................99
Fuel Priming Pump - Remove and Install ..............10 Flywheel - Remove............................................ 101
Flow Control Valve - Remove and Install ..............12 Flywheel - Install ............................................... 102
Fuel Filter Base - Remove and Install ...................13 Crankshaft Rear Seal - Remove and Install ......... 103
Water Separator and Fuel Filter (Primary) - Remove Flywheel Housing - Remove and Install (Stressed
and Install .........................................................17 Cylinder Block) ................................................ 105
Fuel Manifold (Rail) - Remove and Install ..............20 Flywheel Housing - Remove and Install (Non-
Fuel Injection Lines - Remove .............................22 Stressed Cylinder Block) .................................. 107
Fuel Injection Lines - Install .................................25 Power Take-Off Drive - Remove and Install ........ 110
Exhaust Cooler (NRS) - Remove and Install ..........28 Crankshaft Pulley - Remove and Install .............. 113
Throttle Valve (Intake Air) - Remove and Install (Rear Crankshaft Front Seal - Remove and Install......... 114
Facing Inlet Elbow) ............................................30 Front Cover - Remove and Install ....................... 116
Throttle Valve (Intake Air) - Remove and Install (Side Idler Gear - Remove .......................................... 118
Facing Inlet Elbow) ............................................32 Idler Gear - Install.............................................. 120
Fuel Injection Pump - Remove .............................34 Housing (Front) - Remove.................................. 121
Fuel Injection Pump - Install ................................36 Housing (Front) - Install ..................................... 123
Fuel Injection Pump Gear - Remove .....................38 Accessory Drive - Remove and Install ................ 126
Fuel Injection Pump Gear - Install .........................39 Crankcase Breather - Remove ........................... 128
Electronic Unit Injector - Remove..........................40 Crankcase Breather - Install ............................... 128
Electronic Unit Injector - Install .............................42 Valve Mechanism Cover - Remove and Install ..... 129
Turbocharger - Remove (Top Mounted Rocker Shaft and Pushrod - Remove .................. 132
Turbochargers)..................................................44 Rocker Shaft - Disassemble .............................. 134
Turbocharger - Remove (Side Mounted Rocker Shaft - Assemble .................................. 134
Turbochargers)..................................................46 Rocker Shaft and Pushrod - Install...................... 135
Turbocharger - Install (Top Mounted Cylinder Head - Remove.................................... 137
Turbochargers)..................................................48 Cylinder Head - Install ....................................... 139
Turbocharger - Install (Side Mounted Lifter Group - Remove and Install ....................... 142
Turbochargers)..................................................51 Camshaft - Remove and Install .......................... 143
Wastegate Solenoid - Remove and Install .............54 Camshaft Gear - Remove and Install ................. 145
Exhaust Gas Recirculation Valve - Remove and Camshaft Bearings - Remove and Install ............ 147
Install ...............................................................55 Engine Oil Pan - Remove and Install (Pressed Steel
Flexible Exhaust Pipe - Remove and Install ...........59 Oil Pan) .......................................................... 148
Exhaust Manifold - Remove and Install ................63 Engine Oil Pan - Remove and Install (Cast Iron
Diesel Particulate Filter - Remove (Through Flow Engine Oil Pan) ............................................... 150
Diesel Particulate Filter) .....................................66 Balancer - Remove............................................ 154
Diesel Particulate Filter - Remove (Wall Flow Diesel Balancer - Install ............................................... 155
Particulate Filter) ...............................................67 Piston Cooling Jets - Remove and Install ............ 157
Diesel Particulate Filter - Install (Through Flow Diesel Pistons and Connecting Rods - Remove ............. 158
Particulate Filter) ...............................................69 Pistons and Connecting Rods - Disassemble ...... 160
Diesel Particulate Filter - Install (Wall Flow Diesel Pistons and Connecting Rods - Assemble........... 161
Particulate Filter ) ..............................................71 Pistons and Connecting Rods - Install................. 162
Support and Mounting (CEM) - Remove and Install Connecting Rod Bearings - Remove (Connecting
(Option 3) .........................................................73 rods in position) ............................................... 164
Support and Mounting (CEM) - Remove and Install Connecting Rod Bearings - Install (Connecting rods
(Option 2) .........................................................75 in position) ...................................................... 165
Support and Mounting (CEM) - Remove and Install Crankshaft Main Bearings - Remove and Install .. 166
(Option 1) .........................................................76 Crankshaft - Remove......................................... 169
Inlet Manifold - Remove and Install ......................78 Crankshaft - Install ............................................ 171
Inlet and Exhaust Valve Springs - Remove and Crankshaft Timing Ring - Remove and Install ...... 172
Install ...............................................................81 Bearing Clearance - Check ................................ 173
Inlet and Exhaust Valves - Remove and Install.......83 Camshaft Position Sensor - Remove and Install .. 175
Inlet and Exhaust Valve Guides - Remove and Crankshaft Position Sensor - Remove and Install. 176
Install ...............................................................86 Coolant Temperature Sensor - Remove and
Engine Oil Filter Base - Remove and Install ..........88 Install ............................................................. 177
Engine Oil Cooler - Remove.................................89 Engine Oil Pressure Switch - Remove and Install 178
Engine Oil Cooler - Install ....................................91 Fuel Temperature Sensor - Remove and Install ... 179
Engine Oil Relief Valve - Remove and Install .........92 Oxygen Sensor - Remove and Install (Catalytic
Engine Oil Pump - Remove ..................................93 Converter) ...................................................... 181
Engine Oil Pump - Install......................................93 Temperature Sensor (Exhaust) - Remove and
Install ............................................................. 182

This document has been printed from SPI2. NOT FOR RESALE
4 UENR0624-03
Table of Contents

Temperature Sensor (DPF) - Remove and Install . 183

Pressure Sensor (DPF) - Remove and Install ...... 184
Pressure Sensor (Exhaust Back Pressure) - Remove
and Install ....................................................... 185
Inlet Manifold Temperature Sensor - Remove and
Install ............................................................. 187
Inlet Manifold Pressure Sensor - Remove and
Install ............................................................. 188
Glow Plugs - Remove and Install ....................... 190
Alternator Belt - Remove and Install ................... 191
Idler Pulley - Remove and Install ........................ 192
Fan - Remove and Install .................................. 194
Fan Drive - Remove and Install .......................... 194
Alternator - Remove .......................................... 196
Alternator - Install .............................................. 197
Electric Starting Motor - Remove and Install ....... 199

Index Section
Index................................................................ 201

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 5
Disassembly and Assembly Section

Disassembly and
Assembly Section
i05293780

Inspection of Parts

Reuse Guideline for the Flexible

Exhaust Pipe
This Information Element will address the following
applications for the lines group - flex pipe: the Illustration 1 g02211913
installation, the handling and the reusability. The lines Typical example
group - flex pipe is defined as the connection (1) Alignment marks
between the turbocharger diffuser outlet and the (2) Ball clamp
Clean Emissions Module (CEM) inlet. (3) Tube
(4) Slip joint clamp
(5) Bellows
Removal of the Lines Group (6) Ball clamp

Removal Procedure 1. Draw alignment marks that will cover both the lines
group and the associated clamps. Refer to
Illustration 1 .

The ends of the bellows are very sharp. Injury

could occur if the bellows are not handled
properly. Handle the bellows by the convolutions.

NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the uniformity of the spacing between the
convolutions.
Inspect the bellows for damage prior to installation. If
there is any damage to the convolutions, discard the
bellows. If there is any difficulty in installation after
the repair, discard the bellows.
Illustration 2 g02239794
The alignment of the bellows is important. Improper Typical example
lateral alignment is two sealing surfaces that do not
align with each other. The proper lateral adjustment Bellows with protective covering installed
is shown in Illustration 1 .
2. Wrap the bellows with a protective cover to avoid
Proper alignment means that initial alignment of all possible damage to the bellows during the
components that are held together by the removal and installation.
components referenced in Illustration 1 are
maintained. 3. Loosen clamp assemblies (2), and (6).
Note: Do not force the bellows into the position. 4. Remove the lines group.
Note: Failure to reinstall the bellows into the as Note: Removal of the entire line group as a whole is
removed alignment will result in a failure of the part ideal. However, in some applications the assembly
and a needed replacement. must be disassembled further in order for the
assembly to be removed.

This document has been printed from SPI2. NOT FOR RESALE
6 UENR0624-03
Disassembly and Assembly Section

Note: Care should be taken when handling the lines

group. The slightest bump or drop can result in a
misalignment of the bellows and a possible need for
replacement.

5. Discard clamp assemblies (2) and (6). The clamp

assemblies are a one time use part.
Note: Steps 6 through 7 are only necessary if clamp
(4) was loosened to remove the entire lines group.

Illustration 4 g02231059
Typical example
Remove the weld from the bellows assembly with a
grinding device
Illustration 3 g02231056
Typical example 7. Inspect the clamping surface on the outside of the
(7) Weld bellows. Deburr the surface if necessary.

6. Remove clamp (4) from bellows (5) by removing Note: If the bellows assembly is damaged during the
weld (7). Use a grinding device to remove the spot removal of clamp (4), replace the bellows assembly.
weld.
Installation
Note: Use care not to remove excessive amounts of
material and grind on the bellows. Note: Step 1 is only necessary if clamp (4) was
loosened to remove the entire lines group.
Note: Do not use a vice to secure the lines group.
The bellows cannot be damaged in any way during
this procedure.
Note: Use the proper personal protective equipment
when removing clamp (4) from the bellows assembly.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 7
Disassembly and Assembly Section

Illustration 7 g02211913
Typical example
Alignment wrap is not shown for photographic
purposes.

4. Prior to installation, position both ball clamp

Illustration 5 g02231073 assemblies (2) and (6) onto the lines group.
Typical example 5. Position the lines group between the Clean
Emissions Module and the turbocharger adapter.
1. Install new clamp (4) with the tightening assembly
Adjust the length of tube (3) in the slip joint at
centered between reliefs (A). Do not torque the
clamp assembly (4) in order to position the lines
clamp until Step 12
group.
Note: The end of the clamp must be flush with the
Note: Do not force any of the components into the
end of the bellows assembly.
position.

Note: Make sure that you loosely fit all of the parts
before the final torquing is started.
Note: Failure to reinstall the bellows into the original
alignment will result in a failure of the part and a
needed replacement.

Illustration 6 g02211937
Typical example

2. Distance (X) is 40 mm (1.6 inch). Place Mark (B)

onto tube (3) at Distance (X) from the end of tube
(3).
3. Insert tube (3) into the bellows. The tube should be Illustration 8 g02211953
inserted as far as possible without using force. Typical example
This action will minimize the overall length of the The photo is a cutaway view of the ball clamp
lines group and will help with installation. assembly.

This document has been printed from SPI2. NOT FOR RESALE
8 UENR0624-03
Disassembly and Assembly Section

Illustration 9 g02211955 Illustration 11 g02239877

Typical example Typical example
The photo is a cutaway view of the ball clamp Example of configuration with the bellows located
assembly. near the CEM inlet

6. Verify that the cup of the ball joint (E) does not 8. Repeat Step 6 and 7 for ball clamp (6).
touch the radius of the ball (D). Position ball clamp
9. Verify that Mark (B) is not visible at the slip joint
(2) and loosely tighten ball clamp (2).
that is positioned near clamp assembly (4).
Note: The ball clamp that is opposite the bellows
must always be tightened first. Clamp (2) which can Note: Use hand tools to torque clamps on Steps 10
be located at the turbocharger diffuser outlet or the through 12. Do not use power tools in order to torque
CEM inlet must be tightened first. Refer to Illustration clamp assemblies (2), (4), and (6).
10 and Illustration 11 for example of the possible Note: The ball clamp that is opposite the bellows
placement of clamp (2). must always be tightened first. In Illustration 10 the
ball clamp that must be tightened first is located at
7. Verify that the ball clamp is centered.
the CEM inlet. In Illustration 11 the ball clamp that
Measurement (Y) and measurement (Z) must be must be tightened first is located at the turbocharger
within 2 mm (0.07874 inch) of each other. Refer to diffuser outlet.
Illustration 9 .
10. Torque ball clamp (2) to a torque of 35 ± 2 N·m
(26 ± 1 lb ft).
11. Torque ball clamp (6) to a torque of 35 ± 2 N·m
(26 ± 1 lb ft).
12. Torque clamp assembly (4) to a torque of
55 ± 8 N·m (41 ± 6 lb ft).
13. Remove the protective cover that was installed in
Step 2 of the removal section.

Illustration 10 g02239874
Typical example
Example of configuration with the bellows located
near the turbocharger outlet

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 9
Disassembly and Assembly Section

Examples of Possible Misalignment and

Results

Illustration 13 g01016673
Typical example
Example of premature failure due to lateral
Illustration 12 g01023261 misalignment
Typical example
Improper alignment during installation can lead to
Example of lateral misalignment premature failure of the bellows. An Example of
premature failure is shown in Illustration 13 .
Lateral misalignment is shown in Illustration 12 .
Lateral misalignment on the exhaust bellows can
lead to contact between liner and convolutions. The Handling
misalignment can cause premature failure.
Bellows should be handled by the convolutions. The
convolutions are the ribbed portion of the bellows.
The ends of the bellows could be sharp and the ends
Lateral misalignment is identified by visually should be handled carefully. The bellows can be
inspecting the convolutions on the bellows. The damaged if the bellows are dropped.
visual inspection will help ensure an even amount of
spacing between each of the convolutions.
Reusability
Note: If there are any indications of separation of the
layers or difficulty with the installation, discard the
bellows. Failure to replace the bellows could result in
the following problems: improper seating,
subsequent air leakage and Exhaust leakage.
The bellows consist of multiple layers of material that
are pressed together.

This document has been printed from SPI2. NOT FOR RESALE
10 UENR0624-03
Disassembly and Assembly Section

If damage has occurred to the edges of the bellow,

the bellows must be replaced.

i05268254

Fuel Priming Pump - Remove

and Install

Removal Procedure
Table 1
Required Tools

Tool Part Number Part Description Qty

A T412504 Capping Kit 1

NOTICE
Ensure that all adjustments and repairs that are
Illustration 14 g01016669 carried out to the fuel system are performed by
Typical example authorized personnel that have the correct
Example of damage to the convolutions training.
Before beginning ANY work on the fuel system,
Inspect the bellows for damage. The part should be refer to Operation and Maintenance Manual,
discarded if damage to the convolutions is present. “General Hazard Information and High Pressure
Illustration 14 shows that damage to the Fuel Lines” for safety information.
convolutions.
Refer to System Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of
cleanliness that must be observed during ALL
work on the fuel system.

1. Turn the fuel supply to the OFF position.

Illustration 15 g02240434
Typical example
Example of a bad edge

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 11
Disassembly and Assembly Section

d. Remove O-ring seals (3) from connectors (2)

and plugs (5).

Installation Procedure (Mechanical

Priming Pump)
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual,
“General Hazard Information and High Pressure
Fuel Lines” for safety information.
Refer to System Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of
cleanliness that must be observed during ALL
work on the fuel system.
Illustration 16 g02988817
Typical example 1. Ensure that fuel priming pump (4) is clean and free
from wear or damage. If necessary, replace the
2. Make a temporary identification mark on plastic fuel priming pump.
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 primary filter (7). Refer to Operation
and Maintenance Manual, “Fuel System Primary
Filter (Water Separator) Element - Replace”.
4. Disconnect plastic tube assemblies (1). Use
Tooling (A) to plug the tube assemblies with new
plugs.
5. Use Tooling (A) cap open connectors (2) on the
fuel priming pump with new caps.
6. Remove primary filter (6) from fuel priming pump
(4). Refer to Operation and Maintenance, “Fuel
System Primary Filter (Water Separator) Element -
Replace”.
7. Remove bolts (7) from fuel priming pump (4).
Remove fuel priming pump (4) from the mounting
bracket. Illustration 17 g02988817
Typical example
8. If necessary, follow Steps 8.a through 8.d in order
to disassemble fuel priming pump (4).
2. If necessary, follow Steps 2.a through 2.f in order
a. Remove connectors (2) from fuel priming pump to assemble fuel priming pump (4).
(4). Use Tooling (A) to plug fuel priming pump
a. Install new O-ring seals (3) to plugs (5).
(4).
b. Remove caps from connectors (2). Install new
b. Use Tooling (A) to cap connectors (2).
O-ring seals (3) connectors (2).
c. Remove plugs (5) from fuel priming pump (4).
c. Remove plugs from fuel priming pump (4).
Use Tooling (A) to plug fuel priming pump (4).

This document has been printed from SPI2. NOT FOR RESALE
12 UENR0624-03
Disassembly and Assembly Section

d. Install connectors (2) to fuel priming pump (4).

NOTICE
Ensure that all adjustments and repairs that are
e. Install plugs (5) to fuel priming pump (4). carried out to the fuel system are performed by
authorized personnel that have the correct
f. Tighten the plugs and the connectors to a training.
torque of 20 N·m (14 lb ft).
Before beginning ANY work on the fuel system,
3. Position fuel priming pump (4) on the mounting refer to Operation and Maintenance Manual,
bracket. Install bolts (7) to the fuel priming pump . “General Hazard Information and High Pressure
Tighten the bolts to a torque of 44 N·m (32 lb ft). Fuel Lines” for safety information.
4. Remove the plugs from the plastic tube Refer to System Operation, Testing and Adjust-
assemblies. Remove the caps from the ing, “Cleanliness of Fuel System Components”
connectors. for detailed information on the standards of
cleanliness that must be observed during ALL
5. Connect plastic tube assemblies (1) to connectors work on the fuel system.
(2).
Note: Ensure that the plastic tube assemblies are 1. Turn the fuel supply to the OFF position.
installed in the original positions. 2. Turn the battery disconnect switch to the OFF
position.
6. Install a new primary filter (6) to fuel priming pump
(4). Refer to Operation and Maintenance Manual,
“Fuel System Primary Filter (Water Separator)
Element - Replace”.
7. Turn the fuel supply to the ON position.
8. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime”.

i05268256

Flow Control Valve - Remove

and Install

Removal Procedure
Table 2
Required Tools

Tool Part Number Part Description Qty

Illustration 18 g02986577
A T412504 Capping Kit 1
3. Clean the area around flow control valve (2) and
fuel injection pump. Ensure that the area is free
from contamination before beginning disassembly.
Contact with high pressure fuel may cause fluid 4. Disconnect harness assembly (3) from flow control
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow valve (2).
these inspection, maintenance and service in- 5. Make temporary marks on the flow control valve
structions may cause personal injury or death. and the fuel injection pump for installation
purpose.
6. Remove Torx heads screws (1) from the flow
control valve.
7. Remove flow control valve (2) from the fuel
injection pump.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 13
Disassembly and Assembly Section

8. Use Tooling (A) in order to plug the fuel injection Note: Ensure that the Torx screws are tightened
pump. equally. Failure to ensure that the Torx screws are
tightened equally will result in damage to the fuel
9. Remove O-ring seal (4) (not shown) and O-ring injection pump.
seal (5) (not shown).
9. Tighten the Torx head screws to a torque of 9 N·m
Installation Procedure (80 lb in).
1. Ensure that all component at free from wear and 10. Connect harness assembly (1) to flow control
damage. If any part of the flow control valve is valve (3).
worn or damaged, the flow control valve must be
replaced as an assembly. 11. Replace the filters for primary fuel system. Refer
to Operation and Maintenance Manual, “Fuel
System Primary (Water Separator) Element -
Replace” for the correct procedure.
12. Replace the filters for secondary fuel system.
Refer to Operation and Maintenance Manual,
“Fuel System Secondary Filter - Replace” for the
correct procedure.
13. Turn the fuel supply to the ON position.
14. Turn the battery disconnect switch to the ON
position.
15. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime” for more information.
End By:
a. After replacement of the flow control valve, the
fuel injection pump requires a high-pressure
fuel pump calibration procedure to be
performed. Refer to Troubleshooting, “Fuel
Illustration 19 g02986577 Rail Pressure Problem” for the correct
procedure.
2. Position a new O-ring seal (4) (not shown) and
i05268269
new O-ring seal (5) (not shown) onto the flow
control valve assembly.
Fuel Filter Base - Remove and
3. Check O-ring seal (4) (not shown) and O-ring seal Install
(5) (not shown) are correctly positioned. Ensure
that O-ring seals are not damaged.
4. Lubricate O-ring seal (4) (not shown) and O-ring
seal (5) (not shown) with clean fuel. Removal Procedure
Table 3
Note: Ensure that the O-ring seals are not damaged
Required Tools
or misaligned.
Tool Part Number Part Description Qty
5. Remove Tooling (A) from the fuel injection pump.
A T412504 Capping Kit 1
6. Install flow control valve (3) to the fuel injection
pump.
7. Install Torx head screws (2) from the flow control
valve repair kit.
8. Tighten Torx head screws (2) equally until the flow
control valve is seated correctly onto the fuel
injection pump.

This document has been printed from SPI2. NOT FOR RESALE
14 UENR0624-03
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Illustration 20 g03011036
bling any component containing fluids.
4. Make temporary identification marks on plastic
Dispose of all fluids according to local regulations
and mandates. tube assembly (1) and plastic tube assembly (2) in
order to show the correct position of the plastic
tube assemblies.
1. Turn the battery disconnect switch to the OFF
position. 5. Place a suitable container below the fuel filter base
in order to catch any fuel that might be spilled.
2. Turn the fuel supply to the OFF position.
6. Disconnect plastic tube assembly (1) and plastic
3. Drain the secondary filter. Refer to Operation and tube assembly (2) from fuel filter base (3).
Maintenance Manual, “Fuel System Secondary
Filter - Replace” for the correct procedure. 7. Use Tooling (A) in order to plug plastic tube
assembly (1) and plastic tube assembly (2)
8. Use Tooling (A) in order to cap the connection on
fuel filter base (3).
9. Slide locking tab in to the unlock position.
Disconnect harness assembly (5) from fuel
temperature sensor (4).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 15
Disassembly and Assembly Section

Illustration 22 g03011038

12. If necessary, follow Step 1.c through Step 12.c in

order to remove the bracket for secondary fuel
filter.
a. Remove bolts (11) fuel filter bracket (10).
Illustration 21 g03011037

b. Remove fuel filter bracket (10) from the valve

10. Remove cannister (8) from fuel filter base (3). mechanism cover.
Remove secondary filter (7). Refer to Operation
and Maintenance Manual, “Fuel System c. If necessary, remove studs (9). from fuel filter
Secondary Filter - Replace” for the correct bracket (10).
procedure.
Installation Procedure
11. Remove nuts (6) from fuel filter base (3). Remove
the fuel filter base from the mounting bracket. NOTICE
Ensure that all adjustments and repairs that are
Note: Do not disassemble the fuel filter base. carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual,
“General Hazard Information and High Pressure
Fuel Lines” for safety information.
Refer to System Operation, Testing and Adjusting
, “Cleanliness of Fuel System Components” for
detailed information on the standards of cleanli-
ness that must be observed during ALL work on
the fuel system.

NOTICE
Ensure that the wiring harness assembly is correctly
routed and the cable straps are not over tightened.
Over tightening of the cable straps will damage the
wiring harness and the convoluting.

This document has been printed from SPI2. NOT FOR RESALE
16 UENR0624-03
Disassembly and Assembly Section

Illustration 23 g03011038

1. If necessary, follow Step 1.a through Step 1.c in

order to install the bracket for secondary fuel filter.

a. If necessary, install studs (9) to fuel filter bracket

(10). Tighten studs (9) to a torque of 18 N·m Illustration 24 g03011037
(159 lb in).
2. Ensure that fuel filter base (3) is clean and free
b. Position fuel filter bracket (10) onto the valve
from damage. If necessary, replace the complete
mechanism cover. Install bolts (11) to fuel filter
fuel filter base and filter assembly.
bracket (10).
3. Position fuel filter base (3) on the mounting
c. Tighten bolts (11) to a torque of 25 N·m bracket. Install nuts (6). Tighten the bolts to a
(221 lb in). torque of 25 N·m (221 lb in).
4. If necessary, install a new fuel filter (7) to canister
(8). Install cannister (8) to fuel filter base (3). Refer
to Operation and Maintenance Manual, “Fuel
System Secondary Filter - Replace” for the correct
procedure.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 17
Disassembly and Assembly Section

End By:
a. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel
System - Prime” for the correct procedure.

i05268272

Water Separator and Fuel

Filter (Primary) - Remove and
Install

Removal Procedure
Table 4
Required Tools

Tool Part Number Part Description Qty

A T412504 Capping Kit 1

Illustration 25 g03011036

5. Remove the plugs from the plastic tube NOTICE

assemblies. Remove the caps from the ports in Ensure that all adjustments and repairs that are
the fuel filter base. carried out to the fuel system are performed by
authorized personnel that have the correct
NOTICE training.
Ensure that the plastic tube assemblies are installed
in the original positions. Failure to connect the plastic Before beginning ANY work on the fuel system,
tube assemblies to the correct ports will allow con- refer to Operation and Maintenance Manual,
tamination to enter the fuel system. Allowing contami- “General Hazard Information and High Pressure
nation to enter the fuel system will cause serious Fuel Lines” for safety information.
damage to the engine.
Refer to System Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
6. Connect plastic tube assembly (1) and plastic tube for detailed information on the standards of
assembly (2) to the fuel filter base. cleanliness that must be observed during ALL
work on the fuel system.
7. Connect harness assembly (5) to fuel temperature
sensor (4). Slide locking tab in to the lock position. 1. Turn the battery disconnect switch to the OFF
8. Turn the fuel supply to the ON position. position.
9. Turn the battery disconnect switch to the ON 2. Turn the fuel supply to the OFF position.
position.

This document has been printed from SPI2. NOT FOR RESALE
18 UENR0624-03
Disassembly and Assembly Section

Illustration 26 g03011667 Illustration 27 g03011668

3. Make temporary identification marks on plastic 9. If necessary, follow Step 9.a through Step 9.g in
tube assemblies in order to show the correct order to disassembly the assembly of primary fuel
position of the plastic tube assemblies. filter (4).
4. Place a suitable container below the fuel filter base a. Remove vent screw assembly (7) and remove
in order to catch any fuel that might be spilled. O-ring seal (8). Use Tooling (A) in order to plug
5. Disconnect the plastic tube assembly from the primary fuel filter (4). Use Tooling (A) in
connecting (1). Use Tooling (A) in order to plug the order to cap vent screw assembly (7).
plastic tube assemblies. Use Tooling (A) in order
b. Remove connection (1) and remove O-ring seal
to cap connection (1).
(10). Use Tooling (A) in order to plug primary
6. Disconnect the plastic tube assembly from fuel filter (4). Use Tooling (A) in order to cap
connecting (2). Use Tooling (A) in order to plug the connection (1).
plastic tube assemblies. Use Tooling (A) in order
to cap connection (2). c. Remove connection (2) and remove O-ring seal
(13). Use Tooling (A) in order to plug primary
7. Disconnect the Original Equipment Manufactures fuel filter (4). Use Tooling (A) in order to cap
(OEM) harness assembly (6) from water in fuel connection (1).
sensor (5).
d. Remove plug (12) and remove O-ring seal (13).
8. Remove bolts (2) (not shown) and remove the
Use Tooling (A) in order to plug primary fuel filter
assembly of primary fuel filter (4) from the
(4).
mounting bracket.
e. Remove plug (15) and remove O-ring seal (14).
Use Tooling (A) in order to plug primary fuel filter
(4).

f. Remove water in fuel sensor (6) and remove O-

ring seal (17).

g. Remove the filter element from fuel filter

canister (16). Refer to Operation and
Maintenance Manual, “Fuel System Primary
Filter (Water Separator) Element - Replace” for
the correct procedure.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 19
Disassembly and Assembly Section

Installation Procedure
d. Remove cap from connection (2). Install a new
NOTICE O-ring seal (13) to connection (2).
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by e. Remove plug from primary fuel filter (4). Install
authorized personnel that have the correct connection (2) to primary fuel filter (4). Tighten
training.
the connection to a torque of 20 N·m (177 lb in).
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual, f. Install a new O-ring seal (13) to plug (12). Install
“General Hazard Information and High Pressure plug (12) to primary fuel filter (4). Tighten the
Fuel Lines” for safety information. plug to a torque of 20 N·m (177 lb in).
Refer to System Operation, Testing and Adjusting g. Install a new O-ring seal (14) to plug (15). Install
, “Cleanliness of Fuel System Components” for plug (15) to primary fuel filter (4). Tighten the
detailed information on the standards of cleanli-
ness that must be observed during ALL work on plug to a torque of 20 N·m (177 lb in).
the fuel system.
h. Remove cap from vent screw assembly (7).
Install a new O-ring seal (8) to vent screw
1. Ensure that the fuel filter base is clean and free assembly (7). Install vent screw assembly (7) to
from damage. If necessary, replace the complete primary fuel filter (4). Tighten the vent screw
fuel filter base and filter assembly. assembly securely.

i. Install a new O-ring seal (17) to water in fuel

sensor (5). Install water in fuel sensor (5) to
primary fuel filter (4). Tighten water in fuel
sensor (5) hand tight.

Illustration 28 g03011668

2. If necessary, follow Step 2.a through Step 2.i in

order to assembly primary fuel filter (1).

a. Install a new filter element to fuel filter canister Illustration 29 g03011667

(16). Refer to Operation and Maintenance
Manual, “Fuel System Primary Filter (Water 3. Position the assembly of primary fuel filter (4) onto
Separator) Element - Replace” for the correct the mounting bracket.
procedure.
4. Install bolts (3) (not shown) to the assembly of
b. Remove cap from connection (1). Install a new primary fuel filter (4). Tighten the bolts to a torque
O-ring seal (10) to connection (1). of 50 N·m (37 lb ft).

c. Remove plug from primary fuel filter (4). Install

connection (1) to primary fuel filter (4). Tighten
the connection to a torque of 20 N·m (177 lb in).

This document has been printed from SPI2. NOT FOR RESALE
20 UENR0624-03
Disassembly and Assembly Section

NOTICE NOTICE
Ensure that the plastic tube assemblies are installed Ensure that all adjustments and repairs that are
in the original positions. Failure to connect the plastic carried out to the fuel system are performed by
tube assemblies to the correct ports will allow con- authorized personnel that have the correct
tamination to enter the fuel system. Serious damage training.
to the engine will result if contaminated fuel enters
the fuel system. Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual,
“General Hazard Information and High Pressure
5. Remove plug from the plastic tube assembly. Fuel Lines” for safety information.
Remove cap from connecting (1) on primary fuel
filter (4). Connect the plastic tube assembly to Refer to System Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
connecting (1) on primary fuel filter (4). for detailed information on the standards of
6. Remove plug from the plastic tube assembly. cleanliness that must be observed during ALL
work on the fuel system.
Remove cap from connecting (2) on primary fuel
filter (4). Connect the plastic tube assembly to
connecting (2) on primary fuel filter (4). Note: Plug or cap all open ports with new plugs or
new caps.
7. Connect the OEM harness assembly (6) to water
in fuel sensor (5). 1. Thoroughly clean the area around fuel manifold
8. Turn the fuel supply to the ON position. (12).

9. Turn the battery disconnect switch to the ON

position.
End By:
a. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel
System - Prime” for the correct procedure.

i05268273

Fuel Manifold (Rail) - Remove

and Install

Removal Procedure
Table 5
Required Tools

Tool Part Number Part Description Qty

A T412504 Capping Kit 1

Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection
Lines - Remove” for the correct procedure.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 21
Disassembly and Assembly Section

a. Release hose clamp (9) on plastic tube

assembly (6).

b. Disconnect plastic tube assembly (6) from the

fuel manifold (2).

c. Use Tooling (A) to cap the open port in fuel

manifold (2) with a new cap.

d. Remove seal (10).

e. Use Tooling (A) to plug the open end of plastic

tube assembly (6) with a new plug.

Installation Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.

Illustration 30 g02652897 Before beginning ANY work on the fuel system,

refer to Operation and Maintenance Manual,
“General Hazard Information and High Pressure
Fuel Lines” for safety information.
Refer to System Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of
cleanliness that must be observed during ALL
work on the fuel system.

1. Ensure that all ports on the fuel manifold are

capped. Ensure that the fuel manifold is externally
clean and free from damage.

Note: Do not install a fuel manifold that has not been

plugged. All plugs and caps must be left in place until
the fuel injection lines are about to be installed.

Illustration 31 g02856697

2. Disconnect hose assembly connection (8) from

fuel injection pump (7).
3. Disconnect hose assembly connection (5) from
fuel distribution block (4).
4. Remove bolts (1) from fuel manifold (2). Remove
the fuel manifold from the valve mechanism cover
(3).
5. If necessary, follow Step 5.a through Step 5.e in
order to remove plastic tube assembly (6).

This document has been printed from SPI2. NOT FOR RESALE
22 UENR0624-03
Disassembly and Assembly Section

Note: Ensure that the plastic tube assembly is

correctly orientated.

d. Tighten hose clamp (9) securely.

3. Position fuel manifold (2) onto valve mechanism
cover (3). Install bolts (1) to fuel manifold (2) finger
tight.
4. Install new fuel injection lines finger tight. Refer to
Disassembly and Assembly, “Fuel Injection Lines -
Install” for the installation procedure.
Note: Do not torque the nuts for the fuel injection
lines at this stage of the assembly procedure.

5. Tighten bolts (1) to a torque of 27 N·m (239 lb in).

6. Tighten the nuts for the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection Lines -
Install” for the correct torque.
7. Remove the plug from connection (8) and install
Illustration 32 g02652897
plastic tube assembly (6) to the fuel injection pump
(7).
8. Remove the plug from connection (5) and install
plastic tube assembly (6) to distribution block (4).
9. For the remaining installation procedure for the
fuel injection lines, refer to Disassembly and
Assembly, “Fuel Injection Lines - Install”.
End By:
a. If a new fuel manifold is installed, it will be
necessary to use the electronic service tool in
order to perform the “ Rail Pressure Valve
Learn Reset”” procedure.

i05268277

Fuel Injection Lines - Remove

Removal Procedure
Illustration 33 g02856697 Table 6
Required Tools
2. If necessary, follow Step 2.a through Step 2.d in
order to install tube assembly (6) to fuel manifold Tool Part Number Part Description Qty
(2). A T412504 Capping Kit 1

a. Position hose clamp (9) onto plastic tube LASER 4920

assembly (6). B - 1/2 Inch Drive HP Fuel Line 1
Socket Set
b. Install new seal (10) into plastic tube assembly
(6).

c. Install plastic tube assembly (6) to fuel manifold

(2).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 23
Disassembly and Assembly Section

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

Note: Put identification marks on all hoses on all

hose assemblies and on wires and all tube
assemblies for installation purposes. Plug all hose
assemblies and tube assemblies. Plugging all hose
assemblies and tube assemblies will help to prevent
fluid loss and helps to keep contaminants from
entering the system.

1. Turn the fuel supply to the OFF position.

Illustration 35 g02683476
2. Turn the battery disconnect switch to the OFF
position. 4. Disconnect the Original Equipment Manufacturers
3. If necessary, remove the Diesel Particulate Filter (OEM) wiring harness assembly from connection
(DPF). Refer to Disassembly and Assembly, (5) and connection (8).
“Diesel Particulate Filter - Remove” for the correct 5. Cut cable straps (1) from the wiring harness
procedure. assemblies.
6. Slide the locking tab for wiring harness assembly
(3) into the unlocked position. Disconnect wiring
harness assembly (3) from pressure sensor (2).
7. Disconnect wiring harness assembly (14) from oil
pressure switch (13).

This document has been printed from SPI2. NOT FOR RESALE
24 UENR0624-03
Disassembly and Assembly Section

8. If necessary, cut cable straps in order to remove

the wiring harness assemblies.
9. Slide the locking tab for wiring harness assembly
(15) into the unlocked position. Disconnect wiring
harness assembly (15) from crankshaft position
sensor (16).
10. Slide the locking tab for wiring harness assembly
(17) into the unlocked position. Disconnect wiring
harness assembly (17) from camshaft position
sensor (18).
11. Slide the locking tab for wiring harness assembly
(9) into the unlocked position. Disconnect wiring
harness assembly (9) from fuel metering valve
(10).
12. Disconnect the wiring harness assembly from fuel
temperature sensor (4).
13. Remove bolt (6) from wiring harness assembly
(11). Illustration 36 g02848956
14. Position wiring harness assembly (11) away from
fuel injection lines (12).

Illustration 37 g02683858

15. Remove fuel filter base mounting bracket (21)

(not shown). Refer to Disassembly and Assembly,
“Fuel Filter Base - Remove and Install” for the
correct procedure.
16. Remove bolt (23) from tube clamp (22). Remove
tube clamp (22) from fuel injection lines (12).
Note: Make temporary marks to identify the position
of the tube clamps.

17. Repeat Step 16 in order to remove the remaining

tube clamps.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 25
Disassembly and Assembly Section

18. Remove bolt (26). Remove bracket (25) from the 29. Use Tooling (A) in order to cap all open ports
valve mechanism cover. immediately in fuel manifold (24) and in fuel
injection pump (29).
19. Clean the area around the nuts for fuel injection
lines (12). Ensure that the area is free from
i05268279
contamination before beginning disassembly.
20. Use Tooling (B) in order to disconnect fuel Fuel Injection Lines - Install
injection line (12) from electronic unit injector (27).
Note: It may be necessary to remove the front engine
lifting eye in order to gain access to number one Installation Procedure
high-pressure pipe nut.
Table 7
21. Use Tooling (B) in order to disconnect fuel Required Tools
injection line (12) from fuel manifold (24). Part Description Qty
Tool Part Number
22. Remove fuel injection line (12). Discard the fuel LASER 4920
injection lines. B - 1/2 Inch Drive HP Fuel Line 1
Socket Set
23. Use Tooling (A) in order to cap all open ports
immediately in fuel manifold (24) and electronic
unit injectors (27). NOTICE
Ensure that all adjustments and repairs that are
24. Repeat Step 19 through Step 23 in order to carried out to the fuel system are performed by
remove the remaining fuel injection lines from the authorized personnel that have the correct
fuel manifold to the electronic unit injectors. training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual,
“General Hazard Information and High Pressure
Fuel Lines” for safety information.
Refer to System Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of
cleanliness that must be observed during ALL
work on the fuel system.

Note: The following procedure should be adopted in

order to install the fuel injection lines when the
electronic unit injectors or the fuel manifold have not
been removed. If the electronic unit injectors or the
fuel manifold have been removed, refer to
Disassembly and Assembly, “Electronic Unit Injector
- Install” and Disassembly and Assembly, “Fuel
Manifold - Install” for more information.

Illustration 38 g02688011

25. Clean the area around the nuts for fuel injection
line (28). Ensure that the area is free from
contamination before beginning disassembly.
26. Disconnect fuel injection line (28) from fuel
injection pump (29).
27. Disconnect fuel injection line (28) from fuel
manifold (24).
28. Remove fuel injection line (28). Discard the fuel
injection line.

This document has been printed from SPI2. NOT FOR RESALE
26 UENR0624-03
Disassembly and Assembly Section

5. Remove the caps from the port of the electronic

unit injector and from the appropriate port in fuel
manifold (16).
6. Loosely connect the nuts at both ends of fuel
injection line (12) to the electronic unit injector and
to the appropriate port in fuel manifold (16).
Ensure that the ends of the fuel injection line are
correctly seated in the electronic unit injector and
in the fuel manifold.
7. Repeat Step 5 through Step 6 in order to install the
remaining fuel injection lines.
8. Position clamp (22) onto fuel injection lines (12)
and install clamp bolt (20). Tighten the bolt to a
torque of 10 N·m (89 lb in).
Note: Ensure that the rubber separator is correctly
installed around the fuel injection lines. Ensure that
fuel injection lines do not contact any other engine
component.
Illustration 39 g02699457
9. Repeat Step 8 for the remaining fuel injection lines.
10. Use Tooling (B) to tighten the nuts on fuel
injection line (12) to a torque of 25 N·m (221 lb in).
11. Position bracket (25) onto the valve mechanism
cover. Install bolt (26) and tighten the bolt to a
torque of 10 N·m (89 lb in).
12. If necessary, reinstall the front engine lifting eye
(31). Install bolts (30) and tighten the bolts to a
torque of 45 N·m (33 lb ft).

Illustration 40 g02849442

1. Remove the relevant plug from fuel manifold (24)

and fuel injection pump (29).
2. Remove the caps from new fuel injection line (28).
3. Position fuel injection line (28) onto fuel injection
pump (29) and fuel manifold (24). Loosely install
nuts for the fuel injection line onto the fuel manifold
and the fuel injection pump.
4. Use Tooling (B) to tighten the nuts on fuel injection
line (23) to a torque of 25 N·m (221 lb in).

Note: Ensure that fuel injection lines do not contact

any other engine component.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 27
Disassembly and Assembly Section

Illustration 43 g02699462
Illustration 41 g02849446
13. Position bracket (19) onto the valve mechanism
cover. Install bolts (20) and tighten the bolts to a
torque of 25 N·m (221 lb in).
14. Install the fuel filter base mounting bracket (21)
(not shown). Refer to Disassembly and Assembly,
“Fuel Filter Base - Remove and Install” for the
correct procedure.
15. Position the wiring harness assembly (11) over
fuel injection lines (12).
16. Install bolt (6) to wiring harness assembly (11).
Tighten the bolt to a torque of 10 N·m (89 lb in)
17. Install cable straps (1) to the wiring harness and
brackets (25). Ensure that the cable straps meet
the Original Equipment Manufactures (OEM)
specifications.
18. Connect wiring harness assembly (9) to fuel
metering valve (10). Slide the locking tab for wiring
harness assembly (9) into the locked position.
Illustration 42 g02699461 19. Connect wiring harness assembly (14) to oil
pressure switch (13).
20. Connect wiring harness assembly (3) to pressure
sensor (2). Slide the locking tab for wiring harness
assembly (3) into the locked position.
21. Connect wiring harness assembly to fuel
temperature sensor (4). Slide the locking tab for
wiring harness assembly into the locked position.
22. Connect wiring harness assembly (15) to
crankshaft position sensor (16). Slide the locking
tab for wiring harness assembly (15) into the
locked position.

This document has been printed from SPI2. NOT FOR RESALE
28 UENR0624-03
Disassembly and Assembly Section

23. Connect wiring harness assembly (17) to Note: Plug or cap all open ports with new plugs or
camshaft position sensor (18). Slide the locking caps.
tab for wiring harness assembly (17) into the
locked position. 1. If necessary, remove the diesel particulate filter
mounting bracket. Refer to Disassembly and
24. Install cable straps to the wiring harness Assembly, “Support and Mounting (CEM) -
assembly in the relevant positions. Ensure that the Remove and Install” for the correct procedure.
cable straps meet the OEM specifications.
25. Install the OEM wiring harness assembly to
connection (5) and connection (8).
26. If necessary, install the Diesel Particulate Filter
(DPF). Refer to Disassembly and Assembly,
“Diesel Particulate Filter - Install” for the correct
procedure.
27. Turn the fuel supply to the ON position.
28. Turn the battery disconnect switch to the ON
position.
29. Remove trapped air from the fuel system. Refer
to the Operation and Maintenance Manual, “Fuel
System - Prime” for the correct procedure.

i05268286

Exhaust Cooler (NRS) -

Remove and Install
Illustration 44 g02717244

2. Position hose clamp (3) away from the coolant inlet

Removal Procedure in Position (A). Disconnect hose (4) from exhaust
cooler assembly (2).
Start By:
3. Reposition hose clamp (7) and hose clamp (10) in
a. Drain the coolant from the cooling system into order to allow removal of hose (8). Disconnect
a suitable container for storage or disposal. hose (8) from exhaust cooler assembly (2).
Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change” for the 4. Loosen V-band clamp (9) and position the clamp
correct procedure. away from the Exhaust Gas Recirculation (EGR)
valve assembly (1).
5. Remove bolts (5) from exhaust cooler assembly
Sulfuric Acid Burn Hazard may cause serious (2).
personal injury or death.
6. Remove exhaust cooler assembly (2) from the
The exhaust gas cooler may contain a small induction manifold.
amount of sulfuric acid. The use of fuel with sul-
fur levels greater than 15 ppm may increase the 7. Remove gasket (6).
amount of sulfuric acid formed. The sulfuric acid 8. Remove clamp (9) from the exhaust cooler
may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin assembly.
and clothing on contact. Always wear the appro-
priate personal protective equipment (PPE) that Installation Procedure
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for 1. Check all components for wear and damage. If
first aid that are noted on a material safety data necessary, replace any components that are worn
sheet (MSDS) for sulfuric acid. or damaged.
Note: Remove plugs and caps that were previously
installed prior to assembly.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 29
Disassembly and Assembly Section

11. If necessary, install the diesel particulate filter

mounting bracket. Refer to Disassembly and
Assembly, “Support and Mounting (CEM) -
Remove and Install” for the correct procedure.

Illustration 45 g02717358

2. Ensure that the NRS exhaust cooler is free from

restriction and external damage. Ensure that the
NRS exhaust cooler and tube assemblies are free
from wear and damage. Refer to Systems
Operation Testing and Adjusting, “Exhaust Cooler
(NRS) - Test” for the correct inspection procedure.

Note: The NRS exhaust cooler should not be

internally cleaned.

3. Clean the sealing face on the EGR valve assembly

(1) is clean and free from damage.
4. Install a new clamp (9) to NRS mixer chamber (1).

Note: Ensure that the clamp is correctly orientated to

prevent contact with any other engine components.

5. Position a new gasket (6) onto the inlet manifold.

6. Position exhaust cooler assembly (2) onto the
induction manifold. Install bolts (5) finger tight.

Note: Ensure that the exhaust cooler assembly (2)

can still move freely.

7. Tighten clamp (9) to a torque of 10 N·m (89 lb in)

8. Tighten bolts (5) to a torque of 25 N·m (221 lb in)
9. Connect hose (4) to exhaust cooler assembly (2) in
Position (A). Position hose clamp (3) onto the
coolant inlet.
10. Install hose assembly (8) to exhaust cooler
assembly (2). Position hose clamp (7) and position
hose clamp (10) and tighten securely.

This document has been printed from SPI2. NOT FOR RESALE
30 UENR0624-03
Disassembly and Assembly Section

End By:
a. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.

i05268287

Throttle Valve (Intake Air) -

Remove and Install
(Rear Facing Inlet Elbow)

Removal Procedure

Illustration 47 g02906317

1. Loosen the hose clamp and disconnect the hose

assembly from elbow (1).
2. Slide the locking tab into the unlocked position and
disconnect harness assembly (7) from throttle
valve (8).
3. Loosen hose clamp (2) and disconnect hose
assembly (4) from elbow (1).
4. Remove bolts (5) and remove nuts (3) from the
elbow.
5. Remove the air inlet elbow from studs (9).
6. Remove gasket (6) (not shown).
7. Remove throttle valve (8) from studs (9).
Illustration 46 g02906277 8. Remove gasket (6) (not shown).
9. If necessary, remove studs (9). Refer to
Disassembly and Assembly, “Inlet Manifold -
Remove and Install” for the correct procedure.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 31
Disassembly and Assembly Section

Illustration 48 g02906404 Illustration 49 g02906404

10. If necessary, remove adaptor (12) and sealing

washer (11) from elbow (1).

Installation Procedure
Table 8
Required Tools

Tool Part Number Part Description Qty

A - Technologic 15 1

1. Check all components for wear and damage. If

necessary, replace any components that are worn
or damaged.

Illustration 50 g02906317

This document has been printed from SPI2. NOT FOR RESALE
32 UENR0624-03
Disassembly and Assembly Section

13. Install the clamp to the air inlet hose and connect
the air inlet hose to elbow (1).

i05268292

Throttle Valve (Intake Air) -

Remove and Install
(Side Facing Inlet Elbow)

Removal Procedure

Illustration 51 g02906277

2. If necessary, install studs (9). Refer to

Disassembly and Assembly, “Inlet Manifold -
Remove and Install” for the correct procedure.
3. If necessary, install new sealing washer (11) to
adaptor (12) and apply Tooling (A) to the threads
of adaptor (12). Tighten the adaptor to a torque of
20 N·m (177 lb in).
4. Install gasket (10) to studs (9).
5. Install throttle valve (8) to studs (9).
6. Install gasket (6) to studs (9).
7. Install elbow (1) to studs (9). Illustration 52 g02909057

8. Install bolts (5) finger tight. 1. Loosen the hose clamp and disconnect the hose
9. Install nuts (3) finger tight. assembly from elbow (3).

10. Tighten bolts (5) and nuts (3) to a torque of 2. Slide the locking tab into the unlocked position and
10 N·m (89 lb in). disconnect harness assembly (1) from throttle
valve (2).
11. Position hose clamp (2) onto hose assembly (4).
Install hose assembly (4) to adaptor (12) and 3. Loosen hose clamp (6) and disconnect hose
tighten hose clamp (2) securely. assembly (7) from elbow (3).

12. Install harness assembly (7) to throttle valve (8). 4. Remove plug (4) from elbow (3). Remove sealing
Slide the locking tab into the locked position. washer (5) (not shown) from the plug.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 33
Disassembly and Assembly Section

10. If necessary, remove adaptor (11) and sealing

washer (10) from elbow (3).
11. If necessary, remove studs (13). Refer to
Disassembly and Assembly, “Inlet Manifold -
Remove and Install” for the correct procedure.

Installation Procedure
Table 9
Required Tools

Tool Part Number Part Description Qty

A - Technologic 15 1

1. Check all components for wear and damage. If

necessary, replace any components that are worn
or damaged.

Illustration 53 g02909137

Illustration 54 g02909198

5. Remove nuts (9) from studs (13).

6. Remove bolts (8).

Note: Bolt (8) in Position (X) must be removed with

air inlet elbow (3) in order to prevent the bolt from
falling into the induction system.

7. Remove gasket (12).

8. Remove throttle valve (2) from studs (13).
9. Remove gasket (14) (not shown).

This document has been printed from SPI2. NOT FOR RESALE
34 UENR0624-03
Disassembly and Assembly Section

5. Install throttle valve (2) onto studs (13).

6. Install gasket (12) onto studs (13).

Illustration 55 g02909198

Illustration 57 g02909057

7. Install bolt (8) in Position (X) to elbow (3). Install

elbow (3) onto studs (13) and tighten bolt (8) in
Position (X) finger tight. Install remaining bolt (8).
8. Install nuts (9) to studs (13).
9. Tighten bolts (8) and nuts (9) to a torque of 10 N·m
(89 lb in).
10. Install new sealing washer (5) (not shown) to plug
(4).
11. Apply Tooling (A) to plug (4) and install the plug to
air inlet elbow (3). Tighten the plug to a torque of
50 N·m (37 lb ft).
12. Install the clamp to the air inlet hose and connect
the air inlet hose to air inlet elbow (3).
13. Connect harness assembly (1) onto throttle valve
Illustration 56 g02909137 (2). Slide the locking tab into the locked position.

2. If necessary, install studs (13). Refer to i05268296

Disassembly and Assembly, “Inlet Manifold -
Remove and Install” for the correct procedure. Fuel Injection Pump - Remove
3. Install gasket (14) (not shown) onto studs (13).
4. If necessary, follow Step 4.a through Step 4.b in
order to install adaptor (11). Removal Procedure
Table 10
a. Install new sealing washer (10) to adaptor (11).
Required Tools
b. Apply Tooling (A) to adaptor (11). Install adaptor Tool Part Number Part Description Qty
assembly (11) to air inlet elbow (3). Tighten the
adaptor to a torque of 20 N·m (177 lb in). A T412504 Capping Kit 1

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 35
Disassembly and Assembly Section

Start By:
a. Remove the fuel injection pump gear. Refer to
Disassembly and Assembly, “Fuel Injection
Pump Gear - Remove” for the correct
procedure.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
Illustration 58 g02709437
refer to Operation and Maintenance Manual,
“General Hazard Information and High Pressure
Fuel Lines” for safety information. 4. Place a suitable container below the fuel injection
pump in order to catch any fuel that might be
Refer to System Operation, Testing and Adjust- spilled.
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of 5. Clean the fuel injection pump and the area around
cleanliness that must be observed during ALL the fuel injection pump. Ensure that the area is
work on the fuel system.
free from contamination before beginning
disassembly.
1. Turn the fuel supply to the OFF position.
6. Remove fuel injection line (7) that connects fuel
2. Turn the battery disconnect switch to the OFF injection pump (6) to the fuel manifold. Refer to
position. Disassembly and Assembly, “Fuel Injection Lines -
Remove” for the correct procedure.
3. Disconnect harness assembly (1) from the
solenoid on fuel injection pump (6). Note: Discard the fuel injection line.
Note: The harness assemblies should be positioned 7. Use Tooling (A) in order to cap the open port in the
away from fuel injection pump in order to avoid an fuel injection pump immediately.
obstruction to the fuel injection pump.
8. Use Tooling (A) in order to cap the open port in the
fuel manifold immediately.
9. Make temporary identification marks on all plastic
tube assemblies for installation purposes.
10. Disconnect plastic tube assembly (2), plastic tube
assembly (3), plastic tube assembly (4) plastic
tube assembly (5) from fuel injection pump (6).
11. Use Tooling (A) in order to cap the open ports in
the fuel injection pump immediately.
12. Use Tooling (A) in order to plug the plastic tube
assemblies immediately.

This document has been printed from SPI2. NOT FOR RESALE
36 UENR0624-03
Disassembly and Assembly Section

16. If necessary, remove studs (9) from front housing

(10).

i05500629

Fuel Injection Pump - Install

Installation Procedure

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 37
Disassembly and Assembly Section

Illustration 60 g02937680 Illustration 62 g02709437

5. Remove the appropriate caps in order to install a

new fuel injection line (7). Install new fuel injection
line (7) to the fuel injection pump and to the fuel
manifold. Refer to Disassembly and Assembly,
“Fuel Injection Lines - Install” for the correct
procedure.
6. Remove the appropriate plugs and caps and
connect plastic tube assembly (2), plastic tube
assembly (3), plastic tube assembly (4) plastic
tube assembly (5) to fuel injection pump (6).
7. Connect harness assembly (1) to the solenoid on
fuel injection pump (6).
8. Install the fuel injection pump gear. Refer to
Disassembly and Assembly, “Fuel Injection Pump
Gear - Install” for the correct procedure.
9. Replace the filters for primary fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
Primary (Water Separator) Element - Replace” for
Illustration 61 g02937736 the correct procedure.

1. If necessary, install studs (9) into front cover (10). 10. Replace the filters for secondary fuel system.
Tighten the studs to a torque of 18 N·m (159 lb in) Refer to Operation and Maintenance Manual,
“Fuel System Secondary Filter - Replace” for the
2. Install new O-ring seal (11) onto fuel injection correct procedure.
pump (6).
11. Turn the fuel supply to the ON position.
3. Carefully install fuel injection pump (6) into front
housing (10). Ensure that the bore in front housing 12. Turn the battery disconnect switch to the ON
(10) is not damaged as the fuel injection pump is position.
installed.
4. Install nuts (8) onto studs (9). Tighten the nuts to a
torque of 25 N·m (221 lb in).

This document has been printed from SPI2. NOT FOR RESALE
38 UENR0624-03
Disassembly and Assembly Section

13. Remove the air from the fuel system. Refer to

Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure.

i05268312

Fuel Injection Pump Gear -

Remove

Removal Procedure
Table 11
Required Tools

Tool Part Number Part Description Qty

A T400086 Timing Pin (Crankshaft) 1

B T400152 Timing Pin (Camshaft) 1

Snap-on PBS650
C - 1 Illustration 63 g02937156
Small Pry Bar

Start By:
a. Remove the front cover. Refer to Disassembly
and Assembly, “Front Cover - Remove and
Install” for the correct procedure.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 39
Disassembly and Assembly Section

d. Rotate the engine until Hole (X) in the camshaft

gear is aligned with Position (W) in the front
housing.

e. Install Tooling (B) through Position (W) and into

Hole (X) in the camshaft gear.

Illustration 65 g02934298 Illustration 66 g02937163

4. Follow Step 4.a through Step 4.c in order to install 5. Before removing fuel injection pump gear, (8)
the crankshaft positioning tool. ensure that alignment pin (6) is 45 degrees from
vertical and parallel to the center of Torx head plug
a. Remove plug (4) from Position (X) in the (5), refer to Illustration 66 .
cylinder block.
6. Use Tooling (C) in order to remove the fuel
b. Remove O-ring seal (3) from plug (4). injection pump gear from the fuel injection pump
shaft (7).
c. Install Tooling (A) into the cylinder block in
7. If necessary, remove locating pin (6) from fuel
Position (Z).
injection pump shaft (7).
Note: Tooling (A) must be located in Hole (Y) in the
crankshaft. i05268316

Note: Ensure that Tooling (A) is located in the Fuel Injection Pump Gear -
correct drilling in the crankshaft as shown in
Illustration 65 . Install

Installation Procedure
Table 12
Required Tools

Tool Part Number Part Description Qty

A T400086 Timing Pin (Crankshaft) 1

B T400152 Timing Pin (Camshaft) 1

This document has been printed from SPI2. NOT FOR RESALE
40 UENR0624-03
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that all components are clean and free

from wear of damage. If necessary, replace any
components that are worn or damaged.
2. If Tooling (A) and Tooling (B) are not installed,
install Tooling (A) and install Tooling (B). Refer to
Disassembly and Assembly, “Fuel Injection Pump
Gear - Remove” for the correct procedure.

Illustration 68 g02937277

8. Remove Tooling (B) from the front housing.

9. Install new O-ring seal (1) to plug (2).
10. Install plug (2). Tighten the plug to a torque of
25 N·m (221 lb in).
11. Install new O-ring seal (3) to plug (4).
12. Install plug (4). Tighten the plug to a torque of
30 N·m (266 lb in).
13. If equipped, install the accessory drive. Refer to
Disassembly and Assembly, “Accessory Drive -
Remove and Install” for the correct procedure.

i05270670

Electronic Unit Injector -

Remove
Illustration 67 g02937163

3. If necessary, install locating pin (6) into fuel

injection pump shaft (7). Removal Procedure
Table 13
4. Ensure that locating pin (6) is 45 degrees from
Required Tools
vertical and parallel to the center of Torx head plug
(5), refer to Illustration 67 . Tool Part Number Part Description Qty

5. Position gear (8) onto fuel injection pump shaft (7). A T412504 Capping Kit 1

6. Install the front cover. Refer to Disassembly and

Assembly, “Front Cover - Remove and Install” for
the correct procedure.
7. Install the crankcase breather. Refer to
Disassembly and Assembly, “Crankcase Breather
- Install” for the correct procedure.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 41
Disassembly and Assembly Section

Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection
Lines - Remove” for the correct procedure.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct
training.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
Illustration 69 g02701543
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Systems Operation, Testing and Adjust-
ing Manual, “Cleanliness of Fuel System Compo-
nents” for detailed information on the standards
of cleanliness that must be observed during ALL
work on the fuel system.

Note: Place identification marks on all hoses, on all

hose assemblies, on wires and on all tube
assemblies for installation purposes. Plug all hose
assemblies and tube assemblies. Plugging all hose Illustration 70 g02701718
assemblies and tube assemblies will prevent fluid
loss. Plugging all hose assemblies and tube 1. Disconnect wiring harness assembly (5) from
assemblies will to keep contaminants from entering electronic unit injector (3).
the system.
Note: Make a temporary mark on the wiring harness
Note: Plug or cap all open ports with new plugs or assembly in order to ensure that the wiring harness
caps. assembly is connected to the correct electronic unit
injector during assembly.

2. Remove clip (1) from electronic unit injector (3).

3. Disconnect hose assembly (2) from electronic unit
injector (3). Remove O-ring seal (7) from the hose
assembly.

This document has been printed from SPI2. NOT FOR RESALE
42 UENR0624-03
Disassembly and Assembly Section

4. Use Tooling (A) in order to cap electronic unit 13. If necessary, remove studs (9) from the cylinder
injector (3) immediately. Use Tooling (A) in order to head.
plug hose assembly (2) immediately.
i05270671
5. Remove nut (4) and washer (8) from clamp (6).
Note: Note the orientation of the washer.
Electronic Unit Injector - Install
6. Make a temporary mark on the electronic unit Installation Procedure
injector in order to ensure that the electronic unit
injector is reinstalled in the original location.
7. Remove the electronic unit injector and clamp (6) NOTICE
from the cylinder head. Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
Note: Always handle electronic unit injectors with authorised personnel that have the correct
care. training.

8. Remove clamp (6) from electronic unit injector (3). Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
9. If electronic unit injector (3) is to be reused, Follow eral Hazard Information and High Pressure Fuel
Step 10 through Step 11 in order to remove Lines” for safety information.
sealing washer (10).
Refer to Systems Operation, Testing and Adjust-
10. Use a suitable tool in order to remove sealing ing Manual, “Cleanliness of Fuel System Compo-
washer (10) from electronic unit injector (3). If nents” for detailed information on the standards
of cleanliness that must be observed during ALL
sealing washer (10) is not present on the work on the fuel system.
electronic unit injector, ensure that the sealing
washer is removed from the cylinder head.

Note: Ensure that the nozzle for the electronic

unit injector is not damaged in any way during
removal of the sealing washer.

11. Install Tooling (A) to the nozzle for electronic unit

injector (3) immediately.
12. If necessary, repeat Step 1 through Step 10 in
order to remove the remaining electronic unit
injectors.
In some applications removal of the clean
emissions bracket and exhaust gas recirculation
valve will be necessary in order to remove number
four electronic unit injector. Refer to Disassembly
and Assembly, “Support and Mounting (CEM) -
Remove and Install” and Disassembly and
Assembly, “Exhaust Gas Recirculation Valve -
Remove and Install” for the correct procedures.

Illustration 71 g02704596
Injector code

1. If the original electronic unit injector (3) is installed,

ensure that the electronic unit injector is installed
into the original location.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 43
Disassembly and Assembly Section

2. If a replacement electronic unit injector is installed, Note: Ensure that the clamp is correctly positioned
the correct seven digit injector code that is located onto the electronic unit injector.
in Position (A) must be programmed into the
electronic control module. Refer to 9. Push only on injector clamp (6) in order to install
Troubleshooting, “Injector Code - Calibrate” for electronic unit injector (3). Do not apply pressure
more information. on any other part of the electronic unit injector.
Ensure that the electronic unit injector is pushed
Note: Record the seven digit injector code in Position firmly against the seat in the cylinder head.
(A) before the electronic unit injector is installed.
10. Install washer (8) and nut (4) onto stud (9).
3. Ensure that the fuel inlet port of the electronic unit Tighten the nut finger tight.
injector is capped. Ensure that the electronic unit
Note: Ensure that the washer is correctly orientated.
injector is clean.
11. Remove the plugs from the new fuel injection line.
Install the fuel injection line nuts hand tight. Refer
to Disassembly and Assembly, “Fuel Injection
Lines - Install” for the correct installation
procedure.
Note: Ensure that the ends of the fuel injection line
are seated into the electronic unit injector and the fuel
manifold.
Note: Do not torque the fuel injection line nuts
before the final torque has been applied to the
electronic unit injector clamp nuts (4).

12. When nuts (4) are installed, the nuts must be

tightened in two stages. Follow Step 12.a through
12.b for the correct torque sequence.

a. Tighten nuts (4) to an initial torque of 15 N·m

(133 lb in).

b. Tighten nuts (4) to a final torque of 25 N·m

Illustration 72 g02851878 (221 lb in).

4. If necessary, install studs (9) to the cylinder head. 13. If necessary, repeat Step 1 through Step 12.b in
Tighten the studs to a torque of 20 N·m (177 lb in) order to install the remaining electronic unit
injectors.
5. If the original electronic unit injector (3) is to be
reused, remove the protective cap from the nozzle 14. Tighten the fuel injection line nuts to a torque of
and install a new sealing washer (10). 25 N·m (221 lb in). Refer to Disassembly and
Assembly, “Fuel Injection Lines - Install” for further
Note: Ensure that the nozzle for the electronic unit information.
injector is not damaged during installation of the new
sealing washer.

6. Remove the plug from the electronic unit injector

port in the cylinder head.
7. 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 the cylinder head.
8. Position clamp (6) onto electronic unit injector (3).
Align the assembly of electronic unit injector (3) to
the bore for the electronic unit injector in the
cylinder head.

This document has been printed from SPI2. NOT FOR RESALE
44 UENR0624-03
Disassembly and Assembly Section

25. Turn the fuel supply to the ON position.

26. Turn the battery disconnect switch to the ON
position.
27. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure.

i05270673

Turbocharger - Remove
(Top Mounted Turbochargers)

Removal Procedure
Start By:
a. Remove the flexible exhaust pipe from the
turbocharger. Refer to Disassembly and
Illustration 73 g02706897 Assembly, “Flexible Exhaust Pipe - Remove
and Install” for the correct procedure.
15. Install a new O-ring seal (7) to the connection on
hose assembly (2). NOTICE
Keep all parts clean from contaminants.
16. Install hose assembly (2) to electronic unit
injector (3). Contaminants may cause rapid wear and shortened
component life.
17. Install clip (1) to electronic unit injector (3).
18. If necessary, repeat Step 15 through Step 17 in
order to connect the remaining hose assemblies NOTICE
Care must be taken to ensure that fluids are con-
(2). tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
19. Connect wiring harness assemblies (5) to the Be prepared to collect the fluid with suitable contain-
electronic unit injectors. Slide the locking tab into ers before opening any compartment or disassem-
the locked position bling any component containing fluids.
20. If necessary install the exhaust gas recirculation Dispose of all fluids according to local regulations
valve. Refer to Disassembly and Assembly, and mandates.
“Exhaust Gas Recirculation Valve - Remove and
Install” for the correct procedure.
21. If necessary install the diesel particulate filter
supporting bracket. Refer to Disassembly and
Assembly, “Support and Mounting (CEM) -
Remove and Install” for the correct procedure.
22. Install the wiring harness assembly. Refer to
Disassembly and Assembly, “Fuel Injection Lines -
Install” for the correct procedure.
23. Replace the primary fuel filter. Refer to Operation
and Maintenance Manual, “Fuel System Primary
(Water Separator) Element - Replace” for the
correct procedure.
24. Replace the secondary fuel filter. Refer to
Operation and Maintenance Manual, “Fuel System
Secondary Filter - Replace” for the correct
procedure.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 45
Disassembly and Assembly Section

5. Remove hose clamp (7) from hose assembly (8).

Disconnect hose assembly (8) from the wastegate
actuator.
6. Remove bolts (12) from tube assembly (9).
7. Remove gasket (13) (not shown).
8. If necessary, follow Step 8.a through Step 8.d in
order to remove tube assembly (9) from the
cylinder block.

a. Remove bolts (16) and position tube assembly

(18) away from the oil cooler.

b. Remove O-ring seal (15) (not shown) from tube

assembly (18).

c. Remove bolt (17) and remove tube assembly

(9) from the cylinder block.

d. Remove O-ring seal (19) (not shown) from tube

Illustration 74 g02719477
assembly (9).

Illustration 76 g02719524
Illustration 75 g02868099
9. Remove nuts (20) and washers (21) (not shown).
1. Loosen hose clamps and disconnect the hose Remove turbocharger (14) from exhaust manifold
assemblies from turbocharger inlet (6) and from (24).
turbocharger outlet (3).
Note: Do not use the actuator rod to lift the
2. Remove banjo bolt (1) from tube assembly (11). turbocharger.
Remove sealing washers (2) (not shown).
10. Remove gasket (23) (not shown).
3. Loosen nut (10) and remove tube assembly (11)
from turbocharger (14) and the cylinder block. 11. If necessary, remove the studs (22) from
turbocharger (14) and exhaust manifold (24).
4. Remove hose clamp (5) from hose assembly (4).
Disconnect hose assembly (4).

This document has been printed from SPI2. NOT FOR RESALE
46 UENR0624-03
Disassembly and Assembly Section

f. Remove gasket (27) (not shown).

i05270674

Turbocharger - Remove
(Side Mounted Turbochargers)

Removal Procedure
Start By:
a. Remove the flexible exhaust pipe from the
turbocharger. Refer to Disassembly and
Assembly, “Flexible Exhaust Pipe - Remove
and Install” for the correct procedure.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Illustration 77 g02868256 component life.

12. If necessary, follow Step 12.a through Step 12.f in

order to remove boost pressure chamber cover NOTICE
(33). Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
a. Remove the alternator and mounting bracket. nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
Refer to Disassembly and Assembly, “Alternator
ers before opening any compartment or disassem-
- Remove and Install” for the correct procedure. bling any component containing fluids.
b. Remove banjo bolt (28) and remove sealing Dispose of all fluids according to local regulations
washers (29) (not shown) from hose assembly and mandates.
(8).

c. Remove banjo bolt (32) and remove sealing

washers (31) (not shown) from hose assembly
(26).

d. Release the tube assembly (26) from clip (25)

and position the hose assembly away from
boost pressure chamber cover (33).

e. Remove bolts (30) and remove boost pressure

chamber cover (33) from the oil cooler.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 47
Disassembly and Assembly Section

5. Loosen the hose clamp on hose assembly (4).

Disconnect hose assembly (4) from the
turbocharger.
6. Loosen the hose clamp on hose assembly (6).
Disconnect hose assembly (6) from the wastegate
actuator.
7. Remove bolts (10) from tube assembly (9).
8. Remove gasket (7) (not shown).
9. If necessary, remove tube assembly (9) from the
cylinder block. Remove O-ring seals (8) (not
shown).

Illustration 78 g02859585

Illustration 80 g02861996

10. Remove nuts (18) and washers (16) (not shown).

Remove turbocharger from the exhaust manifold
(19).
Note: Do not use the actuator rod to lift the
turbocharger.

Illustration 79 g02859796 11. Remove gasket (20) (not shown).

12. If necessary, remove the studs (17) from the
1. Loosen hose clamps and disconnect the hose
turbocharger and exhaust manifold.
assemblies from turbocharger inlet (5) and from
turbocharger outlet (3).
2. Remove banjo bolt (2) from tube assembly (12).
Remove sealing washers (1) (not shown).
3. Loosen nut (15) and remove tube assembly (12)
from turbocharger (11) and the cylinder block.
4. If necessary, remove connection (14) from the
cylinder block. Remove sealing washer (13) (not
shown).

This document has been printed from SPI2. NOT FOR RESALE
48 UENR0624-03
Disassembly and Assembly Section

f. Remove gasket (23) (not shown).

i05270677

Turbocharger - Install
(Top Mounted Turbochargers)

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that the turbocharger is clean and free from

damage. Inspect the turbocharger for wear. Refer
to Systems Operation, Testing and Adjusting,
Illustration 81 g02862040 “Turbocharger - Inspect” for more information. If
the turbocharger is worn, the complete
13. If necessary, follow Step 13.a through Step 13.f in turbocharger must be replaced.
order to remove boost pressure chamber cover
(29).

a. Remove the alternator and mounting bracket.

Refer to Disassembly and Assembly, “Alternator
- Remove and Install” for the correct procedure.

b. Remove banjo bolt (24) and remove sealing

washers (25) (not shown) from hose assembly
(6).

c. Remove banjo bolt (28) and remove sealing

washers (27) (not shown) from hose assembly
(22).

d. Release the tube assembly (22) from clip (21)

and position the hose assembly away from
boost pressure chamber cover (29).

e. Remove bolts (26) and remove boost pressure

chamber cover (29) from the oil cooler.

Illustration 82 g02868256

2. If necessary, follow Step 2.a through Step 2.f in

order to remove boost pressure chamber cover
(33).

a. Position gasket (27) (not shown) onto boost

pressure chamber cover (33).

b. Position boost pressure chamber cover onto

the engine oil cooler and install bolts (30).
Tighten the bolts to a torque of 10 N·m (89 lb in)

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 49
Disassembly and Assembly Section

c. Install a new sealing washer (31) to banjo bolt

(32). Install the banjo bolt assembly to hose
assembly (26) and install the remaining sealing
washer (31). Install hose assembly (26) to boost
pressure chamber cover (33) finger tight.

d. Install tube assembly (26) into clip (25).

e. Install a new sealing washer (29) to banjo bolt

(28). Install the banjo bolt assembly to hose
assembly (8) and install the remaining sealing
washer (28). Install hose assembly (8) to boost
pressure chamber cover (33) finger tight.

f. Install the alternator and mounting bracket.

Refer to Disassembly and Assembly, “Alternator
- Remove and Install” for the correct procedure.

Illustration 83 g02868099

Illustration 84 g02719524

3. Test the turbocharger actuator for correct

operation. Refer to Systems Operation, Testing
and Adjusting, “Turbocharger - Inspect” for more
information. If the actuator is damaged or the
actuator does not operate within the specified
limits, the complete turbocharger must be
replaced.
4. If necessary, follow Step 4 through Step 5 in order
to install tube assembly (9).

a. Install new O-ring seal (19) (not shown) to tube

assembly (9).

This document has been printed from SPI2. NOT FOR RESALE
50 UENR0624-03
Disassembly and Assembly Section

b. Install tube assembly (9) to the cylinder block. 12. Lubricate the bearings of the turbocharger with
clean engine oil through the oil inlet port. Rotate
c. Install bolt (17) to tube assembly (9). Tighten the the shaft of the turbocharger in order to distribute
bolt to a torque of 25 N·m (221 lb in). the lubricant.
d. Install O-ring seal (15) (not shown) to tube 13. Position a new sealing washer (2) (not shown)
assembly (18). onto banjo bolt (1). Install banjo bolt (1) onto tube
assembly (11) and install remaining new sealing
e. Install tube assembly (18) to the oil cooler washer (2) to banjo bolt (1).
assembly. Install bolts (16) to tube assembly
(18). Tighten the bolts to a torque of 25 N·m 14. Position tube assembly (11) onto the cylinder
(221 lb in). block. Loosely install nut (10).

5. Clean the gasket surface of exhaust manifold (24). 15. Position tube assembly (11) onto the
If necessary, install studs (22) to exhaust manifold turbocharger. Loosely install banjo bolt (1).
(24) and turbocharger (14). Tighten the studs to a 16. Tighten banjo bolt (1) to a torque of 35 N·m
torque of 15 N·m (133 lb in). (26 lb ft).
6. Install a new gasket (23) (not shown) to the Note: Ensure that the tube assembly does not come
exhaust manifold. into contact with any other engine component.
7. Position turbocharger (14) onto exhaust manifold
17. Tighten nut (10) to a torque of 25 N·m (221 lb in).
(24) and install washers (21) and new nuts (20).
Tighten the nuts to a torque of 28 N·m (248 lb in). 18. Connect hose assembly (8) to the wastegate
actuator. Install hose clamp (7) to hose assembly
Note: Do not use the actuator rod to lift the (8). Tighten the hose clamp securely.
turbocharger.
Note: Ensure that hose clamp is correctly positioned
on the hose assembly.

19. Connect hose assembly (4) to the turbocharger.

Install hose clamp (5) to hose assembly (4).
Tighten the hose clamp securely.

Note: Ensure that hose clamp is correctly positioned

on the hose assembly.

20. Connect the hose assemblies to turbocharger

inlet (6) and for turbocharger outlet (3). Securely
tighten the hose clamps.

Illustration 85 g02847785

8. Position a new gasket (13) (not shown) onto tube

assembly (9).
9. Position tube assembly (9) onto the turbocharger.
10. Install bolts (12) finger tight.
11. Tighten bolts (12) to a torque of 10 N·m (89 lb in).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 51
Disassembly and Assembly Section

End By:
a. Install the flexible exhaust pipe to the
turbocharger. Refer to Disassembly and
Assembly, “Flexible Exhaust Pipe - Remove
and Install” for the correct procedure.

i05270679

Turbocharger - Install
(Side Mounted Turbochargers)

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 86 g02862040

1. Ensure that the turbocharger is clean and free from

damage. Inspect the turbocharger for wear. Refer 3. If necessary, follow Step 3.a through Step 3.f in
to Systems Operation, Testing and Adjusting, order to install boost pressure chamber cover (29).
“Turbocharger - Inspect” for more information. If
a. Position gasket (23) (not shown) onto boost
the turbocharger is worn, the complete
pressure chamber cover (29).
turbocharger must be replaced.
2. Test the turbocharger actuator for correct b. Position boost pressure chamber cover onto
operation. Refer to Systems Operation, Testing the engine oil cooler and install bolts (26).
and Adjusting, “Turbocharger - Inspect” for more Tighten the bolts to a torque of 10 N·m (89 lb in)
information. If the actuator is damaged or the
c. Install a new sealing washer (27) to banjo bolt
actuator does not operate within the specified
(28). Install the banjo bolt assembly to hose
limits, the complete turbocharger must be
assembly (22) and install the remaining sealing
replaced.
washer (28). Install hose assembly (22) to boost
pressure chamber cover (29) finger tight.

d. Install tube assembly (22) into clip (21).

e. Install a new sealing washer (25) to banjo bolt

(24). Install the banjo bolt assembly to hose
assembly (6) and install the remaining sealing
washer (24). Install hose assembly (6) to boost
pressure chamber cover (29) finger tight.

f. Install the alternator and mounting bracket.

Refer to Disassembly and Assembly, “Alternator
- Remove and Install” for the correct procedure.

This document has been printed from SPI2. NOT FOR RESALE
52 UENR0624-03
Disassembly and Assembly Section

Illustration 87 g02862480 Illustration 88 g02859585

4. Clean the gasket surfaces of exhaust manifold

(19). If necessary, install studs (17) to exhaust
manifold (19) and turbocharger (11). Tighten the
studs to a torque of 15 N·m (133 lb in).
5. Position a new gasket (20) (not shown) onto
turbocharger (11).
6. Position turbocharger (11) onto exhaust manifold
(19) and install washers (16) and new nuts (15).
Tighten the nuts to a torque of 28 N·m (248 lb in).
Note: Do not use the actuator rod to lift the
turbocharger.

Illustration 89 g02859796

7. If necessary install new O-ring seals (8) onto tube

assembly (9). Install tube assembly (9) into the
cylinder block.
8. Position a new gasket (7) (not shown) onto tube
assembly (9).
9. Position tube assembly (9) onto the turbocharger.
Install bolts (10) to tube assembly (9). Tighten the
bolts to a torque of 10 N·m (89 lb in).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 53
Disassembly and Assembly Section

10. Lubricate the bearings of the turbocharger with 19. Connect the hose assemblies to the turbocharger
clean engine oil through the oil inlet port. Rotate inlet and the turbocharger outlet. Tighten the hose
the shaft of the turbocharger in order to distribute clamps securely.
the lubricant.
11. If necessary, install a new sealing washer (13)
onto connection (14). Install connection assembly
(14) to the cylinder block. Tighten the connection
assembly to a torque of 22 N·m (195 lb in).
12. Position tube assembly (12) onto connection
assembly (14). Loosely install nut (15).
13. Position a new sealing washer (1) (not shown)
onto banjo bolt (2). Install banjo bolt (2) onto tube
assembly (12) and install remaining new sealing
washer (1) to banjo bolt (2). Tighten the banjo bolt
to torque of 35 N·m (26 lb ft).
14. Tighten nut (15) to torque of 25 N·m (221 lb in).
15. Connect hose assembly (6) to the wastegate
actuator. Tighten the hose clamp securely.
16. Connect hose assembly (4) to the turbocharger.
Tighten the hose clamp securely.

Illustration 90 g02862956

17. Tighten banjo bolt (28) to a torque of 12 N·m

(106 lb in).

Note: Ensure that the hose assembly does not come

into contact with any other engine components.

18. Tighten banjo bolt (24) to a torque of 12 N·m

(106 lb in).

Note: Ensure that the hose assembly does not come

into contact with any other engine components.

This document has been printed from SPI2. NOT FOR RESALE
54 UENR0624-03
Disassembly and Assembly Section

20. Install the flexible exhaust pipe to the

turbocharger. Refer to Disassembly and
Assembly, “Flexible Exhaust Pipe - Remove and
Install” for the correct procedure.

i05270685

Wastegate Solenoid - Remove

and Install

Removal Procedure
Start By:
a. Turn the battery disconnect switch to the OFF
position.

Illustration 92 g02720986

1. Disconnect harness assembly (4) from wastegate

solenoid (5).
2. Place temporary marks on all hose assemblies in
order to identify the position on the wastegate
regulator (5).
3. Remove hose clamp (2). Disconnect hose
assembly (3) from wastegate solenoid (5).
4. Remove hose clamp (6). Disconnect hose
assembly (7) from wastegate solenoid (5).
5. Remove hose clamp (9). Disconnect hose
assembly (8) from wastegate solenoid (5).
6. Remove Allen head bolts (1) and remove the
wastegate solenoid from bracket (10).
7. If necessary, remove bolt (11) and remove bracket
Illustration 91 g02720973
(10) from the water temperature regulator housing.

Installation Procedure
1. Ensure that all components of wastegate regulator
are clean and free from wear and damage. If
necessary, replace the wastegate regulator as an
assembly if any of the components are worn or
damaged.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 55
Disassembly and Assembly Section

5. Position hose (8) onto the wastegate solenoid.

Tighten hose clamp (9) securely.
6. Position hose (7) onto the wastegate solenoid.
Tighten hose clamp (6) securely.
7. Position hose (3) onto the wastegate solenoid.
Tighten hose clamp (2) securely.
8. Ensure that the hoses do not come into contact
with any other engine components.
9. Connect harness assembly (4) to the wastegate
solenoid.
End By:
a. Turn the battery disconnect switch to the ON
position.

i05291333

Exhaust Gas Recirculation

Illustration 93 g02721016
Valve - Remove and Install

Removal Procedure
Start By:
a. Drain the coolant from the cooling system into
a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change” for the
correct procedure.

Sulfuric Acid Burn Hazard may cause serious

personal injury or death.
The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sul-
fur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid
may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin
Illustration 94 g02720973 and clothing on contact. Always wear the appro-
priate personal protective equipment (PPE) that
2. If necessary, position bracket (10) onto the water is noted on a material safety data sheet (MSDS)
temperature regulator housing. Ensure that the for sulfuric acid. Always follow the directions for
bracket is correctly located onto the spigot in first aid that are noted on a material safety data
Position (A). sheet (MSDS) for sulfuric acid.

3. Install bolt (11) and tighten the bolt to a torque of

10 N·m (89 lb in). NOTICE
Keep all parts clean from contaminants.
4. Position wastegate solenoid (5) onto bracket (10).
Install Allen head bolts (1) to wastegate solenoid Contaminants may cause rapid wear and shortened
(5). Tighten Allen head bolts (1) to a torque of component life.
10 N·m (89 lb in).

This document has been printed from SPI2. NOT FOR RESALE
56 UENR0624-03
Disassembly and Assembly Section

Note: Plug or cap all open ports with new plugs or

caps.

1. If necessary, remove the diesel particulate

mounting bracket. Refer to Disassembly and
Assembly, “Support and Mounting (CEM) -
Remove and Install” for the correct procedure.

Illustration 95 g02912798

Illustration 96 g02898616

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 57
Disassembly and Assembly Section

Installation Procedure

Sulfuric Acid Burn Hazard may cause serious

personal injury or death.
The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sul-
fur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid
may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin
and clothing on contact. Always wear the appro-
priate personal protective equipment (PPE) that
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for
first aid that are noted on a material safety data
sheet (MSDS) for sulfuric acid.

NOTICE
Illustration 97 g02898617 Ensure that wiring harness are correctly routed and
the cable straps are not over tightened. Over tighten-
2. If necessary, remove bolts (1) and heat shield (2) ing of the cable straps will damage the wiring harness
from exhaust gas recirculation (EGR) valve (4). convoluting.

3. Slide the locking tab into the unlocked position and

disconnect harness assembly (3) from EGR valve NOTICE
(4). Keep all parts clean from contaminants.
4. Loosen clamp (6) and position the clamp away Contaminants may cause rapid wear and shortened
from EGR valve (4). component life.
5. Disconnect hose assembly (5) from EGR valve (4).
1. Ensure that all components are clean and free
6. Remove bolt (18) from the bracket for tube from wear and damage. If necessary, replace any
assembly (19). components that are worn or damaged.
7. Remove bolt (20) and tube assembly (19) from
EGR valve (4).
8. Remove O-ring seal (21) (not shown).
9. If necessary, slide hose clamp (17) along hose
(16). Disconnect tube (19) from hose (16).
10. Apply releasing fluid prior to and during the
removal of bolts (12) and bolts (14).
11. Remove bolts (12) and remove bolts (14).
Remove flexible tube assembly (13) from the
exhaust manifold.
12. Remove bolts (11) from EGR valve (4).
Note: Note the position of different length bolts.

13. Remove from EGR valve (4) from the induction

manifold.
14. If necessary, remove bolt (9) and remove tube
assembly (7) from EGR valve (4). Remove O-ring
seal (8) (not shown).

This document has been printed from SPI2. NOT FOR RESALE
58 UENR0624-03
Disassembly and Assembly Section

Note: Ensure that the bolts are installed into the

correct position.

8. If necessary, install tube (19) to hose (16). Slide

hose clamp (17) into position and tighten securely.
9. Install new O-ring seals (21) (not shown) to tube
assembly (19).
10. Install tube assembly (19) to EGR valve (4).
11. Install bolt (18) and bolt (20) finger tight. Tighten
the bolt
12. Tighten bolt (20) to a torque of 10 N·m (89 lb in).
13. Tighten bolt (18) to a torque of 25 N·m (221 lb in)
.
14. Position new gasket (15) onto flexible tube
assembly (13).
15. Position flexible tube assembly (13) onto the
exhaust manifold. Install bolts (14) finger tight.
Illustration 98 g02898617
Note: Ensure that the flexible tube assembly can
move freely.

16. Position gasket (10) (not shown) between flexible

tube assembly (13) and EGR valve (4). Install
bolts (12) finger tight.

Note: Ensure that the flexible tube assembly can

move freely and the gasket is correctly positioned.

17. Tighten bolts (12) to a torque of 25 N·m

(221 lb in).
18. Tighten bolts (14) to a torque of 25 N·m
(221 lb in).
19. Install hose assembly (5) onto pipe (7). Position
hose clamp and tighten the clamp securely.

Illustration 99 g02898616

2. If necessary, install new O-ring seal (8) (not

shown) to Exhaust Gas Recirculation (EGR) valve
(4). Install tube assembly (7) to EGR valve (4).
3. Install new clamp (6) to EGR valve (4).
4. Position a new clamp (6) onto EGR valve (4).
5. Install bolts (11) to EGR valve (4) finger tight.
6. Position clamp (6). Tighten the clamp to a torque of
10 N·m (89 lb in).
7. Tighten bolts (11) to a torque of 25 N·m (221 lb in).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 59
Disassembly and Assembly Section

The ends of the bellows are very sharp. Injury

could occur if the bellows are not handled
properly. Handle the bellows by the convolutions.

NOTICE
The bellows must be supported at all times when the
bellows are not installed in the application. Failure to
support the bellows adequately could result in the
failure of the bellows. Do not use power tools in order
to disassemble or assemble any part of the flexible
exhaust system.
The alignment of the bellows is important. Incorrect
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the uniformity of the spacing between the
convolutions on the bellows.
Inspect the bellows for damage prior to installation. If
there is any damage to the convolutions, discard the
bellows. If there is any difficulty in installation after
the repair, discard the bellows.
Illustration 100 g02912798

20. If necessary, position heat shield (2) onto EGR

valve (4) and install bolts (1). Tighten the bolts to a
torque of 10 N·m (89 lb in).
21. Connect harness assembly (3) to EGR valve (3)
and slide the locking tab into the locked position.
22. If necessary, install the diesel particulate
mounting bracket. Refer to Disassembly and
Assembly, “Support and Mounting (CEM) -
Remove and Install” for the correct procedure.
End By:
a. Fill the cooling system. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
- Change” for the correct procedure.
b. When the EGR valve is cleaned or a new
replacement is installed, it will be necessary to
use the Electronic Service Tool (EST) in order
to perform the “ EGR Valve Learn Reset””
procedure. Illustration 101 g02354623
Typical example
i05270693

Flexible Exhaust Pipe - 1. The lateral alignment of the bellows is critical. All
the components must be assembled in the same
Remove and Install alignment as prior to disassembly. The
components that require correct lateral alignment
are shown at Positions (A, B, and C).

Removal Procedure for the Flexible

Exhaust Pipe as an Assembly

This document has been printed from SPI2. NOT FOR RESALE
60 UENR0624-03
Disassembly and Assembly Section

Disassembly Procedure for the

Flexible Exhaust Pipe Assembly
1. If any part of the flexible exhaust pipe assembly is
damaged. Refer to Disassembly and Assembly,
“Inspection of Parts” for more information.

Illustration 102 g02354616

Typical example

2. Follow Steps 2.a through Step 2.d in order to

remove the flexible exhaust as an assembly from
the Clean Emission Module (CEM) and the
turbocharger.

a. Use suitable material in order to encase flexible

exhaust pipe (3). Encasing the flexible exhaust
pipe will prevent damage of the bellows. Encase
bellows for the flexible exhaust pipe (3) between
Position (D) and Position (E). Use cable straps
Illustration 103 g02469602
in order to retain the suitable material.
Typical example
Note: Ensure that the flexible exhaust pipe is
supported at all times. 2. If necessary, follow Step 2.a through Step 2.d in
order to disassemble the flexible exhaust pipe
b. Loosen ball clamp (2) from the flexible exhaust assembly.
pipe assembly.
a. Make temporary marks in Position (F) on all
c. Loosen the bolt for V-band clamp (4). components of bellows (3) and tube assembly
(6) in order to show correct orientation and
Note: If V-band clamp (4) remain tight on the alignment.
flanges, apply releasing fluid on the V-band clamp.
Lightly tap the bolt on the V-band clamp with a soft Note: Do not scribe the components in order to
faced hammer in order to assist removal. Do not mark the position of the flexible exhaust pipe
use a prybar in order to remove V-band clamp. assembly.

d. Remove the assembly of the flexible exhaust b. Loosen clamp (7) and remove tube assembly
pipe from the CEM (1) and the turbocharger (5). (6) from bellows (3).
Note: Ensure that the assembly of the flexible c. Loosen ball clamp (8) and remove the ball
exhaust pipe is supported as the clamps are clamp.
removed.
d. Remove bellows (3) from elbow (9).
Note: Ensure that the flexible exhaust pipe bellows
are not subjected to any undue stress.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 61
Disassembly and Assembly Section

Assembly Procedure for the a. If original bellows are to be reinstalled, place the
Flexible Exhaust Pipe Assembly internal area in Position (G) of the bellows on a
suitable support. Use Tooling (A) in order to drill
Table 14 a pilot hole through the spot weld in Position (H)
Required Tools on clamp (7).
Tool Part Number Part Description Qty Note: Do not center punch the spot weld on
Drill Bit clamp (7).
A - 1
3 mm (0.118 inch) Ø
b. Use Tooling (B) in order to drill out the spot weld
Drill Bit
B -
6.5 mm (0.256 inch) Ø
1 in Position (H) on clamp (7). Remove clamp (7)
from the bellows.

1. Ensure that all components of the flexible exhaust c. Remove all burrs from the internal and external
pipe assembly are clean and free from wear and areas of bellows (3). Ensure that debris does
damage. If necessary, replace any components of not enter the bellows.
the flexible exhaust pipe assembly that are worn
or damaged. Refer to Disassembly and Assembly,
“Inspection of Parts” for more information.

Illustration 105 g02354619

Typical example

d. Position a new clamp (7) onto bellows (3). Hand

tighten clamp (7). Ensure that the center of the
clamp is central to Slots (J) on the bellows. The
clamp must be flush with the end of bellows (3).
Note: Ensure that the bellows are not subjected to
any undue stress.
Illustration 104 g02469603
Typical example e. If new bellows (3) are installed, clamp (7) will be
pre-installed to the bellows.
2. If the flexible exhaust pipe assembly was
Note: Ensure that the bellows are not subjected to
previously disassembled. Follow Step 2.a through any undue stress.
Step 2.i in order to assemble the flexible exhaust
pipe assembly. f. Position a new ball clamp (8) onto elbow (9).
NOTICE g. Position bellows (3) onto elbow (9). Align the
Use the correct personal protective equipment when
removing the clamp. bellows and the elbow with temporary marks.

h. Tighten ball clamp (8) hand tight.

This document has been printed from SPI2. NOT FOR RESALE
62 UENR0624-03
Disassembly and Assembly Section

Note: Ensure that the bellows are not subjected to

NOTICE
any undue stress. Failure to reinstall the bellows into the original posi-
tion will result in a failure of the bellows and possible
i. Install tube assembly (6), align the tube emissions failure.
assembly with the temporary marks on the
bellows. Tighten clamp (7) hand tight.
7. Align the assembly of the flexible exhaust pipe with
Installation Procedure for the the temporary marks. Ensure that bellows (3) are
not subjected to any undue stress.
Flexible Exhaust Pipe as an
Assembly
NOTICE
Inspect the bellows for damage prior to installation. If
there is any damage to the convolutions, discard the
bellows. If there is any difficulty in installation after
the repair, discard the bellows.

1. Check the flexible exhaust pipe assembly for

damage. Refer to Disassembly and Assembly,
“Inspection of Parts” for more information.

Illustration 107 g02250353

Typical example

8. If a new bellows assembly has been installed,

ensure that all components of the flexible exhaust
pipe are not subjected to any undue stress and are
correctly aligned.
9. Tighten ball clamp (2) to a torque of 35 N·m
(26 lb ft).
10. Tighten clamp (7) to a torque of 55 N·m (40 lb ft).

Illustration 106 g02354616 11. Tighten ball clamp (8) to a torque of 35 N·m
Typical example (26 lb ft).
12. Tighten V-band clamp (4) to a torque of 25 N·m
2. Position a new ball clamp (2) onto the flexible (221 lb in).
exhaust pipe assembly.
3. Install V-band clamp (4) onto turbocharger (5).
4. Install assembly of the flexible exhaust pipe onto
CEM (1) and turbocharger (5).
Note: Ensure that the assembly of the flexible
exhaust pipe is supported at all times.

5. Tighten V-band clamp (4) hand tight.

6. Tighten ball clamp (2) hand tight.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 63
Disassembly and Assembly Section

13. Cut cable straps from the suitable material that

was encasing bellows (3) between Position (A)
and Position (B). Remove the suitable material
from bellows (3).

i05270715

Exhaust Manifold - Remove

and Install

Removal Procedure
Start By:
a. Remove the turbocharger. Refer to
Disassembly and Assembly, “Turbocharger -
Remove” for the correct procedure.

Illustration 108 g02725206

This document has been printed from SPI2. NOT FOR RESALE
64 UENR0624-03
Disassembly and Assembly Section

Illustration 109 g02725251

Tighten sequence of exhaust manifold

1. Remove tube assembly (1). Refer to Disassembly

and Assembly, “Air Control Valve - Remove and
Install” for the correct procedure.
2. Loosen nuts (5) in reverse numerical order. Refer
to Illustration 109 .
Note: Loosening the bolts in reverse numerical order
will help prevent distortion of the exhaust manifold.

3. Remove nuts (5) and remove exhaust manifold (3)

from the cylinder head.
4. Remove exhaust manifold gasket (6) (not shown).
5. If necessary, remove studs (2) from the exhaust
manifold.
6. If necessary, remove studs (4) from the cylinder
head.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 65
Disassembly and Assembly Section

Installation Procedure
1. Ensure that the exhaust manifold is clean and free
from damage. If necessary, replace the exhaust
manifold. Clean the gasket surface of the cylinder
head.

Illustration 110 g02725206

Illustration 111 g02725251

2. If necessary, install studs (2) to exhaust manifold Note: Ensure that the exhaust manifold gasket is
(3). Tighten the stud to a torque of 18 N·m correctly oriented.
(159 lb in).
4. Position exhaust manifold (3) onto studs (4).
3. Position a new exhaust manifold gasket (6) (not
shown) onto studs (4). 5. Install nuts (5) to studs (4) finger tight. Tighten the
nuts in the sequence that is shown in Illustration
111 in two stages.

This document has been printed from SPI2. NOT FOR RESALE
66 UENR0624-03
Disassembly and Assembly Section

Tighten the nuts to an initial torque of 10 N·m

(89 lb in). NOTICE
Do not strike any part of the assembly of the Diesel
Tighten the nuts to a final torque of 27 N·m Particulate Filter (DPF). Do not allow any object to
(239 lb in). contact the internal element of the DPF. If the internal
element of the DPF becomes damaged, the assem-
6. Install tube assembly (1). Refer to Disassembly bly must be replaced.
and Assembly, “Air Control Valve - Remove and
Install” for the correct procedure.
End By:
a. Install the turbocharger to the exhaust
manifold. Refer to Disassembly and Assembly,
“Turbocharger - Install” for the correct
procedure.

i05270721

Diesel Particulate Filter -

Remove
(Through Flow Diesel Particulate
Filter)

S/N: JR11–Up
S/N: JS11–Up
Illustration 112 g03020017
S/N: JT11–Up

Removal Procedure
Table 15
Required Tools

Tool Part Number Part Description Qty

A - Bellows Protector 1

Wear goggles, gloves, protective clothing, and a

National Institute for Occupational Safety and
Health (NIOSH) approved P95 or N95 half-face
respirator when handling a used Diesel Particu-
late Filter or Catalytic Converter Muffler. Failure
to do so could result in personal injury.

The muffler, catalytic converter/muffler, and die-

sel particulate filter will become extremely hot Illustration 113 g03013138
during engine operation. A hot muffler, catalytic Typical example
converter/muffler and diesel particulate filter can
cause serious burns. Allow adequate cooling
time before working on or near the muffler, cata-
lytic converter/muffler and diesel particulate
filter.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 67
Disassembly and Assembly Section

8. Disconnect pressure sensor tube assembly (5)

from the DPF.
Note: Make temporary identification marks on the
tube assembly for assembly purposes.

9. Disconnect pressure sensor tube assembly (7)

from the DPF.

Note: Make temporary identification marks on the

tube assembly for assembly purposes.

10. Remove bolts (10) from clamps (11). Remove the

clamps from the DPF in order to allow removal of
the DPF.
11. Attach a suitable lifting device to the DPF . The
weight of the DPF is approximately 15 kg (33 lb).
12. Use the suitable lifting device in order to remove
the DPF from bracket (12).
13. If necessary, remove temperature sensor (3) and
Illustration 114 g03013381 temperature sensor (9). Refer to Disassembly and
Typical example Assembly, “Temperature Sensor (DPF) - Remove
and Install” for the correct procedure.
1. If necessary, remove the Original Equipment
Manufacturer's (OEM) exhaust tube assembly i05315169
from outlet (4). Refer to the OEM for the correct
procedure. Diesel Particulate Filter -
2. Make temporary alignment marks on DPF (6) and Remove
clamps (11) in Positions (A), (B), (C) and (D) in
order to ensure that the DPF is installed in the (Wall Flow Diesel Particulate
original position. Filter)
3. If the DPF is installed onto the flywheel housing,
install Tooling (A) in Position (E) in order to
maintain correct alignment of flexible exhaust pipe
assembly (8).
Removal Procedure
Table 16
4. Disconnect the flexible exhaust pipe assembly (8). Required Tools
Refer to Disassembly and Assembly, “Flexible
Exhaust Pipe - Remove and Install” for the correct Tool Part Number Part Description Qty
procedure. A - Bellows Protector 1
5. Make a temporary mark on Diesel Particulate Filter
(DPF) (6) in order to show the direction of the flow
for the exhaust gases.
6. Disconnect the wiring harness from connection (1) Wear goggles, gloves, protective clothing, and a
National Institute for Occupational Safety and
for temperature sensor (9). Health (NIOSH) approved P95 or N95 half-face
respirator when handling a used Diesel Particu-
Note: Make temporary identification marks on all
late Filter or Catalytic Converter Muffler. Failure
connections for assembly purposes. to do so could result in personal injury.
7. Disconnect the wiring harness from connection (2)
for temperature sensor (3)
Note: Make temporary identification marks on all
connections for assembly purposes.

This document has been printed from SPI2. NOT FOR RESALE
68 UENR0624-03
Disassembly and Assembly Section

The muffler, catalytic converter/muffler, and die-

sel particulate filter will become extremely hot
during engine operation. A hot muffler, catalytic
converter/muffler and diesel particulate filter can
cause serious burns. Allow adequate cooling
time before working on or near the muffler, cata-
lytic converter/muffler and diesel particulate
filter.

NOTICE
Do not strike any part of the assembly of the Diesel
Particulate Filter (DPF). Do not allow any object to
contact the internal element of the DPF. If the internal
element of the DPF becomes damaged, the assem-
bly must be replaced.

Illustration 116 g03370799

Typical example

1. If necessary, remove the Original Equipment

Manufacturer's (OEM) exhaust tube assembly
from outlet (6). Refer to the OEM for the correct
procedure.
2. Make temporary alignment marks on DPF (4) and
clamps (5) in Positions (A), (B), (C) and (D) in
order to ensure that the DPF is installed in the
original position.
3. If the DPF is installed onto the flywheel housing,
install Tooling (A) in Position (E) in order to
maintain correct alignment of flexible exhaust pipe
assembly (12).
4. Disconnect the flexible exhaust pipe assembly
Illustration 115 g03370358 (12). Refer to Disassembly and Assembly,
Flexible exhaust pipe assembly with bellows “Flexible Exhaust Pipe - Remove and Install” for
protector Tooling (A) in position. the correct procedure.
Typical example
Note: Do not remove the bellows protector prior to
installing the flexible exhaust pipe assembly.

5. Make a temporary mark on Diesel Particulate Filter

(DPF) (4) in order to show the direction of the flow
for the exhaust gases.
6. Disconnect the wiring harness from connection (1)
for temperature sensor (2).
Note: Make temporary identification marks on all
connections for assembly purposes.

7. Disconnect the wiring harness from connection

(11) for temperature sensor (3)

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 69
Disassembly and Assembly Section

Note: Make temporary identification marks on all

connections for assembly purposes.
Wear goggles, gloves, protective clothing, and a
8. Disconnect pressure sensor tube assembly (7) National Institute for Occupational Safety and
from the DPF. Health (NIOSH) approved P95 or N95 half-face
respirator when handling a used Diesel Particu-
Note: Make temporary identification marks on the late Filter or Catalytic Converter Muffler. Failure
tube assembly for assembly purposes. to do so could result in personal injury.
9. Disconnect pressure sensor tube assembly (9)
from the DPF. NOTICE
Do not strike any part of the assembly of the Diesel
Note: Make temporary identification marks on the Particulate Filter (DPF). Do not allow any object to
tube assembly for assembly purposes. contact the internal element of the DPF. If the internal
element of the DPF becomes damaged, the assem-
10. Remove bolts (8) from clamps (5). Remove the bly must be replaced.
clamps from the DPF in order to allow removal of
the DPF.
1. Ensure that all components are clean and free
11. Attach a suitable lifting device to the DPF . The from wear and damage. If necessary, replace any
weight of the DPF is approximately 15 kg (33 lb). components that are worn or damaged.
12. Use the suitable lifting device in order to remove 2. If the flexible exhaust pipe was removed as an
the DPF from brackets (10). assembly, refer to Disassembly and Assembly,
“Flexible Exhaust Pipe - Remove and Install” for
13. If necessary, remove temperature sensor (2) and
the correct installation procedure.
temperature sensor (3). Refer to Disassembly and
Assembly, “Temperature Sensor (DPF) - Remove
and Install” for the correct procedure.

i05270723

Diesel Particulate Filter -

Install
(Through Flow Diesel Particulate
Filter)

S/N: JR11–Up
S/N: JS11–Up
S/N: JT11–Up

Installation Procedure
Table 17
Required Tools

Tool Part Number Part Description Qty

A - Bellows Protector 1

This document has been printed from SPI2. NOT FOR RESALE
70 UENR0624-03
Disassembly and Assembly Section

Illustration 119 g03022697

Illustration 117 g03017439
3. If necessary, install the temperature sensors (3)
and temperature sensor (9) into the DPF. Refer to
Disassembly and Assembly, “Temperature Sensor
(DPF) - Remove and Install” for the correct
procedure.
4. Position a new V-band clamp onto flexible exhaust
pipe (8).
5. Attach a suitable lifting device to the assembly of
the Diesel Particulate Filter (DPF) (6). The weight
of the DPF is approximately 15 kg (33 lb).
6. Use the suitable lifting device in order to install the
DPF to mounting bracket (12). Ensure that the
flexible exhaust pipe is correctly seated onto the
turbocharger and DPF with the alignment pin (13)
(not shown) fully engaged.

Note: Ensure that the exhaust gases flow in the

direction of temporary mark.

7. Remove the suitable lifting device from the

Illustration 118 g03017436 assembly of the DPF.
8. Position clamps (11) onto DPF (6). Loosely install
bolts (10).
9. Loosely install the Original Equipment
Manufacturer's (OEM) exhaust pipe assembly to
outlet section (4) of the DPF.
10. Align the temporary alignment marks on DPF (6)
and clamps (11) in Positions (A), (B), (C) and (D).

Note: Ensure that the flexible exhaust pipe bellows

are not subjected to any undue stress.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 71
Disassembly and Assembly Section

11. If a new DPF is being installed, the DPF must be End By:
aligned using flexible exhaust pipe (8) as the
reference point. a. If the DPF has had an ash service, it will be
necessary to use the electronic service tool in
order to perform the “ DPF Ash Cleaning””
Note: Ensure that the flexible exhaust pipe bellows
procedure.
are not subjected to any undue stress.
b. If the DPF required replacing and a new DPF
12. Position the V-band clamp onto the DPF. Tighten has been installed, it will be necessary to use
the flexible exhaust pipe clamp. Refer to the electronic service tool in order to perform
Disassembly and Assembly, “Flexible Exhaust the “ DPF Replacement Reset”” procedure.
Pipe - Remove and Install” for the correct
procedure. i05315171

13. Tighten the OEM exhaust pipe assembly to the

outlet section of the DPF. Refer to the OEM for the
Diesel Particulate Filter -
correct procedure. Install
14. Ensure that the DPF is installed in the original (Wall Flow Diesel Particulate
position and all of the temporary alignment marks Filter )
are aligned.

Note: Ensure that the flexible exhaust pipe bellows

are not subjected to any undue stress.
Installation Procedure
15. Tighten bolts (10) evenly in three stages. Table 18
Required Tools
Tighten bolts (10) to an initial torque of 8 N·m
(71 lb in) Tool Part Number Part Description Qty

Tighten bolts (10) to a secondary torque of 16 N·m A - Bellows Protector 1

(141.6 lb in)
Tighten bolts (10) to a final torque of 25 N·m
(221 lb in).
Wear goggles, gloves, protective clothing, and a
16. If necessary, remove Tooling (A) from flexible National Institute for Occupational Safety and
exhaust pipe (8). Health (NIOSH) approved P95 or N95 half-face
17. Connect the wiring harness assembly to respirator when handling a used Diesel Particu-
late Filter or Catalytic Converter Muffler. Failure
connection (1) on temperature sensor (9). to do so could result in personal injury.
18. Connect the wiring harness assembly to
connection (2) on temperature sensor (3).
NOTICE
19. Connect the pressure sensor tube assembly (5) Do not strike any part of the assembly of the Diesel
to the DPF. Tighten the connection to a torque of Particulate Filter (DPF). Do not allow any object to
25 N·m (221 lb in). contact the internal element of the DPF. If the internal
element of the DPF becomes damaged, the assem-
20. Connect the pressure sensor tube assembly (7) bly must be replaced.
to the DPF. Tighten the connection to a torque of
30 N·m (265 lb in). 1. Ensure that all components are clean and free
from wear and damage. If necessary, replace any
components that are worn or damaged. Refer to
Disassembly and Assembly, “Inspection of Parts”
for the correct procedures.
2. If the flexible exhaust pipe was removed as an
assembly, refer to Disassembly and Assembly,
“Flexible Exhaust Pipe - Remove and Install” for
the correct installation procedure.

This document has been printed from SPI2. NOT FOR RESALE
72 UENR0624-03
Disassembly and Assembly Section

6. Use the suitable lifting device in order to install the

DPF to mounting bracket (10). Ensure that the
flexible exhaust pipe is correctly seated onto the
turbocharger and DPF with the alignment pin (not
shown) fully engaged.

Note: Ensure that the exhaust gases flow in the

direction of temporary mark.

7. Remove the suitable lifting device from the

assembly of the DPF.
8. Position clamps (5) onto DPF (4). Loosely install
bolts (8).
9. Loosely install the Original Equipment
Manufacturer's (OEM) exhaust pipe assembly to
outlet section (6) of the DPF.
10. Align the temporary alignment marks on DPF (4)
and clamps (5) in Positions (A), (B), (C) and (D).

Illustration 120 g03372061

Note: Ensure that the flexible exhaust pipe bellows
are not subjected to any undue stress.

11. If a new DPF is being installed, the DPF must be

aligned using flexible exhaust pipe (12) as the
reference point.

Note: Ensure that the flexible exhaust pipe bellows

are not subjected to any undue stress.

12. Position the V-band clamp onto the DPF. Tighten

the flexible exhaust pipe clamp. Refer to
Disassembly and Assembly, “Flexible Exhaust
Pipe - Remove and Install” for the correct
procedure.
13. Tighten the OEM exhaust pipe assembly to the
outlet section of the DPF. Refer to the OEM for the
correct procedure.
14. Ensure that the DPF is installed in the original
position and all of the temporary alignment marks
are aligned.

Note: Ensure that the flexible exhaust pipe bellows

Illustration 121 g03372062
are not subjected to any undue stress.
3. If necessary, install the temperature sensors (3) 15. Tighten bolts (8) evenly in three stages.
and temperature sensor (9) into the DPF. Refer to
Disassembly and Assembly, “Temperature Sensor Tighten bolts (8) to an initial torque of 8 N·m
(DPF) - Remove and Install” for the correct (71 lb in)
procedure. Tighten bolts (8) to a secondary torque of 16 N·m
4. Position a new V-band clamp onto flexible exhaust (141.6 lb in)
pipe (12). Tighten bolts (8) to a final torque of 25 N·m
5. Attach a suitable lifting device to the assembly of (221 lb in).
the Diesel Particulate Filter (DPF) (4). The weight 16. If necessary, remove Tooling (A) from flexible
of the DPF is approximately 15 kg (33 lb). exhaust pipe (12).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 73
Disassembly and Assembly Section

Note: Do not start the engine with the bellows End By:
protector in place.
a. If the DPF has had an ash service, it will be
17. Connect the wiring harness assembly to necessary to use the electronic service tool in
order to perform the “ DPF Ash Cleaning””
connection (1) on temperature sensor (2).
procedure.
18. Connect the wiring harness assembly to
b. If the DPF required replacing and a new DPF
connection (11) on temperature sensor (3). has been installed, it will be necessary to use
19. Connect the pressure sensor tube assembly (9) the electronic service tool in order to perform
to the DPF. Tighten the connection to a torque of the “ DPF Replacement Reset”” procedure.
30 N·m (265 lb in).
i05270725
20. Connect the pressure sensor tube assembly (7)
to the DPF. Tighten the connection to a torque of Support and Mounting (CEM) -
30 N·m (265 lb in).
Remove and Install
(Option 3)

CEM Assembly Removal

Procedure
Start By:
a. Remove the DPF. Refer to Disassembly and
Assembly, “Diesel Particulate Filter - Remove ”
for the correct procedure.

Illustration 122 g03019496

Make temporary marks on all components on support

assemblies (1) and all bolts, in order to aide
alignment during installation.

This document has been printed from SPI2. NOT FOR RESALE
74 UENR0624-03
Disassembly and Assembly Section

CEM Assembly Installation

Procedure

Illustration 123 g03020379

1. Remove bolts (3) from bracket (2).

Illustration 124 g03019496
2. Remove bolts (7) from bracket (2).
3. Remove bolts (6) from bracket (2) and remove
bracket (2) from the engine. The weight of bracket
(2) is approximately 10 kg (22 lb).
4. If necessary, remove bolts (4) from bracket (5).
remove bracket (5) from the engine.
5. Remove bolts (8) from bracket (9) and remove
bracket (9) from the engine.

Illustration 125 g03020379

1. If necessary, using temporary marks position

bracket (5) onto the engine install bolts (4).
Tighten bolts (4) hand tight.
2. If necessary, using temporary marks position
bracket (9) onto the engine. Tighten bolts (8) hand
tight.
3. Position bracket (2) and loosely install bolts (3),
loosely install bolts (6), and loosely install bolts (7).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 75
Disassembly and Assembly Section

4. Using temporary marks align assembly (1) and End By:

tighten the bolts.
a. Install the DPF. Refer to Disassembly and
5. If necessary, tighten bolts (4) to a torque of 25 N·m Assembly, “Diesel Particulate Filter - Install ”
(221 lb in). for the correct procedure.
6. If necessary, tighten bolts (8) to a torque of 25 N·m i05270728
(221 lb in).
7. Tighten bolts (6) to a torque of 25 N·m (221 lb in). Support and Mounting (CEM) -
8. Tighten bolts (7) to a torque of 25 N·m (221 lb in). Remove and Install
9. Tighten bolts (3) to a torque of 45 N·m (33 lb ft). (Option 2)

CEM Assembly Removal

Procedure
Start By:
a. Remove the DPF. Refer to Disassembly and
Assembly, “Diesel Particulate Filter - Remove ”
for the correct procedure.

Illustration 126 g03017437

Make temporary marks on all components on both

support assemblies (1) and all bolts, in order to aide
alignment during installation.
1. Remove bolts (3) from bracket (2) and remove
bracket (2) from the engine.
2. Remove bolts (5) from bracket (4) and remove
bracket (4) from the engine.

This document has been printed from SPI2. NOT FOR RESALE
76 UENR0624-03
Disassembly and Assembly Section

CEM Assembly installation End By:

Procedure a. Install the DPF. Refer to Disassembly and
Assembly, “Diesel Particulate Filter - Install ”
for the correct procedure.

i05270751

Support and Mounting (CEM) -

Remove and Install
(Option 1)

CEM Assembly Removal

Procedure
Start By:
a. Remove the DPF. Refer to Disassembly and
Assembly, “Diesel Particulate Filter - Remove ”
for the correct procedure.

Illustration 127 g03017437

1. Position bracket (2) and loosely install bolts (3).

Position bracket (4) and loosely install bolts (5).
2. Using temporary marks, align bracket (2) and
tighten bolts (3) to a torque of 25 N·m (221 lb in)
3. Using temporary marks, align bracket (4) and
tighten bolts (5) to a torque of 25 N·m (221 lb in)

Illustration 128 g03013176

Typical example

Make temporary marks on all components on the

support assembly (1) and all bolts, in order to aide
alignment during installation.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 77
Disassembly and Assembly Section

CEM Assembly Installation

Procedure

Illustration 129 g03015096

Typical example

1. Remove bolts (2) from bracket (3). Illustration 130 g03013176

2. Remove bolts (4) from bracket (3).

3. Remove bolts (7) from bracket (3) and remove
bracket (3) from the engine. The weight of bracket
(3) is approximately 10 kg (22 lb).
4. If necessary, remove bolts (9) (not shown) and
remove bracket (8) from the engine.
5. If necessary, remove bolts (6) and remove bracket
(5) from the engine.

Illustration 131 g03015096

1. If necessary, using temporary marks position

bracket (8) and install bolts (9) (not shown).
Tighten bolts (9) hand tight.
2. If necessary, using temporary marks position
bracket (5) and install bolts (6). Tighten bolts (6)
hand tight.
3. Position bracket (3) and loosely install bolts (4)
loosely install bolts (2), and loosely install bolts (7).

This document has been printed from SPI2. NOT FOR RESALE
78 UENR0624-03
Disassembly and Assembly Section

4. Using temporary marks, align support assembly

(1) and tighten bolts.
5. Tighten bolts (9) to a torque of 25 N·m (221 lb in)
6. Tighten bolts (6) to a torque of 25 N·m (221 lb in)
7. Tighten bolts (2) to a torque of 45 N·m (33 lb ft)
8. Tighten bolts (4) to a torque of 25 N·m (221 lb in)
9. Tighten bolts (7) to a torque of 25 N·m (221 lb in)
End By:
a. Install the DPF. Refer to Disassembly and
Assembly, “Diesel Particulate Filter - Install ”
for the correct procedure.

i05270754

Inlet Manifold - Remove and

Install
Illustration 132 g02729114

Removal Procedure
Start By:
a. Remove the exhaust gas recirculation valve.
Refer to Disassembly and Assembly, “Exhaust
Gas Recirculation Valve - Remove and Install”
for the correct procedure.
b. Remove the exhaust cooler. Refer to
Disassembly and Assembly, “Exhaust Cooler
(NRS) - Remove and Install” for the correct
procedure.
c. Remove the exhaust back pressure sensor
bracket and tube assembly. Refer to
Disassembly and Assembly, “Pressure Sensor
(Exhaust Back Pressure) - Remove and Install”
for the correct procedure.
d. Remove the throttle valve. Refer to
Disassembly and Assembly, “Throttle Valve
(Intake Air) - Remove and Install” for the
correct procedure.
Illustration 133 g02919516

NOTICE
Keep all parts clean from contaminants. 1. Slide the locking tab into the unlocked position and
disconnect harness assembly (1) from the inlet
Contaminants may cause rapid wear and shortened manifold temperature and pressure sensor.
component life.
2. Position exhaust gas temperature connection (3)
away from bracket (2).
NOTICE
Plug the apertures in the cylinder head in order to 3. Remove bolts (7) from inlet manifold (6).
prevent the entry of loose parts into the engine. 4. Remove the inlet manifold from adaptor plate (10).
5. Remove gasket (8).
6. If necessary, remove studs (4) from inlet manifold
(5).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 79
Disassembly and Assembly Section

7. If necessary, remove diffuser (5) from inlet

manifold (6).
8. If necessary, follow Step 8.a through Step 8.d in
order to remove adaptor plate (10).

a. Remove the electronic unit injectors. Refer to

Disassembly and Assembly, “Electronic Unit
Injector - Remove” for the correct procedure.

b. Remove bolts (9) from adaptor plate (10).

c. Remove adaptor plate (10) from the cylinder

head.
d. Remove O-ring seals (11) (not shown).
Illustration 134 g02921858

Installation Procedure
Table 19
Required Tools

Tool Part Number Part Description Qty

Guide Stud
A - 2
M8 x 1.25mm by 90mm

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 135 g02922116

NOTICE
Remove the plugs that were installed during the dis-
2. If necessary, follow Step 2.a through Step 2.d in
assembly procedure prior to installing components.
Care must be taken to ensure that loose parts and order to install adaptor plate (10).
debris do not enter the engine.
a. Install new O-ring seals (11) into adaptor plate
(10).
1. Clean all gasket surfaces.
b. Position adaptor plate assembly (10) onto the
cylinder head.

c. Install bolts (9) finger tight. Tighten the bolts

evenly in the sequence that is shown in
Illustration 135 to a torque of 25 N·m (221 lb in).

d. Install the electronic unit injectors. Refer to

Disassembly and Assembly, “Electronic Unit
Injector - Install” for the correct procedure.

This document has been printed from SPI2. NOT FOR RESALE
80 UENR0624-03
Disassembly and Assembly Section

10. Install sealing washers (14) (not shown) and

banjo bolt (15) to tube and bracket assembly (13).
Refer to Disassembly and Assembly, “Pressure
Sensor (Exhaust Back Pressure) - Remove and
Install” for the correct procedure.
11. Position bracket (12) onto inlet manifold (6) and
install bolt (7) finger tight. Connect tube and
bracket assembly (13 ) onto bracket (12). Refer to
Disassembly and Assembly, “Pressure Sensor
(Exhaust Back Pressure) - Remove and Install” for
the correct procedure.
12. Remove Tooling (A).
13. Install remaining bolts (7) in available positions.

Illustration 136 g02922816

Illustration 138 g02924860

Illustration 137 g02922879

3. If necessary, install studs (4) into inlet manifold (6).

Tighten the studs to a torque of 5 N·m (44 lb in).
4. If necessary, install diffuser (5) into inlet manifold
(6).
5. Install Tooling (A) in Positions (X) in adaptor plate
assembly (10). Refer to Illustration 135 .
6. Position new gasket (8) onto Tooling (A).
7. Install inlet manifold (6) onto Tooling (A).
8. Position bracket (2) onto inlet manifold (6) and
install bolt (7) finger tight.
9. Position tube and bracket assembly (13) onto inlet Illustration 139 g02924916
manifold (6) and install bolt (7) finger tight.
14. Tighten bolts (7) in the sequence that is shown in
Illustration 138 to a torque of 27 N·m (239 lb in).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 81
Disassembly and Assembly Section

15. Install exhaust gas temperature connection (3)

NOTICE
into bracket (2). Keep all parts clean from contaminants.
16. Connect harness assembly (1) to the inlet Contaminants may cause rapid wear and shortened
manifold temperature and pressure sensor and component life.
slide the locking tab into the locked position.
End By: Note: The following procedure should be adopted in
a. Install the throttle valve. Refer to Disassembly order to remove the valve springs when the cylinder
and Assembly, “Throttle Valve (Intake Air) - head is installed to the engine. Refer to Disassembly
Remove and Install” for the correct procedure. and Assembly, “Inlet and Exhaust Valves - Remove
and Install” for the procedure to remove the valve
b. Install the remaining components for the springs from a cylinder head that has been removed
exhaust back pressure sensor. Refer to from the engine.
Disassembly and Assembly, “Pressure Sensor
(Exhaust Back Pressure) - Remove and Install” Note: Ensure that the appropriate piston is at the top
for the correct procedure. center position before the valve spring is removed.
Failure to ensure that the piston is at the top center
c. Install the exhaust cooler. Refer to position may allow the valve to drop into the cylinder
Disassembly and Assembly, “Exhaust Cooler
(NRS) - Remove and Install” for the correct bore.
procedure.
NOTICE
d. Install the exhaust gas recirculation valve. Plug the apertures for the push rods in the cylinder
Refer to Disassembly and Assembly, “Exhaust head in order to prevent the entry of loose parts into
Gas Recirculation Valve - Remove and Install” the engine.
for the correct procedure.

i05270759

Inlet and Exhaust Valve Personal injury can result from being struck by
parts propelled by a released spring force.
Springs - Remove and Install
Make sure to wear all necessary protective
equipment.

Removal Procedure Follow the recommended procedure and use all

recommended tooling to release the spring force.
Table 20
Required Tools
NOTICE
Tool Part Number Part Description Qty Ensure that the valve spring is compressed squarely
T400156 Housing 1
or damage to the valve stem may occur.
A(1)
T400157 Engine Turning Tool 1
1. Follow Steps 1.a through 1.d in order to position
T400158 Valve Spring Compressor 1 the appropriate piston at top center.
B
- Stud M6 by 25mm 1
a. Install Tooling (B) in position on the cylinder
(1) This Tool is used in the aperture for the electric starting motor. head in order to compress a valve spring for the
appropriate piston.
Start By:
b. Use Tooling (B) in order to compress valve
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and spring (3) and open the valve slightly.
Pushrod - Remove”.
Note: Do not compress the spring so that valve
Note: Either Tooling (A) can be used. Use the Tooling spring retainer (2) touches the valve stem seal.
that is most suitable.
c. Use Tooling (A) in order to rotate the crankshaft
carefully, until the piston touches the valve.

Note: Do not use excessive force to turn the

crankshaft. The use of force can result in bent
valve stems.

This document has been printed from SPI2. NOT FOR RESALE
82 UENR0624-03
Disassembly and Assembly Section

6. Repeat Steps 2 through 5 in order to remove the

d. Continue to rotate the crankshaft and gradually remaining valve spring from the appropriate
release the pressure on Tooling (B) until the cylinder.
piston is at the top center position. The valve is
7. Remove Tooling (B).
now held in a position that allows the valve
spring to be safely removed. Installation Procedure
Table 21
NOTICE
Do not turn the crankshaft while the valve springs are Required Tools
removed.
Tool Part Number Part Description Qty

T400156 Housing 1
Note: Valve springs must be replaced in pairs for the A(1)
inlet valve or the exhaust valve of each cylinder. If all T400157 Engine Turning Tool 1
valve springs require replacement, the procedure can
T400158 Valve Spring Compressor 1
be carried out on two cylinders at the same time. The
B
procedure can be carried out on the following pairs of - Stud M6 by 25mm 1
cylinders, 1 with 4 and 2 with 3. Ensure that all of the
valve springs are installed before changing from one C T400154 Valve Stem Seal Installer 1
pair of cylinders to another pair of cylinders. (1) This Tool is used in the aperture for the electric starting motor.

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE
Do not turn the crankshaft while the valve springs are
removed.

1. Inspect the valve springs for the correct length.

Refer to Specifications, “Cylinder Head Valves ”
for more information.

Illustration 140 g03001601

Typical example

2. Apply sufficient pressure to Tooling (B) in order to

allow removal of valve keepers (1). Remove valve
keepers (1).

Note: Do not compress the spring so that valve

spring retainer (2) touches the valve stem seal.

3. Slowly release the pressure on Tooling (B).

4. Remove valve spring retainer (2) and remove
valve spring (3).
5. If necessary, remove the valve stem seal in order
to remove valve spring seat (4).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 83
Disassembly and Assembly Section

7. Carefully release the pressure on Tooling (B).

Note: Ensure that the valve keepers are correctly
seated.

8. Repeat Steps 3 to 7 for the remaining valves.

The valve spring keepers can be thrown from the

valve when the valve spring compressor is re-
leased. Ensure that the valve spring keepers are
properly installed on the valve stem. To help pre-
vent personal injury, keep away from the front of
the valve spring keepers and valve springs dur-
ing the installation of the valves.

9. Remove Tooling (B).

End By:
a. Install the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Illustration 141 g03001601 Pushrod - Install”.
Typical example
i05270766
2. If necessary, valve spring seat (4) onto cylinder
head. Inlet and Exhaust Valves -
3. If necessary, use Tooling (C) in order to install a Remove and Install
new valve stem seal onto the valve guide.
Note: The outer face of the valve guide must be
clean and dry before installing the valve stem seal. Removal Procedure
4. Install valve spring (3) onto the cylinder head. Table 22
Position valve spring retainer (2) onto valve spring Required Tools
(3). Part Description Qty
Tool Part Number

T400158 Valve Spring Compressor 1

A
- Stud M6 by 25mm 1
Improper assembly of parts that are spring
loaded can cause bodily injury.
Start By:
To prevent possible injury, follow the established
assembly procedure and wear protective a. Remove the cylinder head. Refer to
equipment. Disassembly and Assembly, “Cylinder Head -
Remove”.
5. Install Tooling (B) in the appropriate position on the
cylinder head in order to compress the valve NOTICE
spring. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
NOTICE component life.
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
1. Clean the bottom face of the cylinder head. Check
the depth of the valves below the face of the
6. Apply sufficient pressure to Tooling (B) in order to
cylinder head before the valve springs are
install valve keepers (1). Install valve spring
removed. Refer to Specifications, “Cylinder Head
keepers (1).
Valves” for the correct dimensions.
Note: Do not compress the spring so that valve
spring retainer (2) touches the valve stem seal.

This document has been printed from SPI2. NOT FOR RESALE
84 UENR0624-03
Disassembly and Assembly Section

2. Place a temporary identification mark on the heads

of the valves in order to identify the correct
position. Inlet valves have a recess in the center of
the head.
Note: Do not stamp the heads of the valve. Stamping
or punching the heads of the valves could cause the
valves to fracture.

3. Use a suitable lifting device to position the cylinder

head with the valve springs upward. The weight of
the cylinder head is approximately 56 kg (125 lb).

Note: Ensure that the cylinder head is kept on a

clean, soft surface in order to prevent damage to the
machined face.

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective Illustration 143 g03003337
equipment. Typical example
Follow the recommended procedure and use all
4. Install Tooling (A) in position on the cylinder head
recommended tooling to release the spring force.
in order to compress the appropriate valve spring.

NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.

5. Apply sufficient pressure to Tooling (A) in order to

remove valve keepers (1).
Note: Do not compress the spring so that valve
spring retainer (2) touches valve stem seal (4).

6. Slowly release the pressure on Tooling (A).

7. Remove valve spring retainer (2). Remove valve
spring (3).
8. Repeat Steps 4 to 7 for the remaining valves.
9. Remove Tooling (A).
10. Remove valve stem seals (4) and valve spring
seats (4).
11. Use a suitable lifting device to carefully turn over
Illustration 142 g03003297
the cylinder head.
Typical example
12. Remove valves (6).

Installation Procedure
Table 23
Required Tools

Tool Part Number Part Description Qty

(continued)

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 85
Disassembly and Assembly Section

(Table 23, contd)

T400158 Valve Spring Compressor 1
A
- Stud M6 by 25mm 1

B T400154 Valve Stem Seal Installer 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. Ensure that all ports, all coolant
passages, and all lubrication passages in the
cylinder head are free from debris. Follow Steps 1.
a through 1.e in order to inspect the components
of the cylinder head assembly. Replace any
components that are worn or damaged.
Illustration 144 g03003337
a. Inspect the cylinder head for wear and for
damage. Refer to Systems Operation, Testing
2. Lubricate the stems of valves (6) with clean engine
and Adjusting, “Cylinder Head Inspect”.
oil. Install valves (6) in the appropriate positions in
b. Inspect the valve seats for wear and for the cylinder head. Check the depth of the valves
damage. Refer to Specifications, “Cylinder Head below the face of the cylinder head. Refer to
Valves” for further information. Systems Operation, Testing and Adjusting, “Valve
Depth - Inspect” for more information.
c. Inspect the valve guides for wear and for
damage. Refer to Specifications, “Cylinder Head 3. Use a suitable lifting device to carefully turn over
Valves” and Systems Operation, Testing and the cylinder head. The weight of the cylinder head
Adjusting, “Valve Guide - Inspect” for further is approximately 56 kg (125 lb).
information. Note: Ensure that all of the valves remain in place.
d. Inspect the valves for wear and for damage.
4. Install valve spring seats (5).
Refer to Specifications, “Cylinder Head Valves”.
5. Use Tooling (B) in order to install new valve stem
e. Inspect the valve springs for the correct length. seals (4) onto each of the valve guides.
Refer to Specifications, “Cylinder Head Valves”.
Note: The outer face of the valve guides must be
clean and dry before installing the valve stem seals.

6. Install valve spring (3) onto the cylinder head.

Position valve spring retainer (2) onto valve spring
(3).

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

This document has been printed from SPI2. NOT FOR RESALE
86 UENR0624-03
Disassembly and Assembly Section

End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install”.

i05270769

Inlet and Exhaust Valve Guides

- Remove and Install

Removal Procedure
Table 24
Required Tools

Tool Part Number Part Description Qty

A T400159 Valve Guide Driver 1

Start By:
Illustration 145 g03003297
Typical example a. Remove the inlet valves and the exhaust valves.
Refer to Disassembly and Assembly, “Inlet and
Exhaust Valves - Remove and Install”.
7. Install Tooling (A) in the appropriate position on the
cylinder head in order to compress valve spring
NOTICE
(3). Removal and installation of the valve guide and valve
seat must be carried out by personnel with the correct
NOTICE training. Also special machinery is required. For more
Ensure that the valve spring is compressed squarely information, refer to your authorized Perkins dealer.
or damage to the valve stem may occur.

8. Apply sufficient pressure to Tooling (A) in order to

install valve keepers (1).

Note: Do not compress the spring so that valve

spring retainer (2) touches valve stem seal (4).

The valve spring keepers can be thrown from the

9. Carefully release the pressure on Tooling (A).

10. Repeat Steps 6 to 9 for the remaining valves.
11. Remove Tooling (A) from the cylinder head.
Illustration 146 g03003636

1. Use Tooling (A) in order to remove valve guides (2)

from cylinder head (1).
2. Repeat the Step 1 for the remaining valve guides.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 87
Disassembly and Assembly Section

Installation Procedure
Table 25
Required Tools

Tool Part Number Part Description Qty

T400159 Valve Guide Driver 1

A
T400153 Stop Collar 1

B T400155 Valve Guide Reamer 1

NOTICE
Removal and installation of the valve guide and valve
seat must be carried out by personnel with the correct
training. Also special machinery is required. For more
information, refer to your authorized Perkins dealer. Illustration 148 g03005596

4. Check protrusion (X) of valve guides (2). The valve

NOTICE guides should protrude 8.5 ± 0.15 mm
Keep all parts clean from contaminants. (0.33465 ± 0.00591 inch) above the valve spring
recess. Refer to Specifications, “Cylinder Head
Contaminants may cause rapid wear and shortened
component life. Valves” for more information.
5. After installation of valve guides (2), the valve
1. Clean the parent bores in the cylinder head for the guides must be reamed to the finished diameter.
valve guides. Follow Steps 5.a through 5.c in order to ream the
valve guides.

a. Lubricate the bores of valve guides (2) with

clean engine oil.

b. Use Tooling (B) in order to ream the valve

guides. Ensure that even pressure is applied to
Tooling (B).

c. Ensure that the cylinder head is clean and free

from machining debris.
6. Check the finished diameter of valve guides (2).
Refer to Specifications, “Cylinder Head - Valves”
for more information.
7. Check the depths of the valves below the face of
the cylinder head. Refer to System Operation,
Testing and Adjusting, “Valve Depth - Inspect” for
more information.

Illustration 147 g03003639

2. Lubricate a new valve guide (2) and place the

valve guide in position. Carefully tap the valve
guide in order to start the installation. Use Tooling
(A) to install the valve guide into the cylinder head.
3. Repeat Step 2 for the remaining valve guides.

This document has been printed from SPI2. NOT FOR RESALE
88 UENR0624-03
Disassembly and Assembly Section

End By:
a. Install the inlet valves and the exhaust valves.
Refer to Disassembly and Assembly , “Inlet
and Exhaust Valves - Remove and Install”.

i05270770

Engine Oil Filter Base -

Remove and Install

Removal Procedure
Table 26
Required Tools

Tool Part Number Part Description Qty

A T400083 Filter Cartridge Tool 1

Illustration 149 g02675998

NOTICE
Keep all parts clean from contaminants. Typical example

Contaminants may cause rapid wear and shortened 1. Disconnect wiring harness assembly (1) from
component life. engine oil pressure switch (3).
2. Place a suitable container below engine oil filter (7)
NOTICE in order to catch any oil that might be spilled.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- 3. Use Tooling (A) in order to remove engine oil filter
nance, testing, adjusting and repair of the product. (7). Refer to Operation and Maintenance Manual,
Be prepared to collect the fluid with suitable contain- “Engine Oil and Filter - Change” for the correct
ers before opening any compartment or disassem- procedure.
bling any component containing fluids.
4. Remove bolts (6) from oil filter base (1).
Dispose of all fluids according to local regulations
and mandates. Note: Note the position of the different length bolts
for installation purposes.

5. Remove engine oil filter base (4) from the cylinder

block.
6. Remove gasket (5) (not shown).
7. If necessary, remove plug (2) from engine oil filter
base (4).
8. If necessary, remove plug (11) from engine oil filter
base (4).
9. If necessary, remove plug (10) from engine oil filter
base (4).
10. If necessary, remove plug (9) from engine oil filter
base (1). Remove O-ring seal (8) (not shown) from
plug (9).
11. If necessary, remove the engine oil pressure
switch. Refer to Disassembly and Assembly,
“Engine Oil Pressure Switch - Remove and
Install”.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 89
Disassembly and Assembly Section

Installation Procedure 6. Position new gasket (5) (not shown) onto engine
Table 27 oil filter base (4). Install bolts (6) to engine oil filter
Required Tools
base (4).

Tool Part Number Part Description Qty Note: Ensure that the different length bolts are
installed in the correct position.
A T400083 Filter Cartridge Tool 1
7. Install the assembly of the engine oil filter base to
the cylinder block. Tighten bolts (6) to a torque of
NOTICE 25 N·m (221 lb in).
Keep all parts clean from contaminants.
8. If necessary, install the engine oil pressure switch.
Contaminants may cause rapid wear and shortened Refer to Disassembly and Assembly, “Engine Oil
component life.
Pressure Switch - Remove and Install” for the
correct procedure.
9. Connect wiring harness assembly (1) to engine oil
pressure switch (3).
10. Use Tooling (A) in order to install new engine oil
filter (7). Refer to Operation and Maintenance
Manual, “Engine Oil and Filter - Change” for the
correct procedure.
11. Check the level of the engine oil. Refer to
Operation and Maintenance Manual, “Engine Oil
Level - Check” for the correct procedure.

i05270773

Engine Oil Cooler - Remove

Removal Procedure
Start By:
Illustration 150 g02675998
a. Remove the alternator and mounting bracket.
Typical example Refer to Disassembly and Assembly,
“Alternator - Remove” for the correct
1. Clean the gasket surface of the engine oil filter procedure.
base (4). Clean the gasket surface of the cylinder
block. NOTICE
Keep all parts clean from contaminants.
2. If necessary, install new O-ring seal (8) (not
shown) to plug (9). Install plug (9) to engine oil Contaminants may cause rapid wear and shortened
filter base (1). Tighten the plug to a torque of component life.
30 N·m (266 lb in).
3. If necessary, install new plug (10) to engine oil filter NOTICE
base (4). Tighten the plug to a torque of 30 N·m Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
(266 lb in). nance, testing, adjusting and repair of the product.
4. If necessary, install new plug (11) to engine oil filter Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
base (4). Tighten the plug to a torque of 10 N·m bling any component containing fluids.
(89 lb in).
Dispose of all fluids according to local regulations
5. If necessary, install new plug (2) to engine oil filter and mandates.
base (4). Tighten the plug to a torque of 30 N·m
(266 lb in).

This document has been printed from SPI2. NOT FOR RESALE
90 UENR0624-03
Disassembly and Assembly Section

1. Drain the coolant from the cooling system into a 4. Remove bolts (6) from tube assembly (5). Remove
suitable container. Refer to Operation and tube assembly (5) from engine oil cooler assembly
Maintenance Manual, “Cooling System Coolant - (3).
Change” for the correct procedure.
5. Remove O-ring seal (7) (not shown) from tube
2. If the engine oil has become contaminated with assembly (5).
coolant, the engine oil and filter must be replaced.
6. Remove bolt (8) and bracket (9) from the engine oil
Refer to Operation and Maintenance Manual,
cooler assembly.
“Engine Oil and Filter - Change” for the correct
procedure. 7. Remove boost pressure chamber cover (4). Refer
to Disassembly and Assembly, “Turbocharger -
Remove” for the correct procedure.
8. Remove bolts (1) from the engine oil cooler. Do not
remove the bolts in Position (X). Remove the
engine oil cooler assembly from the cylinder block.

Note: The bolts are different lengths. Note the

position of the different lengths bolts.

9. Remove gasket (2) (not shown).

Illustration 151 g02706998

Illustration 153 g02707318

10. If necessary, follow Step 10.a through Step 10.c

in order to disassemble the engine oil cooler.

a. Remove bolts (13) and bolts (14) from the

engine oil cooler assembly (3).

b. Remove cooler matrix (12) from housing (10).

Illustration 152 g02871078

3. Disconnect the coolant hoses from tube assembly

(5).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 91
Disassembly and Assembly Section

c. Remove gaskets (11).

i05270774

Engine Oil Cooler - Install

Installation Procedure
1. Ensure that all components are free from wear and
damaged. If necessary, replace any components
that are worn or damaged.

Illustration 155 g02871598

Tightening sequence for the engine oil cooler.

Illustration 154 g02707318

2. If necessary, follow Step 2.a through Step 2.d in

order to assembly the engine oil cooler.

a. Ensure that engine oil cooler matrix (12) is

clean, free from damage and restriction.
Replace engine oil cooler matrix (12) if
damaged or restricted.

b. Ensure that housing (10) is clean and free from

Illustration 156 g02706998
damage. Replace housing (10) if damaged.

c. Position new gaskets (11) onto engine oil cooler 3. Clean the gasket surfaces of the cylinder block.
matrix (12). Install engine oil cooler matrix (12) 4. Position a new gasket (4) onto the engine oil
to housing (10). cooler.
d. Install bolts (13) and bolts (14) to the assembly 5. Install assembly of engine oil cooler (5) to the
of oil cooler (3). Tighten bolts (13) and bolts (14) cylinder block. Install bolts (1) to the assembly of
to a torque of 25 N·m (221 lb in). oil cooler (3).
Note: Ensure that the bolts of different lengths are
installed in the correct position.

This document has been printed from SPI2. NOT FOR RESALE
92 UENR0624-03
Disassembly and Assembly Section

6. Tighten bolts (3) to a torque of 25 N·m (221 lb in) 17. Check the level of the engine lubricating oil. Refer
in sequence that is shown in Illustration 155 . to Operation and Maintenance Manual, “Engine
Oil Level - Check” for the correct procedure.
7. Position bracket (9) onto engine oil cooler (3).
Install bolt (8) to bracket (9). Tighten the bolt to a
i05270776
torque of 15 N·m (133 lb in).
8. Install boost pressure chamber cover (4). Refer to Engine Oil Relief Valve -
Disassembly and Assembly, “Turbocharger -
Install” for the correct procedure. Remove and Install
9. If necessary, install the turbo charger oil drain tube
assembly. Refer to Disassembly and Assembly,
“Turbocharger - Install” for the correct procedure. Removal Procedure
10. Install a new O-ring seal (7) (not shown) to tube
assembly (5).
11. Install tube assembly (5) to engine oil cooler (3).
12. Install bolts (6) to tube assembly (5). Tighten the
bolts to a torque of 25 N·m (221 lb in).
13. Connect the coolant hoses to tube assembly (5).
14. Install the Alternator. Refer to Disassembly and
Assembly, “Alternator - Install” for the correct
procedure.
15. Fill the cooling system to the correct level. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.
16. If the engine oil was drained during the engine oil
cooler removal procedure, refill the lubrication
system. Refer to Operation and Maintenance
Manual, “Engine Oil and Filter - Change” for the
Illustration 157 g02953956
correct procedure.
1. Remove bolts (2) from engine oil relief valve (1).
2. Remove engine oil relief valve (1) from the cylinder
block.
3. Remove O-ring seal (3) from engine oil relief valve
(1).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Check all components for wear and damage. If

necessary, replace any components that are worn
or damaged.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 93
Disassembly and Assembly Section

Illustration 158 g02953956

2. Install new O-ring seal (3) to engine oil relief valve

(1).
3. Install engine oil relief valve (1) to the cylinder
block.
4. Install bolts (2) to engine oil relief valve (1). Tighten
the bolts to a torque of 10 N·m (89 lb in)

i05270779
Illustration 159 g02986438

Engine Oil Pump - Remove 1. Remove bolts (2) from engine oil pump (3).
2. Remove engine oil pump (3) from the cylinder
block.
Removal Procedure
i05270780
Start By:
a. Remove the front housing. Refer to Engine Oil Pump - Install
Disassembly and Assembly, “Housing (Front) -
Remove and Install”.

NOTICE Installation Procedure

Keep all parts clean from contaminants.
Table 28
Contaminants may cause rapid wear and shortened Required Tools
component life.
Tool Part Number Part Description Qty

21825617 Dial Indicator 1

A
- Magnetic Base and Stand 1

This document has been printed from SPI2. NOT FOR RESALE
94 UENR0624-03
Disassembly and Assembly Section

End By:
NOTICE
Keep all parts clean from contaminants. a. Install the front housing. Refer to Disassembly
Contaminants may cause rapid wear and shortened and Assembly, “Housing (Front) - Remove and
component life. Install”.

i05270783
1. Ensure that bushing is free from wear or damage.
Refer to Specifications, “Engine Oil Pump” for Water Pump - Remove
more information. If necessary, replace the
bushing.

Removal Procedure
Start By:
a. Remove the alternator belt. Refer to
Disassembly and Assembly, “Alternator Belt -
Remove and Install” for the correct procedure.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 160 g02986456 Dispose of all fluids according to local regulations

and mandates.
2. Ensure that engine oil pump (2) is clean and free
from wear or damage. Refer to Specifications, 1. Drain the coolant from the cooling system into a
“Engine Oil Pump” for more information. If suitable container for storage or disposal. Refer to
necessary, replace the engine oil pump. Operation and Maintenance Manual, “Cooling
3. Lubricate the rotors of the engine oil pump (2) with System Coolant - Change” for the correct
clean engine oil. procedure.

4. Align engine oil pump gear (3) with crankshaft gear

(4). Install the engine oil pump to the cylinder
block.
5. Install bolts (1). Tighten the bolts to a torque of
11 N·m (97 lb in).
6. Use Tooling (A) to check the backlash between oil
pump gear (3) and crankshaft gear (4). Ensure
that the backlash is within specified values. Refer
to Specifications, “Gear Group (Front)” for further
information.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 95
Disassembly and Assembly Section

4. Remove seal (3).

i05270787

Water Pump - Install

Installation Procedure

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that the water pump is clean and free from

wear and damage. If necessary, replace the water
pump. Clean the seal surface of the water pump.

Illustration 161 g02663376

Illustration 162 g02663417

2. Remove bolts (1) from water pump (2).

3. Remove water pump (2) from the cylinder block.

This document has been printed from SPI2. NOT FOR RESALE
96 UENR0624-03
Disassembly and Assembly Section

6. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.
End By:
a. Install the alternator belt. Refer to Disassembly
and Assembly, “Alternator Belt - Remove and
Install” for the correct procedure.

i05270793

Water Temperature Regulator -

Remove and Install

Removal Procedure
NOTICE
Illustration 163 g02663458 Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Drain the coolant from the cooling system to a

level below the water temperature regulator, into a
suitable container for storage or for disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct draining
procedure.

Illustration 164 g02663598

2. Remove the wastegate regulator valve. Refer to
Disassembly and Assembly, “Wastegate Solenoid
2. Clean the seal surface on the cylinder block. - Remove and Install” for the correct procedure.

3. Install a new seal (3) to the water pump (2).

4. Install the water pump (2) to the cylinder block.
Note: Ensure that the water pump is correctly
orientated.

5. Install bolts (1) to the water pump. Tighten the

bolts to a torque of 25 N·m (221 lb in).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 97
Disassembly and Assembly Section

1. Ensure that all components are clean and free of

wear and damage. If necessary, replace any
components that are worn or damaged.
2. Check the water temperature regulator for correct
operation. Refer to System Operation, Testing,
and Adjusting, “Water Temperature Regulator -
Test” for the procedure to test the water
temperature regulator. If the water temperature
regulator is not operating correctly, the complete
assembly must be replaced.
3. If necessary, install the coolant temperature
sensor. Refer to Disassembly and Assembly,
“Coolant Temperature Sensor - Remove and
Install” for the correct procedure.

Illustration 165 g02829476

Typical example

3. Loosen the hose clamps from the upper radiator

hose and disconnect the upper radiator hose from
water temperature regulator housing (1).
4. Loosen clamp (3) and disconnect exhaust gas
recirculation (EGR) cooler hose (2) from water
temperature regulator housing (1). Position the
EGR cooler hose away from the water
temperature regulator housing.
5. Slide the locking tab into the unlocked position and
disconnect the wiring harness from coolant
temperature sensor (4).
6. Remove bolts (6) and remove bolts (7) from water Illustration 166 g02829476
temperature regulator housing (1). Typical example
7. Remove water temperature regulator housing (1)
4. Position gasket (5) (not shown) onto water
from the cylinder head.
temperature regulator housing (1).
8. Remove gasket (5) (not shown).
Note: Ensure that the gasket is correctly orientated.
9. If necessary, remove the coolant temperature
sensor. Refer to Disassembly and Assembly, 5. Install bolts (7) to water temperature regulator
“Coolant Temperature Sensor - Remove and housing (1).
Install” for the correct procedure. 6. Position water temperature regulator housing (1)
onto the cylinder head.
Installation Procedure
7. Install bolts (6) to the water temperature regulator
NOTICE housing finger tight.
Keep all parts clean from contaminants.
8. Tighten the bolts (6) and bolts (7) to a torque of
Contaminants may cause rapid wear and shortened 25 N·m (221 lb in).
component life.
9. Connect hose (2) to the water temperature
regulator housing and tighten clamp (3) securely.

This document has been printed from SPI2. NOT FOR RESALE
98 UENR0624-03
Disassembly and Assembly Section

10. Connect the upper radiator hose to water

temperature regulator housing (1) and tighten the
hose clamps securely.
11. Connect the wiring harness to coolant
temperature sensor (4). Slide the locking tab into
the locked position.
12. Install the wastegate solenoid. Refer to
Disassembly and Assembly, “Wastegate Solenoid
- Remove and Install” for the correct procedure.
13. Fill the cooling system to the correct level. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Check” and Operation and
Maintenance Manual, “Cooling System Coolant -
Change” for the correct filling procedures.

i05270798

Engine Lifting Bracket -

Remove Illustration 168 g03001176
View of the engine lifting brackets on the rear of the
engine

Removal Procedure 1. Remove bolts (2) from lifting bracket (1).

Follow the removal procedure for the configuration of 2. Remove lifting bracket (1) from fan drive assembly
engine lifting brackets that are installed. (3).
3. Remove bolts (7) from lifting bracket (4).
Option 1
4. Remove lifting bracket (4) from the cylinder head.
5. Remove bolts (6) from lifting bracket (5).
6. Remove lifting bracket (5) from the cylinder head.

Illustration 167 g03001156

View of the engine lifting bracket on the front of the
engine

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 99
Disassembly and Assembly Section

Option 2 5. Remove bolt (14) from lifting bracket (12).

6. Remove lifting bracket (12) from the flywheel
housing.

i05270802

Engine Lifting Bracket - Install

Installation Procedure
Follow the installation procedure for the configuration
of engine lifting brackets that are installed.

Option 1

Illustration 169 g03001576

View of the engine lifting bracket on the front of the
engine

Illustration 171 g03001156

View of the engine lifting bracket on the front of the
engine

Illustration 170 g03001603

View of the engine lifting brackets on the rear of the
engine

1. Remove bolts (9) from lifting bracket (8).

2. Remove lifting bracket (8) from fan drive assembly
(10).
3. Remove bolt (13) from lifting bracket (11).
4. Remove lifting bracket (11) from the flywheel
housing.

This document has been printed from SPI2. NOT FOR RESALE
100 UENR0624-03
Disassembly and Assembly Section

Option 2

Illustration 172 g03001176

View of the engine lifting brackets on the rear of the
engine Illustration 173 g03001576
View of the engine lifting bracket on the front of the
1. Position lifting bracket (1) onto fan drive (3). Refer engine
to Illustration 171 .
2. Install bolts (2) finger tight to lifting bracket (1).
Tighten the bolts to a torque of 45 N·m (33 lb ft).
3. Position lifting bracket (4) onto the cylinder head.
Refer to Illustration 172 .
4. Install bolts (7) finger tight to lifting bracket (4).
Tighten the bolts to a torque of 65 N·m (48 lb ft).
5. Position lifting bracket (5) onto the cylinder head.
Refer to Illustration 172 .
6. Install bolts (6) finger tight to lifting bracket (5).
Tighten the bolts to a torque of 65 N·m (48 lb ft).

Illustration 174 g03001603

View of the engine lifting brackets on the rear of the
engine

1. Position lifting bracket (8) onto fan drive (10). Refer

to Illustration 173 .
2. Install bolts (9) finger tight to lifting bracket (8).
Tighten the bolts to a torque of 45 N·m (33 lb ft).
3. Position lifting bracket (11) onto the flywheel
housing. Refer to Illustration 174 .

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 101
Disassembly and Assembly Section

4. Install bolt (13) finger tight to lifting bracket (11).

Tighten the bolt to a torque of 110 N·m (81 lb ft).
5. Position lifting bracket (12) onto the flywheel
housing. Refer to Illustration 174 .
6. Install bolt (14) finger tight to lifting bracket (12).
Tighten the bolts to a torque of 110 N·m (81 lb ft).

i05270805

Flywheel - Remove

Removal Procedure
Table 29
Required Tools

Tool Part Number Part Description Qty

Guide Stud
A - 2 Illustration 175 g02657336
M12 x 1.25mm by 100mm

1. Remove bolts from Position (X) from flywheel (1).

Start By: Discard the bolts.
a. Remove the electric starting motor. Refer to 2. Install Tooling (A) in Position (X) to flywheel (1).
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install” for the correct 3. Install a suitable lifting device onto flywheel (1).
procedure. Support the weight of the flywheel. The flywheel
can weigh 75 kg (165 lb).
NOTICE
Keep all parts clean from contaminants. 4. Remove remaining bolts (2). Discard the bolts.
Contaminants may cause rapid wear and shortened 5. Use the suitable lifting device to remove the
component life. flywheel from the engine.

Illustration 176 g02657439

6. Inspect flywheel (1) and ring gear (3) for wear and
damage. Replace any worn or damaged
components.
7. To remove flywheel ring gear (3), follow Step 7.a
through Step 7.b.

This document has been printed from SPI2. NOT FOR RESALE
102 UENR0624-03
Disassembly and Assembly Section

a. Place the flywheel assembly on a suitable 1. If the flywheel ring gear was removed, follow Step
support. 1.a through Step 1.c in order to install a new ring
gear (3) to flywheel (1).
b. Use a hammer and a punch in order to remove
ring gear (3) from flywheel (1). a. Identify the orientation of teeth (4) on new ring
gear (3).
Note: Identify the orientation of the teeth on the
flywheel ring gear. Note: The chamfered side of ring gear teeth (4)
must face toward the starting motor when the
i05270806 flywheel is installed. The chamfered side of ring
gear teeth ensures the correct engagement of the
Flywheel - Install starting motor.

b. Heat flywheel ring gear (3) in an oven to a

maximum temperature of 250 °C (482 °F) prior
Installation Procedure to installation.
Table 30
Note: Do not use a torch to heat the ring gear.
Required Tools

Part Description Qty c. Ensure that the orientation of ring gear (3) is
Tool Part Number
correct and quickly install the ring gear onto
Guide Stud flywheel (1).
A - 2
M12 x 1.25 by 100mm
2. Inspect the crankshaft rear seal for leaks. If there
B 27610289 Angle Gauge 1 are any oil leaks, replace the crankshaft rear seal.
Refer to Disassembly and Assembly, “Crankshaft
Rear Seal - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Check all components for wear and damage. If

necessary, replace any components that are worn
or damaged.

Illustration 178 g02659160

Typical example
Illustration 177 g02659159
Typical example 3. Install a suitable lifting device to flywheel (1). The
flywheel can weigh 75 kg (165 lb).
4. Install Tooling (A) in Position (X) on the crankshaft.

Always wear protective gloves when handling 5. Use the suitable lifting device to position flywheel
parts that have been heated. (1) onto Tooling (A).
6. Install new bolts (2) hand tight to flywheel (1).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 103
Disassembly and Assembly Section

7. Remove Tooling (A) and install remaining new

NOTICE
bolts (2) hand tight to flywheel (1). Keep all parts clean from contaminants.
8. Remove the lifting device from flywheel (1). Contaminants may cause rapid wear and shortened
9. Use a suitable tool to prevent the flywheel from component life.
rotating. Tighten bolts (2) to a torque of 30 N·m
(266 lb in). Use Tooling (B) to rotate bolts (2)
through an additional 90 degrees in a clockwise
direction in order to achieve the required final
torque.
10. Check the run out of the flywheel. Refer to
System Operation, Testing and Adjusting,
“Flywheel” for further information.
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install” for the correct
procedure.

i05270810

Crankshaft Rear Seal -

Remove and Install

Illustration 179 g02873976

Removal Procedure Typical example

Table 31
1. Apply clean grease to Tooling (A) in order to
Required Tools
prevent any swarf that is generated from entering
Tool Part Number Part Description Qty the engine. Use Tooling (A) to drill three evenly
spaced holes in crankshaft rear seal (4).
A - Drill Bit (3 mm) 1
2. Use Tooling (B) with care in order to remove
B 27610311 Slide Hammer Puller 1 crankshaft rear seal (4) from flywheel housing (1).
Alternate the position of Tooling (B) from one hole
C - Telescopic Magnet 1
to another. Alternating the position of Tooling (B)
will allow the crankshaft rear seal to be easily
Start By: removed from the flywheel housing.
a. Remove the flywheel. Refer to Disassembly 3. Apply clean grease to Tooling (A) in order to
and Assembly, “Flywheel - Remove” for the prevent any swarf that is generated from entering
correct procedure. the engine. Use Tooling (A) to drill two evenly
spaced holes in crankshaft wear sleeve (3).
NOTICE
Care must be taken to ensure that fluids are con- 4. Use Tooling (B) with care in order to remove
tained during performance of inspection, mainte- crankshaft wear sleeve (3) from crankshaft (2).
nance, testing, adjusting and repair of the product. Alternate the position of Tooling (B) from one hole
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- to the other. Alternating the position of Tooling (B)
bling any component containing fluids. will allow the crankshaft wear sleeve to be easily
removed from the crankshaft.
Dispose of all fluids according to local regulations
and mandates. 5. Use Tooling (C) to collect any swarf that is on the
flywheel housing or crankshaft assembly.

This document has been printed from SPI2. NOT FOR RESALE
104 UENR0624-03
Disassembly and Assembly Section

Installation Procedure
Table 32
Required Tools

Tool Part Number Part Description Qty

Crankshaft Rear Seal

D T400089 1
Installer

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that the flange of the crankshaft and the

inside of the flywheel housing are clean and free
from oil and damage.

Illustration 181 g02876596

Sectional view of the crankshaft rear seal, the
crankshaft, and the installation tool

2. Crankshaft rear seal (4) and crankshaft wear

sleeve (3) are supplied as a crankshaft rear seal
assembly (5) and should not be separated for
installation.

Note: Do not remove the crankshaft rear seal from

the crankshaft wear sleeve.

3. Use Tooling (D) and follow Step 3.a through Step

3.f in order to install crankshaft rear seal assembly
(5).

a. Position the adaptor of Tooling (D) onto the

palm of the crankshaft and secure with bolts.

Illustration 180 g02876556

b. Position the new crankshaft rear seal assembly
(5) over the adaptor onto the rear of the
Typical example
crankshaft.
c. Align the seal installer of Tooling (D) with the
crankshaft.
Note: Check that the installer of Tooling (D) is
parallel to the adaptor.

d. Install the nut and washer to the locator.

e. Tighten the nut until the installer bottoms out on
the adaptor in order to install crankshaft rear
seal assembly (5) into flywheel housing (1) and
onto crankshaft (2).

f. Remove Tooling (D).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 105
Disassembly and Assembly Section

End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install”.

i05270813

Flywheel Housing - Remove

and Install
(Stressed Cylinder Block)

Removal Procedure
Table 33
Required Tools

Tool Part Number Part Description Qty

Guide Stud
A - 2
M8 by 100 mm
Illustration 182 g02879298

Start By:
a. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
Seal - Remove and Install” for the correct
procedure.
b. Remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan -
Remove and Install” for the correct procedure.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 183 g02879337

1. Remove the electric starting motor. Refer to

Disassembly and Assembly, “Electric Starting
Motor - Remove and Install” for the correct
procedure.
2. Remove bolts (3) from Position (X) from flywheel
housing (1).
3. Install Tooling (A) into Position (X) on flywheel
housing (1).

This document has been printed from SPI2. NOT FOR RESALE
106 UENR0624-03
Disassembly and Assembly Section

4. Install a suitable lifting device to the flywheel

housing in order to support the flywheel housing.
The weight of the flywheel housing is
approximately 40 kg (88 lb).
5. Remove bolts (2) from flywheel housing (1).
6. Remove bolts (4) from flywheel housing (1).
7. Use the suitable lifting device in order to remove
flywheel housing (1) from the cylinder block.

Illustration 185 g02881996

Illustration 184 g02879456

8. If necessary, remove dowels (5).

Installation Procedure
Table 34
Required Tools

Tool Part Number Part Description Qty

Guide Stud
A - 2
M8 by 100 mm

B - Loctite 5970 1
Illustration 186 g02879298

NOTICE
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 flywheel
housing.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 107
Disassembly and Assembly Section

End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
Install” for the correct procedure.
b. Install the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
Seal - Remove and Install” for the correct
procedure.

i05270819

Flywheel Housing - Remove

and Install
(Non-Stressed Cylinder Block)

Removal Procedure
Illustration 187 g02879337 Table 35
Required Tools
2. Clean the rear face of the cylinder block.
Tool Part Number Part Description Qty
3. If necessary, install dowels (5) to the cylinder
block. -
Guide Stud
A 2
M8 by 100 mm
4. Apply a 3mm bead of Tooling (B) in Position (Y) to
the cylinder block as shown in Illustration 185 .
Start By:
5. Install Tooling (A) into the cylinder block in
Positions (X). a. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
6. Install a suitable lifting device onto the flywheel Seal - Remove and Install” for the correct
housing. The weight of the flywheel housing is procedure.
approximately 40 kg (88 lb). b. Remove the engine oil pan. Refer to
7. Use the suitable lifting device to align flywheel Disassembly and Assembly, “Engine Oil Pan -
Remove and Install” for the correct procedure.
housing (1) with Tooling (A). Install the flywheel
housing to the cylinder block. NOTICE
8. Install bolts (4) and bolts (2) finger tight. Keep all parts clean from contaminants.

9. Remove Tooling (A). Install bolts (3) finger tight. Contaminants may cause rapid wear and shortened
component life.
10. Tighten bolts (4) and bolts (2) to a torque of
110 N·m (81 lb ft).
11. Tighten bolts (3) to a torque of 35 N·m (26 lb ft).
12. Check the alignment of flywheel housing (1) with
the crankshaft. Refer to System Operation, Testing
and Adjusting, “Flywheel Housing - Inspect” for
more information.
13. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install” for the correct
procedure.

This document has been printed from SPI2. NOT FOR RESALE
108 UENR0624-03
Disassembly and Assembly Section

4. Install Tooling (A) into Position (X) on flywheel

housing (1).
5. Install a suitable lifting device to the flywheel
housing in order to support the flywheel housing.
The weight of the flywheel housing is
approximately 40 kg (88 lb).
6. Remove bolts (2) from flywheel housing (1).
7. Remove bolts (4) from flywheel housing (1).
8. Use the suitable lifting device in order to remove
flywheel housing (1) from the cylinder block.

Illustration 188 g02659276

Illustration 190 g02882157

Illustration 189 g02659298

1. Remove the electric starting motor. Refer to

Disassembly and Assembly, “Electric Starting
Motor - Remove and Install” for the correct
procedure.
2. If necessary install the diesel particulate filter Illustration 191 g02661536
supporting bracket. Refer to Disassembly and
Assembly, “Support and Mounting (CEM) - 9. If necessary, remove dowels (5).
Remove and Install” for the correct procedure.
10. If necessary, remove bolts (7) and inspection
3. Remove bolts (3) from Position (X) from flywheel cover (6) from flywheel housing (1).
housing (1).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 109
Disassembly and Assembly Section

Installation Procedure
Table 36
Required Tools

Tool Part Number Part Description Qty

Guide Stud
A - 2
M8 by 100 mm

B - Loctite 5970 1

NOTICE
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 flywheel
housing.

Illustration 192 g02882197

Illustration 193 g02659298

This document has been printed from SPI2. NOT FOR RESALE
110 UENR0624-03
Disassembly and Assembly Section

Illustration 195 g02661536

13. If necessary, install inspection cover (6) and bolts

(7) to flywheel housing (1). Tighten the bolts to a
torque of 25 N·m (221 lb in).
Illustration 194 g02659276
14. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
2. Clean the rear face of the cylinder block. If Motor - Remove and Install” for the correct
necessary, install dowels (5) to the cylinder block. procedure.
3. If necessary, install dowels (5) to the cylinder End By:
block.
a. Install the engine oil pan. Refer to Disassembly
4. Apply a 3mm bead of Tooling (B) in Position (Y) to and Assembly, “Engine Oil Pan - Remove and
the cylinder block as shown in Illustration 192 . Install” for the correct procedure.
5. Install Tooling (A) into the cylinder block in b. Install the crankshaft rear seal. Refer to
Positions (X). Disassembly and Assembly, “Crankshaft Rear
Seal - Remove and Install” for the correct
6. Install a suitable lifting device onto the flywheel procedure.
housing. The weight of the flywheel housing is
approximately 40 kg (88 lb). i05270821

7. Use the suitable lifting device to align flywheel Power Take-Off Drive -
housing (1) with Tooling (A). Install the flywheel
housing to the cylinder block. Remove and Install
8. Install bolts (4) and bolts (2) finger tight.
9. Remove Tooling (A). Install bolts (3) finger tight.
Removal Procedure
10. Tighten bolts (4) and bolts (2) to a torque of
110 N·m (81 lb ft). NOTICE
Keep all parts clean from contaminants.
11. Tighten bolts (3) to a torque of 35 N·m (26 lb ft).
12. Check the alignment of flywheel housing (1) with Contaminants may cause rapid wear and shortened
component life.
the crankshaft. Refer to System Operation, Testing
and Adjusting, “Flywheel Housing - Inspect” for
more information.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 111
Disassembly and Assembly Section

Illustration 196 g02901518

Illustration 197 g02901685

1. If necessary, remove the Original Equipment

Manufacturer's (OEM) driven equipment from
power take-off drive (1). Refer to the OEM for the
correct procedure.
2. Remove bolts (2) from power take-off drive (1).

Note: Note the positions of the different length bolts.

3. Remove the power take-off drive (1) from the

cylinder block.
4. Remove O-ring seal (3) from power take-off drive
(1).

This document has been printed from SPI2. NOT FOR RESALE
112 UENR0624-03
Disassembly and Assembly Section

5. Note the position of dowel (4) and dowel (5) in the

power take-off drive. Do not remove the dowels
unless the dowels are damaged.

Installation Procedure
Table 37
Required Tools

Tool Part Number Part Description Qty

Delphi Lockheed Compound

A - 1
Rubber Grease

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that all components are clean and free

from wear and damage. If necessary, replace any
Illustration 198 g02901518
components that are worn or damaged.

Illustration 199 g02901685

2. If necessary, install dowel (4) and dowel (5) into

power take-off drive (1).
3. Install a new O-ring seal (3) onto power take-off
drive (1).
4. Apply Tooling (A) onto O-ring seal (3).
5. Position power take-off drive (1) onto the cylinder
block.
Note: Ensure that the drive gear for the power take-
off drive is correctly engaged with the gear on the
crankshaft.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 113
Disassembly and Assembly Section

6. Equally tighten bolts (2) in order to pull power take- 4. Remove crankshaft multi V-pulley (3).
off drive (1) into the cylinder block
Installation Procedure
7. Tighten bolts (2) to a torque of 25 N·m (221 lb in)
8. Ensure that there is tactile backlash between the NOTICE
Keep all parts clean from contaminants.
idler gear and the accessory drive gear.
9. If necessary, install the OEM driven equipment to Contaminants may cause rapid wear and shortened
component life.
power take-off drive (1). Refer to the OEM for the
correct procedure.
1. Ensure that all components are clean and free
i05270822 from wear and damage. If necessary, replace any
components that are free from wear and damage.
Crankshaft Pulley - Remove
and Install

Removal Procedure
Start By:
a. Remove the alternator belt. Refer to
Disassembly and Assembly, “Alternator Belt -
Remove and Install” for the correct procedure.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 201 g02926996

2. Install crankshaft multi V-pulley (3) onto the

crankshaft.
3. If equipped, install crankshaft V-pulley (2).
4. Install bolts (1) to the crankshaft pulley. Tighten the
bolts to a torque of 45 N·m (33 lb ft)

Note: Use a suitable method in order to prevent the

crankshaft from rotating when torquing the bolts.

Illustration 200 g02926996

1. Use a suitable method in order to prevent the

crankshaft from rotating.
2. Remove bolts (1) from crankshaft pulley (2).
3. If equipped, remove crankshaft V-pulley (2).

This document has been printed from SPI2. NOT FOR RESALE
114 UENR0624-03
Disassembly and Assembly Section

End By:
a. Install the alternator belt. Refer to Disassembly
and Assembly, “Alternator Belt - Remove and
Install” for the correct procedure.

i06096313

Crankshaft Front Seal -

Remove and Install

Removal Procedure
Table 38
Required Tools

Tool Part Number Part Description Qty

A - Drill Bit (3 mm) 1

B 27610311 Slide Hammer Puller 1

Illustration 202 g02927001

C - Telescopic Magnet 1
1. Apply clean grease to Tooling (A) in order to
prevent any swarf that is generated from entering
Start By: the engine. Use Tooling (A) to drill three evenly
spaced holes in crankshaft front seal (1).
a. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft 2. Use Tooling (B) with care in order to remove
Pulley - Remove and Install” for the correct crankshaft front seal (1) from front cover (3) and
procedure. crankshaft pulley adaptor (2). Alternate the
position of Tooling (B) from one hole to another.
NOTICE Alternating the position of Tooling (B) will allow the
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- crankshaft front seal to be easily removed from the
nance, testing, adjusting and repair of the product. crankshaft.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- 3. Use Tooling (C) to collect any swarf that has
bling any component containing fluids. entered the engine.

Dispose of all fluids according to local regulations Installation Procedure

and mandates. Table 39
Required Tools
NOTICE Tool Part Number Part Description Qty
Keep all parts clean from contaminants.
Crankshaft Front Seal
Contaminants may cause rapid wear and shortened D(1) T400450 1
Installer
component life.
D(2) Crankshaft Front Seal
T400090
Installer
(1) Used for Procedure 1
(2) Used for Procedure 2

Note: The tool used is determined by which

crankshaft front seal is installed.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 115
Disassembly and Assembly Section

Procedure 1 End By:

NOTICE a. Install the crankshaft pulley. Refer to

Keep all parts clean from contaminants. Disassembly and Assembly, “Crankshaft
Pulley - Remove and Install” for the correct
Contaminants may cause rapid wear and shortened procedure.
component life.
Procedure 2
1. Ensure that the crankshaft pulley adaptor and the 1. Ensure that the crankshaft pulley adaptor and the
front cover are clean and free from oil and front cover are clean and free from oil and
damage. damage.

Illustration 203 g02927218 Illustration 204 g03805916

Sectional view of the crankshaft front seal, the Sectional view of the crankshaft front seal, the
crankshaft pulley adaptor, and the installation tool crankshaft pulley adaptor, and the installation tool

2. Use Tooling (D) and follow Step 2.a through Step 2. Use Tooling (D) and follow Step 2.a through Step
2.f in order to install crankshaft front seal (1). 2.e in order to install crankshaft front seal (1).

a. Position the adaptor of Tooling (D) onto the a. Position the new crankshaft front seal (1) over
crankshaft pulley adaptor and secure with bolts. the nose of the crankshaft into the recess in the
front cover.
b. Position the new crankshaft front seal (1) over
the adaptor onto the front of the crankshaft. b. Position Tooling (D) onto the new crankshaft
front seal.
c. Align the seal installer of Tooling (D) with the
crankshaft. c. Align Tooling (D) with the crankshaft.

Note: Check that the installer of Tooling (D) is d. Use a suitable tool to drive (D) and the new
parallel to the adaptor. crankshaft front seal (1) into position.

d. Install the nut and washer to the locator. e. Remove Tooling (D).

e. Tighten the nut until the installer bottoms out on

the adaptor in order to install crankshaft front
seal (1) into front cover (3) and onto crankshaft
pulley adaptor (2).

f. Remove Tooling (D).

This document has been printed from SPI2. NOT FOR RESALE
116 UENR0624-03
Disassembly and Assembly Section

End By: 4. Remove the crankshaft front seal using a suitable

tool. Ensure that the front cover (3) is not
a. Install the crankshaft pulley. Refer to damaged during the removal of the crankshaft
Disassembly and Assembly, “Crankshaft
Pulley - Remove and Install” for the correct front seal.
procedure.
Installation Procedure
i05270827 Table 40
Required Tools
Front Cover - Remove and Tool Part Number Part Description Qty
Install Guide Stud
A - 2
M8 by 70 mm

Front Cover Alignment Tool

B T400090 1
Removal Procedure (Crankshaft)

Start By: Front Cover Alignment Tool

C T400087 1
(Crankcase Breather)
a. If the engine is equipped with a fan, remove the
fan. Refer to Disassembly and Assembly, “Fan
- Remove and Install” for the correct procedure.
b. Remove the camshaft position sensor. Refer to
Disassembly and Assembly, “Camshaft
Position Sensor - Remove and Install” for the
correct procedure.
c. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft
Pulley - Remove and Install” for the correct
procedure.

Illustration 205 g02727693

1. Remove bolts (1) from front cover (3).

2. Remove front cover (3) from the front housing.
3. Remove gasket (2) (not shown) from the front
cover.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 117
Disassembly and Assembly Section

6. Install bolts (1) finger tight.

7. Use Tooling (B) and Tooling (C) in order to align
the front cover.
8. Remove Tooling (A) and install remaining bolts (1).

Illustration 206 g02727693

Illustration 208 g02727967

9. Tighten bolts (1) to a torque of 25 N·m (221 lb in).

10. Remove Tooling (B) and Tooling (C) from the
front cover.
11. Install the crankshaft front seal to the front cover.
Refer to Disassembly and Assembly, “Crankshaft
Front Seal - Remove and Install” for the correct
procedure.

Illustration 207 g02727966

1. Thoroughly clean the gasket surface of the front

housing.
2. Ensure that all components are clean and free
from wear and damage. If necessary, replace any
components that are worn or damaged.
3. Position a new gasket (2) (not shown) onto the
front cover.
4. Install Tooling (A) into Holes (X) in the front
housing.
5. Use Tooling (A) in order to position the front cover
assembly onto the front housing.

This document has been printed from SPI2. NOT FOR RESALE
118 UENR0624-03
Disassembly and Assembly Section

End By:
a. Install the crankshaft pulley. Refer to
Disassembly and Assembly, “Crankshaft
Pulley - Remove and Install” for the correct
procedure.
b. If the engine was equipped with a fan, install
the fan. Refer to Disassembly and Assembly,
“Fan - Remove and Install” for the correct
procedure.
c. Install the camshaft position sensor. Refer to
Disassembly and Assembly, “Camshaft
Position Sensor - Remove and Install” for the
correct procedure.

i05270830

Idler Gear - Remove

Removal Procedure Illustration 209 g02937156

Table 41
Required Tools

Tool Part Number Part Description Qty

A T400086 Timing Pin (Crankshaft) 1

B T400152 Timing Pin (Camshaft) 1

Start By:
a. Remove the front cover. Refer to Disassembly
and Assembly, “Front Cover - Remove and
Install” for the correct procedure.

Note: Care must be taken in order to ensure that the

fuel injection pump timing is not lost during the
removal of the idler gear.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shorten
component life. Illustration 210 g02937157
Camshaft timing ring removed for clarity.

1. Follow Step 1.a through Step 1.e in order to install

the camshaft timing tool.

a. If equipped, remove the accessory drive. Refer

to Disassembly and Assembly, “Accessory Drive
- Remove and Install” for the correct procedure.

b. Remove plug (2) in Position (W) from the front

housing.

c. Remove O-ring seal (1) from plug (2).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 119
Disassembly and Assembly Section

d. Rotate the engine until Hole (X) in the camshaft

gear is aligned with Position (W) in the front
housing.

e. Install Tooling (B) through Position (W) and into

Hole (X) in the camshaft gear.

Illustration 211 g02934298 Illustration 212 g02937163

2. Follow Step 2.a through Step 2.c in order to install

the crankshaft positioning tool.

a. Remove plug (4) from Position (X) in the

cylinder block.

b. Remove O-ring seal (3) from plug (4).

c. Install Tooling (A) into the cylinder block in

Position (Z).

Note: Tooling (A) must be located in Hole (Y) in the

crankshaft.
Note: Ensure that Tooling (A) is located in the
correct drilling in the crankshaft as shown in
Illustration 211 .

Illustration 213 g02939977

3. Before removing the idler gear ensure that

alignment pin (6) on the fuel injection pump gear is
45 degrees from vertical and parallel to the center
of Torx head plug (5), refer to Illustration 212 .
4. Make temporary identification marks on idler hub
(10) for installation purposes.

This document has been printed from SPI2. NOT FOR RESALE
120 UENR0624-03
Disassembly and Assembly Section

5. Remove bolt (12) from idler hub (10).

6. Remove the idler hub (10) and gear (9) from front
housing (13).
7. Remove idler hub (10) from gear (9).
8. If necessary, remove lubricating jet (11) from front
housing (13).

i05270835

Idler Gear - Install

Installation Procedure
Table 42
Required Tools

Tool Part Number Part Description Qty

A T400086 Timing Pin (Crankshaft) 1

B T400152 Timing Pin (Camshaft) 1

C - Loctite 506 1

NOTICE
Keep all parts clean from contaminants. Illustration 214 g02937163

Contaminants may cause rapid wear and shortened

component life.

1. Ensure that all components are clean and free

Illustration 215 g02939977

3. If necessary, Apply Tooling (C) to lubricating jet

(11) and install the lubricating jet into front housing
(13). Tighten the lubricating jet to a torque of
18 N·m (159 lb in).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 121
Disassembly and Assembly Section

4. Ensure that locating pin (6) is 45 degrees from 15. If equipped, install the accessory drive. Refer to
vertical and parallel to the center of Torx head plug Disassembly and Assembly, “Accessory Drive -
(5), refer to Illustration 214 . Remove and Install” for the correct procedure.
5. Position gear (9) into the front housing. Ensure that
i05270836
the teeth on all gears mesh correctly.
6. Install idler hub (10) to gear (9). Ensure that the Housing (Front) - Remove
temporary marks are aligned and the idler hub
(10) is correctly installed into the front housing.
7. Install bolt (12) to idler hub (10). Tighten the bolt to Removal Procedure
a torque of 50 N·m (37 lb ft)
Start By:
8. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install” for a. Remove the engine oil pan . Refer to
the correct procedure. Disassembly and Assembly, “Engine Oil Pan -
Remove and Install” for the correct procedure.
b. Remove the camshaft gear. Refer to
Disassembly and Assembly, “Camshaft Gear -
Remove and Install” for the correct procedure.
c. Remove the fuel injection pump. Refer to
Disassembly and Assembly, “Fuel Injection
Pump - Remove” for the correct procedure.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shorten
component life.

12. Remove Tooling (A) from the cylinder block.

13. Install new O-ring seal (3) to plug (4).
14. Install plug (4). Tighten the plug to a torque of
30 N·m (266 lb in).

This document has been printed from SPI2. NOT FOR RESALE
122 UENR0624-03
Disassembly and Assembly Section

Illustration 217 g02729108 Illustration 218 g03025257

2. Remove bolts (5) from front housing (1).

Note: Note the positions of the different length bolts
for installation purposes.

3. Remove front housing (1) from the cylinder block

and dowels (6) (not shown).
4. Dowels (6) (not shown) should only be removed if
damaged.
5. If necessary, follow Step 5.a through Step 5.c in
order to remove engine oil filler (2).

a. Remove bolts (3) from engine oil filler (2).

b. Remove engine oil filler (2) from front housing

(1).

c. Remove O-ring seal (4) (not shown).

Illustration 219 g03025256

6. If necessary, follow Step 6.a through Step 6.c in

order to remove cover plate (8) from the front
housing.

a. Remove bolts (9) from cover plate (8).

b. Remove cover plate (8) from front housing (1).

c. Remove O-ring seal (10) from the cover plate.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 123
Disassembly and Assembly Section

7. If necessary, remove plug (7) in Position (Y) from

the front housing.

i05270839

Housing (Front) - Install

Installation Procedure
Table 43
Required Tools

Tool Part Number Part Description Qty

Loctite 5970
A - 1
Silicone Sealant
Guide Bolt
B - 2
M8 x 1.25 by 35 mm

C - Loctite 506 1
Delphi Lockheed Com- Illustration 220 g03022878
D - 1
pound Rubber Grease
2. If a new front housing is being installed, it will be
necessary to remove plug (7) in Position (Y) for
NOTICE engines that are equipped with any accessory
Keep all parts clean from contaminants.
drive in order to maintain the lubrication of the
Contaminants may cause rapid wear and shorten accessory drive.
component life.
3. If the accessory drive was removed but will not be
installed, the oil gallery in Position (Y) must be
1. Ensure that all components are clean and free plugged. Follow Step 3.a through Step 3.c in order
from wear and damage. If necessary, replace any to maintain engine oil circulation.
components that are worn or damaged.
a. Apply Tooling (C) to plug (7).

b. Install plug (7) into front housing (1).

c. Tighten plug (7) to a torque of 15 N·m

(133 lb in).

This document has been printed from SPI2. NOT FOR RESALE
124 UENR0624-03
Disassembly and Assembly Section

Illustration 221 g02951196 Illustration 223 g02729108

4. Thoroughly clean the gasket surface of the front

housing (1) and the cylinder block.
5. If necessary, install dowels (6) (not shown) to the
cylinder block.
6. Install Tooling (B) into the cylinder block in
Positions (X).
7. Apply a 3mm bead of Tooling (A) to front housing
(1) as shown in Illustration 222 .
8. Install front housing (1) onto Tooling (B) and
dowels (6) (not shown).
9. Apply Tooling (C) onto the threads of bolts (5).
10. Install bolts (5) into front housing (1) in available
location finger tight.
11. Remove Tooling (B) from the cylinder block.

Illustration 222 g02729111

Front housing sealant path.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 125
Disassembly and Assembly Section

Illustration 224 g02951436 Illustration 225 g02951696

12. Install remaining bolts (5). Tighten the bolts in the 17. If necessary, follow Step 17.a through Step 17.c
sequence that is shown in Illustration 224 to a in order to install engine oil filler (2).
torque of 25 N·m (221 lb in).
a. Install new O-ring seal (4) (not shown) onto
13. Install the camshaft gear. Refer to Disassembly engine oil filler (2).
and Assembly, “Camshaft Gear - Install” for the
correct procedure. b. Install engine oil filler (2) into front housing (1).
14. Install the fuel injection pump. Refer to c. Install bolts (3) into engine oil filler (2). Tighten
Disassembly and Assembly, “Fuel Injection Pump the bolts to a torque of 25 N·m (221 lb in).
- Install” for the correct procedure.
15. Install the engine oil pan . Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove” for the
correct procedure.
16. If necessary, install the accessory drive. Refer to
Disassembly and Assembly, “Accessory Drive -
Remove and Install” for the correct procedure.

Illustration 226 g03025197

18. If necessary, install cover plate (8) to the front

housing. Follow Step 18.a through Step 18.c in
order to install the cover plate.

This document has been printed from SPI2. NOT FOR RESALE
126 UENR0624-03
Disassembly and Assembly Section

a. Install new O-ring seal (10) to cover plate (8).

Apply Tooling (D) to O-ring seal (10).

b. Install cover plate (8) to the front housing.

c. Install bolts (9) to the cover plate and tighten the

bolts to a torque of 25 N·m (221 lb in).
19. If necessary, install the fan drive. Refer to
Disassembly and Assembly, “Fan Drive - Remove
and Install” for the correct procedure.
End By:
a. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Fill” for the correct
procedure.

i05270844

Accessory Drive - Remove and Illustration 227 g02898881

Install

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. If necessary, remove the Original Equipment

Manufacturer's (OEM) driven equipment from
accessory drive (4). Refer to the OEM for the
correct procedure.
2. If the OEM driven equipment was not installed onto
accessory drive (4). Remove cover plate (2) and
remove gasket (3) (not shown).
3. Remove Allen head bolts (6) from accessory drive
(4). Remove the accessory drive housing from the
front housing.
4. Remove O-ring seals (7) from the accessory drive.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 127
Disassembly and Assembly Section

Installation Procedure
Table 44
Required Tools

Tool Part Number Part Description Qty

Delphi Lockheed Com-

A - 1
pound Rubber Grease

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Inspect the bore in the front housing for damage. If

necessary, replace the front housing. Refer to
Disassembly and Assembly, “Housing (Front) -
Remove” and Disassembly and Assembly,
“Housing (Front) - Install” for the correct
procedure. Illustration 229 g02898938

Illustration 230 g02898881

2. Install new O-ring seals (7) onto accessory drive

(4).
3. Apply Tooling (A) onto O-ring seals (7).
4. Install accessory drive (4) to housing (5).
5. Install Allen head bolts (6) to accessory drive (4).
6. Equally tighten the Allen head bolts (6) in order to
pull accessory drive (4) into housing (5).
7. Tighten Allen head bolts to a torque of 25 N·m
(221 lb in).

This document has been printed from SPI2. NOT FOR RESALE
128 UENR0624-03
Disassembly and Assembly Section

8. Ensure that there is tactile backlash between the

idler gear and the accessory drive gear.
9. If necessary, install the OEM driven equipment to
accessory drive (4). Refer to the OEM for the
correct procedure.
10. If the OEM driven equipment was not installed
onto accessory drive (4), position new gasket (3)
(not shown) and cover plate (2) onto accessory
drive (4).
11. Install bolts (1) to cover plate (2). Tighten the
bolts to a torque of 25 N·m (221 lb in).

i05270847

Crankcase Breather - Remove

Removal Procedure
Illustration 231 g02689857

NOTICE
Keep all parts clean from contaminants. 1. Disconnect hose (8) from crankcase breather
cover (11).
Contaminants may cause rapid wear and shortened
component life. 2. If necessary, disconnect hose (9) from crankcase
breather cover (11).
Table 45
3. Remove nuts (10) from studs (12).
Required Tools
4. Remove crankcase breather cover (11) from front
Tool Part Number Part Description Qty cover (1). Remove O-ring (7) from the crankcase
1/2 Inch Drive x 19 breather cover.
A - 1
mm Hex Drive
5. Remove circlip (6) from spigot (3).
6. Remove breather element (5) from spigot (3).
7. If necessary, use Tooling (A) in order to remove
threaded insert (4) and spigot (3) from fuel
injection pump shaft (2).
8. If necessary, remove studs (12) from front cover
(1).

i05270850

Crankcase Breather - Install

Installation Procedure

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 129
Disassembly and Assembly Section

Table 46
Required Tools 7. Install nuts (10) to studs (12). Tighten the nuts to a
Tool Part Number Part Description Qty torque of 10 N·m (7 lb ft).
1/2 Inch Drive x 19 8. Ensure that hose (8) is clean and free from
A - 1
mm Hex Drive restriction.
9. Connect hose (8) to crankcase breather cover (11)
1. Ensure that all components of the crankcase and tighten the hose clip securely.
breather are clean and free from wear and
damage. Replace any components that are worn 10. Ensure that hose (9) is clean and free from
or damaged. restriction.
11. Connect hose (9) to crankcase breather cover
(11) and tighten the hose clip securely.

i05275350

Valve Mechanism Cover -

Remove and Install

Removal Procedure
Table 47
Required Tools

Tool Part Number Part Description Qty

A T412504 Capping Kit 1

Start By:
a. Remove the fuel manifold. Refer to
Illustration 232 g02665516 Disassembly and Assembly, “Fuel Manifold
(Rail) - Remove and Install” for the correct
2. If necessary, install studs (12) to front cover (1). procedure.
Tighten the studs to a torque of 8 N·m (71 lb in).
b. Remove the electronic unit injectors. Refer to
3. If necessary, install spigot (3) and threaded insert Disassembly and Assembly, “Electronic Unit
(4). Press the spigot onto fuel injection pump shaft Injector - Remove” for the correct procedure.
(2). Ensure that the spigot is correctly positioned
onto fuel injection pump shaft (2). Install threaded NOTICE
Ensure that all adjustments and repairs that are
insert (4). Use a suitable tool in order to prevent carried out to the fuel system are performed by
the crankshaft from rotating. Use Tooling (A) in authorised personnel that have the correct
order to tighten threaded insert (4) to a torque of training.
85 N·m (63 lb ft).
Before begining ANY work on the fuel system, re-
4. Install new breather element (4) to spigot (3). fer to Operation and Maintenance Manual, “Gen-
Install circlip (6) to spigot (3). eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Note: Ensure that the circlip is correctly seated into
the retaining groove in the spigot. Refer to Systems Operation, Testing and Adjust-
ing Manual, “Cleanliness of Fuel System Compo-
5. Install new O-ring (7) to crankcase breather cover nents” for detailed information on the standards
of cleanliness that must be observed during ALL
(11). work on the fuel system.
6. Position crankcase breather cover (11) onto front
cover (1).

This document has been printed from SPI2. NOT FOR RESALE
130 UENR0624-03
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Note: Plug or cap all open ports and tube

assemblies.

Illustration 234 g03010836

Typical example

1. If necessary, remove exhaust gas recirculation

valve (1). Refer to Disassembly and Assembly,
“Exhaust Gas Recirculation Valve - Remove and
Install” for the correct procedure.
2. Disconnect the hose assembly (3) from fuel
distribution block (4).
3. Use Tooling (A) in order to plug hose assembly (3).
4. Use Tooling (A) in order to cap fuel distribution
block (4).
5. Remove bolt (6) from clip for hose assembly (3).
Position the hose assembly away from the valve
mechanism cover.
6. Remove bolts (7) and bolt (8) from valve
mechanism cover (2).
Illustration 233 g03010837
Typical example 7. Remove valve mechanism cover (2) from the
cylinder head.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 131
Disassembly and Assembly Section

1. Thoroughly clean all gasket surfaces of valve

mechanism cover (2). Clean the gasket surfaces
of the cylinder head.
2. Install a new gasket (9) to valve mechanism cover
(2).
Note: Ensure that the gasket is fully seated into the
groove of the valve mechanism cover.

Illustration 235 g03010838

Typical example

8. Remove gasket (9) from valve mechanism cover

(2).

Installation Procedure
NOTICE
Keep all parts clean from contaminants. Illustration 237 g03010836

Contaminants may cause rapid wear and shortened Typical example

component life.

Illustration 238 g02671296

3. Position valve mechanism cover (2) onto the

cylinder head.
4. Install bolts (7) and bolt (8) to the valve mechanism
cover.
5. Tighten the bolts in the numerical sequence that is
Illustration 236 g03010838
shown in Illustration 238 .
Typical example

This document has been printed from SPI2. NOT FOR RESALE
132 UENR0624-03
Disassembly and Assembly Section

Tighten the bolts 1 through 7 to a torque of 10 N·m End By:

(89 lb in).
a. Install the electronic unit injectors. Refer to
Tighten the bolt 8 to a torque of 27 N·m (239 lb in) Disassembly and Assembly, “Electronic Unit
. Injector - Remove” for the correct procedure.
Repeat Step 5 in order to ensure the correct b. Install the fuel manifold. Refer to Disassembly
torque. and Assembly, “Fuel Manifold (Rail) - Remove
and Install” for the correct procedure.

i05275356

Rocker Shaft and Pushrod -

Remove

Removal Procedure
Table 48
Required Tools

Tool Part Number Part Description Qty

A T400086 Timing Pin (Crankshaft) 1

Start By:
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve
Illustration 239 g03010837 Mechanism Cover - Remove and Install” for the
Typical example correct procedure.

6. Remove plug from hose assembly (3). Remove

cap from fuel distribution block (4).
7. Connect hose assembly (3) to the fuel distribution
block (4).
8. Position clip (5) for hose assembly (3) onto the
cylinder block. Install bolt (6) to clip (5).
9. Tighten the bolt (6) to a torque of 25 N·m
(221 lb in)
10. If necessary, install exhaust gas recirculation
valve (1). Refer to Disassembly and Assembly,
“Exhaust Gas Recirculation Valve - Remove and
Install” for the correct procedure.

Illustration 240 g02942738

1. Follow Step 1.a through Step 1.c in order to install

the crankshaft positioning tool.

a. Remove plug (4) from Position (X) in the

cylinder block.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 133
Disassembly and Assembly Section

b. Remove O-ring seal (3) from plug (4).

c. Install Tooling (A) into the cylinder block in

Position (Z).
Note: Tooling (A) must be located in Hole (Y) in the
crankshaft.

Note: Ensure that Tooling (A) is located in the

correct drilling in the crankshaft as shown in
Illustration 240 .

Illustration 241 g02942696

Illustration 242 g02942756

2. Remove bolts (6) from rocker shaft (4) in the

reverse numerical sequence shown in Illustration
242 .
3. Remove rocker shaft (4) from the cylinder head.
4. Make temporary identification marks on push rods
(5). Remove the push rods from the cylinder head.
5. Remove wear caps (3) from the valve stems.
Identify the position of the wear caps in order for
the wear caps to be installed in the original
location.

This document has been printed from SPI2. NOT FOR RESALE
134 UENR0624-03
Disassembly and Assembly Section

6. If necessary, remove dowel (7) (not shown).

i05275370

Rocker Shaft - Disassemble

Disassembly Procedure
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove” for the correct procedure.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 243 g02942776

2. Remove grub screw (1) from rocker shaft housing

Personal injury can result from being struck by (4).
parts propelled by a released spring force.
3. Remove rocker shaft (5) from rocker shaft housing
Make sure to wear all necessary protective (4).
equipment.
4. Remove rocker arm assembly (3) for the exhaust
Follow the recommended procedure and use all
recommended tooling to release the spring force. valve from rocker shaft (5). Remove rocker arm
assembly (2) for the inlet valve from rocker shaft
(5).
1. Make an identification mark on each rocker arm
assembly in order to show the location. Note: The rocker arm assembly for the inlet valve is
shorter than the rocker arm assembly for the exhaust
Note: The components must be reinstalled in the valve.
original location. Do not interchange components.
i05275372

Rocker Shaft - Assemble

Assembly Procedure

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that all components are clean and free

from wear and damage. Refer to Specifications,
“Rocker Shaft” for more information. If necessary,
replace any components that are worn or
damaged.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 135
Disassembly and Assembly Section

End By:
a. Install the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install” for the correct procedure.

i05275374

Rocker Shaft and Pushrod -

Install

Installation Procedure
Table 49
Required Tools

Tool Part Number Part Description Qty

A T400086 Timing Pin (Crankshaft) 1

Illustration 244 g02942879

NOTICE
2. Lubricate the bore of rocker arm assemblies (2) for Keep all parts clean from contaminants.
the inlet valve with clean engine oil. Contaminants may cause rapid wear and shortened
3. Lubricate the bore of rocker arm assemblies (3) for component life.
the exhaust valve with clean engine oil.
1. Ensure that all components are clean and free
4. Lubricate rocker shaft (5) with clean engine oil.
from damage. If necessary, replace any
5. Install rocker shaft (5) into rocker shaft housing (4). components that are worn or damaged.
Hole (X) must be in the upper most position in
2. If Tooling (A) is not installed, install Tooling (A).
order for grub screw (1) to secure rocker shaft (5)
Refer to Disassembly and Assembly, “Rocker
in the correct position.
Shaft and Pushrod - Remove” for the correct
6. Install rocker arm assembly (2) for number 1 inlet procedure.
valve to the rocker shaft. Install rocker arm
assembly (3) for number 1 exhaust valve to rocker
shaft (5).

Note: The rocker arm assembly for the inlet valve is

shorter than the rocker arm assembly for the exhaust
valve. Used components should be installed in the
original location.

7. Repeat Step 6 in order to assemble the remaining

components to rocker shaft (5).
8. Install new grub screw (1) to rocker shaft housing
(4). Tighten the grub screw to a torque of 15 N·m
(133 lb in)
Note: Ensure that Hole (X) is in the upper most
position.

This document has been printed from SPI2. NOT FOR RESALE
136 UENR0624-03
Disassembly and Assembly Section

Note: Ensure that the push rods are seated in the

cups of the lifters

6. Position rocker shaft assembly (4) onto the

cylinder head.
7. Install bolts (6) to rocker shaft assembly (4).
Tighten the bolts in the numerical sequence that is
shown in Illustration 246 to a torque of 10 N·m
(89 lb in).

Note: Ensure that the rocker arms are seated in the

cups of the push rods.
Note: Ensure that the wear caps are not displaced
from the valve stems when the rocker shaft assembly
is installed.

Illustration 245 g02942696

Illustration 247 g02942738

8. Remove Tooling (A) from the cylinder block.

9. Install new O-ring seal (1) onto plug (2).
10. Install plug (2) into Position (Z) in the cylinder
Illustration 246 g02942756 block. Tighten the plug to a torque of 30 N·m
(266 lb in).
3. If necessary, install dowel (7) (not shown).
4. Apply clean engine oil to wear caps (3). Install the
wear caps to the valve stems.

Note: If the wear caps were previously used, the

wear caps must be installed in the original location.

5. Apply clean engine oil to both ends of push rods

(5). Install the push rods into the cylinder head.
Note: If the push rods have previously been used,
the push rods must be installed in the original
location.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 137
Disassembly and Assembly Section

End By: Note: Put identification marks on all hoses, on all

hose assemblies, on wires and on all tube
a. Install the valve mechanism cover. Refer to assemblies for installation purposes. Plug all hose
Disassembly and Assembly, “Valve assemblies and tube assemblies. Plugging all hose
Mechanism Cover - Remove and Install” for the
correct procedure. assemblies helps to prevent fluid loss and helps to
keep contaminants from entering the system.
i05275396
1. Drain the coolant from the cooling system into a
Cylinder Head - Remove suitable container for storage or for disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct draining
procedure.
Removal Procedure 2. Disconnect the upper radiator hose from the water
Table 50 temperature regulator housing.
Required Tools

Tool Part Number Part Description Qty

E14 Torx 1/2 Inch Drive

A - 1
Socket
E18 Torx 1/2 Inch Drive
B 27610299 1
Socket

Start By:
a. Remove the exhaust manifold. Refer to
Disassembly and Assembly, “Exhaust
Manifold - Remove and Install”.
b. Remove the injectors. Refer to Disassembly
and Assembly, “Injector - Remove”.
c. Remove the rocker shaft assembly and the
pushrods. Refer to Disassembly and Assembly
Manual, “Rocker Shaft and Pushrod - Remove”.
d. Remove the glow plugs. Refer to Disassembly
and Assembly, “Glow Plugs - Remove and
Install”. Illustration 248 g03005656
Typical example
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
138 UENR0624-03
Disassembly and Assembly Section

Illustration 249 g03005658 Illustration 250 g03005660

Sequence for tightening the bolts for the cylinder Typical example
head
5. Attach a suitable lifting device to cylinder head (3).
3. Use Tooling (A) and Tooling (B) in order to Support the weight of the cylinder head. The
gradually loosen bolts (1) and bolts (2) in the weight of the cylinder head is approximately 30 kg
reverse numerical order to the sequence that is (66 lb).
shown in Illustration 249 .
Note: Use a spreader bar during the lifting operation
Note: Follow the correct sequence in order to help in order to distribute the weight of the cylinder head.
prevent distortion of the cylinder head.
6. Use the lifting device to lift cylinder head (3)
4. Remove bolts (1) and bolts (2) from cylinder head carefully off the cylinder block.
(3).
Note: Do not use a lever to separate the cylinder
Note: The bolts are two different lengths. Note the head from the cylinder block. Take care not to
positions of the different bolts. damage the machined surfaces of the cylinder head
during the removal procedure.

NOTICE
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 139
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Thoroughly clean the gasket surfaces of the

cylinder head and the cylinder block. Do not
damage the gasket surfaces of the cylinder head
or the cylinder block. Ensure that no debris enters
the cylinder bores, the coolant passages, or the
lubricant passages.
2. Inspect the gasket surface of the cylinder head for
distortion. Refer to Specifications, “Cylinder Head”
for more information.

Illustration 251 g03005663

7. Remove cylinder head gasket (4).

8. Note the position of dowel (5) and dowel (6) in the
cylinder block. Do not remove the dowels unless
the dowels are damaged.
9. If necessary, remove the water temperature
regulator from the cylinder head. Refer to
Disassembly and Assembly, “Water Temperature
Regulator - Remove and Install”.

i05275401

Cylinder Head - Install

Illustration 252 g03005897
Typical example
Installation Procedure
Table 51 3. Inspect dowel (5) and dowel (6) for damage. If
Required Tools necessary, replace the dowels in the cylinder
block.
Tool Part Number Part Description Qty

E14 Torx 1/2 Inch Drive

4. Install Tooling (D) to the cylinder block. Refer to
A - 1 Illustration 252 .
Socket
E18 Torx 1/2 Inch Drive 5. Align cylinder head gasket (4) with Tooling (D) and
B 27610299 1
Socket with dowel (5) and dowel (6). Install the cylinder
C 27610289 Angle Gauge 1 head gasket onto the cylinder block.

Guide Bolt
D - 1
(M12 by 115mm)

E - Straight Edge 1

This document has been printed from SPI2. NOT FOR RESALE
140 UENR0624-03
Disassembly and Assembly Section

Illustration 253 g03005660 Illustration 254 g03005656

6. Use a suitable lifting device to lift the cylinder

head. The weight of the cylinder head is
approximately 30 kg (66 lb).
Note: Use a spreader bar during the lifting operation
in order to distribute the weight of the cylinder head.

7. Use Tooling (D) to align cylinder head (3) with the

cylinder block. Install the cylinder head to the
cylinder block.

Note: Ensure that the cylinder head is correctly

positioned onto dowels.

Illustration 255 g03005937

8. Clean Torx bolts (1) and Torx bolts (2). Follow

Steps 8.a and 8.b for the procedure to inspect the
Torx bolts.
a. Check the length of the Torx bolts (1) and Torx
bolts (2).

b. Use Tooling (E) in order to check the threads of

the Torx bolts. Refer to Illustration 255 . Replace
any Torx bolts that show visual reduction in the
diameter of the thread over length (Y).
9. Lubricate the threads and the shoulder of Torx
bolts (1) and Torx bolts (2) with clean engine oil.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 141
Disassembly and Assembly Section

10. Install Torx bolts (1) and Torx bolts (2) to cylinder
head (3).
11. Remove Tooling (D).
12. Install remaining Torx bolts (1) to cylinder head
(3).

Illustration 257 g03005916

15. Use Tooling (A), Tooling (B), and Tooling (C) in

order to turn Torx bolts (1) and Torx bolts (2)
through an additional angle in the sequence that is
shown in Illustration 256 .
Illustration 256 g03005658 Turn Torx bolts (2) through 90 degrees.
Sequence for tightening the bolts for the cylinder
head Turn Torx bolts (1) through 90 degrees.

13. Use Tooling (A) in order to tighten Torx bolts (2) to

a torque of 130 N·m (96 lb ft) in the sequence that
is shown in Illustration 256 .
14. Use Tooling (B) in order to tighten Torx bolt (1) to
a torque of 65 N·m (48 lb ft) in the sequence that
is shown in Illustration 256 .

Illustration 258 g03017298

16. Use Tooling (A), Tooling (B), and Tooling (C) in

order to turn Torx bolts (1) and Torx bolts (2)
through an additional angle in the sequence that is
shown in Illustration 256 .
Turn Torx bolts (2) through 70 degrees.

This document has been printed from SPI2. NOT FOR RESALE
142 UENR0624-03
Disassembly and Assembly Section

Turn Torx bolts (1) through 60 degrees. Start By:

17. Install the injectors. Refer to Disassembly and a. Remove the camshaft. Refer to Disassembly
Assembly, “Injector - Install” for the correct and Assembly, “Camshaft - Remove and
procedure. Install” for the correct procedure.
18. Install the glow plugs. Refer to Disassembly and NOTICE
Assembly, “Glow Plugs - Remove and Install” for Keep all parts clean from contaminants.
the correct procedure.
Contaminants may cause rapid wear and shortened
19. Install the rocker shaft assembly and the component life.
pushrods. Refer to Disassembly and Assembly
Manual, “Rocker Shaft and Pushrod - Remove” for
the correct procedure.
20. Install the exhaust manifold. Refer to
Disassembly and Assembly, “Exhaust Manifold -
Remove and Install” for the correct procedure.
21. If necessary, install the water temperature
regulator housing to the cylinder head. Refer to
Disassembly and Assembly, “Water Temperature
Regulator Housing - Remove and Install” for the
correct procedure.
22. Connect the upper radiator hose to the water
temperature regulator housing .
23. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct filling
procedure.
24. If necessary, fill the engine oil pan to the correct
level. Refer to Operation and Maintenance
Manual, “Engine Oil Level - Check”. Illustration 259 g02729121

i05275402
1. If the crankshaft is installed, rotate the crankshaft
in order to gain access to the appropriate lifters.
Lifter Group - Remove and 2. Use Tooling (A) in order to remove lifters (1) from
Install the cylinder block.
Note: Place a temporary identification mark on each
lifter in order to identify the correct location.
Removal Procedure
Table 52
Installation Procedure
Table 53
Required Tools
Required Tools
Tool Part Number Part Description Qty
Tool Part Number Part Description Qty
A - Telescoping Magnet 1
A - Telescoping Magnet 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 143
Disassembly and Assembly Section

End By:
NOTICE
Replace all lifters when a new camshaft is installed. a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove and Install” for
1. Ensure that all components are clean and free the correct procedure.
from wear and damage. If necessary, replace any
i05293777
components that are worn or damaged.
2. Clean the lifters. Follow Step 2.a through Step 2.c Camshaft - Remove and Install
in order to inspect the lifters. Replace any worn
lifters or damaged lifters.

a. Inspect the seat of the pushrod in the lifter for Removal Procedure
visual wear and damage.
Start By:
b. Inspect the shank of the lifter for wear and
a. Remove the camshaft gear. Refer to
damage. Refer to Specifications, “Lifter Group” Disassembly and Assembly, “Camshaft Gear -
for more information. Remove and Install” for the correct procedure.
c. Inspect the face of the lifter that runs on the
NOTICE
camshaft for visual wear and damage. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. The engine should be mounted on a suitable stand

and placed in the inverted position.

Illustration 260 g02729121

3. If the crankshaft is installed, rotate the crankshaft

in order to allow access for the installation of
appropriate lifters (1).
4. Lubricate lifters (1) with clean engine oil.
Illustration 261 g02946416
5. Use Tooling (A) to install lifters (1) to the cylinder
block. Ensure that used lifters are installed in the 2. Remove bolts (3) from thrust plate (1).
original location.
3. Make a temporary mark in order to identify the
Note: The lifters should be free to rotate. orientation of thrust plate (1). Slide the camshaft
towards the front of the engine in order to allow
removal of the thrust plate. Remove the thrust
plate.

This document has been printed from SPI2. NOT FOR RESALE
144 UENR0624-03
Disassembly and Assembly Section

3. Inspect the lifters for wear and for damage. Refer

NOTICE
Do not damage the lobes or the bearings when the to Specifications, “Lifter Group” for more
camshaft is removed or installed. information. If necessary, replace any lifters that
are worn or damaged. Refer to Disassembly and
Assembly, “Lifter Group - Remove and Install” for
4. Carefully remove camshaft (3) from the cylinder
the correct procedure.
block.
4. Lubricate the lobes and the bearing surfaces of the
Installation Procedure camshaft with clean engine oil.

NOTICE NOTICE
Keep all parts clean from contaminants. Do not damage the lobes or the bearings when the
camshaft is removed or installed.
Contaminants may cause rapid wear and shortened
component life.
5. Carefully install camshaft (3) into the cylinder
block. Leave the camshaft slightly protruding in
order to allow installation of the thrust plate.

Illustration 263 g02948296

6. Lubricate thrust plate (1) with clean engine oil.

Position the thrust plate onto the camshaft with the
Illustration 262 g02946416 chamfer in Position (X) facing towards the cylinder
block. Slide the camshaft into the cylinder block.
1. Clean camshaft (2) and clean thrust plate (1).
7. Install bolts (3) to thrust plate (1). Tighten the bolts
Inspect the camshaft and the thrust plate for wear
to a torque of 25 N·m (221 lb in)
and damage. Refer to Specifications, “Camshaft”
for more information. If necessary, replace any
components that are worn or damaged.
2. Clean the camshaft bearing in the cylinder block.
Inspect the camshaft bearing for wear and
damage. Refer to Specifications, “Camshaft
Bearings” for more information. If necessary,
replace the camshaft bearing. Refer to
Disassembly and Assembly, “Camshaft Bearing -
Remove and Install”.

NOTICE
Replace all lifters when a new camshaft is installed.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 145
Disassembly and Assembly Section

End By:
a. Install the camshaft gear. Refer to Disassembly
and Assembly, “Camshaft Gear - Remove and
Install” for the correct procedure.

i05279011

Camshaft Gear - Remove and

Install

Removal Procedure
Table 54
Required Tools

Tool Part Number Part Description Qty

A T400089 Timing Pin (Crankshaft) 1

B T400152 Timing Pin (Camshaft) 1

Illustration 264 g02945576
Snap-on PBS650
C - 1
Small Pry Bar 4. Remove bolts (3) from camshaft (4).
5. Remove camshaft timing ring (2) from dowels (5).
Start By:
6. Use Tooling (C) in order to remove camshaft gear
a. Remove the rocker shaft and pushrods. Refer (1) from camshaft (4).
to Disassembly and Assembly, “Rocker Shaft
and Pushrod - Remove” for the correct Installation Procedure
procedure.
Table 55
NOTICE Required Tools
Keep all parts clean and free from contaminants.
Tool Part Number Part Description Qty
Contaminants may cause rapid wear and shorten
component life. A T400089 Timing Pin (Crankshaft) 1

B T400152 Timing Pin (Camshaft) 1

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- NOTICE
nance, testing, adjusting and repair of the product. Keep all parts clean from contaminants.
Be prepared to collect the fluid with suitable contain- Contaminants may cause rapid wear and shortened
ers before opening any compartment or disassem- component life.
bling any component containing fluids.
Dispose of all fluids according to local regulations 1. Ensure that all components are clean and free
and mandates.
from wear and damage. If necessary, replace any
components that are worn or damaged.
1. Remove the idler gear. Refer to Disassembly and
2. If Tooling (A) is not installed, install Tooling (A).
Assembly, “Idler Gear - Remove” for the correct
Refer to Disassembly and Assembly, “Idler Gear -
procedure.
Remove” for the correct procedure.
2. Ensure that Tooling (A) remains in position during
the removal and installation procedures for the
camshaft gear.
3. Remove Tooling (B).

This document has been printed from SPI2. NOT FOR RESALE
146 UENR0624-03
Disassembly and Assembly Section

Illustration 267 g02945716

Illustration 265 g02945576

Illustration 268 g02945837

Illustration 266 g02945776
3. Lubricate the teeth of gear (1) with clean engine
oil.
4. Align the timing mark on camshaft (4) in Position
(V) with the timing mark on the front housing in
Position (W).
5. Position camshaft gear (1) onto camshaft (4).
Ensure that dowel (6) is installed into Hole (X) in
the camshaft.
6. Ensure that the chamfered tooth on the crankshaft
gear in Position (Y) is between the timing marks in
Positions (Z) on the camshaft gear.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 147
Disassembly and Assembly Section

7. Install Tooling (B). Refer to Disassembly and

Assembly, “Idler Gear - Remove” for the correct
procedure.
8. Install camshaft timing ring (2) onto dowels (5).
9. Install bolts (3) into camshaft (4). Tighten the bolts
to a torque of 25 N·m (221 lb in).
End By:
a. Install the idler gear. Refer to Disassembly and
Assembly, “Idler Gear - Install” for the correct
procedure.
b. Install the rocker shaft and pushrods. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install” for the correct procedure.

i05279035

Camshaft Bearings - Remove

and Install Illustration 269 g02729141

1. Inspect camshaft bearing (1). Refer to

Specifications, “Camshaft Bearings” for more
Removal Procedure information.
Table 56
2. If camshaft bearing (1) is worn or damaged, use
Required Tools
Tooling (A) and Tooling (B) in order to remove the
Tool Part Number Part Description Qty camshaft bearing from the cylinder block.
Camshaft Bushing Punch Note: Remove the camshaft bearing from the front of
A T400085 1
Tool the cylinder block.
B T400084 Handle for Punch Tool 1
Installation Procedure
Start By: Table 57
Required Tools
a. Remove the camshaft. Refer to Disassembly
and Assembly, “Camshaft - Remove and Tool Part Number Part Description Qty
Install” for the correct procedure.
Camshaft Bushing Punch
A T400085 1
NOTICE Tool
Keep all parts clean from contaminants. B T400084 Handle for Punch Tool 1
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Keep all parts clean from contaminants.
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.

This document has been printed from SPI2. NOT FOR RESALE
148 UENR0624-03
Disassembly and Assembly Section

Illustration 270 g02948516

2. Lubricate the bearing housing in the cylinder block

with clean engine oil.
3. Accurately align large oil Hole (X) in camshaft
bearing (1) with the oil hole in the cylinder block.
4. Use Tooling (A) and Tooling (B) in order to install
camshaft bearing (1) into the cylinder block.

Note: Ensure that the oil holes are correctly aligned.

If the oil is not correctly aligned, the camshaft bearing Illustration 271 g02823478
should be removed.
1. Remove oil drain plug (6). Drain the engine oil into
End By: a suitable container for storage or disposal.
a. Install the camshaft. Refer to Disassembly and 2. Remove sealing washer (5) (not shown) from oil
Assembly, “Camshaft - Remove and Install” for drain plug (5).
the correct procedure.
3. Remove two M10 bolts (7) and remove M8 bolts
i05279037 (3) from engine oil pan (4).

Engine Oil Pan - Remove and Note: Support the weight of the engine oil pan.

Install 4. Remove spacer (2) from engine oil pan (4).

5. Remove engine oil pan (4) from the cylinder block.
(Pressed Steel Oil Pan)
6. Remove gasket (1) (not shown).

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 149
Disassembly and Assembly Section

Illustration 272 g02823476 Illustration 273 g02823476

7. If necessary, follow Step 7.a through Step 7.d in 2. If necessary, follow Step 2.a through Step 2.f in
order to remove oil suction pipe (9) from the order to install oil suction pipe (9).
cylinder block.
a. Install new O-ring seal (8) to oil suction pipe (9).
a. Remove Allen head cap screw (10) from oil
suction pipe (9). b. Install oil suction pipe (9) to the cylinder block.

b. Remove bolts (11) from oil suction pipe (9). c. Apply Tooling (A) onto the threads of Allen head
cap screw (10). Install the Allen head cap screw
c. Remove oil suction pipe (9) from the cylinder to the oil suction pipe.
block.
d. Apply Tooling (A) onto the threads of bolts (11).
d. Remove O-ring (8) from oil suction pipe (9). Install bolts (11) to the oil suction pipe support.

Installation Procedure e. Tighten Allen head cap screw (10) to a torque of

Table 58 10 N·m (89 lb in).
Required Tools
f. When a M8 bolts are installed, tighten bolts (11)
Tool Part Number Part Description Qty to a torque of 25 N·m (221 lb in).
A - Technologic 15 1 When a M10 bolts are installed, tighten bolts
(11) to a torque of 45 N·m (33 lb ft).

NOTICE 3. Clean the mating surface of the cylinder block.

Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that all components are clean and free

from damage. If necessary, replace any
components that are worn or damaged.

This document has been printed from SPI2. NOT FOR RESALE
150 UENR0624-03
Disassembly and Assembly Section

Tighten bolts (7) to a torque of 45 N·m (33 lb ft).

9. Install a new sealing washer (5) to oil drain plug
(6).
10. Install oil drain plug (6) to the engine oil pan .
Tighten the oil drain plug to a torque of 50 N·m
(37 lb ft).
11. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for the correct procedure.

i05279039

Engine Oil Pan - Remove and

Install
(Cast Iron Engine Oil Pan)

Illustration 274 g02823478

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Note: Ensure that the engine lubricating oil is

drained. Refer to Operation and Maintenance
Manual, “Engine Oil and Filter - Change” for the
correct procedure.
Illustration 275 g02826556
Note: In order to remove a cast iron oil pan, the
4. Position gasket (1) (not shown) onto engine oil pan engine must be removed from the machine. The
(4). engine should be mounted in a suitable stand and
placed in the inverted position.
5. Position spacer (2) onto the engine oil pan.
6. Position engine oil pan assembly (4) onto the
cylinder block. Use a suitable tool to support the
weight of the engine oil pan.
7. Install bolts (3) and install bolts (7) finger tight.
8. Tighten bolts (3) and bolts (7) in the sequence that
is shown in Illustration 275 .
Tighten bolts (3) to a torque of 25 N·m (221 lb in).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 151
Disassembly and Assembly Section

Illustration 276 g02835137 Illustration 277 g02835177

Typical example
1. Mount the engine in a suitable stand and place in
the inverted position. 8. If necessary, follow Step 8.a through Step 8.d in
order to remove oil suction pipe (8) from the
2. If necessary, remove dipstick (2) from engine oil
cylinder block.
pan (3).
3. Remove sealing washer (5) (not shown) from oil a. Remove Allen head cap screw (9) from oil
drain plug (6). suction pipe (8).
4. Remove bolts (4) from engine oil pan (3). b. Remove bolts (10) from the oil suction pipe.
5. Attach a suitable lifting device to engine oil pan (3). c. Remove the oil suction pipe from the cylinder
The engine oil pan can weigh 45 kg (99 lb). block.
6. Use the lifting device in order to remove engine oil
d. Remove O-ring (7) from oil suction pipe (8).
pan (3) from the cylinder block.
7. Remove gasket (1) (not shown). Installation Procedure
Table 59
Required Tools

Tool Part Number Part Description Qty

A - Technologic 15 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that all components are clean and free

from wear and damage. If necessary, replace any
components that are worn or damaged.

This document has been printed from SPI2. NOT FOR RESALE
152 UENR0624-03
Disassembly and Assembly Section

Illustration 278 g02835177 Illustration 279 g02835137

Typical example

2. If necessary, follow Step 2.a through Step 2.f in

order to install oil suction pipe (8).

a. Install new O-ring seal (7) to oil suction pipe (8).

b. Install the oil suction pipe to the cylinder block.

c. Apply Tooling (A) onto the threads of Allen head

cap screw (9). Install the Allen head cap screw
to the oil suction pipe.

d. Apply Tooling (A) onto the threads of bolts (10).

Install bolts (10) to the oil suction pipe support.

e. Tighten Allen head cap screw (9) to a torque of

10 N·m (89 lb in).

f. When M8 bolts are installed, tighten bolts (10)

to a torque of 25 N·m (221 lb in).
When M10 bolts are installed, tighten bolts
(10) to a torque of 45 N·m (33 lb ft).
3. Clean the mating surface of the cylinder block.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 153
Disassembly and Assembly Section

Illustration 280 g02835539

Initial tightening sequence

Illustration 281 g02835357

Secondary tightening sequence

4. Position gasket (1) (not shown) onto engine oil pan 8. Align the rear face of the engine oil pan with the
(4). rear of the cylinder block.
5. Attach a suitable lifting device to engine oil pan (3). 9. Tighten bolts (4) in the initial sequence that is
The engine oil pan can weigh 45 kg (99 lb). shown in Illustration 280 .
6. Use the lifting device in order to position engine oil Tighten bolts (7) to a torque of 45 N·m (33 lb ft).
pan (3) onto the cylinder block.
10. Tighten bolts (4) in the final sequence that is
7. Apply Tooling (A) to bolts (4).Install the bolts finger shown in Illustration 281 .
tight.
Tighten bolts (7) to a torque of 45 N·m (33 lb ft).

This document has been printed from SPI2. NOT FOR RESALE
154 UENR0624-03
Disassembly and Assembly Section

11. Ensure that the face of engine oil pan (3) and the
cylinder block are still correctly aligned.
12. Install a new sealing washer (5) to oil drain plug
(6).
13. Install oil drain plug (6) to the engine oil pan .
Tighten the oil drain plug to a torque of 50 N·m
(37 lb ft).
14. Remove the engine from the suitable stand.
15. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for the correct procedure.

i05279046

Balancer - Remove

Removal Procedure Illustration 282 g02887016

Table 60
Required Tools

Tool Part Number Part Name Qty

A T400086 Crankshaft Locking Pin 1

Balancer Timing Pin

B - 1
(Bolt M8 by 22mm)

Start By:
a. Remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan -
Remove and Install” for the correct procedure.
Note: In order to remove the balancer safely, the
engine must be removed from the machine. The
engine should be mounted in a suitable stand and
placed in the inverted position.

NOTICE
Keep all parts clean from contaminants.
Illustration 283 g02709625
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 155
Disassembly and Assembly Section

10. Do not remove dowels (9) unless the dowels are

damaged.

i05279048

Balancer - Install

Installation Procedure
Table 61
Required Tools

Tool Part Number Part Name Qty

A T400086 Crankshaft Locking Pin 1

Balancer Timing Pin

B - 1
(Bolt M8 by 22mm)

Illustration 284 g02893017

NOTICE
Keep all parts clean from contaminants.
1. Remove plug (2) from Position (X) in the cylinder
block. Remove O-ring seal (1) from the plug. Contaminants may cause rapid wear and shortened
component life.
2. Install Tooling (A) into the cylinder block in Position
(X).
1. Check all components for wear and damage. If
Note: Tooling (A) must be located in Position (Y) in necessary, replace any components that are worn
the crankshaft. or damaged.

Note: Ensure that Tooling (A) is located in the correct 2. Check that the balancer drive gear is not worn or
drilling in the crankshaft as shown in Illustration 282 . damaged. If necessary, replace the balancer drive
gear.
3. Remove bolts (6) from oil suction pipe (3).
4. Remove bolt (7) from oil suction pipe (3).
5. Remove oil suction pipe (3) from the cylinder
block. Remove O-ring seal (8) from the oil suction
pipe.

Movement of the counterweight can cause per-

sonal injury.

6. Install Tooling (B) in Position (Z) in order to prevent

movement of the counterweights.
Note: If Tooling (B) cannot be installed to the
balancer, the crankshaft is not in the correct position.

7. Remove bolts (5).

8. Attach a suitable lifting device to balancer (4).
Support the weight of balancer, the weight is
approximately 15 kg (33 lb).
9. Use the suitable lifting device in order to remove
the balancer from the cylinder block.

This document has been printed from SPI2. NOT FOR RESALE
156 UENR0624-03
Disassembly and Assembly Section

Illustration 287 g02709625

Illustration 285 g02887016
3. Install Tooling (A) into Position (X) in the cylinder
block. Tooling (A) must be located in Position (Y)
in the crankshaft.

Note: Ensure that Tooling (A) is located in the correct

drilling in the crankshaft as shown in Illustration 285 .

Note: Failure to locate the crankshaft in the correct

position will cause severe engine damage.

4. Ensure that Tooling (B) is installed to balancer (4).

Note: New balancers will be supplied with Tooling (B)

in position.

5. If necessary, install dowels (9) to balancer (4).

6. Attach a suitable lifting device to the balancer. The
weight is approximately 15 kg (33 lb).
7. Use the suitable lifting device in order to install the
balancer to the cylinder block.
8. Install bolts (5) to the balancer. Tighten the bolts to
Illustration 286 g02893017 a torque of 70 N·m (52 lb ft).
9. Remove the suitable lifting device from the
balancer.
10. Install a new O-ring seal (8) onto suction pipe (3).
Install the suction pipe assembly to the cylinder
block.
11. Install bolt (7) finger tight.
12. Install bolts (6) finger tight.
13. Tighten bolt (7) to a torque of 10 N·m (89 lb in)
14. When M8 bolts are installed, tighten bolts (6) to a
torque of 25 N·m (221 lb in).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 157
Disassembly and Assembly Section

When M10 bolts are installed, tighten bolts (6) to a

torque of 45 N·m (33 lb ft).
15. Remove Tooling (B) from Position (Z) in the
balancer.
16. Remove Tooling (A) from Position (X) in the
cylinder block.
17. Install a new O-ring seal (1) to plug (2). Install
plug (2) into Position (X) in the cylinder block.
Tighten the plug to a torque of 50 N·m (37 lb ft).
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
Install” for the correct procedure.

i05279052

Piston Cooling Jets - Remove

and Install Illustration 288 g02895676

1. Remove banjo bolt (2) and piston cooling jet (1)

from the cylinder block.
Removal Procedure
2. Repeat Step 1 in order to remove the remaining
Start By:
piston cooling jets.
a. Remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan - Installation Procedure
Remove and Install” for the correct procedure.
NOTICE
b. Remove the crankshaft. Refer to Disassembly Keep all parts clean from contaminants.
and Assembly, “Crankshaft - Remove” for the
correct procedure. Contaminants may cause rapid wear and shortened
component life.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
158 UENR0624-03
Disassembly and Assembly Section

End By:
a. Install the crankshaft. Refer to Disassembly
and Assembly, “Crankshaft - Install” for the
correct procedure.
b. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install” for the
correct procedure.

i05279061

Pistons and Connecting Rods

- Remove

Removal Procedure
Table 62
Required Tools

Illustration 289 g02895676 Tool Part Number Part Description Qty

A 27610274 Ridge Reamer 1

1. Clean the piston cooling jets and inspect the piston
cooling jets for damage. Replace any damaged
piston cooling jets. The procedure for checking Start By:
that the alignment of the piston cooling jets is a. Remove the oil suction pipe. Refer to
described in Specifications, “Piston Cooling Jet Disassembly and Assembly, “Engine Oil Pan -
Alignment” for the correct information. Remove and Install” for the correct procedure.
2. Install banjo bolt (2) to piston cooling jet (1). Install b. If necessary, remove the balancer. Refer to
the piston cooling jet assembly into the recess in Disassembly and Assembly, “Balancer -
the cylinder block. Remove” for the correct procedure.
3. Tighten banjo bolt (2) to a torque of 18 N·m c. Remove the cylinder head. Refer to
(159 lb in). Disassembly and Assembly, “Cylinder Head -
Remove” for the correct procedure.
4. Repeat Step 2 through Step 3 for the remaining
piston cooling jets. NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Rotate crankshaft until the required connecting rod

is at bottom dead center.
2. Using tooling (A), remove carbon build-up from the
top of the cylinder bore.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 159
Disassembly and Assembly Section

Illustration 290 g03001196 Illustration 291 g02998516

Typical example Typical example

Note: Do not stamp the connecting rod assembly. 6. Carefully push piston (4) and the connecting rod
Stamping or punching the connecting rod assembly out of the cylinder bore. Lift piston (4) out of the
could cause the connecting rod to fracture. top of the cylinder block.
3. The connecting rod and the connecting rod cap Note: Do not apply force to the fracture split surfaces
should have an etched number in Position (X). of the connecting rod as damage may result.
The number on the connecting rod and the
connecting rod cap must match. Ensure that 7. Temporarily install connecting rod cap (1) and bolts
connecting rod (3) and connecting rod cap (1) are (2) to connecting rod (3) when the assembly is out
marked for the correct location. If necessary, make of the engine. Ensure that the etched number on
a temporary mark on the connecting rod and the connecting rod cap matches the etched number
connecting rod cap in order to identify the cylinder on connecting rod . Ensure the correct orientation
number and orientation of the assembly. of the connecting rod cap . The locating tab for the
upper bearing shell and the lower bearing shell
4. Remove the bolts (2) and remove connecting rod should be on the same side. Tighten bolts (2) to a
cap (1) from connecting rod (3). torque of 20 N·m (177 lb in).
5. Rotate crankshaft so that the required piston is at 8. Repeat Step 1 through Step 7in order to remove
top center position. the remaining pistons and connecting rods.

This document has been printed from SPI2. NOT FOR RESALE
160 UENR0624-03
Disassembly and Assembly Section

Fracture split connecting rods should not be left

without the connecting rod caps installed.

i05279089

Pistons and Connecting Rods

- Disassemble

Disassembly Procedure
Table 63
Required Tools

Tool Part Number Part Description Qty

A - Retaining Ring Pliers 1

B - Ring Expander 1

Start By:
a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, “Piston
and Connecting Rods - Remove” for the
correct procedure.
Note: Make a temporary mark on the components of
Illustration 292 g03001216
the piston and connecting rod assembly. Making
temporary marks will ensure that the components of
each piston and connecting rod assembly can be 1. Remove lower bearing shell (10) from connecting
reinstalled in the original location. Mark the underside rod cap (11). Remove upper bearing shell (9) from
of the piston on the front pin boss. Do not connecting rod (7). Keep the bearing shells
interchange components. together.
2. Place the piston and connecting rod assembly on a
NOTICE suitable surface with the connecting rod upward.
Keep all parts clean from contaminants.
Use Tooling (A) in order to remove circlips (5).
Contaminants may cause rapid wear and shortened 3. Remove piston pin (6) from bushing (8) in
component life.
connecting rod (7). Remove connecting rod (7 )
from piston (4).
Note: If the piston pin cannot be removed by hand,
heat the piston to a temperature of 45 ± 5 °C
(113 ± 9 °F). Do not use a torch to heat the piston.
Note the orientation of connecting rod (7) and piston
(4).

4. Place the piston on a suitable surface with the

crown upward. Use Tooling (B) in order to remove
compression ring (1), compression ring (2), and oil
control ring (3) from piston (4).
Note: Make temporary identification marks to Identify
the position and orientation of compression ring (1),
compression ring (2), and oil control ring (3).

5. Inspect the connecting rod for wear and damage. If

necessary, replace connecting rod (7) .

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 161
Disassembly and Assembly Section

6. Repeat Step 1 through Step 5 in order to 3. Position the oil control ring with the word “TOP” in
disassemble the remaining pistons and connecting the upward position. Use Tooling (B) to install oil
rods. control ring (3) over the piston and the spring.

i05282636 Note: Ensure that the central wire is 180 degrees

from the ring gap.
Pistons and Connecting Rods 4. Use Tooling (B) to install intermediate compression
- Assemble ring (2) into the second groove in piston (4). The
word “TOP” must be upward.
5. Use Tooling (B) to install top compression ring (1)
Assembly Procedure into the top groove in piston (4). The word “TOP”
must be upward.
Table 64
6. Position the piston ring gaps at approximately 120
Required Tools
degrees away from each other.
Tool Part Number Part Description Qty
Note: A new piston assembly is supplied with new
A - Retaining Ring Pliers 1 piston rings.
B - Ring Expander 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 294 g03001779

(A) Cut away for piston cooling jet
(9) Upper bearing shell for connecting rod
(X) Connecting rod identification marks
(Y) Location tag on connecting rod shells
(Z) Location tag in connecting rod for shells (not shown)
(10) Lower shell bearing for connecting rod cap

7. Use Illustration 294 as an assembly guide.

Illustration 293 g03003219

1. Ensure that all components are clean and free

from wear and damage. If necessary, replace any
components that are worn or damaged.
2. Position the spring for oil control ring (3) into the oil
ring groove in piston (4). The central wire must be
located inside the end of the spring.

This document has been printed from SPI2. NOT FOR RESALE
162 UENR0624-03
Disassembly and Assembly Section

13. Temporarily install connecting rod cap (11) and

bolts (12) to connecting rod (7) when the assembly
is out of the engine. Ensure that the etched
number on connecting rod cap matches the
etched number on connecting rod. Ensure the
correct orientation of the connecting rod cap. The
locating tab for the upper bearing shell and the
lower bearing shell should be on the same side.
Tighten bolts (12) to a torque of 20 N·m (177 lb in)
.
14. Repeat Step 1 through Step 13 for the remaining
piston and connecting rod assemblies.
Note: Fracture split connecting rods should not be
left without the connecting rod caps installed.
End By:
a. Install the pistons and the connecting rods.
Refer to Disassembly and Assembly, “Piston
and Connecting Rods - Install” for the correct
procedure.

i05282637

Pistons and Connecting Rods

Illustration 295 g03001216
- Install
8. Lubricate bushing (8) for piston pin (6) in the
connecting rod with clean engine oil. Lubricate the Installation Procedure
bore for the piston pin in piston (4) with clean
Table 65
engine oil.
Required Tools
9. Install piston pin (6) to piston (4).
Tool Part Number Part Description Qty
Note: If the piston pin cannot be installed by hand,
B 21825491 Piston Ring Compressor 1
heat the piston to a temperature of 45° ± 5°C
(113° ± 9°F). C 27610289 Angle Gauge 1

10. Use Tooling (A) in order to install circlips (5) to the

piston pin bore in piston (4). NOTICE
Keep all parts clean from contaminants.
Note: Ensure that the circlips are seated in the
grooves in the piston. Contaminants may cause rapid wear and shortened
component life.
11. Install upper bearing shell (9) into connecting rod
(7). Ensure that the locating tab for the upper
1. If the connecting rod caps were temporarily
bearing shell is correctly seated in slot in the
installed, remove the connecting rod caps. If
connecting rod.
necessary, thoroughly clean all of the components.
12. Install lower bearing shell (10) into connecting rod
cap (11). Ensure that the locating tab for the lower Note: Discard all used connecting rod bolts.
bearing shell is correctly seated in the slot in the
2. Apply clean engine oil to the cylinder bore, piston,
connecting rod cap.
piston rings, connecting rod shell, and the shell in
the connecting rod cap.
3. Rotate crankshaft until the required crankshaft
journal is at bottom center position. Lubricate the
crankshaft journal with clean engine oil.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 163
Disassembly and Assembly Section

Illustration 296 g02999358 Illustration 298 g03001177

Typical example
4. Lightly lubricate Tooling A with clean engine oil.
Install Tooling (A) onto piston (4) 7. Ensure that etched number in Position (X) on
connecting rod cap (1) matches etched number in
Note: Ensure that the piston assembly is installed
Position (X) on connecting rod (3). Ensure the
into the correct cylinder. Also, ensure the correct
orientation of the assembly, refer to Illustration 297 . correct orientation of connecting rod cap (1). The
locating tab for the upper bearing shell and the
lower bearing shell should be on the same side.
Install the connecting rod cap (1) and install new
bolts (2).
8. Tighten the new bolts to 50 N·m (37 lb ft). Turn the
bolts for an additional 70 degrees in a clockwise
direction. Use Tooling (C) in order to achieve the
correct final torque.
9. Ensure that the installed connecting rod assembly
has tactile side play. Rotate the crankshaft in order
to ensure that there is no binding.
10. Repeat Step 1 through Step 9 in order to install
the remaining pistons and connecting rod
assemblies
Illustration 297 g02999579
(4) Piston
(A) Cut out for piston cooling jet
(Y) Cooling jet
(X) Connecting rod identification marks

5. Ensure that Tooling (B) is installed correctly and

that piston (4) can easily slide from the tool.

Note: Ensure alignment of the connecting rod

assembly to the crankshaft journal.

6. Carefully push the piston and the connecting rod

assembly into the cylinder bore and onto the
crankshaft pin.

This document has been printed from SPI2. NOT FOR RESALE
164 UENR0624-03
Disassembly and Assembly Section

End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
correct procedure.
b. If necessary, install the balancer. Refer to
Disassembly and Assembly, “Balancer -
Install” for the correct procedure.
c. Install the oil suction pipe. Refer to
Disassembly and Assembly, “Engine Oil Pan
Remove and Install” for the correct procedure.

i05282665

Connecting Rod Bearings -

Remove
(Connecting rods in position)

Illustration 299 g03005637

Removal Procedure (X) Identification marks
Start By:
a. Remove the engine oil suction pipe. Refer to
Disassembly and Assembly, “Engine Oil Pan -
Remove and Install” for the correct procedure.
b. If necessary, remove the balancer. Refer to
Disassembly and Assembly, “Balancer -
Remove ” for the correct procedure

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

NOTICE Illustration 300 g01341322

Discard all used Connecting Rod fasteners.
1. The connecting rod and the connecting rod cap
should have an etched number in Positions (X).
Note: If all connecting rod bearings require
replacement, the procedure can be carried out on The number on the connecting rod and the
two cylinders at the same time. The procedure can connecting rod cap must match. If necessary,
be carried out on the following pairs of cylinders. 1 make a temporary mark on connecting rod (5) and
and 4 then 2 and 3. Ensure that the installation connecting rod cap (2) in order to identify the
procedure on one pair connecting rods is cylinder number.
completed before starting the removal procedure
on the next pair of connecting rods. Note: Do not punch identification marks onto fracture
split connecting rods. Do not stamp identification
marks onto fracture split connecting rods.

2. Rotate the crankshaft so that required connecting

rods are at bottom center position. Remove bolts
(1) and discard the bolts.
3. Remove connecting rod cap (2) from connecting
rod (5).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 165
Disassembly and Assembly Section

4. Remove lower bearing shell (3) from connecting 1. Inspect the pins of the crankshaft for damage. If
rod cap (2). Keep the bearing shell and the the crankshaft is damaged, replace the crankshaft.
connecting rod cap together. Refer to Disassembly and Assembly, “Crankshaft -
Remove” and Disassembly and Assembly,
5. Carefully push connecting rod (5) into the cylinder
“Crankshaft - Install” for the correct procedure.
bore until connecting rod (5) is clear of the
Ensure that the main bearing shells are clean and
crankshaft. Remove upper bearing shell (4) from
free from wear and damage. If necessary, replace
the connecting rod. Keep the bearing shells
the main bearing shells.
together.
Note: If the main bearing shells are replaced, check
Note: Do not push the fracture split surfaces of the
whether oversize main bearing shells were
connecting rod as damage may result. Do not allow
previously installed.
the connecting rod to contact the piston cooling jet.
2. Ensure that the crankshaft is in the bottom center
6. Repeat Step 1 through Step 5 in order to remove
position.
the remaining bearing shells.

Note: Fracture split connecting rods should not be

left without the connecting rod caps installed. After
the removal procedure for the bearing shells is
complete, carry out the installation procedure as
soon as possible. Refer to Disassembly and
Assembly, “Connecting Rod Bearings - Install” for the
correct procedure.

i05282667

Connecting Rod Bearings -

Install
(Connecting rods in position)
Illustration 301 g02015553

3. Install upper bearing shell (4) into connecting rod

Installation Procedure (5). Ensure that the locating tab for the upper
Table 66 bearing shell is correctly seated in the slot in the
connecting rod.
Required Tools

Tool Part Number Part Description Qty Note: The ends of the upper bearing shell must be
centered in the connecting rod. The ends of the
A 27610289 Angle Gauge 1 upper bearing shell must be equally positioned in
relation to the mating faces of the connecting rod.

NOTICE 4. Lubricate upper bearing shell (4) with clean engine

Keep all parts clean from contaminants. oil.
Contaminants may cause rapid wear and shortened 5. Carefully guide connecting rod (5) against the
component life. crankshaft pin.
Note: Do not allow the connecting rod to contact the
NOTICE piston cooling jet.
Discard all used Connecting Rod fasteners.
6. Clean connecting rod cap (2). Install lower bearing
shell (3) into connecting rod cap (2). Ensure that
the locating tab for the lower bearing shell is
correctly seated in the slot in the connecting rod
cap.
7. Lubricate the pin of the crankshaft and lubricate
lower bearing shell (3) with clean engine oil.

This document has been printed from SPI2. NOT FOR RESALE
166 UENR0624-03
Disassembly and Assembly Section

End By:
a. If necessary, install the balancer. Refer to
Disassembly and Assembly, “Balancer Install”
for the correct procedure.
b. Install the engine oil suction pipe. Refer to
Disassembly and Assembly, “Engine Oil Pan -
Remove and Install” for the correct procedure.

i05282668

Crankshaft Main Bearings -

Remove and Install

Removal Procedure
Table 67
Required Tools

Illustration 302 g03005637 Tool Part Number Part Description Qty

T400157 Housing 1
8. Install connecting rod cap (2) to connecting rod (5). A(1)
T400156 Engine Turning Tool 1
Note: Ensure that etched number in Position (X) on (1) This tool is used in the aperture for the electric starting motor.
connecting rod cap (2) matches etched number in
Position (X) on connecting rod (5). Ensure the correct
Start By:
orientation of the connecting rod cap. The locating
tab for the upper bearing shell and the lower bearing a. Remove the engine oil pan and suction pipe.
shell should be on the same side. Refer to Disassembly and Assembly, “Engine
Oil Pan - Remove and Install” for the correct
Note: Do not reuse the old bolts in order to secure procedure.
the connecting rod cap.
b. If necessary, remove the balancer. Refer to
9. Install new bolts (1) and tighten to 50 N·m (36 lb ft) Disassembly and Assembly, “Balancer -
. Turn the bolts an additional 70 degrees in a Remove” for the correct procedure.
clockwise direction. Use Tooling (A) in order to
achieve the required torque. NOTICE
This procedure must only be used to remove and in-
10. Ensure that the installed connecting rod stall the main bearing shells with the crankshaft in
assembly has tactile side play. Rotate the position.
crankshaft in order to ensure that there is no The removal procedure and the installation proce-
binding. dure must be completed for each pair of main bearing
shells before the next pair of main bearing shells are
Note: If all connecting rod bearings require removed.
replacement, the procedure can be carried out on
two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders. 1 NOTICE
and 4 then 2 and 3. Ensure that the installation Keep all parts clean from contaminants.
procedure on one pair connecting rods is
completed before starting the removal procedure Contaminants may cause rapid wear and shortened
on the next pair of connecting rods. component life.

11. Repeat Step 1 through Step 10 in order to install

1. Ensure that the main bearing cap is marked for the
the remaining connecting rod bearings.
correct location and orientation.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 167
Disassembly and Assembly Section

Illustration 303 g03003177 Illustration 305 g03003457

Typical example

2. Remove bolts (1) and remove main bearing cap (2)

from the cylinder block.

Illustration 306 g03003257

4. Push out upper main bearing shell (5) with a

suitable tool from the side opposite the locating
Illustration 304 g03003178
tab. Use Tooling (A) in order to rotate the
Typical example crankshaft while you push on the bearing shell.
Remove upper main bearing shell (5) from the
3. Remove lower main bearing shell (3) from main cylinder block. Keep the bearing shells together.
bearing cap (2). Keep the main bearing shell and The thrust washers (4) are attached to number
the main bearing cap together. three upper main bearing shell. Make a note of the
Note: The lower main bearing shell is a plain bearing orientation of the thrust washers for installation
that has no oil holes. purposes.

Note: The upper main bearing shell has a groove

and oil hole.

This document has been printed from SPI2. NOT FOR RESALE
168 UENR0624-03
Disassembly and Assembly Section

Installation Procedure
Table 68
Required Tools

Tool Part Number Part Description Qty

B 27610289 Angle Gauge 1

21825617 Dial Indicator 1

C
- Magnetic Base and Stand 1

NOTICE
This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in
position.
The removal procedure and the installation proce-
dure must be completed for each pair of main bearing
shells before the next pair of main bearing shells are
removed.

Illustration 307 g03003457

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that the main bearing shells are clean and

free from wear and damage. If necessary, replace
the main bearing shells.

Note: If the main bearing shells are replaced, check

whether oversize main bearing shells were
previously installed. If the thrust washers are
replaced, check whether oversize thrust washers
were previously installed.

2. Clean the journals of the crankshaft. Inspect the

Illustration 308 g03003257
journals of the crankshaft for damage. If
necessary, replace the crankshaft or recondition
3. For number three main bearing, ensure that two
the crankshaft.
thrust washers (4) are clean and free from wear
and damage. If necessary, replace the thrust
washers. Lubricate thrust washers (4) with clean
engine oil.
Note: The upper main bearing shell has a groove
and oil hole.

4. Lubricate the crankshaft journal and upper main

bearing shell (8) with clean engine oil. Slide upper
main bearing shell (8) into position between the
crankshaft journal and the cylinder block. Ensure
that the locating tab for the upper main bearing
shell is correctly seated in the slot in the cylinder
block.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 169
Disassembly and Assembly Section

8. Install bolts (4) to main bearing cap (5). Evenly

tighten the bolts in order to pull cap (5) into
position. Ensure 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 (4) to an initial torque of 50 N·m

(37 lb ft).
10. Tighten bolts (4) to a torque of 80 N·m (59 lb ft).
Use Tooling (C) in order to turn the bolts through
an additional 90 degrees in a clockwise direction
in order to achieve the correct final torque.

Illustration 309 g03003178 11. Check the crankshaft end play. Use Tooling (C) to
measure the crankshaft end play. Refer to
5. Install lower main bearing shell (3) into main Specifications, “Crankshaft” for the correct
bearing cap (2). Ensure that the locating tab for information.
the lower main bearing shell is correctly seated 12. Remove Tooling (C).
into the slot in the bearing cap.
End By:
Note: The lower main bearing shell is a plain bearing
that has no oil holes. a. If necessary, install the balancer. Refer to
Disassembly and Assembly, “Balancer -
Install” for the correct procedure.
b. Install the suction pipe and engine oil pan.
Refer to Disassembly and Assembly, “Engine
Oil Pan - Remove and Install” for the correct
procedure.

i05282671

Crankshaft - Remove

Removal Procedure
Table 69
Required Tools

Tool Part Number Part Description Qty

A - Lifting Sling 2

Illustration 310 g03003700

6. Lubricate the crankshaft journal and the lower

main bearing shell with clean engine oil. Install
main bearing cap (5) to the cylinder block.
Note: Ensure the correct orientation of the main
bearing cap. The locating tab for the upper and the
lower bearing should be on the same side of the
engine.

7. Lubricate the threads of bolts (4) with clean engine

oil. Lubricate the underside of the heads of bolts
(4) with clean engine oil.

This document has been printed from SPI2. NOT FOR RESALE
170 UENR0624-03
Disassembly and Assembly Section

Start By:
a. Remove the engine oil suction pipe. Refer to
Disassembly and Assembly, “Engine Oil Pan -
Remove and Install” for the correct procedure.
b. If necessary, remove the balancer. Refer to
Disassembly and Assembly, “Balancer -
Remove” for the correct procedure.
c. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
housing - Remove and Install” for the correct
procedure.
d. Remove the front housing. Refer to
Disassembly and Assembly, “Housing (Front) -
Remove” for the correct procedure.
e. If necessary, remove the power take-off drive.
Refer to Disassembly and Assembly, “Power
Take-Off Drive - Remove and Install” for the
correct procedure.
f. If necessary, remove the cylinder head. Refer to Illustration 311 g03008176
Disassembly and Assembly, “Cylinder Head -
Remove” for the correct procedure. 3. Attach Tooling (A) and a suitable lifting device to
g. If necessary, remove the pistons and crankshaft (2). Lift the crankshaft out of the
connecting rods. Refer to Disassembly and cylinder block. The weight of the crankshaft is
Assembly, “Pistons and Connecting Rods - approximately 35 kg (77 lb).
Remove” for the correct procedure.
Note: Do not damage any of the finished surfaces on
h. Remove the main bearing caps. Refer to the crankshaft. When the crankshaft is removed from
Disassembly and Assembly, “Crankshaft Main the engine, the crankshaft must be supported on a
Bearings - Remove and Install” for the correct suitable stand in order to prevent damage to the
procedure. crankshaft timing ring.

NOTICE 4. Remove upper main bearing shells from the

Keep all parts clean from contaminants. cylinder block. Refer to Disassembly and
Contaminants may cause rapid wear and shortened Assembly, “Crankshaft Main Bearings - Remove
component life. and Install” for the correct procedure.
Note: The upper main bearing shells have a groove
1. The engine should be mounted on a suitable stand and an oil hole.
and placed in the inverted position.
2. If the cylinder head, the pistons and the connecting
rods have not been removed already, remove the
connecting rod bearings. Refer to Disassembly
and Assembly, “Connecting Rod Bearings -
Remove” for the correct procedure.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 171
Disassembly and Assembly Section

5. If necessary, remove the crankshaft timing ring (1).

Refer to Disassembly and Assembly, “Crankshaft
Timing Ring - Remove and Install” for the correct
procedure.

i05282673

Crankshaft - Install

Installation Procedure
Table 70
Required Tools

Tool Part Number Part Description Qty

A - Lifting Sling 2

21825617 Dial Indicator 1

B
- Magnetic Base and Stand 1
Illustration 312 g03008302

NOTICE 2. If necessary, install a new crankshaft timing ring

Keep all parts clean from contaminants. (1). Refer to Disassembly and Assembly,
Contaminants may cause rapid wear and shortened “Crankshaft Timing Ring - Remove and Install” for
component life. the correct procedure.
3. Ensure that parent bores for bearing shells in the
1. Clean the crankshaft and inspect the crankshaft for cylinder block are clean. Ensure that the threads
wear and damage. Refer to Specifications, for the main bearing bolts in the cylinder block are
“Crankshaft” for more information. If necessary, clean and free from damage.
replace the crankshaft or recondition the 4. Clean the main bearing shells and the thrust
crankshaft. washers. Inspect the main bearing shells and the
thrust washers for wear and damage. If necessary,
replace the main bearing shells and the thrust
washers.

Note: If the main bearing shells are replaced, check

whether oversize main bearing shells were
previously installed. If the thrust washers are
replaced, check whether oversize thrust washers
were previously installed.

5. Install upper main bearing shells to the cylinder

block. Refer to Disassembly and Assembly,
“Crankshaft Main Bearings - Remove and Install”
for the correct procedure.
Note: The upper main bearing shells have a groove
and an oil hole.

6. Lubricate upper main bearing shells with clean

engine oil.
7. Attach Tooling (A) and a suitable lifting device to
crankshaft (2). Lift the crankshaft into the cylinder
block. The weight of the crankshaft is
approximately 35 kg (77 lb).

This document has been printed from SPI2. NOT FOR RESALE
172 UENR0624-03
Disassembly and Assembly Section

Note: Do not damage any of the finished surfaces on End By:

the crankshaft. Do not damage the main bearing
shells. a. If necessary, install the power take-off drive.
Refer to Disassembly and Assembly, “Power
8. Lubricate lower main bearing shells and lubricate Take-Off Drive - Remove and Install” for the
correct procedure.
the journals of the crankshaft with clean engine oil.
Install lower main bearing caps. Refer to b. If necessary, install the balancer. Refer to
Disassembly and Assembly, “Crankshaft Main Disassembly and Assembly, “Balancer -
Bearings - Remove and Install” for the correct Install” for the correct procedure.
procedure.
c. Install the engine oil suction pipe. Refer to
Note: The lower main bearing shells are plain Disassembly and Assembly, “Engine Oil Pan -
bearings that do not have an oil hole. Remove and Install” for the correct procedure.
d. If necessary, install the cylinder head. Refer to
9. Rotate the crankshaft in order to ensure that there Disassembly and Assembly, “Cylinder head -
is no binding. Install” for the correct procedure.
10. Check the crankshaft end play. Push the e. Install the flywheel housing. Refer to
crankshaft toward the front of the engine. Install Disassembly and Assembly, “Flywheel
Tooling (B) to the cylinder block and the rear face Housing - Remove and Install” for the correct
of the crankshaft. Push the crankshaft toward the procedure.
rear of the engine. Use Tooling (B) to measure the
f. Install the front housing. Refer to Disassembly
crankshaft end play. Refer to Specifications, and Assembly, “Housing (Front) - Install” for
“Crankshaft” for the correct information. the correct procedure.
11. If necessary, install the pistons and connecting
i05282676
rods. Refer to Disassembly and Assembly,
“Pistons and Connecting Rods - Install” for the
correct procedure. Crankshaft Timing Ring -
12. If the crankshaft has not been replaced or the
Remove and Install
crankshaft has not been reconditioned, install the
connecting rod bearings. Refer to Disassembly
and Assembly, “Connecting Rod Bearings - Install”
for the correct procedure.
Removal Procedure
Start By:
a. Remove the crankshaft. Refer to Disassembly
and Assembly, “Crankshaft - Remove ” for the
correct procedure.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 173
Disassembly and Assembly Section

Illustration 313 g03010798 Illustration 314 g03010798

1. Support crankshaft (4) on a suitable stand. 3. If dowel (3) was removed, install a new dowel to
crankshaft (4).
2. Remove Torx screws (1) from crankshaft timing
ring (2). Do not reuse the Torx screws. 4. Position crankshaft timing ring (2) onto the
crankshaft with the chamfer toward the crankshaft
3. Carefully remove crankshaft timing ring (2) from
web. Align the hole in crankshaft timing ring with
crankshaft (4).
dowel (3) in the crankshaft. Carefully install the
Note: Ensure that the seal surface on adaptor (5) is crankshaft timing ring to the crankshaft.
not damaged when the crankshaft timing ring is
removed. Note: Ensure that the seal surface on adaptor (5) is
not damaged when the crankshaft timing ring is
Note: Do not remove dowel (3) from the crankshaft installed.
unless the dowel is damaged.
5. Install new Torx screws (1). Tighten the Torx
Installation Procedure screws to a torque of 10 N·m (89 lb in).
End By:
NOTICE
Keep all parts clean from contaminants. a. Install the crankshaft. Refer to Disassembly
and Assembly, “Crankshaft - Install ” for the
Contaminants may cause rapid wear and shortened correct procedure.
component life.
i05980323

1. Ensure that the teeth of the crankshaft timing ring

are clean and free from damage.
Bearing Clearance - Check
2. Support crankshaft (4) on a suitable stand.

Measurement Procedure
Table 71
Required Tools

Tool Part Number Part Description Qty

(continued)

This document has been printed from SPI2. NOT FOR RESALE
174 UENR0624-03
Disassembly and Assembly Section

(Table 71, contd) Note: Do not allow Tooling (A) to extend over the
Plastigauge (Green) edge of the bearing.
- 0.025 to 0.076 mm 1
(0.001 to 0.003 inch) 2. Use the correct torque-turn specifications in order
to install the bearing cap. Do not use an impact
Plastigauge (Red)
0.051 to 0.152 mm
wrench. Be careful not to dislodge the bearing
- 1
(0.002 to 0.006 inch) when the cap is installed.
A
Plastigauge (Blue) Note: Do not turn the crankshaft when Tooling (A) is
- 0.102 to 0.229 mm 1 installed.
(0.004 to 0.009 inch)

Plastigauge (Yellow)
3. Carefully remove the cap, but do not remove
- 0.230 to 0.510 mm 1 Tooling (A). Measure the width of Tooling (A) while
(0.009 to 0.020 inch) Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 315 .

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Note: Perkins does not recommend the checking of

the actual clearances of the bearing shells
particularly on small engines. Checking of the actual
clearances of the bearing shells is because of the
possibility of obtaining inaccurate results and of
damaging the bearing shell or the journal surfaces.
Each Perkins bearing shell is quality checked for
specific wall thickness.

Note: The measurements should be within

specifications and the correct bearings should be
used. If the crankshaft journals and the bores for the
block and the rods were measured during
disassembly, no further checks are necessary. Illustration 315 g01152855
However, if the technician still wants to measure the Typical Example
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with 4. Remove all of Tooling (A) before you install the
small diameters if clearances are less than 0.10 mm
bearing cap.
(0.004 inch).

NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.

The technician must use Tooling (A) correctly. The

following points must be remembered:

• Ensure that the backs of the bearings and the

bores are clean and dry.
• Ensure that the bearing locking tabs are properly
seated in the tab grooves.
• The crankshaft must be free of oil at the contact
points of Tooling (A).

1. Put a piece of Tooling (A) on the crown of the

bearing that is in the cap.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 175
Disassembly and Assembly Section

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
major width in order to ensure that the parts are
within the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and
Specifications Manual, “Main Bearing Journal” for the
correct clearances.

i05282685

Camshaft Position Sensor -

Remove and Install

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Illustration 316 g02672140
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- 1. Slide the locking tab into the unlocked position and
bling any component containing fluids. disconnect harness assembly (4) from camshaft
Dispose of all fluids according to local regulations position sensor (3).
and mandates. 2. Remove bolt (1). Carefully remove camshaft
position sensor (3) from front cover (2).
NOTICE Note: Do not use a lever to remove the camshaft
Keep all parts clean from contaminants. position sensor. Make a note of the orientation of the
Contaminants may cause rapid wear and shortened camshaft position sensor for installation purposes.
component life.
3. Remove O-ring seal (5) from camshaft position
sensor (3).

Installation Procedure
Table 72
Required Tools

Tool Part Number Part Description Qty

A - Loctite 506 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
176 UENR0624-03
Disassembly and Assembly Section

Illustration 317 g02672140 Illustration 318 g02673817

1. Install a new O-ring seal (5) to camshaft position 1. Slide the locking tab into the unlocked position.
sensor (3). Disconnect harness assembly (2) from crankshaft
position sensor harness (1).
2. Install camshaft position sensor (3) to front cover
(2). Ensure that the camshaft position sensor is 2. Cut cable strap (6).
correctly orientated.
3. Remove bolt (3) from the cylinder block.
3. Apply Tooling (A) onto the threads of bolt (1).
4. Carefully remove crankshaft position sensor (5)
Install bolt (1) to the camshaft position sensor.
from the cylinder block.
Tighten the bolt to a torque of 10 N·m (89 lb in)
4. Connect harness assembly (4) to camshaft Note: Do not use a lever to remove the crankshaft
position sensor from the cylinder block.
position sensor (3). Slide the locking tab into the
locked position. 5. Remove O-ring seal (4) (not shown) from
crankshaft position sensor (5).
i05282713
Installation Procedure
Crankshaft Position Sensor -
NOTICE
Remove and Install Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 177
Disassembly and Assembly Section

1. Drain the coolant from the cooling system to a

level below the coolant temperature sensor. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct draining
procedure.

Illustration 319 g02673817

1. Install a new O-ring seal (4) (not shown) to

crankshaft position sensor (5).
2. Install crankshaft position sensor (5) to the cylinder
block. Install bolt (3) and tighten the bolt to a
torque of 10 N·m (89 lb in).
3. Connect harness assembly (2) to crankshaft
position sensor harness (1). Slide the locking tab
into the locked position.
4. Install a new cable strap (6).

Note: Ensure that the cable strap meets the Original

Equipment Manufacturers (OEM) specification.

i05282714 Illustration 320 g02671576

Coolant Temperature Sensor - 2. Slide the locking tab into the unlocked position.
Disconnect harness assembly (1) from coolant
Remove and Install temperature sensor (2).
3. Remove coolant temperature sensor (2) from the
water temperature regulator housing.
Removal Procedure 4. Remove seal washer (3) from coolant temperature
sensor (2).
NOTICE
Keep all parts clean from contaminants.
Installation Procedure
Contaminants may cause rapid wear and shortened
component life. NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
178 UENR0624-03
Disassembly and Assembly Section

Illustration 321 g02671797

1. Install a new seal washer (3) onto coolant

temperature sensor (2).
2. Install coolant temperature sensor (2) to the water
temperature regulator housing. Tighten the
coolant temperature sensor to a torque of 25 N·m
(221 lb in).
3. Connect harness assembly (1) to coolant
temperature sensor (2). Slide the locking tab into
Illustration 322 g02673736
the locked position.
4. Fill the cooling system to the correct level. Refer to 1. Disconnect harness assembly (2) from engine oil
Operation and Maintenance Manual, “Cooling pressure switch (3).
System Coolant Level - Check” and refer to 2. Using a deep socket remove engine oil pressure
Operation and Maintenance Manual, “Cooling switch (3) from oil filter head (1).
System Coolant - Change” for the correct filling
procedures. 3. Remove O-ring seal (4) from the engine oil
pressure switch.
i05282729
Installation Procedure
Engine Oil Pressure Switch -
NOTICE
Remove and Install Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 179
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
Illustration 323 g02673736 ers before opening any compartment or disassem-
bling any component containing fluids.
1. Install a new O-ring seal (4) onto engine oil
Dispose of all fluids according to local regulations
pressure switch (3). and mandates.
2. Install engine oil pressure switch (3) to oil filter
head (1).
NOTICE
3. Using a deep socket tighten the oil pressure switch Keep all parts clean from contaminants.
to a torque of 25 N·m (221 lb in).
Contaminants may cause rapid wear and shortened
4. Connect harness assembly (2) to engine oil component life.
pressure switch (3).
1. Turn the fuel supply to the OFF position.
i05282736
2. Turn the battery disconnect switch to the OFF
Fuel Temperature Sensor - position.
Remove and Install

Removal Procedure
Table 73
Required Tools

Tool Part Number Part Description Qty

A T412504 Capping Kit 1

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

This document has been printed from SPI2. NOT FOR RESALE
180 UENR0624-03
Disassembly and Assembly Section

Illustration 324 g02876777 Illustration 325 g02876777

3. Disconnect harness assembly (3) from fuel 2. Ensure that the new sealing washer (4) (not
temperature sensor (2). shown) on the fuel temperature sensor (2) is free
from damage.
4. Use a deep socket in order to remove fuel
temperature sensor (2) from fuel filter base (1). 3. Remove the plug from the fuel filter base (1).
5. Use Tooling (A) to plug the open port of the fuel 4. Install fuel temperature sensor (2) to the fuel filter
injection pump. base. Use a deep socket to tighten the fuel
temperature sensor to a torque of 22 N·m
6. Remove sealing washer (4) (not shown) from fuel
(195 lb in).
temperature sensor (2).
5. Connect harness assembly (3) to fuel temperature
Installation Procedure sensor (2).

NOTICE 6. Turn the fuel supply to the ON position.

Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that all components are free from wear and

damage. Replace any components that are worn
or damaged.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 181
Disassembly and Assembly Section

7. Turn the battery disconnect switch to the ON Installation Procedure

position. Table 74
Required Tools
i05282745
Tool Part Number Part Description Qty
Oxygen Sensor - Remove and Bostik Pure Nickel
A - 1
Install Anti-Seize Compound

(Catalytic Converter)
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Removal Procedure component life.
Start By:
a. Turn the battery disconnect switch to the OFF
Position.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 327 g02725166

1. Install a new sealing washer (4) (not shown) to

oxygen sensor (2).
2. Apply Tooling (A) to the threads of oxygen sensor
(4) (not shown).
3. Install oxygen sensor (2) to exhaust tube assembly
(3). Tighten the oxygen sensor to a torque of
Illustration 326 g02725166
50 N·m (37 lb ft).
1. Disconnect harness assembly (1). 4. Connect harness assembly (1).
2. Remove oxygen sensor (2) from exhaust tube
assembly (3).
3. Remove sealing washer (4) from the oxygen
sensor.

This document has been printed from SPI2. NOT FOR RESALE
182 UENR0624-03
Disassembly and Assembly Section

End By: Installation Procedure

a. Turn the battery disconnect switch to the ON 1. Ensure that all components are clean and free
Position. from wear and damage. If necessary, replace any
components that are worn or damaged.
b. When a new oxygen sensor is installed, it will
be necessary to use the Electronic Service
Tool (EST) in order to perform the “ Lambda
Sensor Replacement Reset”” , “ Lambda Sensor
Learn Reset”” and “ Lambda Sensor
Temperature Learn Reset”” procedures.

i05282750

Temperature Sensor (Exhaust)

- Remove and Install

Removal Procedure
1. If necessary, remove the diesel particulate filter
mounting bracket. Refer to Disassembly and
Assembly, “Support and Mounting (CEM) -
Remove and Install” for the correct procedure.

Illustration 329 g02876918

2. Install exhaust temperature sensor (5) to exhaust

manifold (4). Tighten the exhaust temperature
sensor to a torque of 45 N·m (33 lb ft)
Note: Ensure that the harness for the exhaust
temperature sensor is correctly routed.

3. Slide exhaust temperature sensor connection (1)

into bracket (3).
4. Connect harness assembly (2) (not shown) to
exhaust temperature sensor connection (1).

Illustration 328 g02876918

2. Disconnect harness assembly (2) (not shown) from

exhaust temperature sensor connection (1).
3. Slide exhaust temperature sensor connection (1)
out of bracket (3).
4. Remove exhaust temperature sensor (5) from
exhaust manifold (4).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 183
Disassembly and Assembly Section

5. If necessary, install the diesel particulate filter 3. If necessary, repeat Step 1 through Step 2 in order
mounting bracket. Refer to Disassembly and to remove the remaining temperature sensor from
Assembly, “Support and Mounting (CEM) - the DPF.
Remove and Install” for the correct procedure.
Installation Procedure
i05282753 Table 75
Required Tools
Temperature Sensor (DPF) -
Tool Part Number Part Description Qty
Remove and Install Bostik Pure Nickel
A - 1
Anti-Seize Compound

Removal Procedure 1. Ensure that all components are clean and free
from wear and damage. If necessary, replace any
NOTICE components that are worn or damaged.
Do not strike any part of the assembly of the Diesel
Particulate Filter (DPF). Do not allow any object to
contact the internal element of the DPF. If the internal
element of the DPF becomes damaged, the assem-
bly must be replaced.

NOTICE
The temperature sensors for the Diesel Particulate
Filter (DPF) are of different lengths and should be in-
stalled in the original position.

Illustration 331 g02728556

2. Use tooling (A) in order to lubricate the thread of

temperature sensor (2).
3. Install temperature sensor (2) to DPF (3). Tighten
temperature sensor to a torque of 50 N·m
(37 lb ft)

Note: Ensure correct positioning of the temperature

sensor.
Illustration 330 g02728556
4. Connect harness assembly (1).
1. Disconnect the harness assembly from connection
(1).
2. Make temporary identification marks on
temperature sensor (2) for installation purpose.
Remove the temperature sensor from Diesel
Particulate Filter (DPF) (3).

This document has been printed from SPI2. NOT FOR RESALE
184 UENR0624-03
Disassembly and Assembly Section

5. If necessary, repeat Step 2 through Step 4 in order Installation Procedure

to install the remaining temperature sensor to the
DPF.

i05282755

Pressure Sensor (DPF)

-Remove and Install

Removal Procedure

Illustration 333 g03005940

1. Position DPF differential pressure sensor (2) onto

bracket (1).
2. Install bolt (3) finger tight to DPF differential
pressure sensor (2). Tighten the bolt to a torque of
9 N·m (80 lb in)
3. Position a new clip (4) onto hose assembly (6).
4. Install hose assembly (6) and clip (4) onto DPF
differential pressure sensor (2). Tighten clip (4)
Illustration 332 g03005940 securely.
1. Disconnect the harness connector from Diesel Note: Do not over tighten clip (4).
Particulate Filter (DPF) differential pressure
sensor (2). 5. Position a new clip (5) onto hose assembly (7).

2. Remove clip (4) from hose assembly (6). Remove 6. Install hose assembly (7) and clip (5) onto DPF
clip (5) from hose assembly (7). differential pressure sensor (2). Tighten clip (5)
securely.
3. Disconnect hose assembly (6) and hose assembly
(7) from DPF differential pressure sensor (2). Note: Do not over tighten clip (5).
4. Remove bolt (3) from DPF differential pressure 7. Connect the harness assembly to DPF differential
sensor (2). pressure sensor (2).
5. Remove DPF differential pressure sensor (2) from
bracket (1).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 185
Disassembly and Assembly Section

End By:
a. When a new DPF differential pressure sensor
is installed, use the Electronic Service Tool
(EST) in order to perform the “ DPF Differential
Pressure Sensor Replacement”” procedure.

i05284598

Pressure Sensor (Exhaust

Back Pressure) - Remove and
Install

Removal Procedure

Illustration 335 g02915178

1. Slide the locking tab into the unlocked position and

disconnect harness assembly (3) from exhaust
back pressure sensor (5).
2. Using a deep socket in order to remove exhaust
back pressure sensor (5) from adaptor bracket (7).
3. Remove O-ring (6) (not shown) from exhaust back
pressure sensor (5).
4. If necessary, follow Step 4.a through Step 4.j in
order to remove tube assembly (6).

a. If necessary, remove the diesel particulate

mounting bracket. Refer to Disassembly and
Assembly, “Support and Mounting (CEM) -
Remove and Install” for the correct procedure.
Illustration 334 g02917036
b. If necessary, remove the exhaust gas
recirculation cooler. Refer to Disassembly and
Assembly, “Exhaust Cooler (NRS) - Remove
and Install” for the correct procedure.

c. If necessary, remove the exhaust gas

temperature sensor. Refer to Disassembly and
Assembly, “Temperature Sensor (Exhaust) -
Remove and Install” for the correct procedure.

d. Disconnect harness assembly (4) from the

retaining clip.

e. Loosen nut (8) and disconnect tube assembly

(9).

f. Remove bolt (2) and remove adaptor bracket (7)

from the induction manifold.
g. Remove banjo bolt (10) from tube assembly (9).

This document has been printed from SPI2. NOT FOR RESALE
186 UENR0624-03
Disassembly and Assembly Section

h. Remove bolt (1) from the bracket for tube

assembly (9).

i. Remove tube assembly (9) from the exhaust

manifold.
j. Remove and sealing washers (11) (not shown).

Installation Procedure
1. Check all components for wear and damage. If
necessary, replace any components that are worn
or damaged.

Illustration 336 g02915178

Illustration 337 g02917036

2. If necessary, follow Step 2.a through Step 2.i in

order to install tube assembly (6).

a. Install a new sealing washer (11) (not shown) to

banjo bolt (10).

b. Install banjo bolt assembly (10) into tube

assembly (9). Install the remaining new sealing
washer (11) (not shown) to banjo bolt assembly
(10).

c. Install tube assembly (9) onto the exhaust

manifold and exhaust back pressure sensor

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 187
Disassembly and Assembly Section

bracket (7). Tighten banjo bolt assembly (10) 10. Install bolt (2) to exhaust back pressure sensor
finger tight. (4). Tighten the bolt to a torque of 25 N·m
(221 lb in).
d. Install bolt (1) to the bracket for tube assembly
(6). i05296475

e. Position adaptor bracket (7) onto the induction Inlet Manifold Temperature
manifold and install bolt (2).

f. Tighten nut (8) finger tight.

Sensor - Remove and Install
g. Tighten bolt (1) and bolt (2) to a torque of
25 N·m (221 lb in). Removal Procedure
h. Tighten banjo bolt (10) to a torque of 15 N·m
(133 lb in).

i. Tighten nut (8) to a torque of 15 N·m (133 lb in).

3. Install new O-ring seal (6) (not shown) to exhaust
back pressure sensor (5).
4. Install exhaust back pressure sensor (5). Tighten
the sensor to a torque of 15 N·m (133 lb in)
5. Connect harness assembly (3) to exhaust back
pressure sensor (5) and slide the locking tab into
the locked position.
6. If necessary, install the exhaust gas temperature
sensor. Refer to Disassembly and Assembly,
“Temperature Sensor (Exhaust) - Remove and
Install” for the correct procedure.
7. If necessary, install the exhaust gas recirculation
cooler. Refer to Disassembly and Assembly,
“Exhaust Cooler (NRS) - Remove and Install” for
Illustration 338 g03366344
the correct procedure.
8. If necessary, install the diesel particulate mounting 1. Disconnect the wiring harness assembly (not
bracket. Refer to Disassembly and Assembly, shown) from inlet manifold temperature sensor (3).
“Support and Mounting (CEM) - Remove and
2. Remove inlet manifold temperature sensor (3)
Install” for the correct procedure.
from inlet manifold (1).
9. Install harness assembly (4) onto exhaust back
3. Remove seal (2) (not shown) from the inlet
pressure sensor bracket (7).
manifold temperature sensor.

This document has been printed from SPI2. NOT FOR RESALE
188 UENR0624-03
Disassembly and Assembly Section

Installation Procedure 3. Connect the wiring harness assembly (not shown)

to inlet manifold temperature sensor (3).

i05296471

Inlet Manifold Pressure Sensor

- Remove and Install

Removal Procedure

Illustration 339 g03366344

1. Install new seal (2) (not shown) to the inlet

manifold temperature sensor (3).
2. Install inlet manifold temperature sensor (3) to inlet
manifold (1). Tighten the inlet manifold
temperature sensor to a torque of 25 N·m
(221 lb in).

Illustration 340 g03364100

1. Disconnect the wiring harness assembly (not

shown) from inlet manifold temperature sensor (1).
2. Remove Allen head bolt (2) from inlet manifold
temperature sensor (1).
3. Remove inlet manifold temperature sensor (1)
from inlet manifold temperature sensor housing
(4).
4. Remove seal (3) (not shown).
5. If necessary, follow Step 5.a through Step 5.f in
order to remove inlet manifold temperature sensor
housing (7) and tube assembly (6).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 189
Disassembly and Assembly Section

Installation Procedure

Illustration 341 g03364176

a. Loosen nut (6) on tube assembly (7). Illustration 342 g03364176

b. Remove bolt (5) from inlet manifold temperature 1. If necessary, follow Step 1.a through Step 1.f in
sensor housing (7). order to install the inlet manifold temperature
sensor housing (4) and tube assembly (7).
c. Disconnect tube assembly (7) from inlet
manifold temperature sensor housing (4). a. Install new sealing washers (9) (not shown) and
banjo bolt (10) to tube assembly (7).
d. Remove inlet manifold temperature sensor
housing (4) from inlet manifold (8). b. Position tube assembly onto induction manifold
(8) and loosely install banjo bolt (10).
e. Remove banjo bolt (10) and sealing washers (9)
(not shown). c. Position inlet manifold temperature sensor
housing (4) onto inlet manifold (8). Tighten nut
f. Remove tube assembly (7).
(6) finger tight.

d. Install bolt (5). Tighten the bolt to a torque of

10 N·m (89 lb in).

e. Tighten nut (6) to a torque of 10 N·m (89 lb in).

f. Tighten banjo bolt (10) to a torque of 10 N·m

(89 lb in).

This document has been printed from SPI2. NOT FOR RESALE
190 UENR0624-03
Disassembly and Assembly Section

2. If necessary, remove the Exhaust Gas

Recirculation (EGR) valve. Refer to Disassembly
and Assembly, “ Exhaust Gas Recirculation Valve -
Remove and Install” for the correct procedure.

Illustration 343 g03364100

2. Install new seal (3) (not shown) to inlet manifold

temperature sensor (1).
3. Install inlet manifold temperature sensor (1) to inlet Illustration 344 g02837996
manifold temperature sensor housing (4).
3. Disconnect wiring harness (1) from the glow plugs
4. Install Allen head bolt (2). Tighten the Allen head
(2).
bolt to a torque of 10 N·m (89 lb in)
Note: Make temporary identification marks on the
i05284612 wiring harness assembly for installation purposes.

Glow Plugs - Remove and 4. Clean the area around the glow plugs. Ensure that
the area is free from contamination before removal
Install of the glow plugs.
5. Use a deep socket in order to remove glow plugs
(2) from the cylinder head.
Removal Procedure
Start By:
Installation Procedure
a. Remove the combined inlet manifold NOTICE
temperature and pressure sensor. Refer to Keep all parts clean from contaminants.
Disassembly and Assembly, “Inlet Manifold
Temperature and Pressure Sensor - Remove Contaminants may cause rapid wear and shortened
and Install” for the correct procedure. component life.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

1. Turn the battery disconnect switch to the OFF

position.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 191
Disassembly and Assembly Section

End By:
a. Install the combined inlet manifold temperature
and pressure sensor. Refer to Disassembly
and Assembly, “Inlet Manifold Temperature
and Pressure Sensor - Remove and Install” for
the correct procedure.

i05284613

Alternator Belt - Remove and

Install

Removal Procedure
1. If the engine has guards, remove the guards. Refer
to the Original Equipment Manufacture (OEM) for
the correct procedure.

Illustration 345 g02837996

1. Before installing glow plugs (5), ensure that the

glow plugs are operating correctly. Refer to
Troubleshooting, “Glow Plug Starting Aid - Test”
“Check the Operation of the Glow Plugs” for the
correct procedure.
2. Ensure that the threads of the glow plugs are clean
and free from damage. Replace any damaged
glow plugs.
3. Install glow plugs (2) into the cylinder head .
Tighten the glow plugs to a torque of 9 N·m
(80 lb in).
4. Connect wiring harness (1) to glow plugs (2).
5. Turn the battery disconnect switch to the ON
position.
6. If necessary, install the Exhaust Gas Recirculation
(EGR) valve. Refer to Disassembly and Assembly, Illustration 346 g02553437

“ Exhaust Gas Recirculation Valve - Remove and Typical example

Install” for the correct procedure.
2. Loosen locking nut (2) and alternator tensioning
bolt (1).
3. Loosen nut and bolt (4).
4. Loosen bolt (3) for adjusting bracket (5).
5. Remove alternator belt (6).

Note: Note the routing of the alternator belt before

removal.

This document has been printed from SPI2. NOT FOR RESALE
192 UENR0624-03
Disassembly and Assembly Section

Installation Procedure Note: The ribs on the alternator belt must be located
into the grooves of all pulleys.

4. Tighten bolt (1) until adjusting bracket (5) has

reached the full extent of the available adjustment
in Position (A).
5. Tighten bolt (3) to a torque of 50 N·m (37 lb ft).
6. Tighten nut and bolt (4) to a torque of 50 N·m
(37 lb ft)
7. Rotate tensioning bolt (1) two complete revolutions
in a counterclockwise direction. Tighten locking
nut (2) to a torque of 30 N·m (266 lb in).
8. If the engine has guards, install the guards. Refer
to the OEM for the correct procedure.

i05284614

Idler Pulley - Remove and

Install
Illustration 347 g02553437
Typical example
Removal Procedure
Start By:
a. Remove the alternator belt. Refer to
Disassembly and Assembly, “Alternator Belt -
Remove” for the correct procedure.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 348 g02553697

1. Ensure that all components of the pulleys and

guide rollers are clean and free from wear and
damage. If necessary, replace any components
that are worn or damaged.
2. Ensure that the pulleys and guide rollers are free
from dirt and build up from the old belt.
3. Position new alternator belt (6). Ensure that the
alternator belt is centered on all pulleys.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 193
Disassembly and Assembly Section

Illustration 349 g02710322 Illustration 350 g02710444

Typical example Typical example

1. If necessary, remove bolts (1) and remove engine 2. Install bolts (4) to idler pulley (3). Position idler
lifting bracket (2). pulley (3) onto the cylinder head.
2. Remove bolt (4) and remove idler pulley (3). 3. Tighten bolt (4) to a torque of 40 N·m (30 lb ft).

Installation Procedure 4. If necessary, install bolts (1) to engine lifting

bracket (2). Position the engine lifting bracket onto
NOTICE the idler pulley.
Keep all parts clean from contaminants.
5. Tighten bolt (1) to a torque of 40 N·m (30 lb ft).
Contaminants may cause rapid wear and shortened
component life.

1. Ensure that all components of the idler pulley are

clean and free from wear and damage. If
necessary, replace any components that are worn
or damaged.

This document has been printed from SPI2. NOT FOR RESALE
194 UENR0624-03
Disassembly and Assembly Section

End By:
a. Install a new alternator belt. Refer to
Disassembly and Assembly, “Alternator Belt -
Install” for the correct procedure.

i05284618

Fan - Remove and Install

Removal Procedure
Start By:
a. Remove the alternator belt. Refer to
Disassembly and Assembly, “Alternator Belt -
Remove and Install” for the correct procedure.

Illustration 352 g02829456

Typical example

2. If necessary, install studs (5) to fan drive (6).

Tighten studs (5) to a torque of 11 N·m (97 lb in).
3. If studs (5) have not been previously removed from
fan drive (6). Check for the correct installation of
the studs to the fan drive. Tighten studs (5) to a
torque of 25 N·m (221 lb in).
4. Install fan pulley (4).
5. Install fan adapter (3).
6. Install fan (2).

Note: Ensure that the fan is correctly oriented.

7. Inspect the condition of locking nuts (1). If

Illustration 351 g02829456 necessary, replace the locking nuts. Install locking
Typical example nuts (1). Tighten locking nuts (1) to a torque of
22 N·m (195 lb in).
1. Remove nuts (1).
End By:
2. Remove fan (2).
a. Install the Alternator Belt. Refer to
Note: Note the orientation of the fan. Disassembly and Assembly, “Alternator Belt -
Remove and Install” for the correct procedure.
3. Remove fan adapter (3).
i05284619
4. Remove fan pulley (4).
5. If necessary, remove studs (5) from fan drive (6). Fan Drive - Remove and Install
Installation Procedure
1. Ensure that all the components are free from wear
and damage. If necessary, replace any
Removal Procedure
components that are worn or damaged. 1. If necessary, remove the fan. Refer to
Disassembly and Assembly, “Fan - Remove and
Install” for the correct procedure.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 195
Disassembly and Assembly Section

Illustration 353 g02827145 Illustration 354 g02827145

2. If necessary, remove nuts (5) from studs (6). 2. If necessary, follow Step 2.a through Step 2.b in
order to assemble the fan drive.
3. Remove the alternator belt. Refer to Disassembly
and Assembly, “Alternator Belt - Remove and a. Install studs (6) to fan drive (7). Tighten the
Install” for the correct procedure. studs to a torque of 18 N·m (159 lb in)
4. Remove fan drive pulley (4). b. Position lifting bracket (1) onto fan drive (7).
5. Remove the alternator belt tensioning bracket. Install bolts (2) to lifting bracket (1). Tighten the
Refer to Disassembly and Assembly, “Alternator - bolts to a torque of 45 N·m (33 lb ft).
Remove and Install” for the correct procedure. 3. Position fan drive (7) onto the cylinder head. Install
6. Remove bolts (3) and remove the fan drive bolts (3) and tighten the bolts to a torque of
assembly (7) from the cylinder head. 25 N·m (221 lb in).
7. If necessary, follow Step 7.a through Step 7.b in 4. Position fan drive pulley (4) onto studs (6).
order to disassemble the fan drive assembly. 5. If necessary, install the fan. Refer to Disassembly
a. Remove studs (6) from the fan drive (7). and Assembly, “Fan - Remove and Install” for the
correct procedure.
b. Remove bolts (2) and remove lifting bracket (1). 6. Install the alternator belt tensioning bracket. Refer
to Disassembly and Assembly, “Alternator -
Installation Procedure Remove and Install” for the correct procedure.
1. Check all components for wear and damage. If
7. Install nuts (5) and tighten the nuts to a torque of
necessary, replace any components that are worn
25 N·m (221 lb in).
or damaged.

This document has been printed from SPI2. NOT FOR RESALE
196 UENR0624-03
Disassembly and Assembly Section

8. Install the alternator belt. Refer to Disassembly

and Assembly, “Alternator Belt - Remove and
Install” for the correct procedure.

i05284622

Alternator - Remove

Removal Procedure
Start By:
a. Remove the alternator belt. Refer to
Disassembly and Assembly, “Alternator Belt -
Remove and Install” for the correct procedure.
1. Turn the battery disconnect switch to the OFF
position.

Illustration 355 g02673920

Illustration 356 g02815777

2. Make temporary marks on the alternator harness

in order to identify the locations for the
connections during the assembly procedure.
3. Disconnect the harness assembly from alternator
(6).
4. Support the weight of the alternator and remove
nut (1) and bolt (2).
5. Remove nut (3) and bolt (5) (not shown) from
alternator (6).
6. Remove alternator (6) from alternator bracket (4).

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 197
Disassembly and Assembly Section

7. If necessary, follow Step 7.a through Step 7.e in Note: Support the weight of the alternator bracket
order to remove pulley (7) from alternator (6). as the bolts are removed.

Note: A suitable tool may be required in order to i05284624

carry out the removal of the alternator pulley.
Alternator - Install
a. Place the alternator in a suitable support.

b. Hold shaft (9) of alternator (6) with a suitable

tool. Use a cranked ring spanner to loosen nut Installation Procedure
(8).
1. Ensure that all components are clean and free
c. Make a temporary mark on pulley (7) in order to from wear and damage. If necessary, replace any
show the correct orientation. components that are worn or damaged.
d. Remove nut (8) and pulley (7) from shaft (9). 2. If necessary, follow Step 2.e through Step 2.f in
order to install alternator bracket (11) onto the
e. Remove fan (10) from shaft (9). cylinder block.

Illustration 357 g02815797

8. If necessary, follow Step 8.a through Step 8.c in

order to remove tensioner (11) and alternator
bracket (14) from the cylinder block.

a. Remove bolt (12) and remove tensioner bracket

(11).

b. If necessary, remove bolt (14) (not shown) from

the coolant tube assembly.

c. Remove bolts (13) from alternator bracket (15).

Remove the alternator bracket from the cylinder
block.

This document has been printed from SPI2. NOT FOR RESALE
198 UENR0624-03
Disassembly and Assembly Section

Illustration 360 g02815777

Illustration 358 g02815797

a. Position bracket (14) onto the cylinder block.

b. Install bolts (13) to bracket (14).

c. If necessary, install bolt (13) to the coolant tube

assembly.

d. Tighten bolts (13) to a torque of 50 N·m

(37 lb ft).

e. Position tensioner (11) onto the fan drive

assembly.

f. Install bolt (12) to tensioner (11) finger tight.

3. If necessary, follow Step 3.a through Step 3.f in
order to install pulley (8) to alternator (2).

a. Place alternator (6) in a suitable support.

b. Ensure that fan (10) is correctly oriented.

Illustration 359 g02673920 c. Install fan (10) to shaft (9).

d. Ensure that pulley (7) is correctly oriented.

e. Install pulley (7) and a new nut (8) to alternator

shaft (9).

f. Position a cranked ring spanner onto nut (9).

Use a suitable tool in order to turn the shaft of
the alternator in a counterclockwise direction.
Tighten the nut to the correct torque. Refer to
Specifications, “Alternator” for the correct
torque.
4. Position the alternator onto bracket (4) and
tensioner (11).
5. Install bolt (5) (not shown) and nut (3) finger tight.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 199
Disassembly and Assembly Section

6. Install bolt (2) and nut (1) (not shown) finger tight.
7. Install the alternator belt. Refer to Disassembly
and Assembly , “Alternator Belt - Remove and
Install” for the correct procedure.
8. Tighten the nut and bolt (2) to a torque of 50 N·m
(37 lb ft).
9. Tighten nut and bolt (5) to a torque of 50 N·m
(37 lb ft).
10. Connect the wiring harness assembly to the
alternator. Refer to Specifications, “Alternator” for
the correct torque.
11. Turn the battery disconnect switch to the ON Illustration 361 g02844537
position.
Typical example
i05284625
3. Disconnect the harness assembly from the electric
Electric Starting Motor - starting motor and the solenoid.
4. Support electric starting motor (3).
Remove and Install
5. Remove bolts (2) from electric starting motor (3).
6. Remove electric starting motor (3).
Removal Procedure 7. If a gasket is installed, remove gasket (4).

Installation Procedure
Accidental engine starting can cause injury or
death to personnel working on the equipment.
To avoid accidental engine starting, disconnect
the battery cable from the negative (−) battery ter-
minal. Completely tape all metal surfaces of the
disconnected battery cable end in order to pre-
vent contact with other metal surfaces which
could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop
switch location to inform personnel that the
equipment is being worked on.

1. Turn the battery disconnect switch to the OFF

position. Illustration 362 g02844537
Typical example
2. Place identification marks on the harness
assembly that is connected to the electric starting 1. If necessary, position a new gasket (4) onto
motor and the solenoid. electric starting motor (3).
2. Position electric starting motor (3) onto flywheel
housing (1).
Note: Ensure that the electric starting motor is
seated correctly in the starter motor pocket.

3. Install bolts (2) to electric starting motor (3).

Tighten the bolts to a torque of 45 N·m (33 lb ft)
4. Connect the harness assembly to the electric
starting motor and the solenoid.

This document has been printed from SPI2. NOT FOR RESALE
200 UENR0624-03
Disassembly and Assembly Section

5. Turn the battery disconnect switch to the ON

position.

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 201
Index Section

Index
A Installation Procedure .................................... 176
Removal Procedure ....................................... 176
Accessory Drive - Remove and Install................. 126 Crankshaft Pulley - Remove and Install............... 113
Installation Procedure .................................... 127 Installation Procedure .................................... 113
Removal Procedure ....................................... 126 Removal Procedure ....................................... 113
Alternator - Install .............................................. 197 Crankshaft Rear Seal - Remove and Install ......... 103
Installation Procedure .................................... 197 Installation Procedure .................................... 104
Alternator - Remove .......................................... 196 Removal Procedure ....................................... 103
Removal Procedure ....................................... 196 Crankshaft Timing Ring - Remove and Install ...... 172
Alternator Belt - Remove and Install.................... 191 Installation Procedure .................................... 173
Installation Procedure .................................... 192 Removal Procedure ....................................... 172
Removal Procedure ....................................... 191 Cylinder Head - Install ....................................... 139
Installation Procedure .................................... 139
B Cylinder Head - Remove.................................... 137
Removal Procedure ....................................... 137
Balancer - Install ............................................... 155
Installation Procedure .................................... 155
Balancer - Remove............................................ 154 D
Removal Procedure ....................................... 154 Diesel Particulate Filter - Install (Through Flow
Bearing Clearance - Check ................................ 173 Diesel Particulate Filter) .....................................69
Measurement Procedure ................................ 173 Installation Procedure ......................................69
Diesel Particulate Filter - Install (Wall Flow
C Diesel Particulate Filter ) ....................................71
Installation Procedure ......................................71
Camshaft - Remove and Install .......................... 143 Diesel Particulate Filter - Remove (Through
Installation Procedure .................................... 144 Flow Diesel Particulate Filter) .............................66
Removal Procedure ....................................... 143 Removal Procedure .........................................66
Camshaft Bearings - Remove and Install ............ 147 Diesel Particulate Filter - Remove (Wall Flow
Installation Procedure .................................... 147 Diesel Particulate Filter) .....................................67
Removal Procedure ....................................... 147 Removal Procedure .........................................67
Camshaft Gear - Remove and Install .................. 145 Disassembly and Assembly Section .......................5
Installation Procedure .................................... 145
Removal Procedure ....................................... 145
Camshaft Position Sensor - Remove and Install .. 175 E
Installation Procedure .................................... 175 Electric Starting Motor - Remove and Install ........ 199
Removal Procedure ....................................... 175 Installation Procedure .................................... 199
Connecting Rod Bearings - Install (Connecting Removal Procedure ....................................... 199
rods in position) ............................................... 165 Electronic Unit Injector - Install .............................42
Installation Procedure .................................... 165 Installation Procedure ......................................42
Connecting Rod Bearings - Remove Electronic Unit Injector - Remove..........................40
(Connecting rods in position) ............................ 164 Removal Procedure .........................................40
Removal Procedure ....................................... 164 Engine Lifting Bracket - Install ..............................99
Coolant Temperature Sensor - Remove and Installation Procedure ......................................99
Install ............................................................. 177 Engine Lifting Bracket - Remove ..........................98
Installation Procedure .................................... 177 Removal Procedure .........................................98
Removal Procedure ....................................... 177 Engine Oil Cooler - Install ....................................91
Crankcase Breather - Install............................... 128 Installation Procedure ......................................91
Installation Procedure .................................... 128 Engine Oil Cooler - Remove.................................89
Crankcase Breather - Remove ........................... 128 Removal Procedure .........................................89
Removal Procedure ....................................... 128 Engine Oil Filter Base - Remove and Install...........88
Crankshaft - Install ............................................ 171 Installation Procedure ......................................89
Installation Procedure .................................... 171 Removal Procedure .........................................88
Crankshaft - Remove......................................... 169 Engine Oil Pan - Remove and Install (Cast Iron
Removal Procedure ....................................... 169 Engine Oil Pan) ............................................... 150
Crankshaft Front Seal - Remove and Install......... 114 Installation Procedure .................................... 151
Installation Procedure .................................... 114 Removal Procedure ....................................... 150
Procedure 1 .................................................. 115 Engine Oil Pan - Remove and Install (Pressed
Procedure 2 .................................................. 115 Steel Oil Pan).................................................. 148
Removal Procedure ....................................... 114 Installation Procedure .................................... 149
Crankshaft Main Bearings - Remove and Install... 166 Removal Procedure ....................................... 148
Installation Procedure .................................... 168 Engine Oil Pressure Switch - Remove and
Removal Procedure ....................................... 166 Install ............................................................. 178
Crankshaft Position Sensor - Remove and Installation Procedure .................................... 178
Install ............................................................. 176

This document has been printed from SPI2. NOT FOR RESALE
202 UENR0624-03
Index Section

Removal Procedure ....................................... 178 Fuel Injection Pump Gear - Remove .....................38
Engine Oil Pump - Install......................................93 Removal Procedure .........................................38
Installation Procedure ......................................93 Fuel Manifold (Rail) - Remove and Install ..............20
Engine Oil Pump - Remove ..................................93 Installation Procedure ......................................21
Removal Procedure .........................................93 Removal Procedure .........................................20
Engine Oil Relief Valve - Remove and Install .........92 Fuel Priming Pump - Remove and Install...............10
Installation Procedure ......................................92 Installation Procedure (Mechanical Priming
Removal Procedure .........................................92 Pump) ........................................................... 11
Exhaust Cooler (NRS) - Remove and Install ..........28 Removal Procedure .........................................10
Installation Procedure ......................................28 Fuel Temperature Sensor - Remove and Install ... 179
Removal Procedure .........................................28 Installation Procedure .................................... 180
Exhaust Gas Recirculation Valve - Remove and Removal Procedure ....................................... 179
Install ...............................................................55
Installation Procedure ......................................57
Removal Procedure .........................................55 G
Exhaust Manifold - Remove and Install .................63 Glow Plugs - Remove and Install ........................ 190
Installation Procedure ......................................65 Installation Procedure .................................... 190
Removal Procedure .........................................63 Removal Procedure ....................................... 190

F H
Fan - Remove and Install ................................... 194 Housing (Front) - Install ..................................... 123
Installation Procedure .................................... 194 Installation Procedure .................................... 123
Removal Procedure ....................................... 194 Housing (Front) - Remove.................................. 121
Fan Drive - Remove and Install .......................... 194 Removal Procedure ....................................... 121
Installation Procedure .................................... 195
Removal Procedure ....................................... 194
Flexible Exhaust Pipe - Remove and Install ...........59 I
Assembly Procedure for the Flexible Exhaust Pipe
Assembly ......................................................61 Idler Gear - Install.............................................. 120
Disassembly Procedure for the Flexible Exhaust Installation Procedure .................................... 120
Pipe Assembly ...............................................60 Idler Gear - Remove .......................................... 118
Installation Procedure for the Flexible Exhaust Removal Procedure ....................................... 118
Pipe as an Assembly ......................................62 Idler Pulley - Remove and Install ........................ 192
Removal Procedure for the Flexible Exhaust Pipe Installation Procedure .................................... 193
as an Assembly..............................................59 Removal Procedure ....................................... 192
Flow Control Valve - Remove and Install ...............12 Important Safety Information ..................................2
Installation Procedure ......................................13 Inlet and Exhaust Valve Guides - Remove and
Removal Procedure .........................................12 Install ...............................................................86
Flywheel - Install ............................................... 102 Installation Procedure ......................................87
Installation Procedure .................................... 102 Removal Procedure .........................................86
Flywheel - Remove............................................ 101 Inlet and Exhaust Valve Springs - Remove and
Removal Procedure ....................................... 101 Install ...............................................................81
Flywheel Housing - Remove and Install (Non- Installation Procedure ......................................82
Stressed Cylinder Block) .................................. 107 Removal Procedure .........................................81
Installation Procedure .................................... 109 Inlet and Exhaust Valves - Remove and Install.......83
Removal Procedure ....................................... 107 Installation Procedure ......................................84
Flywheel Housing - Remove and Install Removal Procedure .........................................83
(Stressed Cylinder Block)................................. 105 Inlet Manifold - Remove and Install .......................78
Installation Procedure .................................... 106 Installation Procedure ......................................79
Removal Procedure ....................................... 105 Removal Procedure .........................................78
Front Cover - Remove and Install ....................... 116 Inlet Manifold Pressure Sensor - Remove and
Installation Procedure .................................... 116 Install ............................................................. 188
Removal Procedure ....................................... 116 Installation Procedure .................................... 189
Fuel Filter Base - Remove and Install....................13 Removal Procedure ....................................... 188
Installation Procedure ......................................15 Inlet Manifold Temperature Sensor - Remove
Removal Procedure .........................................13 and Install ....................................................... 187
Fuel Injection Lines - Install ..................................25 Installation Procedure .................................... 188
Installation Procedure ......................................25 Removal Procedure ....................................... 187
Fuel Injection Lines - Remove ..............................22 Inspection of Parts ................................................5
Removal Procedure .........................................22 Reuse Guideline for the Flexible Exhaust Pipe .....5
Fuel Injection Pump - Install .................................36
Installation Procedure ......................................36
Fuel Injection Pump - Remove .............................34 L
Removal Procedure .........................................34 Lifter Group - Remove and Install ....................... 142
Fuel Injection Pump Gear - Install .........................39 Installation Procedure .................................... 142
Installation Procedure ......................................39 Removal Procedure ....................................... 142

This document has been printed from SPI2. NOT FOR RESALE
UENR0624-03 203
Index Section

O Installation Procedure .................................... 182

Removal Procedure ....................................... 182
Oxygen Sensor - Remove and Install (Catalytic Throttle Valve (Intake Air) - Remove and Install
Converter) ...................................................... 181 (Rear Facing Inlet Elbow) ...................................30
Installation Procedure .................................... 181 Installation Procedure ......................................31
Removal Procedure ....................................... 181 Removal Procedure .........................................30
Throttle Valve (Intake Air) - Remove and Install
P (Side Facing Inlet Elbow) ...................................32
Installation Procedure ......................................33
Piston Cooling Jets - Remove and Install ............ 157 Removal Procedure .........................................32
Installation Procedure .................................... 157 Turbocharger - Install (Side Mounted
Removal Procedure ....................................... 157 Turbochargers)..................................................51
Pistons and Connecting Rods - Assemble........... 161 Installation Procedure ......................................51
Assembly Procedure ...................................... 161 Turbocharger - Install (Top Mounted
Pistons and Connecting Rods - Disassemble ...... 160 Turbochargers)..................................................48
Disassembly Procedure ................................. 160 Installation Procedure ......................................48
Pistons and Connecting Rods - Install................. 162 Turbocharger - Remove (Side Mounted
Installation Procedure .................................... 162 Turbochargers)..................................................46
Pistons and Connecting Rods - Remove ............. 158 Removal Procedure .........................................46
Removal Procedure ....................................... 158 Turbocharger - Remove (Top Mounted
Power Take-Off Drive - Remove and Install ......... 110 Turbochargers)..................................................44
Installation Procedure .................................... 112 Removal Procedure .........................................44
Removal Procedure ....................................... 110
Pressure Sensor (DPF) - Remove and Install ...... 184
Installation Procedure .................................... 184 V
Removal Procedure ....................................... 184 Valve Mechanism Cover - Remove and Install ..... 129
Pressure Sensor (Exhaust Back Pressure) - Installation Procedure .................................... 131
Remove and Install .......................................... 185 Removal Procedure ....................................... 129
Installation Procedure .................................... 186
Removal Procedure ....................................... 185
W
R Wastegate Solenoid - Remove and Install .............54
Installation Procedure ......................................54
Rocker Shaft - Assemble ................................... 134 Removal Procedure .........................................54
Assembly Procedure ...................................... 134 Water Pump - Install ............................................95
Rocker Shaft - Disassemble............................... 134 Installation Procedure ......................................95
Disassembly Procedure ................................. 134 Water Pump - Remove ........................................94
Rocker Shaft and Pushrod - Install...................... 135 Removal Procedure .........................................94
Installation Procedure .................................... 135 Water Separator and Fuel Filter (Primary) -
Rocker Shaft and Pushrod - Remove .................. 132 Remove and Install ............................................17
Removal Procedure ....................................... 132 Installation Procedure ......................................19
Removal Procedure .........................................17
S Water Temperature Regulator - Remove and
Install ...............................................................96
Support and Mounting (CEM) - Remove and Installation Procedure ......................................97
Install (Option 1) ................................................76 Removal Procedure .........................................96
CEM Assembly Installation Procedure ...............77
CEM Assembly Removal Procedure..................76
Support and Mounting (CEM) - Remove and
Install (Option 2) ................................................75
CEM Assembly installation Procedure ...............76
CEM Assembly Removal Procedure..................75
Support and Mounting (CEM) - Remove and
Install (Option 3) ................................................73
CEM Assembly Installation Procedure ...............74
CEM Assembly Removal Procedure..................73

T
Table of Contents ..................................................3
Temperature Sensor (DPF) - Remove and
Install ............................................................. 183
Installation Procedure .................................... 183
Removal Procedure ....................................... 183
Temperature Sensor (Exhaust) - Remove and
Install ............................................................. 182

This document has been printed from SPI2. NOT FOR RESALE

Kubota Motor V1902-BBS-1
No ratings yet
Kubota Motor V1902-BBS-1
45 pages
Volvo EW160D Wheeled Excavator Service Repair Manual Instant Download
No ratings yet
Volvo EW160D Wheeled Excavator Service Repair Manual Instant Download
21 pages
Disassembly and Assembly 3500C Marine Engines PDF
100% (10)
Disassembly and Assembly 3500C Marine Engines PDF
132 pages
Chapter 19 (Heavy Duty Truck Axle) PDF
100% (2)
Chapter 19 (Heavy Duty Truck Axle) PDF
29 pages
Engine ADG 1.9D
100% (1)
Engine ADG 1.9D
36 pages
Caterpillar T300 Parts Manual
100% (1)
Caterpillar T300 Parts Manual
173 pages
Chapter 22 (Suspension System) PDF
100% (3)
Chapter 22 (Suspension System) PDF
37 pages
30d-7sa Operator's Manual
No ratings yet
30d-7sa Operator's Manual
79 pages
Handout RamHino 5.1
No ratings yet
Handout RamHino 5.1
58 pages
Operation and Maintenance Manual: 854F-E34TA Industrial Engine
No ratings yet
Operation and Maintenance Manual: 854F-E34TA Industrial Engine
120 pages
JCB436
100% (1)
JCB436
14 pages
Cpcd50-Cu3g Cpcd60-Cu3g Cpcd70-Cu3g Cpcd85-Cu1g Cpcd100-Cu1g Cummins Qsb4.5-c110 Engine Error Code List
0% (1)
Cpcd50-Cu3g Cpcd60-Cu3g Cpcd70-Cu3g Cpcd85-Cu1g Cpcd100-Cu1g Cummins Qsb4.5-c110 Engine Error Code List
11 pages
Ergos 15-18-20-25-30-35 D/G: Spare Parts Catalogue
No ratings yet
Ergos 15-18-20-25-30-35 D/G: Spare Parts Catalogue
108 pages
Technical Training: Cummins Pacific Training Center
80% (10)
Technical Training: Cummins Pacific Training Center
25 pages
1 DIESEL EMISSIONS TECHNOLOGY Sulzer 33
No ratings yet
1 DIESEL EMISSIONS TECHNOLOGY Sulzer 33
33 pages
Chapter 18 (Drive Shafts)
100% (2)
Chapter 18 (Drive Shafts)
31 pages
Syllabus in Human Behavior and Victimology
100% (2)
Syllabus in Human Behavior and Victimology
8 pages
The Low Power AM Broadcasters Handbook
No ratings yet
The Low Power AM Broadcasters Handbook
113 pages
854F-Testing and Adjusting
No ratings yet
854F-Testing and Adjusting
96 pages
Pieces plaque vibrante WEBER CR6
0% (1)
Pieces plaque vibrante WEBER CR6
52 pages
Operation and Maintenance Manual: 854F-E34T and 854E-E34TA Industrial Engines
No ratings yet
Operation and Maintenance Manual: 854F-E34T and 854E-E34TA Industrial Engines
120 pages
Hangcha CPD-series Electrical Forklift Truck - Operation and Maintenance Manual
No ratings yet
Hangcha CPD-series Electrical Forklift Truck - Operation and Maintenance Manual
82 pages
Mitsubishi s4s
No ratings yet
Mitsubishi s4s
76 pages
S4Q2 Engine N-Series
No ratings yet
S4Q2 Engine N-Series
96 pages
DEUTZ G2.2 Parts Catalogue
No ratings yet
DEUTZ G2.2 Parts Catalogue
170 pages
T41140SLP_T40180SLP 7283381 enUS sm
No ratings yet
T41140SLP_T40180SLP 7283381 enUS sm
851 pages
20D/25D/30D/33D-7: Dimension Specification
No ratings yet
20D/25D/30D/33D-7: Dimension Specification
7 pages
Fbesf 10-15
No ratings yet
Fbesf 10-15
321 pages
Service Manual For Mitsubishi Diesel Engines PDF
100% (1)
Service Manual For Mitsubishi Diesel Engines PDF
219 pages
KOMATSU D65EXi-18
No ratings yet
KOMATSU D65EXi-18
184 pages
Doosan Generator Engine DB58 Parts Book PDF
No ratings yet
Doosan Generator Engine DB58 Parts Book PDF
60 pages
A - NANO SP PLUS - JLG POWER TOWERS - Parts - English
No ratings yet
A - NANO SP PLUS - JLG POWER TOWERS - Parts - English
30 pages
Parts Catalog D722-E4B-SXN-1
100% (1)
Parts Catalog D722-E4B-SXN-1
54 pages
PC75 123 Manual
No ratings yet
PC75 123 Manual
72 pages
Parts Catalog: 2011/7 (Jul.) Published
No ratings yet
Parts Catalog: 2011/7 (Jul.) Published
27 pages
Recommendation List of Concession'S Spare Parts: Machine
No ratings yet
Recommendation List of Concession'S Spare Parts: Machine
6 pages
Lombardinie LDW 2204M
0% (1)
Lombardinie LDW 2204M
58 pages
WB93R 5 S N F50003 Up PDF
No ratings yet
WB93R 5 S N F50003 Up PDF
759 pages
Тех.описание По Маслам,Фильтрам,Ремням Для Каждой Модели
No ratings yet
Тех.описание По Маслам,Фильтрам,Ремням Для Каждой Модели
300 pages
No 56 (Carloader D) Parts Manual
No ratings yet
No 56 (Carloader D) Parts Manual
164 pages
GTH 2506 From 10841 To 18956 Part Manual
100% (1)
GTH 2506 From 10841 To 18956 Part Manual
116 pages
01-43-02 REAR AXLE SYSTEM (PART-2) Dp30N 98733-06110 Cat Chassis, Mast, Options & Internal Hosing Chassis Axle 01-43-02 Rear Axle System (PART-2)
No ratings yet
01-43-02 REAR AXLE SYSTEM (PART-2) Dp30N 98733-06110 Cat Chassis, Mast, Options & Internal Hosing Chassis Axle 01-43-02 Rear Axle System (PART-2)
3 pages
Manitou Mc Msi 25-30-35 d k St5 s1 Spare Parts Catalog 647839
No ratings yet
Manitou Mc Msi 25-30-35 d k St5 s1 Spare Parts Catalog 647839
22 pages
Nissan 1D1 Option 2013-07 Crystal Cabin Kit
No ratings yet
Nissan 1D1 Option 2013-07 Crystal Cabin Kit
36 pages
Caterpillar Cat Dp40k Dp40kl Dp45k Dp50k Forklift Lift Trucks Service Repair Manual Instant Download
0% (1)
Caterpillar Cat Dp40k Dp40kl Dp45k Dp50k Forklift Lift Trucks Service Repair Manual Instant Download
47 pages
Kaup T411 T411D EN
No ratings yet
Kaup T411 T411D EN
8 pages
Manual de Partes GENIE GTH10E-13135
100% (1)
Manual de Partes GENIE GTH10E-13135
366 pages
4tne94 G1a
No ratings yet
4tne94 G1a
22 pages
Komatsu t11 - Forklift Truck
No ratings yet
Komatsu t11 - Forklift Truck
370 pages
Komatsu PC88MR 6 1010 Page
No ratings yet
Komatsu PC88MR 6 1010 Page
2 pages
Power Shift Transmission Testing and Adjusting
No ratings yet
Power Shift Transmission Testing and Adjusting
10 pages
Caterpillar Sit On Catalogep1.0 3.0ca
No ratings yet
Caterpillar Sit On Catalogep1.0 3.0ca
7 pages
HYSTER - H50CT(A274)
No ratings yet
HYSTER - H50CT(A274)
400 pages
Skyjack - Sjiii 3220-26 - Service
No ratings yet
Skyjack - Sjiii 3220-26 - Service
191 pages
B - 2632R, 3246R - JLG - Service - English
No ratings yet
B - 2632R, 3246R - JLG - Service - English
188 pages
Mitsubishi FG20-30N
0% (1)
Mitsubishi FG20-30N
86 pages
DES - Foerdertechnik - Motorteile CATALOG PIESE PDF
100% (2)
DES - Foerdertechnik - Motorteile CATALOG PIESE PDF
534 pages
Part Engine
No ratings yet
Part Engine
55 pages
Cat S4S Service Manual
No ratings yet
Cat S4S Service Manual
168 pages
SK714 815 5 WEBM003400 SM Eng WM
No ratings yet
SK714 815 5 WEBM003400 SM Eng WM
250 pages
C40-55sD (Lot No 9913,8311)
100% (1)
C40-55sD (Lot No 9913,8311)
278 pages
MT523, MLT523 547790AS Rev11 10
0% (1)
MT523, MLT523 547790AS Rev11 10
144 pages
V1505 Bg2-Sae2
No ratings yet
V1505 Bg2-Sae2
55 pages
3 Engine Manual - Kubota 2607 E - A-AGE2-700-00006_02.8.2
100% (1)
3 Engine Manual - Kubota 2607 E - A-AGE2-700-00006_02.8.2
51 pages
Parts Manual: Forklifts C 500 H
No ratings yet
Parts Manual: Forklifts C 500 H
147 pages
Cat Gp15k - Gp35k Dp20k-Dp35k Service Manjel
100% (1)
Cat Gp15k - Gp35k Dp20k-Dp35k Service Manjel
370 pages
Senr6564 19 00 All
No ratings yet
Senr6564 19 00 All
452 pages
Upload-Download - Setup & Use
No ratings yet
Upload-Download - Setup & Use
39 pages
Service Report - Training
No ratings yet
Service Report - Training
58 pages
Whats New STW, Cat ET, SIS and On Line Licensing Fall 2009
No ratings yet
Whats New STW, Cat ET, SIS and On Line Licensing Fall 2009
79 pages
Service Report - Fields That Upload To DBS
No ratings yet
Service Report - Fields That Upload To DBS
17 pages
Effect of PWHT Cycles On Fatigue Crack Growth and Toughness of Quenched and Tempered Pressure Vessel Steels bxl97wpj
No ratings yet
Effect of PWHT Cycles On Fatigue Crack Growth and Toughness of Quenched and Tempered Pressure Vessel Steels bxl97wpj
8 pages
2009A What's New Version 3-17-2009
No ratings yet
2009A What's New Version 3-17-2009
55 pages
STZ-L - STZ-H MPA : Product Brochure
No ratings yet
STZ-L - STZ-H MPA : Product Brochure
7 pages
Engineered: To Go Where Other Cranes
No ratings yet
Engineered: To Go Where Other Cranes
4 pages
Komatsu Training Academy Training Calendar
100% (1)
Komatsu Training Academy Training Calendar
4 pages
Specifications: 854E-E34TA, 854F-E34T and 854F-E34TA Industrial Engines
No ratings yet
Specifications: 854E-E34TA, 854F-E34T and 854F-E34TA Industrial Engines
60 pages
Chapter 20 (Heavy Duty Truck Axle Service and Repair)
No ratings yet
Chapter 20 (Heavy Duty Truck Axle Service and Repair)
32 pages
1 Diesel Engineer Cruise Notebook 1 385 PDF
No ratings yet
1 Diesel Engineer Cruise Notebook 1 385 PDF
385 pages
Ship'S Engineering: Books
No ratings yet
Ship'S Engineering: Books
2 pages
Chapter 17 (Allison World Transmission) PDF
No ratings yet
Chapter 17 (Allison World Transmission) PDF
39 pages
Chapter 23 (Wheels and Tires)
100% (2)
Chapter 23 (Wheels and Tires)
44 pages
Chapter 14 (Automatic Transmission Maintenance)
No ratings yet
Chapter 14 (Automatic Transmission Maintenance)
19 pages
Chapter 13 (Automatic Transmission)
100% (1)
Chapter 13 (Automatic Transmission)
26 pages
Chapter 16 (Allison Commercial Electronic Control Transmission) PDF
No ratings yet
Chapter 16 (Allison Commercial Electronic Control Transmission) PDF
17 pages
Led TV: Service Manual
No ratings yet
Led TV: Service Manual
77 pages
Design Thinking Toolkit by Echos Innovation Lab
100% (2)
Design Thinking Toolkit by Echos Innovation Lab
91 pages
Approved Vendors List
No ratings yet
Approved Vendors List
12 pages
CPR Palazhy
No ratings yet
CPR Palazhy
29 pages
Diagnostic & Treatment Breast Carcinoma: Dr. Dr. Effif Syofra Tripriadi, Sp. B (K) Onk
No ratings yet
Diagnostic & Treatment Breast Carcinoma: Dr. Dr. Effif Syofra Tripriadi, Sp. B (K) Onk
64 pages
Broadband in Malaysia
No ratings yet
Broadband in Malaysia
4 pages
Brite Toolkit I
No ratings yet
Brite Toolkit I
5 pages
UNit 1 Expressions and Control Statements in PHP
No ratings yet
UNit 1 Expressions and Control Statements in PHP
81 pages
Ferri Yanto: Mengapa Merekrut Saya?
No ratings yet
Ferri Yanto: Mengapa Merekrut Saya?
4 pages
Summit 2 Workbook PDF by Joan M. Saslow
No ratings yet
Summit 2 Workbook PDF by Joan M. Saslow
1 page
Medi-Caps University, Indore: Oral Examination, (Even Sem) May 2021 Slot Details
No ratings yet
Medi-Caps University, Indore: Oral Examination, (Even Sem) May 2021 Slot Details
2 pages
Labour NR - 5
No ratings yet
Labour NR - 5
5 pages
PET RUBRIC l.o
No ratings yet
PET RUBRIC l.o
3 pages
CH5014 Final Exam Samplepaper
No ratings yet
CH5014 Final Exam Samplepaper
2 pages
20241112 Training Catalogue 2025 en Web
No ratings yet
20241112 Training Catalogue 2025 en Web
114 pages
Electronics and Wiring Diagram EPA13 Part 1 PDF
0% (1)
Electronics and Wiring Diagram EPA13 Part 1 PDF
32 pages
Broadly, There Are 3 Types of Machine Learning Algorithms.
No ratings yet
Broadly, There Are 3 Types of Machine Learning Algorithms.
33 pages
DAICEL Catalog 2005
No ratings yet
DAICEL Catalog 2005
23 pages
Coek - Info Skid-Grouting
100% (1)
Coek - Info Skid-Grouting
14 pages
CH 1. Introduction To Assurance
No ratings yet
CH 1. Introduction To Assurance
45 pages
Laser Engineered Net Shaping
50% (2)
Laser Engineered Net Shaping
11 pages
CSC_5SL03_TP-pt3-Tutorial4-RBAC-answers
No ratings yet
CSC_5SL03_TP-pt3-Tutorial4-RBAC-answers
3 pages
Vanilla Sponge Cake, Step-By-Step - The Scranline
No ratings yet
Vanilla Sponge Cake, Step-By-Step - The Scranline
5 pages
Cry of Balintawak or Pugad Lawin
No ratings yet
Cry of Balintawak or Pugad Lawin
3 pages
Handout 8 - Employment
No ratings yet
Handout 8 - Employment
4 pages
Skeletal System Coloring
No ratings yet
Skeletal System Coloring
5 pages
Idoc - Pub Omr Sheet 50 Questionspdf
No ratings yet
Idoc - Pub Omr Sheet 50 Questionspdf
1 page
Ignore The Awkward by Uffe Ravnskov
100% (1)
Ignore The Awkward by Uffe Ravnskov
91 pages