Perkins 1506D Engine Manual

UENR4511-01 UENR4511-01 (en-us) December 2015

Disassembly and Assembly 1506A1506A-E88 E88T TA, 1506C1506C-E88 E88T TA and 1506D1506D-E88 E88T TA Indust Industria riall Engine Engines s LG (Engine) PK9 (Engine)

This document has been printed from SPI2. NOT FOR RESALE

Important Safety Information M ost ac cid en ts tha t invol nv olve p rod uc t op erat erati ion , m ainten nten an ce an d rep air are are ca used us ed b y failure ure to o b ser se rve b a sic saf sa fe ty ru le s or p re c a uti utio n s. A n ac c id e n t c an o fte n b e avo av o id e d b y re c o g n izing p ote ote n tia lly ha zard zard ou s situa tion s be fore ore an a cc id en t oc cu rs. A p erson erson m ust b e alert ert to p oten oten tial ha zard zard s. Th is p e rso n sh s h o u ld a lso h a ve th e n e c e ssa ry tra in in g , skills an a n d to o ls to p e rfo rm th e se fu n c tio n s p ro p e rly.

Improper operation, lubrication, maintenance maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. S afet afety y p rec au tion s and a nd w arni arning s ar a re p rovi ov id ed in this m anu a nu al an d on the p rod uc t. If the se ha zar za rd w arni arning s are are no t he ed ed , b od ily injury ury or d ea th cou c ou ld oc cu r to you yo u o r to o the r p erson erson s. T h e h a za rd s ar a re id e n tifie d b y th e “ S a fe ty A le rt S ym b o l”a n d fo llo w e d b y a “ S ig n a l W or o rd ”suc su c h a s “ D AN G ER” ,“ W A R N IN G ”o r “ C A U TI T IO N ” . T h e S a fe ty A le rt “ W A R N IN G ”la b e l is sh o w n b e lo w .

T h e m e a n in g o f th is saf sa fe ty al a le rt sym b o l is as a s fo llo w s:

Attention! Become Alert! Your Safety is Involved. Th e m e ssag ssa g e tha tha t ap p ea rs und u nd er the w arning exp ex p lains the ha zard zard an d ca n b e e ithe r w ritten or p ic to ria lly pr p re se n te d . O pe p e ra tio n s tha t m ay a y ca c a u se p ro d u c t d a m ag a g e a re id e n tifie d b y “ N O TIC E ”la b e ls on o n th th e p rod u c t a n d in th is p u b lic a tio n .

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance maintenance or repair procedures that you choose. T h e in fo rm at atio n , sp e c ific a tio n s, a n d illu str stra tio n s in th th is p u b lic a tio n ar a re on o n th th e b a sis of o f in fo rm at atio n th th a t w a s a va ila b le a t th e tim e th a t th e p u b lic a tio n w a s w ritte n . T h e sp e c ific a tio n s, to rq u e s, p re ssu re s, m ea surem surem e nts, nts, ad justm ustm en ts, illustr ustrati ation s, an d othe othe r item s c an ch an g e a t an y tim e. Th ese ch an g es c an a ffe c t th e se s e rvic e th th a t is g iven ve n to to th th e p ro d u c t. O bt b ta in th th e c o m p le te a n d m ost o st c u rre n t in fo rm at a tio n b e fo re yo u st s ta rt a n y jo b . P e rkin s d e a le rs or o r P e rkin s d istr strib u to rs h a ve th e m ost o st c u rre n t in fo rm at atio n a va ila b le .

When replacement replacement parts are required for this product Perkins recommends using Perkins replacement parts. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.


UENR4511-01

3 Table of Contents

Table of Contents Disassembly and Assembly Section Fuel Priming Pump - Remove and Install ................5 Fuel Fuel Filter Base - Remove Remove .................................... .6 Fuel Filter Base Base - Remove Remove (Option 2) ...... ...... ...... .... 7 Fuel Filter Base - Disassemble...............................8 Fuel Filter Base - Disassemble (Option 2) ...............9 Fuel Filter Base - Assemble .................................10 Fuel Filter Filter Base - Assemble Assemble (Option (Option 2)...... ...... ...... 11 Fuel Fuel Filter Filter Base - Install Install ...................................... 11 Fuel Filter Base - Install (Option 2)........................13 Water Separator and Fuel Filter (Primary) - Remove and Insta Install ll ......................................................... 14 Electronic Unit Injector - Remove..........................17 Electr Electroni onic c Unit Unit Inject Injector or - Instal Installl .............................19 Electronic Unit Injector Sleeve - Remove ..............21 Electronic Electronic Unit Unit Injector Injector Sleeve Sleeve - Install Install ...... ...... ...... 23 Unit Injector Hydraulic Pump - Remove.................24 Unit Injector Hydraulic Pump - Install ....................25 Air Cleaner - Remove and Install ...... ... ...... ...... ...... ...... ...... ...... ..... .. 27 Turbo Turbocha charge rgerr - Remove.......................................29 Remove.......................................29 Turbo Turbocha charge rgerr - Instal Installl .......................................... 30 Exhaust Exhaust Manifold Manifold - Remove Remove and Install ...... ...... .... 32 Exhaust Elbow - Remove and Install ....................35 Inlet and Exhaust Valve Springs - Remove and Instal Installl ............................................................... 36 Inlet and Exhaust Valves Valves - Remove and Install...... . 38 Inlet and Exhaust Valve Guides - Remove and Instal Installl ............................................................... 40 Engine Oil Filter Base and Oil Cooler - Remove ....41 Engine Oil Filter Base and Oil Cooler - Install ........43 Engine Engine Oil Pump - Remove.................................. Remove.................................. 46 Engine Engine Oil Pump - Disass Disassemb emble le ...........................47 Engine Oil Pump - Assemble................................49 Engine Engine Oil Pump Pump - Install. Install...................................... ..................................... 51 Water Water Pump - Remove Remove ........................................ 52 Water Water Pump - Disass Disassemb emble le ................................. 53 Water Water Pump Pump - Assemble Assemble ..................................... 54 Water Water Pump - Install Install ............................................ 56 Water Temperature Regulator - Remove and Instal Installl ............................................................... 57 Engine Lifting Bracket - Remove and Install ..........60 Engine Engine Support (Front) (Front) - Remove and Install Install ...... ... 62 Engine Support (Front) - Remove and Install (Option 2) ..................................................................... 64 Flywhe Flywheel el - Remove Remove.............................................. .............................................. 65 Flywhe Flywheel el - Install Install ................................................. 66 Crankshaft Crankshaft Rear Seal - Remove Remove ...... ...... ...... ...... ... 68 Crankshaft Rear Seal - Install...............................68 Flywheel Housing - Remove and Install ................69 Vibration Vibration Damper and Pulley - Remove and Install 72 Crankshaft Front Seal - Remove ..........................74 Cranks Crankshaf haftt Front Front Seal - Install Install .............................. 75 Front Front Cover Cover - Remove Remove ......................................... 75 Front Front Cover - Install............................................. Install............................................. 76 Gear Group (Front) - Remove ..............................77 Gear Gear Group Group (Front) (Front) - Instal Installl ..................................78 Housing (Front) - Remove....................................80 Housin Housing g (Front) (Front) - Instal Installl ....................................... 81 Crankcase Crankcase Breather Breather - Remove Remove and Install Install ...... ...... 83 Cylinder Block Cover - Remove and Install............84 Valve Mechanism Mechanism Cover - Remove and Install Install ...... . 88

Valve Mechanism Cover Base - Remove and Instal Installl ............................................................... 91 Rocker Rocker Arm and Shaft Shaft - Remove Remove .......................... 93 Rocker Arm - Disassemble...................................94 Rocker Rocker Arm - Assemb Assemble le ....................................... 95 Rocker Rocker Arm and Shaft - Install.............................. Install.............................. 96 Cylind Cylinder er Head Head - Remove......................................98 Remove......................................98 Cylind Cylinder er Head - Install Install ....................................... 102 Lifter Lifter Group - Remove Remove and Install Install ....................... 107 Camsha Camshaft ft - Remove Remove .......................................... 108 Camsha Camshaft ft - Install Install .............................................. 110 Camshaft Camshaft Gear - Remove Remove and Install Install ...... ...... ..... 111 Camshaft Camshaft Bearings Bearings - Remove Remove ........... ...... ...... ..... 113 Camsha Camshaft ft Bearing Bearings s - Instal Installl ................................ 113 Engine Oil Pan - Remove Remove and and Install Install ..... ...... ...... . 115 Cylind Cylinder er Liner - Remove Remove .................................... 118 Cylind Cylinder er Liner Liner - Install........................................ Install........................................ 119 Piston Cooling Jets - Remove and Install ............120 Pistons Pistons and Connect Connecting ing Rods Rods - Remove Remove ...... ...... . 121 Pistons Pistons and Connecting Connecting Rods - Disassemble Disassemble ...... 122 Pistons and Connecting Rods - Assemble...........123 Pistons and Connecting Rods - Install.................124 Connecting Rod Bearings - Remove...................125 Connecting Rod Bearings - Install.......................126 Crankshaft Main Bearings - Remove (Crankshaft in Positio Position) n) ......................................................... 127 Crankshaft Main Bearings - Install (Crankshaft in Positio Position) n) ......................................................... 128 Cranks Crankshaf haftt - Remove.........................................130 Remove.........................................130 Cranks Crankshaf haftt - Install Install ............................................ 132 Crankshaft Gear - Remove and Install ................137 Bearin Bearing g Cleara Clearance nce - Check Check ................................ 138 Refrigerant Refrigerant Compressor Compressor - Remove Remove and Install Install .... 139 Atmospheric Pressure Sensor - Remove and Instal Installl ............................................................. 142 Coolant Temperature Sensor - Remove and Instal Installl ............................................................. 143 Engine Oil Pressure Sensor - Remove and Instal Installl ............................................................. 144 Fuel Pressure Pressure Sensor - Remove and and Install..... .... 145 Fuel Pressure Sensor - Remove and Install (Option 2) ................................................................... 146 Fuel Tempera Temperature ture Sensor - Remove and Install ... 147 Injection Actuation Pressure Sensor - Remove and Instal Installl ............................................................. 148 Speed/Timi Speed/Timing ng Sensor Sensor - Remove and Install Install ...... .. 150 Inlet Manifold Temperature Sensor - Remove and Instal Installl ............................................................. 151 Inlet Manifold Pressure Sensor - Remove and Instal Installl ............................................................. 152 V-Belts - Remove and Install (Charging Alternator Drive Drive Belts) Belts) ..................................................... 154 V-Belts - Remove and Install (Water Pump Drive Belt) Belt) ............................................................... 155 Alternator Belt - Remove and Install ... ...... ... ...... ...... ...... ..... 156 Idler Pulley - Remove and Install (Grooved Idler Pulley Pulley)) ............................................................ 157 Belt Tensioner - Remove and Install....................158 Fan - Remove Remove and Insta Install ll .................................. 159 Fan Drive Drive - Remove Remove ......................................... 160 Fan Drive Drive - Disass Disassemb emble le ................................... 161 Fan Drive Drive - Assem Assemble ble ....................................... 162 Fan Drive Drive - Install Install .............................................. 164 Electronic Electronic Control Module Module - Remove Remove and Install.. . 164 Alternator - Remove and Install ...... ... ...... ... ...... ... ...... ...... ...... ..... 167


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Table of Contents

Alternator - Remove and Install (High Mounted Alternator). ...... ... ...... ...... ...... ...... ... ...... ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 169 Electric Electric Starting Starting Motor - Remove Remove and Install Install ...... . 172 Air Compressor - Remove and Install ...... ... ...... ...... ...... ..... .. 174

Index Section Index................................................................177


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Disassembly and Assembly Section


3. Remove 3. Remove gasket (3).

Installation Procedure i05986296

Fuel Priming Pump - Remove

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

and Install Removal Procedure NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accordi according ng to local local regula regulatio tions ns and mandates.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 2

1. Turn 1. Turn the fuel supply to the OFF position.

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Typical example 1. Position 1. Position a new gasket (3) on fuel filter base (4). Note: Ensure Note: Ensure correct orientation of the joint. 2. Position 2. Position fuel priming pump (1) on fuel filter base (4) and install bolts (2). Tighten Tighten the bolt to a torque of 12 N·m (105 lb in). Tighten Tighten the bolt bolt to a torque of 28 N·m N·m (248 lb in). 3. Turn 3. Turn the fuel supply to the ON position.

Illustration 1

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Typical example 2. Remove 2. Remove bolts (2). Remove fuel priming pump (1) from fuel filter base (4).


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4. Remove 4. Remove the air from the fuel system. system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. i05986293

Fuel Filter Base Filter Base - Remove Removal Procedure

NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accordi according ng to local local regula regulatio tions ns and mandates.


1. Turn 1. Turn the fuel supply to the “OFF” position. 2. Place 2. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.

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Typical example 3. Disconnect 3. Disconnect harness assembly (4) from fuel pressure sensor (3) and fuel temperature sensor (7). 4. Disconnect 4. Disconnect hose assembly (5) and hose assembly (6). Remove O-ring seal (7) (not shown) and Oring seal (9) (not shown). Plug the open hose assemblies and open port on the connections secondary fuel filter base (10). 5. Use 5. Use a suitable tool in order to remove secondary fuel filter (11). Remove the O-ring seal. Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for more information. 6. Remove 6. Remove bolts (1) and washers (2). Support the fuel filter base (10) as the bolts are removed. Remove fuel filter base (10).


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NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn 1. Turn the fuel supply to the “OFF” position. 2. Place 2. Place a suitable container below the fuel filter base to catch any fuel that might be spilled. spilled.

Illustration 4

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Typical example 7. If 7. If necessary, follow Step 7.a Step 7.a through through Step 7.b Step 7.b in in order to remove bracket (12) from the cylinder block. a.

b.

If necessa necessary ry,, remove remove the the assembly assembly of primary primary fuel filter. Refer to Disassembly and Assembly, “Water Separator and Fuel Filter (Primary) Remove and Install” for the correct procedure. Remove Remove bolts bolts (14) (14) and washers washers (13). (13). Remove Remove bracket (12) from the cylinder block. i06539447

Fuel Filter Base Filter Base - Remove (Option 2) Removal Procedure NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids.

Illustration 5

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Typical example 3. Cut 3. Cut cable strap (4). Disconnect fuel pressure sensor (5) from the engine harness. 4. Disconnect 4. Disconnect tube assembly (3) and hose assembly (6). Plug the open hose assemblies and open port on the connections secondary fuel filter base (7). 5. Use 5. Use a suitable tool to remove secondary fuel filter (8). Remove the O-ring seal. Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for more information. 6. Remove 6. Remove bolts (1) and washers (2). Support the fuel filter base (7) as the bolts are removed. removed. Remove fuel filter base (7).

Dispos Dispose e of all fluids fluids accordi according ng to local local regula regulatio tions ns and mandates.


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Illustration 6

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Typical example 7. If 7. If necessary, follow Step 7.a Step 7.a through through Step 7.b Step 7.b to to remove bracket (12) from the cylinder block. a.

b.

If necessa necessary ry,, remove remove the the assembly assembly of primary primary fuel filter. Refer to Disassembly and Assembly, “Water Separator and Fuel Filter (Primary) Remove and Install” for the correct procedure. Remove Remove bolts bolts (9) (9) and and washers washers (13). Remove bracket (11) and bracket (12) from the cylinder block. i05986291

Fuel Filter Base Filter Base - Disassemble Disassembly Procedure Start By: a. Remove the fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 7

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Typical example 1. Remove 1. Remove fuel priming pump (17) from fuel filter base assembly (22). Refer to Disassembly and Assembly, Assembly, “Fuel “ Fuel Priming Pump - Remove and Install” for the correct procedure. 2. Remove 2. Remove fuel temperature sensor (6) from fuel filter base assembly (22). Refer to Disassembly and Assembly, Assembly, “Fuel “ Fuel Temperature Sensor - Remove and Install” for the correct procedure. 3. Remove 3. Remove fuel pressure sensor (4) from fuel filter base assembly (22). Refer to Disassembly and Assembly, Assembly, “Fuel “ Fuel Pressure Sensor - Remove and Install” for the correct procedure. 4. Remove 4. Remove adapter (3) from fuel filter base assembly (22). Remove the O-ring seal (5) from the adapter. 5. Remove 5. Remove fuel check valve (2) from fuel filter base assembly (22). Remove the O-ring seal (1) from the fuel check valve. 6. Remove 6. Remove fuel check valve (16) from fuel filter base assembly (22). Remove the O-ring seal (15) from the fuel check valve. 7. Make 7. Make temporary marks on elbow connection (11) for installation purposes. Loosen locking nut (10) and remove elbow connection from adapter (8). Remove O-ring seal (9) from the elbow connection.


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9 Disassembly and Assembly Section

8. Remove 8. Remove adapter (8) from fuel filter base assembly (22). Remove the O-ring seal (7) from the adaptor. 9. Make 9. Make temporary marks on elbow connection (12) for installation purposes. Loosen locking nut (13) and remove elbow connection from fuel filter base assembly (22). Remove O-ring seal (14) from the elbow connection. 10. Remove 10. Remove plug (19), and plug (20) from fuel filter base assembly (22). Remove the O-ring seal (18) and O-ring seal (21) from the plugs. i06541703

Fuel Filter Base - Disassemble (Option 2) Disassembly Procedure Start By: a. Remove the fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base Remove (Option 2)” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 8

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Typical example 1. Remove 1. Remove fuel priming pump (1) from fuel filter base assembly (15). Refer to Disassembly and Assembly, Assembly, “Fuel Priming Pump - Remove and Install” for the correct procedure. 2. Remove 2. Remove fuel pressure sensor (10) from elbow connection (11). Refer to Disassembly and Assembly, Assembly, “Fuel Pressure Sensor - Remove and Install” for the correct procedure. 3. Remove 3. Remove adapter (6) from fuel filter base assembly (15). Remove the O-ring seal (5) from the adapter. 4. Remove 4. Remove fuel check valve (13) from fuel filter base assembly (15). Remove O-ring seal (14) and cap (12) from the fuel check valve. 5. Make 5. Make temporary marks on elbow connection (2) for installation purposes. Loosen locking nut (3) and remove elbow connection from fuel filter base assembly assembly (15). Remove O-ring seal (4) from the elbow connection. 6. Make 6. Make temporary marks on elbow connection (11) for installation purposes. Remove elbow connection from fuel filter base assembly (15). Remove O-ring seal (9) from the elbow connection.


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7. Remove 7. Remove plug (7) from fuel filter base assembly (15). Remove the O-ring seal (8) from the plug. i05986289

Fuel Filter Base Filter Base - Assemble Assembly Procedure

3. Install 3. Install a new O-ring seal (14) to elbow connection (12). Install the elbow connection into fuel filter base assembly (22). Align the elbow connection with the temporary marks. Tighten locking nut (13) to a torque of 50 N·m (37 lb ft). Ensure Ensure that the elbow connection remains align after the locking nut is tightened. 4. Install 4. Install a new O-ring seal (7) to adapter (8). Install the adapter into fuel filter base assembly (22). Tighten Tighten the adapter adapter to a torque of 50 N·m (37 lb ft) .

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the all components of the filter base are clean and free from damage. If necessary, replace any component that is worn or damaged

5. Install 5. Install a new O-ring seal (9) to elbow connection (11). Install the elbow connection to adapter (8). Align the elbow connection with the temporary marks. Tighten locking nut (10) to a torque of 50 N·m (37 lb ft). Ensure Ensure that that the elbow connection remains align after the locking nut is tightened. 6. Install 6. Install a new O-ring seal (15) to fuel check valve valve (16). Install the fuel check valve into fuel filter base assembly (22). Tighten the fuel check valve to a torque of of 65 N·m (48 lb ft). ft). 7. Install 7. Install a new O-ring seal (1) to fuel check valve (2). Install the fuel check valve into fuel filter base assembly (22). Tighten the fuel check valve to a torque of of 65 N·m (48 lb ft). ft). 8. Install 8. Install a new O-ring seal (5) to adapter (8). Install the adapter into fuel filter base assembly (22). Tighten Tighten the adapter adapter to a torque of 50 N·m (37 lb ft) . 9. Install 9. Install fuel pressure sensor (4) to adapter (8). Refer to Disassembly and Assembly, “Fuel Pressure Sensor - Remove and Install” for the correct procedure. 10. Install 10. Install fuel temperature sensor (6) to fuel filter base assembly (22). Refer to Disassembly and Assembly, Assembly, “Fuel Temperature Sensor - Remove and Install” for the correct procedure. 11. Install 11. Install fuel priming pump (17) to fuel filter base assembly (22). Refer to Disassembly and Assembly, Assembly, “Fuel “ Fuel Priming Pump - Remove and Install” for the correct procedure.

Illustration 9

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Typical example 2. Install 2. Install a new O-ring seal (18), and a new O-ring seal (21) to plug (19), and plug (20). Install the plugs into fuel filter base assembly (22). Tighten plugs to a torque torque of 40 N·m (30 lb ft).


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End By: a. Install the fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base - Install” for the correct procedure. i06541719

Fuel Filter Base Filter Base - Assemble (Option 2) Assembly Procedure

3. Install 3. Install a new O-ring seal (4) to elbow connection (3). Install the elbow connection into fuel filter base assembly (15). Align the elbow connection with the temporary marks. Tighten locking nut (3) to a torque of 50 N·m (37 lb ft). Ensure Ensure that the elbow connection remains aligned after the locking nut is tightened. 4. Install 4. Install a new O-ring seal (9) to elbow connection (11). Install the elbow connection to fuel filter base assembly (15). Align the elbow connection with the temporary marks. Tighten elbow connection (11) to a torque of of 40 N·m (30 lb ft). 5. Install 5. Install a new O-ring seal (14) to fuel check valve valve (13). Install the fuel check valve into fuel filter base assembly (15). Tighten the fuel check valve to a torque of of 30 N·m (22 lb ft). ft).

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the all components of the filter base are clean and free from damage. If necessary, replace any component that is worn or damaged

6. Install 6. Install a new O-ring seal (5) to adapter (6). Install the adapter into fuel filter base assembly (15). Tighten Tighten the adapter adapter to a torque of 40 N·m (30 lb ft) . 7. Install 7. Install fuel pressure sensor (10) to elbow connection (11). Refer to Disassembly and Assembly, Assembly, “Fuel Pressure Sensor - Remove and Install” for the correct procedure. 8. Install 8. Install fuel priming pump (1) to fuel filter base assembly (15). Refer to Disassembly and Assembly, Assembly, “Fuel Priming Pump - Remove and Install” for the correct procedure. End By: a. Install the fuel filter base. Refer to Disassembly Disassembly and Assembly, “Fuel Filter Base - Install (Option 2)” for the correct procedure. i05986292

Fuel Filter Base Filter Base - Install Installation Procedure


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Typical example

1. Ensure 1. Ensure that all components of the fuel filter base are free from wear or damage. If necessary, replace any component that is worn or damaged.

2. Install 2. Install a new O-ring seal (8) to plug (7). Install the plug into fuel filter base assembly (15). Tighten plugs to a torque torque of 40 N·m (30 lb ft).


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Illustration 11

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Typical example 2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.b Step 2.b in in order to install bracket (12) to the cylinder block. a.

b.

Position Position bracket bracket (12) onto onto the the cylinder cylinder block. Install washers (3) to bolts (14). Torque bolts to a torque of of 240 N·m (177 lb ft). If necessary necessary,, install install the assembl assembly y of primary primary fuel filter. Refer to Disassembly and Assembly, “Water Separator and Fuel Filter (Primary) Remove and Install” for the correct procedure.

Illustration 12

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Typical example 3. Position 3. Position fuel filter base (10) and install washers (2) and bolts (1). Tighten Tighten the bolts to a torque of 55 N·m N·m (41 lb lb ft). 4. Install 4. Install a new O-ring seal to secondary fuel filter (11). Install the secondary fuel filter. Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for more information. 5. Install 5. Install a new O-ring seal (8) (not shown) shown) and a new O-ring seal (9) (not shown). Ensure that the O-ring seals are correctly located into the recess of the elbow connections 6. Connect 6. Connect hose assembly (5). Connect hose assembly (6). Securely tighten the hose assemblies to the elbow connections. 7. Connect 7. Connect harness assembly (4) to fuel pressure sensor (3) and fuel temperature sensor (7). 8. Turn 8. Turn the fuel supply to the ON position.


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Fuel Filter Base Filter Base - Install (Option 2) Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 14

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3. Position 3. Position fuel filter base (7) and install washers (2) and bolts (1). Tighten Tighten the bolts to a torque of 28 N·m N·m (21 lb lb ft). 4. Install 4. Install a new O-ring seal to secondary fuel filter (8). Install the secondary fuel filter. Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for more information. 5. Connect 5. Connect hose assembly (6). Securely tighten the hose assembly to the elbow connection. 6. Connect 6. Connect tube assembly (3). Securely tighten the tube assembly to the adaptor. 7. Connect 7. Connect the engine harness to fuel pressure sensor (5).

Illustration 13

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Typical example

8. Secure 8. Secure fuel pressure sensor (5) to the bracket using a new cable strap (4). 9. Turn 9. Turn the fuel supply to the ON position.

1. Ensure 1. Ensure that all components of the fuel filter base are free from wear or damage. If necessary, replace any component that is worn or damaged. 2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.b Step 2.b to to install bracket (12) to the cylinder block. a.

Position Position bracket bracket (12) onto onto the the cylinder cylinder block. Install washers (10) to bolts (9). Install bracket (11) to one bolt (9). Torque bolts to a torque of 55 N·m N·m (41 lb ft). ft).

b.

If necessary necessary,, install install the assembl assembly y of primary primary fuel filter. Refer to Disassembly and Assembly, “Water Separator and Fuel Filter (Primary) Remove and Install” for the correct procedure.


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Water Separator and Separator and Fuel Filter (Primary) Filter (Primary) - Remove and Install Removal Procedure NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accordi according ng to local local regula regulatio tions ns and mandates.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn 1. Turn the battery disconnect switch to the OFF position. 2. Turn 2. Turn the fuel supply to the OFF position. 3. Place 3. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.

Illustration 15

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Typical example 4. Disconnect 4. Disconnect hose assembly (3) from the assembly of primary fuel filter (5). 5. Remove 5. Remove bolts (1) and washers (2). Position bracket (4) away from the assembly of primary fuel filter (5). Remove the assembly of primary fuel filter (5) from the mounting bracket.


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Illustration 17

g03780742

Typical example 7. If 7. If necessary, follow Step 7.a Step 7.a through through Step 6.e Step 6.e in in order to remove bracket (20) from the cylinder block. Illustration 16

g03780722

Typical example 6. If 6. If necessary, follow Step 6.a Step 6.a through through Step 6.e Step 6.e in in order to disassembly the assembly of primary fuel filter (5).

a.

If necessary necessary,, remove remove the fuel filter filter base. base. Refer Refer to Disassembly and Assembly, “Fuel Filter Base - Remove” for the correct procedure.

b.

Remove bolts (22) and and washers washers (21). Remove Remove bracket (20) from the cylinder block.

a.

Remove Remove adaptor adaptor (7) and and remove remove O-ring seal (6).

Installation Procedure

b.

Remove Remove plug plug (7) and remove remove O-ring seal (9).

NOTICE Keep all parts clean from contaminants.

c.

Remove Remove plug plug (14). (14).

d.

Remove Remove plug plug (11), (11), plug plug (12), (12), plug plug (17), (17), and and plug (18). Remove O-ring seal (10), O-ring seal (13), O-ring seal (16), and O-ring seal (19) from plugs.

e.

Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the fuel filter base is clean and free from damage. If necessary, replace the complete fuel filter base and filter assembly.

Remove Remove fuel fuel filter filter canister canister (15). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter (Water Separator) Element - Replace” for the correct procedure.


16

UENR4511-01


Illustration 18

g03780742

Typical example 2. If 2. If necessary, follow Step 2 Step 2 through through Step 4 Step 4 in in order to install bracket (20) from the cylinder block. 3. Position 3. Position bracket (20) to the cylinder block. Install washers washers (21) to bolts (22). Install Install bolts (22) to bracket (20). Tighten bolts to a torque of 240 N·m (177 lb ft) 4. If 4. If necessary, install the fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base Remove” for the correct procedure.

Illustration 19

g03780722

Typical example 5. If 5. If necessary, follow Step 5.a Step 5.a through through Step 5.e Step 5.e in in order to assembly primary fuel filter (1). a.

Install a new new filter filter element element (15). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter (Water Separator) Element - Replace” for the correct procedure.

b.

Install a new O-ring seal (6) to adaptor adaptor (7). Install adaptor (7) to the assembly of primary fuel filter (5). Tighten Tighten the adaptor to a torque of 30 N·m (266 lb lb in).

c.

Install a new new O-ring O-ring seal seal (9) to plug plug (8). Install Install plug (8) to the assembly assembly of primary fuel filter (5). Tighten Tighten the plug to a torque of 22 N·m (195 lb in).

d.

Install plug (14) (14) to the assembly assembly of primary primary fuel filter (5). Tighten Tighten the plug to a torque of 30 N·m (266 lb lb in).

e.

Install a new O-ring seal (10) O-ring O-ring seal (13), (13), O-ring seal (16), O-ring seal (19) to plug (11), plug (12), plug (17), and plug (18). Install plug (11), plug (12), plug (17), and plug (18) to assembly primary fuel filter (5). Tighten the plugs to a torque torque of 30 N·m N·m (266 lb in).


UENR4511-01


End By: a. Remove the air from the fuel system. system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. i05986707

Electronic Unit Injector Remove Removal Procedure Table 1

Required Tools Tool ool A

Part art Numbe umber r

T401081

Part art Desc escrip ription tion Fuel Injector Installer and Removal Tooling

Qty Qty 2

Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure. Illustration 20

g03780720

Typical example 6. Position 6. Position the assembly of primary fuel filter (5) onto the mounting bracket. Position bracket (4) to the assembly assembly of primary fuel filter (5). 7. Install 7. Install washers washers (2) to bolts (1). Install bolts (1) to the assembly of primary fuel filter (5). Tighten the bolts to a torque torque of 55 N·m (41 lb ft). 8. Connect 8. Connect hose assembly (3) to the assembly of primary fuel filter (5).

NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, maintemaintenance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartme tment nt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regula regulation tions s and mandates.

9. Turn 9. Turn the fuel supply to the ON position.


10. Turn 10. Turn the battery disconnect switch to the ON position.

Contaminants may cause rapid wear and shortened component life.


18

UENR4511-01


Illustration 21

g03775306

Illustration 22

g03774344

Illustration 23

g03774346

1. Remove 1. Remove plug (1) from the rear of the cylinder cylinder head. Remove O-ring seal (2) (not shown) from the plug. Allow the engine oil to drain from the cylinder head before the unit injector is removed.

2. Use 2. Use a suitable tool to disconnect harness assembly (3) from electronic unit injector (4). 3. Remove 3. Remove Allen head bolts (5) from electronic unit injector (4). 4. Install 4. Install Tooling (A) to electronic unit injector (4). 5. Use 5. Use Tooling (A) to remove electronic unit injector (4) from the cylinder cylinder head. Note: Do Note: Do not use a wire brush on the tip of the electronic unit injector. Damage to the unit injector will occur.


UENR4511-01


(Table 2, contd) F

G

T401080

Seal Installer

1

GE50028

Vacuum Pump

1

GE50046

Bottle Assembly

1

Clear Plastic Tubing 7.92 mm (0.312 inch) OD

1

GE50030

H

T401077

Reamer

1

J

T401078

Tube Brush

1

K

GE50023

Tapered Brush

1

L

-

Vacuum Gun Kit

1

M

-

Tap Wrench

1


Illustration 24

g03774348

Note: Tooling Note: Tooling (L) is available to clean loose material from the sleeve bore for electronic unit injector and the cylinder.

6. Remove 6. Remove O-ring seal (8) from electronic unit injector (4). 7. Remove 7. Remove O-ring seal (9) and backup ring (10) from electronic unit injector (2). 8. Remove 8. Remove O-ring seal (7) and backup ring (6) from unit injector (4). 9. If 9. If necessary, follow Step 2 Step 2 through through Step 8 Step 8 in in order to remove the remaining electronic unit injector (4). i05986518

Electronic Unit Injector Injector - Install Installation Procedure Table 2 Required Tools Tool ool

Part Part Numb Number er

Part Description

Qty

Fuel Injector Installer and Removal Tooling

2

Seal Protector

1

A

T401081

E

T401079

1. Evacuate 1. Evacuate as much fuel and oil as possible from the cylinder head before installing the electronic unit injector. Several evacuations may be necessary. Use Tooling (G) to remove the fuel and oil from the cylinder head.

2. Inspect 2. Inspect the electronic unit injector sleeve for damage and carbon deposits. 3. Clean 3. Clean the carbon from the sleeve for the electronic unit injector, the sleeve bore. Clean the carbon from the end of the electronic unit injector, if the electronic unit injector is being reused. Clean the carbon from the seat area that is inside of the cylinder head. A fine grade of Scotch Brite material is preferred. Use Tooling (H) to clean the bore of the electronic electronic unit injector tip. Use the Surface Reconditioning Pad in order to clean the carbon in the cylinder head. Use Tooling (J) in order to remove the carbon from the surface of the sleeve. Note: Using Note: Using power tools in order to rotate the material should not be necessary. The carbon in the electronic unit injector sleeve is more removable than the carbon at locations that are exposed to higher temperatures. The following procedure is the preferred method of cleaning the sleeve bore.

(continued)


20

UENR4511-01


Place a 38 mm (1.5 inch) inch) square piece piece of Scotch Brite material on the end of Tooling (K). Twist Tooling (K) with Tooling (M) against the lower surface of the electronic unit injector sleeve bore. The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore should be cleaned in order to remove any loose carbon particles. Note: Tooling Note: Tooling (J) is available to clean loose material from the electronic unit injector sleeve bore and the cylinder. 4. When 4. When you install a new electronic unit injector, the E-Trim value must be programmed into the Electronic Control Module (ECM). The E-Trim value is a six digit alphanumeric alphanumeric code that is supplied with the data sheet that comes with the new electronic unit injector. Use the following menu to program the E-Trim value. • ECM Summary Summary Screen Screen •

Serv Servic ice e Menu Menu

• Calibra Calibratio tion n • Electronic Electronic Unit Injecto Injectorr Code Code Calibratio Calibration n Illustration 25

NOTICE The correc correctt proced procedure ures s and toolin tooling g specif specifica icatio tions ns must always be used. Failure to follow any of the procedures cedures may result in damage, damage, malfunction, malfunction, or possipossible engine failure.

NOTICE The O-ring seals and the backup rings must be installed in the correct orientation. Damaged seals will result in excessive oil consumption or excessive leakage under the valve cover. Use care to prevent nicks or damage to the seals. Note: Do not hit or strike the electronic electronic unit injector during installation. Do not use a wire brush to clean the tip of the electronic unit injector. Damage to the electronic unit injector will occur.

g03774348

5. The 5. The correct installation of the electronic unit injector is important. Damage to the upper highpressure seals can cause excessive oil leakage under the valve cover. The incorrect installation of the electronic unit injector may cause the engine not to start due to a low actuation actuation pressure. pressure. Damage to the lower high-pressure seals may allow high-pressure oil to leak into the fuel supply passage. Damage to the lower high-pressure seals will result in excessive oil consumption. 6. Use 6. Use Tooling (E) and Tooling (F) to install backup ring (6) to electronic electronic unit injector (4). 7. Lubricate 7. Lubricate a new O-ring seal (7) with clean engine oil. Install the O-ring seal to electronic unit injector (4). 8. Use 8. Use Tooling (E) and Tooling (F) to install backup ring (10) to unit injector (4). 9. Lubricate 9. Lubricate a new O-ring seal (9) with clean engine oil. Install the O-ring seal to electronic unit injector (4). 10. Lubricate 10. Lubricate a new O-ring seal (8) with clean engine oil. Install the O-ring seal to electronic unit injector (4).


UENR4511-01


Illustration 26

g03774936

Illustration 28

g03775306

16. Install 16. Install a new O-ring seal (2) (not shown) to plug (1). Install the plug (1) to the rear of the cylinder cylinder head. Tighten Tighten the plug to a torque of 400 N·m (295 lb ft). End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure. i05986716

Illustration 27

g03774344

11. Lubricate 11. Lubricate the bore of the sleeve for electronic unit injector (4) with clean engine oil. 12. Position 12. Position electronic unit injector (4) into sleeve for the electronic unit injector. Ensure that the electronic unit injector is correctly orientated. 13. Use 13. Use Tooling (A) to install electronic unit injector (4) in the cylinder head. 14. Install 14. Install Allen head bolt (5) on the exhaust exhaust side of the bracket. Tighten the exhaust side of Allen head bolt (5) until the bolt is seated. seated. Tighten the inlet side of Allen head bolt (5) to a torque of 12 N·m (106 lb in).

Electronic Unit Injector Sleeve - Remove Removal Procedure Table 3 Required Tools Tools Tool ool


Part Description

Qty

A

T401082

Plug Tap

1

B

T401083

Guide Sleeve

1

T401084

Bridge Plate

1

T401085

Puller Stud

1

T401086

Full Nut

1

T401087

Hard Washer

1

T401088

Thrust Bearing

1

T401064

Rubber Stopper

1

C

15. Connect 15. Connect harness assembly (3) to electronic unit injector (4). D


22

UENR4511-01


Start By: a. Remove the unit injectors. Refer to Disassembly and Assembly, “Unit Injector Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accordi according ng to local local regula regulatio tions ns and mandates. Illustration 29

g03775999

Illustration 30

g03776048

1. Drain 1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change” for the correct procedure.

2. Position 2. Position Tooling (D) at the bottom of electronic unit injector sleeve (1). 3. Coat 3. Coat Tooling (A) with clean grease. Use Tooling (A) and Tooling (B) to cut threads into electronic unit injector sleeve (1). 4. Install 4. Install Tooling (C) in electronic unit injector sleeve (1). 5. Remove 5. Remove electronic unit injector sleeve (1) (not shown). Remove O-ring seals (2).


UENR4511-01


6. If 6. If necessary, follow Step 2 Step 2 through through Step 5 Step 5 in in order to remove the remaining electronic unit injector sleeve. i05986722

Electronic Unit Injector Sleeve - Install Installation Procedure Table 4 Required Tools Tool ool


Part Description

Qty

E

T401065

Sleeve Installer

1

F

T401066

Large Bore Brush

1

G

T401067

Retaining Compound

1 Illustration 31

g03776048

Illustration 32

g03776078


1. Thoroughly 1. Thoroughly clean a new electronic unit injector sleeve (1) and the bores for the unit injectors injectors with Tooling (F). 2. Apply 2. Apply clean engine oil to O-ring seals (2). Install the O-ring seals on electronic unit injector sleeve (1). 3. Position 3. Position electronic unit injector sleeve (1) on Tooling (E). 4. Apply 4. Apply a thin coating of Tooling (G) around the outer circumference of electronic unit injector sleeve (1) at Area (C).


24

UENR4511-01


5. Position 5. Position electronic unit injector sleeve (1) in the cylinder cylinder head. Use a hammer to install the electronic unit injector sleeve into the cylinder head. Note: Allow Note: Allow Tooling (G) to cure for two hours at 21 °C (70 °F) before filling the engine with fuel or coolant. coolant. Longer curing time is required for lower temperatures. 6. If 6. If necessary, follow Step 1 Step 1 through through Step 5 Step 5 in in order to install remaining the electronic unit injector sleeve. 7. Fill 7. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) Change” for the correct procedure. End By: a. Install the unit injectors. Refer to Disassembly and Assembly, “Unit Injector - Install” for the correct procedure. i05986486

Unit Injector Hydraulic Injector Hydraulic Pump Remove Removal Procedure

Illustration 33

g03782498

1. Disconnect 1. Disconnect harness assembly (1) from unit injector hydraulic pump (2). 2. Remove 2. Remove hose assembly (6) and hose assembly (7) from fuel transfer pump (5). 3. Remove 3. Remove hose assembly (4) and breather (3). Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install” for the correct procedure.



Illustration 34

g03782499

4. Remove 4. Remove tube assembly (8) from unit injector hydraulic pump (2) and elbow connection (15).


UENR4511-01


5. Remove 5. Remove tube assembly (13) from fuel transfer pump (5) and the cylinder head. 6. Remove 6. Remove O-ring seal (12) (not shown) and O-ring seal (14) (not shown) from the connections. 7. Remove 7. Remove bolts (9) from unit injector hydraulic pump (2). Support the unit injector injector hydraulic pump as the bolts are removed. 8. Remove 8. Remove unit injector hydraulic pump (2) from housing front (10). 9. Remove 9. Remove O-ring seal (11) (not shown).

pump (5). g.

Remove O-ring seal (22) (not shown). shown).

h.

Remove connection connection (26) and and connec connection tion (31) (31) from fuel transfer pump (5).

i.

Remove O-ring seal (25) and O-ring O-ring seal seal (30). (30).

11. If 11. If necessary, follow Step 11.a Step 11.a through through Step 11.b Step 11.b to remove fuel transfer pump (5). a.

Remove Remove Torx Torx bolts bolts (28) and and Torx Torx bolts bolts (29). Remove fuel transfer pump (5) from unit injector hydraulic pump (2).

b.

Remove Remove O-ring O-ring seal (27) (not shown). shown). i05986485

Unit Injector Hydraulic Injector Hydraulic Pump Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 35

g03782516

10. If 10. If necessary, follow Step 10.a Step 10.a through through Step 10.i Step 10.i in in order to disassemble unit injector hydraulic pump (2). a.

Use a suitable suitable tool tool in order to to prevent prevent unit injector hydraulic pump gear (21) from rotating. Ensure that the gear is not damaged as nut (19) is loosened.

b.

Remove Remove nut nut (19) (19) and washer washer (20). (20).

c.

Use a suitable suitable tool tool to remove unit injector injector hydraulic pump gear (21).

d.

Make a temporary temporary mark on connect connection ion (18) (18) for installation purposes. Loosen locking nut (17) and remove the connection from unit injector hydraulic pump (2).

e.

Remove Remove O-ring O-ring seal (16) (not shown). shown).

f.

NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates. 1. Ensure 1. Ensure that all the components of the unit injector hydraulic pump are free from wear or damage. Replace any component that is worn or damaged.

Make a temporary temporary mark on connect connection ion (24) (24) for installation purposes. Loosen locking nut (23) and remove the connection from fuel transfer


26

UENR4511-01


Illustration 36

e.

Install a new O-ring seal (25) and and a new O-ring O-ring seal (30) to connection (26) and connection (31).

f.

Install connection connection (26) and and connec connection tion (31) (31) to fuel transfer pump (5). Tighten the connections, refer to Specifications, “Unit Injector Hydraulic Pump” for the correct tighten procedure.

g.

Install a new O-ring seal (22) (not (not shown) shown) to to connection (24). Install the connection to fuel transfer pump (5) and align with temporary marks.

h.

Tighten Tighten locking locking nut nut (23), (23), refer to Specifications, “Unit Injector Hydraulic Pump” for the correct tighten procedure. Ensure that the connections are still align after the locking nut has been tightened.

g03782516

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.d Step 2.d to to install fuel transfer pump (5). a.

Install Install a new new O-ring O-ring seal seal (27) (27) (not (not shown). shown).

b.

Install Install fuel transfer transfer pump pump (5) to unit unit injector injector hydraulic pump (2).

c.

Install Install Torx Torx bolts bolts (28) and and Torx Torx bolts bolts (29) hand hand tight.

d.

Tighten Tighten Torx Torx bolts bolts (28) and and Torx Torx bolts bolts (29). Refer to Specifications, “Unit Injector Hydraulic Pump” for the correct tighten procedure.

3. If 3. If necessary, follow Step 3.a Step 3.a through through Step 3.h Step 3.h in in order to assemble unit injector hydraulic pump (2). a.

Ensure that the the shaft shaft of unit injecto injectorr hydraulic hydraulic pump (2) and unit injector hydraulic pump gear (21) are clean and free from damage.

b.

Install Install unit injector injector hydrauli hydraulic c pump gear (21), washer washer (20), and nut (19). Hand tighten the nut.

c.

Use a suitable suitable tool in in order order to prevent prevent unit unit injector hydraulic pump gear (21) from rotating. Ensure that the gear is not damaged as nut (19) is tightened.

d.

Tighten Tighten nut (19), (19), refer refer to Specification Specifications, s, “Unit “Unit Injector Hydraulic Pump” for the correct tighten procedure.

Illustration 37

g03782499

4. Install 4. Install a new -ring seal (11) (not shown) to unit injector hydraulic pump (2). Ensure that the O-ring seal is correctly seated into the recess of the unit injector hydraulic pump. 5. Install 5. Install unit injector hydraulic pump (2) onto housing front (10). 6. Install 6. Install bolts (9) to unit injector hydraulic pump (2). Support the unit injector hydraulic pump as the bolts are installed. 7. Tig 7. Tighten hten bolts (9) (9) to a torque of 55 N·m (41 lb ft).


UENR4511-01


8. Install 8. Install a new O-ring seal (12) (not shown) shown) and a new O-ring seal (14) (not shown) to fuel transfer transfer pump (5) and the cylinder head. Ensure that the O-ring seals are correctly seated into the recess of the connections. 9. Install 9. Install tube assembly (13) to fuel transfer pump (5) and the cylinder head. Tighten the tube nuts for the tube assembly assembly to a torque of 65 N·m (48 lb ft). 10. Install 10. Install tube assembly (8) to unit injector hydraulic pump (2) and elbow connection (15). Tighten the tube nuts for the tube assembly to a torque of 100 N·m N·m (74 lb ft).

13. Install 13. Install breather (3) and hose assembly (4). Refer to Disassembly and Assembly, “Crankcase Breather Breather - Remove and Install” for the correct procedure. i05986223

Air Cleaner Air Cleaner -- Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 38

g03782498

11. Install 11. Install hose assembly (6) and hose assembly (7) to fuel transfer transfer pump (5). Tighten Tighten the tube nuts for the hose assemblies assemblies to a torque of 30 N·m (266 lb in). Ensure that the hose assemblies are not strained as the tube nuts are tightened. 12. Connect 12. Connect harness assembly (1) to unit injector hydraulic pump (2).

Illustration 39

g03749679

Typical example 1. Loosen 1. Loosen hose clamp (8) and hose clamp (10). 2. Remove 2. Remove hose assembly (9) from air cleaner assembly (1) and the turbocharger. 3. Attach 3. Attach a suitable lifting device in order to support the weight of air cleaner assembly (1). The weight of the air cleaner cleaner is approximately approximately 23 kg (51 lb). 4. Make 4. Make temporary marks on clamp (2) for installation purposes. Remove the nuts and bolts (3) from the clamp. Remove the clamp from the air cleaner assembly (1). 5. Use 5. Use the suitable lifting device in order to remove air cleaner assembly (1) from bracket (7).


28

UENR4511-01


6. If 6. If necessary, remove service indicator (6) from air cleaner assembly (1). 7. If 7. If necessary, loosen hose clamp (5) and remove rain cap (4) from air cleaner assembly (1).

Illustration 41

g03749680

Typical example 2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.d Step 2.d in in order to install bracket (7) onto the cylinder head. Illustration 40

g03749680

Typical example 8. If 8. If necessary, follow Step 2.b Step 2.b through through Step 2.d Step 2.d in in order to remove bracket (7) from the cylinder head. a.

Attach a suitable suitable lifting device in order order to support the weight of bracket (7). The weight of the bracket bracket is approximately approximately 23 kg (51 lb).

b.

Remove Remove bolts (11) (11) and bolts (12) (12) from from bracket bracket (7).

c.

Use the the suitable suitable lifting device in order order to remove bracket (7) from the cylinder head.

a.

Attach a suitable suitable lifting device in order order to support the weight of bracket (7). The weight of the bracket bracket is approximately approximately 23 kg (51 lb).

b.

Use the the suitable suitable lifting device device in order to position bracket (7) onto the cylinder head.

c.

Install bolts (11) (11) and bolts (12) (12) to bracket bracket (7) hand tight.

d.

Tighten Tighten bolts bolts (1 (11) to a torque torque of 55 N·m (41 lb ft). Tighten Tighten bolts (12) to a torque of 100 N·m (74 lb ft).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the air cleaner assembly and the bracket bracket are free from wear or damage. damage. Replace any component that is worn or damaged.


UENR4511-01


10. Tighten 10. Tighten the nuts and bolts (3) to a torque of 44 N·m N·m (32 lb lb ft). i06541855

Turbocharger Turbocharger - Remove Removal Procedure


Illustration 42

g03749679

Typical example 3. If 3. If necessary, install service indicator (6) to air cleaner assembly (1). Hand tighten the service indicator.

NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.

4. If 4. If necessary, install rain cap (4) onto air cleaner assembly (1). Tighten hose clamp (5) to a torque of 7 N·m (62 lb lb in). 5. Attach 5. Attach a suitable lifting device to air cleaner assembly assembly (1). The weight of the air cleaner is approximately approximately 23 23 kg (51 lb). 6. Use 6. Use the suitable lifting device in order to position air cleaner assembly (1) onto bracket (7). 7. Install 7. Install clamp (2) onto air cleaner assembly (1). Align the t he clamp to the original marks. Install bolt s (3) to the clamp and install install new nuts. Hand tighten the nuts and bolts. 8. Install 8. Install hose assembly (9) onto air cleaner assembly (1) and the turbocharger. Ensure that air cleaner assembly (1) is correctly aligned in the vertical position. 9. Tighten 9. Tighten hose clamp (10) to a torque of 11 N·m (97 lb in). Illustration 43

Tighten hose clamp (8) to a torque of 7 N·m (62 lb in).

g03781905

Typical example. Some engines may have a different configuration. Some engines are equipped with a wastegate actuator. 1. Remove 1. Remove exhaust elbow (3). Refer to Disassembly and Assembly, “Exhaust Elbow - Remove and Install” for the correct procedure.


30

UENR4511-01


2. Loosen 2. Loosen hose clamp (4) and hose clamp (6). Remove hose assembly (5). 3. Loosen 3. Loosen hose clamps (2) and remove tube assembly (1).

Illustration 45

g03781908

Typical example. Some engines may have a different configuration. Some engines are equipped with a wastegate actuator. 8. Remove 8. Remove nuts (18) from turbocharger (9). 9. Attach 9. Attach a suitable lifting device onto turbocharger (9). The weight of the turbocharger turbocharger is approximatel approximately y 27 kg (60 lb). Illustration 44

g03781906

Typical example. Some engines may have a different configuration. Some engines are equipped with a wastegate actuator.

10. Remove 10. Remove turbocharger (9) from exhaust manifold (20). 11. Remove 11. Remove gasket (19) (not shown) from exhaust manifold (20). 12. If 12. If necessary, remove studs (17).

4. Disconnect 4. Disconnect hose assembly (7) from turbocharger (9). Position the hose assembly away from the turbocharger.

13. If 13. If necessary, remove adapter (16) from turbocharger (9). Remove O-ring seal (15) (not shown).

5. Remove 5. Remove O-ring seal (8) (not shown). 6. Remove 6. Remove bolts (11) and bolts (14) from tube assembly (12). Remove the tube assembly from turbocharger (9) and the cylinder block. 7. Remove 7. Remove O-ring seal (10) (not shown) and O-ring seal (13) (not shown).

i06541865

Turbocharger Turbocharger - Install Installation Procedure Table 5 Required Tools Tools Tool ool A


CV6-0889

Part Description Anti-Seize Compound

Qty -


UENR4511-01


4. Attach 4. Attach a suitable lifting device to turbocharger (9). The weight of the turbocharger is approximately 27 kg kg (60 lb).

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components of the turbocharger are free from wear or damage. If necessary, replace turbocharger as an assembly. Refer to Specifications, “Turbocharger” for further information.

Illustration 46

5. Position 5. Position a new gasket (19) (not shown) onto exhaust manifold (20). 6. Apply 6. Apply Tooling (A) to studs (17). 7. Use 7. Use the suitable lifting device to install turbocharger (9) to exhaust manifold (20). 8. Install 8. Install new nuts (18). Tighten the nuts to a torque of 54 N·m N·m (40 lb ft). ft).

g03781908

Typical example. Some engines may have a different configuration. Some engines are equipped with a wastegate actuator. 2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.b Step 2.b to to install new studs (17).

Illustration 47

g03781906

Typical example.

a.

Apply Tooling (A) to studs (17).

Some engines may have a different configuration.

b.

Install Install studs studs (17) (17) to exhaust exhaust manifold manifold (20). Tighten Tighten the studs to a torque of 25 N·m (221 lb in).

Some engines are equipped with a wastegate actuator.

3. If 3. If necessary, follow Step 3.a Step 3.a through through Step 3.b Step 3.b to to install adapter (16). a.

Install Install a new new O-ring O-ring seal seal (15) (15) (not (not shown) shown) to adapter (16).

b.

Install Install adapter adapter (16) to turbocha turbocharger rger (9). Tighten Tighten the adapter to a torque of 30 N·m (266 lb in).

9. Install 9. Install new O-ring seal (10) (not shown) and new O-ring seal (13) (not shown) onto tube assembly (12). 10. Position 10. Position tube assembly (12) onto turbocharger (9) and the cylinder block. Ensure that the tube assembly is correctly installed onto the turbocharger and the cylinder block. Install bolts (11) and bolts (14) to the tube assembly. 11. Tighten 11. Tighten bolts (11) and bolts (14) to a torque of 28 N·m (248 lb lb in).


32

UENR4511-01


12. Lubricate 12. Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times to lubricate the bearings.

19. Tighten 19. Tighten hose clamp (4) to a torque of 11 N·m (97 lb in).

13. Install 13. Install a new O-ring seal (8) (not shown) onto the adapter. Ensure that the O-ring seal is correctly installed into the recess of the adapter.

Exhaust Manifold - Remove and Install

14. Connect 14. Connect hose assembly (7) to turbocharger (9). Tighten Tighten the tube nut for the adapter to a torque of 30 N·m (266 lb lb in).

Removal Procedure

i05986470

Start By: a. Remove the turbocharger. Refer to Disassembly and Assembly, “Turbocharger Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 48

g03781905

Typical example. Some engines may have a different configuration. Some engines are equipped with a wastegate actuator. Illustration 49

15. Install 15. Install exhaust elbow (3). Refer to Disassembly and Assembly, “Exhaust Elbow - Remove and Install” for the correct procedure.

g03780721

Exhaust manifold tightening sequence

16. Install 16. Install tube assembly (1) and tighten hose clamps (2) to a torque of of 7 N·m (62 lb in). 17. Install 17. Install hose assembly (5). Ensure that hose assembly is correctly located onto the turbocharger and the air filter assembly. 18. Install 18. Install hose clamp (4) and hose clamp (6). Tighten hose clamp (6) to a torque of 7 N·m (62 lb in).


UENR4511-01


c.

Remove the front front section section of exhaust exhaust manifold manifold (9) from the center section of exhaust manifold (8).

d.

If necessary necessary,, remove remove studs studs (7) from from the center section of exhaust manifold (9).

Installation Procedure Table 6 Required Tools Tools Tool ool A

Part art Num Number ber

CV60889

Part art Des Descri criptio ption n

Qty

Anti-Seize Compound

1


g03780412

1. Loosen 1. Loosen nuts (2) and nuts (3) for the exhaust manifold in the reverse sequence shown in Illustration 55 Illustration 55 . .

1. Ensure 1. Ensure that all components of the exhaust manifolds are free from wear or damage. Replace any component that is worn or damaged.

2. Remove 2. Remove nuts (1), nuts (3), and spacers (2). 3. Remove 3. Remove exhaust manifold assembly (4) from the cylinder head. 4. Remove 4. Remove gaskets (5) (not shown).

Illustration 52

g03780741

Step 2.a through through Step 2.f Step 2.f in in 2. If 2. If necessary, follow Step 2.a order to assemble the assembly of exhaust manifold (4).

Illustration 51

a.

Place the assemb assembly ly of exhaust exhaust manifold manifold (4) in a suitable support.

b.

If necessary necessary,, install install studs studs (7) to the center center section of exhaust manifold (9). Tighten the studs to a torque torque of 27 N·m N·m (239 lb in).

c.

Apply Tooling (A) to Position Position (W) on rear rear section of exhaust manifold (6) and center section of exhaust manifold (8).

d.

Install the rear rear section section of exhaust exhaust manifold manifold (6) to the center section of exhaust manifold (8).

g03780724

5. If 5. If necessary, follow Step 2.a Step 2.a through through Step 3 Step 3 in in order to disassemble the assembly of exhaust manifold (4). a.

Place the assemb assembly ly of exhaust exhaust manifold manifold (4) in a suitable support.

b.

Remove Remove the rear section section of exhaust exhaust manifold manifold (6) from the center section of exhaust manifold (8).


34

UENR4511-01


e.

Apply Tooling (A) to Position Position (W) on front front section of exhaust manifold (9) and center section of exhaust manifold (8).

f.

Install Install the front section section of exhaust exhaust manifold manifold (9) to the center section of exhaust manifold (8).

Illustration 53

g03780746

Illustration 54

g03780412

Illustration 55

g03780721

Exhaust manifold tightening sequence


UENR4511-01


3. Check 3. Check the condition of studs (10). If necessary replace the studs. Tighten the studs to a torque of 27 N·m (239 lb lb in). 4. Position 4. Position new gaskets (5) (not shown) on the cylinder. Ensure that the gaskets are correctly orientated. 5. Install 5. Install exhaust manifold assembly (4) to the cylinder head. 6. Install 6. Install spacers (2) onto studs (10). The spacers are only installed onto the top studs. 7. Install 7. Install new nuts (1) and new nuts (3) to studs (10). 8. Tighte 8. Tighten n nuts (2) and nuts (3) to a torque of 55 N·m (41 lb ft) in the sequence sequence shown in Illustration Illustration 55 55 . . End By: a. Install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install” for the correct procedure. i05986263

Exhaust Elbow - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 56

g03780322

1. Remove 1. Remove the Original Equipment Manufacture (OEM) exhaust system (1) from exhaust elbow (7). Refer to OEM for the correct procedure 2. Remove 2. Remove the nuts and bolts (2) from bracket (3). Remove the bracket from exhaust elbow (7). 3. Loosen 3. Loosen V-band clamp (6) and remove exhaust elbow (7) and the V-band clamp. Support the exhaust elbow as the V-band clamp is loosened. 4. Remove 4. Remove exhaust elbow (7) and V-band clamp (6) from turbocharger (5). 5. If 5. If necessary, follow Step 2.a Step 2.a through through Step 3 Step 3 in in order to remove bracket (4). a.

Remove bolts (8) (not (not shown) shown) from bracke brackett (4).

b.

Remove bracket bracket (4) from the exhaust exhaust manifold.

Installation Procedures NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the exhaust elbow and the bracket are free from wear or damage. Replace any components that are worn or damaged.


36

UENR4511-01


7. Install 7. Install the OEM exhaust system (1) to exhaust elbow (7). Refer to OEM for the correct correct procedure i05986432

Inlet and Exhaust Valve Springs - Remove and Install Removal Procedure Table 7 Required Tools Tools Tool ool

Illustration 57

g03780322

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.b Step 2.b in in order to install bracket (4). a.

Position Position bracket bracket (4) onto onto the exhaust exhaust manifold. manifold.

b.

Install Install bolts bolts (8) (not shown) shown) to bracke brackett (4). Tighten Tighten the bolts to a torque of 55 N·m (41 lb ft).

3. Install 3. Install exhaust elbow (7) and V-band clamp (6) to turbocharger (5). Hand tighten the V-band clamp. Support the exhaust elbow as the V-band clamp is tightened. 4. Install 4. Install bracket (3) onto exhaust elbow (7). Install the nuts and bolts (2) to the bracket hand tight. tight. 5. Tighten 5. Tighten V-band clamp (6) to a torque of 13.5 N·m (10 lb ft). 6. Tighte 6. Tighten n the nuts and bolts (2) to a torque of 55 N·m (41 lb ft).


Part Description

Qty

A

T401068

Valve Valve Spring Compressor

1

B

CH11148

Turning Tool

1

Start By: a. Remove the electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: The Note: The following procedure is for the removal of the inlet valve springs and the exhaust valve springs without removing the cylinder head. This procedure can be performed on only one cylinder cylinder at a time. Performing the procedure on only one cylinder at a time will prevent the inlet valves and the exhaust valves from falling into the cylinder. 1. Use 1. Use Tooling (B) to rotate the crankshaft in order to bring the piston to the top center position in the cylinder.


UENR4511-01




T401068

Part Description

Qty

Valve Valve Spring Compressor

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Install 1. Install the valve spring seats for the inlet valve springs and the exhaust valve springs.

Illustration 58

g03781637

Personal injury can result from being struck by parts propelled by a released spring force. Make Make sure sure to wear wear all all nece necess ssar ary y prot protec ecti tive ve equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 2. Use 2. Use Tooling (A) in order to compress the inlet valve springs and the exhaust valve springs. 3. Remove 3. Remove valve keepers (4). 4. Remove 4. Remove Tooling (A).

Illustration 59

g03781637

5. Remove 5. Remove spring retainer (5). 6. Remove 6. Remove inner valve spring (6) and outer valve spring (7) from each valve (1). Remove valve spring seats (3) (not shown) from the cylinder head. 7. If 7. If necessary, remove valve stem seals (2) (not shown) from the valve guides. 8. Install the inlet valve springs and the exhaust valve springs before you rotate the crankshaft.

Impr Improp oper er asse assemb mbly ly of part parts s that that are are spri spring ng loaded can cause bodily injury. To prevent possible injury, follow the established asse assemb mbly ly proc proce edure dure and wea wear prot protec ecti tiv ve equipment. 2. If 2. If necessary, Install new valve stem seals (2) (not shown) to the valve guides.


38

UENR4511-01


3. Install 3. Install valve spring seats (3) (not shown) shown) to the cylinder head. 4. Install 4. Install inner valve spring (4) and outer valve spring (5) on each valve (1). 5. Install 5. Install spring retainer (3). Install inner valve spring (6) and outer valve spring (7) to each valve (1). 6. Use 6. Use Tooling (A) in order to compress the inlet valve springs and the exhaust valve springs. 7. Install 7. Install valve keepers (4). 8. Remove 8. Remove Tooling (A). End By: a. Install the electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove” for the correct procedure. i05986444

Inlet and Exhaust Valves Remove and Install Removal Procedure Table 9 Required Tools Tool ool A


T401068

Part Description Valve Valve Spring Compressor

Qty 1 Illustration 60

Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

The valve spring keepers can be thrown from the valve valve when when the valve valve spring spring compre compresso ssorr is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves.

g03781634

1. Place 1. Place a temporary identification mark on the heads of valves (7) in order to identify the correct position.

Personal injury can result from being struck by parts propelled by a released spring force. Make Make sure sure to wear wear all all nece necess ssar ary y prot protec ecti tive ve equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 2. Use 2. Use Tooling (A) to compress valve springs (3) and valve springs (4). Remove valve keepers (1). Note: Do Note: Do not compress the springs so that valve spring retainers (2) touches valve stem seals (5). 3. Remove 3. Remove Tooling (A). Remove spring retainers (2) and valve springs (3) and valve springs (4).


UENR4511-01


4. Remove 4. Remove valve stem seals (5), spring seat washer (6). 5. Remove 5. Remove valves (7) from the cylinder head. 6. Repeat 6. Repeat Step 1 Step 1 through through Step 5 Step 5 in in order to remove remaining valves (7) from the cylinder head.

Installation Procedure Table 10 Required Tools Tool ool A


T401068

Part Description Valve Valve Spring Compressor

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure all the components are free from wear or damage. If necessary, replace any component that is worn or damaged.

Illustration 61

g03781634

Impr Improp oper er asse assemb mbly ly of part parts s that that are are spri spring ng loaded can cause bodily injury. To prevent possible injury, follow the established asse assemb mbly ly proc proce edure dure and wea wear prot protec ecti tiv ve equipment. 2. Install 2. Install spring seat washer (6) and install new valve stem seals (5) to the valve guides. 3. Lubricate 3. Lubricate the stems of valves (7) with clean engine oil. Install the valve into the cylinder head. 4. Install 4. Install valve springs (3) and valve springs (4). Install spring retainers (2).


40

UENR4511-01


The valve spring keepers can be thrown from the valve valve when when the valve valve spring spring compre compresso ssorr is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves. 5. Use 5. Use Tooling (A) to compress valve springs (3) and valve springs (4). Note: Do Note: Do not compress the springs so that valve spring retainers (2) touches valve stem seals (5). 6. Install 6. Install valve keepers (1) to spring retainers (2). 7. Repeat 7. Repeat Step 2 Step 2 through through Step 6 Step 6 in in order to install remaining valves (7) to the cylinder head. End By: a. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install” for the correct procedure. i05986472

Inlet and Exhaust Valve Guides - Remove and Install Removal Procedure


1. Use 1. Use Tooling (A) to remove inlet valve guides(1) and exhaust valve guides (2) from the cylinder head assembly. assembly.

Table 12

Required Tools Tool ool

g03781704


Table 11

Part Description

Illustration 62

Required Tools Tools Qty Tool ool


Part Description

Qty

GE50043

A

or

Valve Guide Driver

GE50043

1

or

A

27610262(1)

' Valve Guide Driver

1

27610262(1) (1)

If necessary, use Tooling on inlet valve guides.

Start By: a. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install” for the correct procedure. NOTICE Keep all parts clean from contaminants.

(1)

B

T401070

Guide Collar

1

C

T401069

Guide Collar

1

If necessary, use Tooling on inlet valve guides.




UENR4511-01


End By: a. Install the inlet and exhaust valves. valves. Refer to Disassembly and Assembly, “Inlet and Exhaust Valves - Remove and Install” for the correct procedure. i05986996

Engine Oil Filter Base and Oil Cooler - Remove Removal Procedure Table 13 Required Tools Tools

Illustration 63

Tool ool


A

-

Part Description Strap Wrench Assembly

Qty 1

g03781702



Illustration 64

g03781729

1. Drain 1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure.

Valve guide protrusion 1. Position 1. Position inlet valve guide (1) and exhaust valve guide (1) in the cylinder head. Tap on the top of the valve guides in order to start the inlet valve guides and exhaust valve guides into the cylinder head assembly. 2. Use 2. Use Tooling (A) and Tooling (B) to install exhaust valve guide (2). Use Tooling (A) and Tooling (C) to install intake valve guide (1). Install the valve guides until the protrusion is Distance (X). Distance Distance (X) is 12.0 ± 0.5 mm (0.47 ± 0.02 inch) inch) above the cylinder head assembly.


42

UENR4511-01


Illustration 67

g03777559

2. Use 2. Use Tooling (A) to remove engine oil filter (5) from engine oil filter base (4).

Illustration 65

g03777557

3. Disconnect 3. Disconnect hose assembly (1) from elbow connection (3). Remove O-ring seal (2) (not shown). 4. Remove 4. Remove bolts (5) from engine oil filter base (4). Support Support the engine oil filter base as the bolts are removed. 5. Remove 5. Remove bolts (7). Remove engine oil filter base (4). Remove gasket (6) (not shown). 6. Remove 6. Remove oil cooler core (9) from the cylinder block. 7. Remove 7. Remove gasket (8).

Illustration 66

g03777558


UENR4511-01


Personal injury can result from being struck by parts propelled by a released spring force. Make Make sure sure to wear wear all all nece necess ssar ary y prote protecti ctive ve equipment. Follow Follow the recomme recommende nded d proced procedure ure and use all recommended tooling to release the spring force. g.

Remove plug (15) from from engine engine oil filter filter base base (4). Remove O-ring seal (16).

h.

Remove spring (19) and valve (22) from engine oil filter base (4).

i.

Remove plug (28) from from engine engine oil filter filter base base (4). Remove O-ring seal (27).

j.

Remove spring (26) and valve (25) from engine oil filter base (4). i05986414

Illustration 68

g03777625

8. If 8. If necessary, follow Step 8.a Step 8.a through through Step 8.j Step 8.j in in order to disassemble engine oil filter base (4). a.

Make temporary temporary marks marks on elbow elbow connection connection (10) and engine oil filter base (4) for installation purposes.

b.

Remove Remove cap (13) from from valve valve (12). (12). Remove Remove the valve from elbow connection (10). Remove Oring seal (11).

c.

Loosen Loosen locking locking nut (17) and remove elbow connection (10). Remove O-ring seal (18).

d.

Remove Remove adapter adapter (20) from engine oil filter base (4). Remove O-ring seal (24).

e.

Make temporary temporary marks marks on elbow elbow connection connection (14) and engine oil filter base (4) for installation purposes.

f.

Loosen Loosen locking locking nut (21) and remove elbow connection (14). Remove O-ring seal (23).

Engine Oil Filter Base and Oil Cooler - Install Installation Procedure Table 14 Required Tools Tools Tool ool


A

-

Part Description Guide Studs M8 by 60 mm

Qty 2

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components are free from wear, damage, and restriction. Replace any component that is worn, damaged, damaged, or not free from restriction. restriction.


44

UENR4511-01


Illustration 69

g03777625

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.j Step 2.j in in order to assemble engine oil filter base (4).

e.

Tighten Tighten plug plug (28) and plug plug (15) to a torque torque of 55 N·m (41 lb lb ft).

f.

Install a new O-ring seal (24) to to adapter adapter (20). (20). Install the adapter from engine oil filter base (4). Tighten Tighten the adapter to a torque of 20 N·m (177 lb in).

g.

Install a new O-ring seal (11) (11) to elbow connection (10). Install elbow connection to adapter (20) and align to temporary marks. Tighten Tighten locking nut (17) to a torque of 40 N·m (30 lb ft). Use a suitable tool to hold the elbow connection as the locking nut is tightened. Ensure that the elbow connection is still aligned to the temporary marks.

h.

Install a new O-ring seal (18) to to valve valve (12). (12). Install the valve to elbow connection (10). Tighten Tighten the valve to a torque of 25 N·m (221 lb in).

i.

Install Install cap (13) (13) to valv valve e (12). (12).

j.

Install a new O-ring seal (23) to elbow connection (14). Install the elbow connection to engine oil filter base (4) and align temporary temporary marks. Tighten locking nut (21) to a torque of 80 N·m (59 lb ft). Use a suitable suitable tool to hold the elbow connection as the locking nut is tightened. Ensure that the elbow connection is still aligned to the temporary marks.

Personal injury can result from being struck by parts propelled by a released spring force. Make Make sure sure to wear wear all nece necess ssar ary y prote protecti ctive ve equipment. Follow Follow the recomm recommend ended ed proced procedure ure and use all recommended tooling to release the spring force. a.

Install Install valve valve (22) (22) and spring (19) to engine engine oil oil filter base (4). Ensure that the valve is free to move in the engine oil filter base.

b.

Install Install a new new O-ring O-ring seal seal (16) (16) to plug (15). Install Install the plug to engine oil filter base (4) hand tight.

c.

Install Install valve valve (25) (25) and spring (26) to engine engine oil oil filter base (4). Ensure that the valve is free to move in the engine oil filter base.

d.

Install Install a new new O-ring O-ring seal seal (27) (27) to plug (28). Install Install the plug to engine oil filter base (4) hand tight.


UENR4511-01


Illustration 72 Illustration 70

g03778436

g03778397

3. Install 3. Install Tooling (A) in position (X) in the cylinder block. 4. Position 4. Position a new gasket (8) onto the cylinder block. Ensure that the gasket is correctly orientated. 5. Install 5. Install oil cooler core (9) to the cylinder block. 6. Install 6. Install a new gasket (6) (not shown) and ensure that the gasket is correctly orientated. Install engine oil filter base (4) and install bolts (5) hand tight. 7. Remove 7. Remove Tooling (A) from the cylinder block. Install remaining bolts (5) hand tight. 8. Tigh 8. Tighten ten bolts (5) to a torque torque of 28 N·m (248 lb in) in the numerical sequence that is shown in Illustration 72 Illustration 72 . .

Illustration 71

g03777558


46

UENR4511-01


Start By: a. 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 73

g03777557

9. Install 9. Install a new oil filter (5) to engine oil filter base (4) 10. Install 10. Install a new O-ring seal (2) (not shown) to elbow connection (3). Connect hose assembly (1) to elbow connection (3). Tighten the tube nut for the hose assembly assembly to a torque of 80 N·m (59 lb ft). Use a suitable tool to hold the elbow connection as the tube nut is tightened. 11. Fill 11. Fill the engine with coolant to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”. i05986424 Illustration 74

Engine Oil Pump - Remove

g03779762

1. Remove 1. Remove bolts (3) from suction pipe (4). Remove the suction pipe from the engine engine oil pump (1).

Removal Procedure

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

Table 15

3. Remove 3. Remove bolts (6) and bolts (7) from tube assembly assembly (9). Remove the tube assembly from engine oil pump (1) and the cylinder block.

Required Tools Tool A

Part Part Numb umber

27610275

Part Part Desc Descri ript ptio ion n Driver Gp

Qty Qty 1

4. Remove 4. Remove O-ring seal (5) (not shown) and O-ring seal (8) (not shown).


UENR4511-01


c.

Remove idler gear (15) from from engine engine oil oil pump pump (1).

d.

Remove idler hub (12) (12) from engine oil pump pump (1).

8. If 8. If necessary, follow Step 8.a Step 8.a through through Step 8.b Step 8.b in in order to remove bushing (13) from idler gear (14). a.

Place idler gear (14) on on a suitable suitable support. support.

b.

Use Tooling Tooling (A) and and a suitable suitable press press to remove bushing (13) from idler gear (14). i05986422

Engine Oil Pump Disassemble Illustration 75

g03779763

5. Remove 5. Remove bolts (10) from engine oil pump (1). Remove the engine oil pump from the cylinder block. 6. If 6. If necessary, remove ring dowel (11) (not shown).

Disassembly Procedure Table 16 Required Tools Tools Tool ool A


27610275

B

-

Part Description

Qty

Driver Gp

1

Combination Puller

1

Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, maintemaintenance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartme tment nt or disass disassemembling any component containing fluids. Illustration 76

g03779764

7. If 7. If necessary, follow Step 7.a Step 7.a through through Step 7.d Step 7.d in in order to disassemble engine oil pump (1). a.

Place engine engine oil pump (1) in a suitable suitable support.

b.

Remove Remove Allen Allen head head bolt bolt (15) and the the washer washer from engine oil pump (1).

Dispos Dispose e of all fluids fluids accord according ing to local local regula regulation tions s and mandates.


48

UENR4511-01


Illustration 77

g03779790

1. Remove 1. Remove bolt (5) and the washer from idler gear (4). Remove the idle gear from idler hub (2). 2. Remove 2. Remove idler hub (2) from engine oil pump (1). 3. Use 3. Use Tooling (B) to remove drive gear (6). 4. If 4. If necessary, follow Step 4.a Step 4.a through through Step 4.b Step 4.b in in order to remove bushing (3) from idler gear (4). a.

Place idler gear (4) on a suitable suitable support. support.

b.

Use Tooling (A) and and a suitable suitable press press to remove bushing (3) from idler gear (4).

Illustration 78

g03779791

5. Remove 5. Remove bolts (9) from front cover (10). Remove the front cover from the body of engine oil pump (1). NOTICE Before removing the drive shaft from the pump housing, be sure that no burrs exist on the drive shaft. If the drive shaft has burrs on it, the bores in the pump housing may be scratched. 6. Remove 6. Remove inner rotor (8) from the body of engine oil pump (1). 7. Remove 7. Remove outer rotor (8) from the body of engine oil pump (1). 8. Remove 8. Remove shaft assembly (8) and shaft assembly (11) from oil pump body (9).


UENR4511-01


NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all of the parts of the engine oil pump are thoroughly clean prior to assembly. Lubricate assembly. Lubricate all internal parts parts of the engine oil pump with clean engine oil.

Illustration 79

g03779792

9. Position 9. Position engine oil pump (1) into a suitable support.

Personal injury can result from parts and/or covers under spring pressure. Spring Spring force will be releas released ed when when covers covers are removed.

Illustration 80

g03779792

Be prepared to hold spring loaded covers as the bolts are loosened. 10. Remove 10. Remove plug (13) from engine oil pump (1). As the plug is removed from the engine oil pump, the spring force will be released. 11. Remove 11. Remove spring (13) and oil pressure relief plunger plunger (12) from engine oil pump (1). i05986421

Engine Oil Pump - Assemble

Required Tools

A

27610275

Part Description Driver Gp

2. Position 2. Position engine oil pump (1) into a suitable support.

4. Install 4. Install spring (13) into oil pressure relief plunger (12). Ensure that the spring is correctly located into oil pressure relief plunger.

Table 17


To prevent possible injury, follow the established asse assemb mbly ly proc proce edure dure and wea wear prot protec ecti tiv ve equipment.

3. Install 3. Install oil pressure relief plunger (12) into engine oil pump (1). Ensure that the oil pressure relief plunger plunger is free to move in the bore of the engine oil pump.

Assembly Procedure

Tool ool

Impr Improp oper er asse assemb mbly ly of part parts s that that are are spri spring ng loaded can cause bodily injury.

Qty 1

5. Install 5. Install plug (13) to engine oil pump (1) hand tight. 6. Tigh 6. Tighten ten plug (13) to a torque torque of 70 N·m (52 lb ft).


50

UENR4511-01


b.

Position Position engine engine oil oil pump (1) onto onto a suitable suitable press and a suitable surface with the shaft of inner rotor in the vertical position. Ensure that inner rotor (8) is correctly supported.

c.

Position Position drive drive gear gear (6) onto the shaft shaft of of inner inner rotor (8). Use the suitable press in order to press the drive gear flush with the end of the shaft of inner rotor (8). Ensure that the inner rotor is free to turn and has the correct end clearance.

8. If 8. If necessary, follow Step 8.a Step 8.a through through Step 8.b Step 8.b in in order to install bushing bushing (3) to idler gear (4).

Illustration 81

g03779791

a.


b.

Use Tooling Tooling (A) and a suitable suitable press press to install install bushing bushing (3) to idler gear (4). Install the bearing so the distance between the hub bolt face of the idler gear and the bearing is 0.75 ± 0.25 mm (0.030 ± 0.010 0.010 inch). inch).

9. Install 9. Install idler hub (2) into engine oil pump (1). Ensure that the idler hub is correctly located into the engine oil pump. 10. Install 10. Install idler gear (4) to engine engine oil pump (1). Ensure that the idler gear is correctly orientated onto idler hub (2). 11. Install 11. Install Allen head bolt (5) and the washer to engine oil pump (1). Tighten Tighten the bolt to a torque of 55 N·m N·m (41 lb lb ft). 12. Install 12. Install outer rotor (8) to the body of engine oil pump (1). 13. Install 13. Install front cover (10) to the body of engine engine oil pump (1). Ensure that the front cover is correctly orientated onto the engine oil pump. 14. Install 14. Install bolts (9) to front cover (1). Tighten the bolts to a torque of of 28 N·m (248 lb in). in).

Illustration 82

g03779790

7. Follow 7. Follow Step 7.a Step 7.a through through Step 7.c Step 7.c in in order to install install drive gear (6) to the shaft of inner rotor (8). NOTICE Before removing the drive shaft from the pump housing, be sure that no burrs exist on the drive shaft. If the drive shaft has burrs on it, the bores in the pump housing may be scratched. a.

Install Install inner inner rotor rotor (8) to the body of engine engine oil oil pump (1).


UENR4511-01


End By:

bushing is correctly located into the idler gear.

a. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install” for the correct procedure.

3. If 3. If necessary, follow Step 3.a Step 3.a through through Step 3.d Step 3.d in in order to assemble engine oil pump (1). a.

Place engine engine oil pump (1) into into a suitable suitable support.

Engine Oil Pump - Install

b.

Install idler hub hub (12) (12) into engine oil pump pump (1). (1). Ensure that the idler hub is correctly located into the engine oil pump.


c.

Install idler gear gear (15) (15) to engine engine oil pump (1). Ensure that the idler gear is correctly orientated onto idler hub (12).

d.

Install Allen head bolt (15) (15) and and the washer washer to engine oil pump (1). Tighten the bolt to a torque of of 55 N·m (41 lb ft). ft).

i05986423

Table 18 Required Tools Tool ool A


27610275

Part art Desc Descri ript ptiion Driver Gp

Qty Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components of the engine oil pump are free from wear or damage. Replace any component that is worn or damaged.

Illustration 84

g03779775

4. If 4. If necessary, install ring dowel (11) (not shown). 5. Install 5. Install engine oil pump (1) onto the cylinder block. Ensure that ring dowel (11) (not shown) is correctly located into the cylinder block. 6. Install 6. Install bolts (10) to engine oil pump (1). Tighten the bolts to a torque torque of 55 N·m (41 lb ft). Illustration 83

g03779764

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.b Step 2.b in in order to install bushing (13) to idler gear (14). a.

Place idler gear (14) on on a suitable suitable support. support.

b.

Use Tooling Tooling (A) and a suitable suitable press press to install bushing bushing (13) to idler gear (14). Ensure that the


52

UENR4511-01


End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install” for the correct procedure. i06542515

Water Pump Water Pump - Remove Removal Procedure

Pers Person onal al injur injury y can can resu result lt from from hot hot cool coolan ant, t, steam and alkali.

Illustration 85

g03779762

7. Install 7. Install new O-ring seal (5) (not shown) and O-ring seal (8) (not shown) into the recess of tube assembly (9). Ensure that the O-rings are correctly located into the recess of the tube assembly.

At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heat heater ers s or the the engi engine ne cont contai ain n hot hot cool coolan antt or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.

8. Install 8. Install tube assembly (9) engine oil pump (1) and the cylinder block.

Do not attempt to tighten hose connections connections when the coolant is hot, the hose can come off causing burns.

9. Install 9. Install bolts (6) and bolts (7) to tube assembly assembly (9). Tighten the bolts hand tight.

Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

10. Tighte 10. Tighten n bolts (6) and bolts (7) to a torque of 55 N·m (41 lb ft). Ensure Ensure that the tube assembly assembly is not strained as the bolts are tightened. 11. Position 11. Position a new gasket gasket (2) (not shown) onto suction pipe (4). Position the suction pipe onto engine oil pump (1) and install bolts (3) hand tight. 12. Tigh 12. Tighten ten bolts (3) to a torque torque of 55 N·m (41 lb ft). Ensure that the suction pipe is not strained as the bolts are tightened.




UENR4511-01


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 (ELC) - Change” for the correct procedure. b. Remove the alternator bracket. Refer to Disassembly and Assembly, “Alternator Remove and Install” for the correct procedure. c. Remove the V-belt from the water pump. Refer to Disassembly and Assembly, “V- Belts Remove and Install (Water Pump Drive Belt)” or refer to Disassembly and Assembly, “Alternator Belt - Remove and Install” for the correct procedure.

Removal Procedure

Illustration 87

g06015544

2. Loosen 2. Loosen hose clamp (5) for hose assembly (4). 3. Remove 3. Remove bolts (6) from water pump (3). Support the water pump as the bolts are removed. 4. Remove 4. Remove water pump (3) from hose assembly (4) and the cylinder block. 5. Remove 5. Remove O-ring seal (7) (not shown) and O-ring seal (8) (not shown). i05986475

Water Pump Water Pump - Disassemble

Illustration 86

g06015537

Typical example 1. Loosen 1. Loosen hose clamp (1) and disconnect hose assembly (2) from the water pump elbow connection.

Disassembly Procedure Table 19 Required Tools Tools Tool ool A


27610275


Qty 1


54

UENR4511-01


Start By: a. Remove the water pump. Refer to Disassembly and Assembly, “Water Pump - Remove” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regula regulatio tions ns and mandates.


g03783243

6. Use 6. Use Tooling (A) and a suitable press in order to remove impeller (10) from shaft assembly (12). 7. Use 7. Use Tooling (A) and a suitable press in order to remove shaft assembly (12) from water pump housing (4). 8. Use 8. Use Tooling (A) to remove seal (11) from water pump housing (4). 9. Use 9. Use Tooling (A) to remove hub (13) from shaft assembly (12). i05986474

Water Pump Water Pump - Assemble Assembly Procedure Illustration 88

g03783238

Table 20 Required Tools Tools

1. Remove 1. Remove bolts (1) from cover (2). 2. Remove 2. Remove cover (2) and gasket (3) from water pump (4). 3. Use 3. Use a suitable suitable tool to hold pulley (5) and remove bolts (6). Remove the pulley from the water pump (4). 4. Remove 4. Remove bolts (7) and remove inlet elbow (8) from water pump (4).

Tool ool A B


27610275

T401071

Part Description

Qty

Driver Gp

1

Seal Driver

1


5. Remove 5. Remove gasket (8) (not shown).


55

UENR4511-01


Illustration 90

g03783243

1. Use 1. Use Tooling (A) and a suitable press in order to install shaft assembly (12) in water pump housing (4). After installation, the bearing on the shaft assembly should be flush with the face of the water pump housing. Refer to Specifications, “Water Pump” for further information. 2. Use 2. Use Tooling (B) to install seal (11) over shaft assembly (12) and into water pump housing (4). Install the seal to the correct working height. Refer to Specifications, “Water Pump” for the correct working height. 3. Use 3. Use Tooling (A) and a suitable press in order to install impeller (10) onto shaft assembly (12). Install the impeller until the distance between the impeller and the machined surface of the water pump housing housing is 0.75 ± 0.25 mm (0.030 ± 0.010 inch). Refer to Specifications, “Water Pump” for further information. 4. Use 4. Use Tooling (A) to install hub (13) to shaft assembly (12). Install the hub to the correct distance distance from the front of the hub to water pump housing (8). Refer to Specifications, “Water Pump” for the correct distance.

Illustration 91

g03783238

5. Position 5. Position a new gasket (9) (not shown) onto inlet elbow (8). Ensure that the gasket is correctly orientated onto the inlet elbow. 6. Install 6. Install inlet elbow (8) to water pump housing housing (4). Install bolts (7) to the inlet elbow. Ensure that the inlet elbow is correctly orientated. 7. Tig 7. Tighten hten bolts (7) (7) to a torque of 28 N·m (248 lb in). 8. Position 8. Position a new gasket (3) onto cover (2). Ensure that the gasket is correctly orientated onto the cover. 9. Position 9. Position cover (2) onto water pump housing (4). Install bolts (1) to the cover. Hand tighten the bolts and ensure that the bolt holes for the water pump retaining bolts are correctly aligned. 10. Tigh 10. Tighten ten bolts (1) to a torque torque of 28 N·m (248 lb in) . 11. Install 11. Install pulley (5) to the water pump (4). Install bolts (6) to the pulley. suitable tool to hold pulley (5) and tighten 12. Use 12. Use a suitable bolts (6) to a torque torque of 28 N·m N·m (248 lb in). in).


56

UENR4511-01


End By: a. Install the water pump. Refer to Disassembly and Assembly, “Water Pump - Install” for the correct procedure.

6. Tighten 6. Tighten hose clamp (5) for hose assembly (4) to a torque of of 7 N·m (62 lb in). in).

i06542542

Water Pump Water Pump - Install Installation Procedure

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components of the water pump and the cylinder block are clean and free from wear or damage. Illustration 93

g06015537

Typical example 7. Connect 7. Connect hose assembly (2) to the water pump elbow connection. Tighten hose clamp (1) to a torque of 11 11 N·m (97 lb in).

Illustration 92

g06015544

2. Install 2. Install a new O-ring seal (7) (not shown) and a new O-ring seal (8) (not shown) to water pump (5). Ensure that the O-ring seals are correctly located into the recess of the water pump. 3. Install 3. Install water pump (3) to hose assembly (4) and the cylinder block. Ensure that the O-ring seals are not damaged or dislodged from the recess of the water pump. 4. Install 4. Install bolts (6) to water pump (3). Support Support the water pump as the bolts are installed. ten bolts (6) to a torque torque of 55 N·m (41 lb ft). 5. Tigh 5. Tighten


57

UENR4511-01


End By: a. Install the V-belt to the water pump. Refer to Disassembly and Assembly, “V- Belts Remove and Install (Water Pump Drive Belt)” or refer to Disassembly and Assembly, “Alternator Belt - Remove and Install” for the correct procedure.

NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, maintemaintenance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartme tment nt or disass disassemembling any component containing fluids.

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

Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.

c. Fill the cooling cooling system with coolant. coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change” and Operation and Maintenance Manual, “Capacities (Refill)”.

1. Drain 1. Drain the coolant coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change”.

i05986893

Water Temperature Regulator Regulator Remove and Install Removal Procedure

Pers Person onal al injur injury y can can resu result lt from from hot hot cool coolan ant, t, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heate heaters rs or the the engi engine ne cont contai ain n hot hot coola coolant nt or steam. Any contact can cause severe burns. Remove Remove cooling cooling system pressure pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.


Illustration 94

g03783784

2. Loosen 2. Loosen hose clamp (2) for hose assembly (1). Disconnect the hose assembly from water temperature regulator housing (4). 3. Loosen 3. Loosen hose clamp (5) for hose assembly (6). Ensure that the hose clamp is sufficiently loosened in order to allow hose to disconnected from water temperature regulator housing (4). 4. Remove 4. Remove bolts (3) from water temperature regulator housing (4). Support the water temperature regulator housing as the bolts are removed. 5. Remove 5. Remove water temperature regulator housing (4) from the cylinder head. 6. Remove 6. Remove gasket (7) (not shown).


58

UENR4511-01


c.

Remove adapter adapter (10) (10) from water temperature temperature regulator housing (4).

d.




27610309

Part Description Seal Installer

Qty 1


Illustration 95

g03783785

1. Clean 1. Clean the gasket surfaces of the water temperature regulator housings and the cylinder head. Ensure that all components are free from wear or damage. Replace any component that is worn or damaged. 2. Check 2. Check the water temperature regulator for correct operation. Refer to System Operation, Testing and Adjusting, “ Water Temperature Temperature Regulator - Test” for the correct procedure to test the water temperature regulator.

Illustration 96

g03783817

7. Remove 7. Remove water temperature regulator (12) from water temperature regulator housing (4). 8. Use 8. Use a suitable suitable tool to remove seal seal (13) from water temperature regulator housing (4). Care should be taken not to damage the water temperature regulator housing. 9. If 9. If necessary, follow Step 11 Step 11 through through Step 9 Step 9 in in order to remove valve (11) and adapter (10). a.

Remove Remove cap cap (9) from valve (11). (11).

b.

Remove Remove valve valve (11) (11) from from adapter adapter (10).


UENR4511-01


4. Use 4. Use Tooling (A) to install a new seal (13) to water temperature regulator housing (4). Ensure that the seal is installed in the correct orientation. 5. Apply 5. Apply glycerin to new seal (13). 6. Install 6. Install water temperature regulator (12) to water temperature regulator housing (4).

Illustration 97

g03783785

Illustration 99

g03783784

7. Ensure 7. Ensure that hose clamp (5) is correctly positioned onto hose assembly. 8. Position 8. Position gasket (7) (not shown) onto water temperature regulator housing (4). 9. Position 9. Position water temperature regulator housing (4) onto the cylinder head and install bolts (3) to the water temperature regulator housing. Support the water temperature regulator housing as the bolts are installed. Note: Ensure Note: Ensure that the water temperature regulator housing is correctly located onto the hose assembly. Illustration 98

g03783823

ten bolts (3) to a torque torque of 55 N·m (41 lb ft). 10. Tigh 10. Tighten 3. If 3. If necessary, follow Step 3.a Step 3.a through through Step 3.d Step 3.d in in order to install adapter (10) and valve (11). a.

Install Install a new new O-ring O-ring seal seal (8) (8) (not shown) shown) to adapter (10).

b.

Install Install adapter adapter (10) to water water temperature temperature regulator housing (4). Tighten the adapter to a torque of 100 N·m N·m (74 lb ft). ft).

c.

Install Install valve (11) (11) to adapter adapter (10). (10). Tighten Tighten the valve to a torque torque of 25 N·m (221.26875 (221.26875 lb in).

d.

Install Install cap cap (9) (9) to to valve valve (11). (11).

11. Tighten 11. Tighten hose clamp (5) for hose assembly (6) to a torque of 11 11 N·m (97 lb in). 12. Connect 12. Connect hose assembly (1) to water temperature regulator housing (4). Tighten hose clamp (5) to a torque of 11 11 N·m (97 lb in).


60

UENR4511-01


13. Fill 13. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change” and Operation and Maintenance Manual, “Capacities (Refill)”. i06548014

Engine Lifting Bracket Remove and Install Start By Start By: a. Remove the alternator and the alternator bracket. Refer to Disassembly and Assembly, Alternator - Remove and Install for the correct procedure. b. Remove the belt tensioner. Refer to Disassembly and Assembly, Belt Tensioner Remove and Install for the correct procedure. c. Remove the idler pulley. Refer to Disassembly and Assembly, Idler Pulley - Remove and Install for the correct procedure.

Illustration 101

2. Follow 2. Follow step 2.a step 2.a through through step 2.d step 2.d to to remove the front engine lifting bracket. a.

Remove bolts (6) and and washers washers (5) from from bracket (4).

b.

Remove Remove bracke brackett (4)

Removal Procedure

Illustration 100

g06019372

1. Follow 1. Follow step 1.a step 1.a through through step 1.b step 1.b to to remove rear engine lifting bracket (1). a.

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

b.

Remove Remove bracke brackett (1). (1).

g06019376

Illustration 102

c.

g06019384

Remove bolts (9) and and washers washers (8) from from bracket (7). Support the weight of bracket (7) as the bolts are removed.

d.

Remove Remove bracke brackett (7).


UENR4511-01


Installation Procedure 1. Follow 1. Follow step 1.b step 1.b through through step 1.c step 1.c to to install rear engine lifting bracket (1).

Illustration 103

Illustration 104

g06019384

Illustration 105

g06019376

g06019372

a.

Position Position bracket bracket (1) to the cylinder cylinder head. head.

b.

Install Install bolts bolts (3) and washers washers (2) to bracket bracket (1).

c.

Tighten Tighten bolts bolts (3) (3) to a torque torque of of 100 N·m (74 lb ft).

2.

a.

Position Position bracket bracket (7) to to the cylinder cylinder head. head.

b.

Install bolts (9) and and washers washers (8) finger finger tight. tight.

c.

Position Position bracket bracket (4) to bracket bracket (7) and the the water temperature regulator housing.

d.

Install bolts (6) and and washers washers (5) to bracket bracket (4).

e.

Tight Tighten en bolts bolts (9) (9) to a torq torque ue of 55 55 N·m (41 lb ft).

f.

Tight Tighten en bolts bolts (6) (6) to a torq torque ue of 55 N·m N·m (41 lb ft).


62

UENR4511-01


End By: a. Install the idler pulley. Refer to Disassembly and Assembly, Idler Pulley - Remove and Install for the correct procedure. b. Install the belt tensioner. Refer to Disassembly and Assembly, Belt Tensioner - Remove and Install for the correct procedure. c. Install the alternator and the alternator bracket. Refer to Disassembly and Assembly, Alternator - Remove and Install for the correct procedure. i05986259

Engine Support (Front) Remove and Install Removal Procedure Table 22

Required Tools Tool

Part Part Number Number

A

-

Part art Des Descri cripti ption Guide Studs (1/2 - 13 UNC by 6 inch)

Qty 2


Illustration 106

g03780280

1. If 1. If necessary, remove tube assembly (3), tube assembly (6), guards (2), radiator supports (1), radiator assembly (5) and coolant tube assemblies and radiator support brackets (4) in order to access engine support front. Refer to the Original Equipment Manufacture (OEM) for the correct removal procedure. 2. Remove 2. Remove the assembly of the vibration damper and the crankshaft pulley. Refer to Disassembly and Assembly, Assembly, “Vibration “ Vibration Damper and Pulley Remove and Install” for the correct procedure.



UENR4511-01


Illustration 107

g03780281

Illustration 108

g03780281

Illustration 109

g03780294

3. Use 3. Use a suitable lifting device to support the engine in order to remove engine engine support (8). The weight of the engine is approximately approximately 1202 1202 kg (2650 lb). 4. Remove 4. Remove bolts (7) from Position (X). Install Tooling (A). 5. Remove 5. Remove remaining bolts (7). 6. Remove 6. Remove engine support (8) from the cylinder block. The weight of the engine support is approximately approximately 33.5 33.5 kg (74 lb).

Installation Procedure Table 23

Required Tools Tool


A

-

Part art Des Descri cripti ption Guide Studs (1/2 - 13 UNC by 6 inch)

Qty 2


Tightening sequence


2. Use 2. Use a suitable lifting device to support the engine in order to install install engine support (8). The weight of the engine is approximate approximately ly 1202 kg (2650 lb).

1. Ensure 1. Ensure that all components of the engine support are free from wear or damage. damage. Place any component that is worn or damaged.

3. Install 3. Install Tooling (A) into Position (X). 4. Install 4. Install engine support (8) onto the cylinder block. The weight of the engine support is approximately 33.5 kg kg (74 lb). lb). 5. Install 5. Install bolts (7) hand tight.


64

UENR4511-01


6. Remove 6. Remove Tooling (A) and install remaining bolts (7). Tighten Tighten the bolts to a torque torque of 105 N·m (77 lb ft) in the order that is shown in Illustration Illustration 109 . 109 . 7. Install 7. Install the assembly of the vibration damper and the crankshaft pulley. Refer to Disassembly and Assembly, Assembly, “Vibration “ Vibration Damper and Pulley Remove and Install” for the correct procedure.

Illustration 110

g03780280

8. If 8. If necessary, install tube assembly (3), tube assembly (6), guards (2), radiator supports (1), radiator assembly (5) and coolant tube assemblies and radiator support brackets (4) in order to access engine support front. Refer to the OEM for the correct removal procedure. i06548084

Engine Support (Front) Remove and Install (Option 2) Removal Procedure NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.


UENR4511-01



Illustration 112

g06019409

2. Use 2. Use a suitable lifting device to support the engine to install engine support brackets (2). The weight of the engine is approximately approximately 1202 1202 kg (2650 lb). Illustration 111

g06019409

1. Use 1. Use a suitable lifting device to support the engine to remove engine support brackets (2). The weight of the engine is approximately approximately 1202 1202 kg (2650 lb). 2. Remove 2. Remove bolts (1) from engine support bracket (2). 3. Remove 3. Remove engine support bracket (2) from the cylinder block. 4. Repeat 4. Repeat step 2 step 2 through through step 3 step 3 to to remove the other engine support bracket.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the engine support brackets are free from wear or damage. Replace any component that is worn or damaged.

3. Position 3. Position engine support bracket (2) onto the cylinder block. 4. Install 4. Install new bolts (1). Tighten Tighten bolts (1) to a torque of 240 N·m N·m (177 lb ft) 5. Repeat 5. Repeat step 2 step 2 through through step 4 step 4 to to install the other engine support bracket. i05986278

Flywheel - Remove Removal Procedure Table 24

Required Tools Tool

Part Number Number

A

-

Part Description Guide Stud M16 x 2 by 12inch

Qty 2


66

UENR4511-01


Start By: a. Remove the electric starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 114

g03794644

Typical example 5. Inspect 5. Inspect flywheel flywheel (2) and ring gear (3) for wear or damage. Replace any components that are worn or damaged. 6. To 6. To remove the flywheel ring gear, follow Steps 6.a and 6.b and 6.b.. a. Illustration 113

g03794642

Typical example 1. Use 1. Use a suitable tool to lock the flywheel. Loosen bolts (1). 2. Attach 2. Attach a suitable lifting device to flywheel (2). Support Support the weight of the flywheel. flywheel. The weight of the flywheel is approximately 50 kg (110 (110 lb).

Place the assembly assembly of flywhee flywheell (2) on a suitable support.

orientation of the teeth on the Note: Identify Note: Identify the orientation flywheel ring gear. b.

Use a hammer and a punch in order order to remove ring gear (3) from flywheel (2). i05986277

Flywheel - Install

3. Remove 3. Remove two bolts (1). Install Tooling (A). 4. Remove 4. Remove the remaining bolts (1). Use the lifting device in order to remove flywheel (2).




A

-

B

-

Part Desc escrip ription tion

Qty Qty

Guide Stud M16 x 2 by 12 inch

2

Loctite 242

1


UENR4511-01



2. Inspect 2. Inspect the crankshaft rear seal for leaks. If there are any oil leaks, replace the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove” for the correct procedure.


g03794644

g03794642

Typical example

Typical example

3. Install 3. Install a suitable lifting device to flywheel (2). The weight of the flywheel is approximately 31 kg (68 lb).

Always Always wear wear protec protective tive gloves gloves when when handli handling ng parts that have been heated.

4. Install 4. Install Tooling (A) on the crankshaft.

1. If 1. If flywheel ring gear (3) was removed, follow Steps 1.a through 1.a through 1.c 1.c in in order to install a new ring gear to flywheel (2). a.

Identify Identify the orientation orientation of the teeth on the the new ring gear (3).

Note: The Note: The chamfered side of the ring gear teeth must face toward the starting motor when the flywheel is installed. The chamfered side of the ring gear teeth will ensure the correct engagement of the starting motor. b.

Heat flywheel flywheel ring gear (3) in an oven oven to to a maximum maximum temperature temperature of 316 °C (600 °F) prior to installation.

5. Align 5. Align the arrows on flywheel (2) and the crankshaft. Use the lifting device in order to position the flywheel onto Tooling (A). 6. Apply 6. Apply Tooling (B) to the threads of new bolts (1). 7. Install 7. Install bolts (1). Remove Tooling (A). Install remaining bolts (1). 8. Use 8. Use a suitable tool to prevent the flywheel from rotating. rotating. Tighten bolts (1) to a torque of 300 N·m (221 lb ft). 9. Remove 9. Remove the lifting device from flywheel (1). 10. Check 10. Check the run out of the flywheel. flywheel. Refer to Systems Operations, Testing and Adjusting, “Flywheel - Inspect” for the correct procedure.

Note: Do Note: Do not use a torch to heat the ring gear. gear. c.

Ensure that the orientati orientation on of ring gear gear (3) (3) is correct and quickly install the ring gear onto flywheel (2).


68

UENR4511-01


End By: a. Install the electric starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install” for the correct procedure. i05986493

Crankshaft Rear Seal Remove Removal Procedure Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accordi according ng to local local regula regulatio tions ns and mandates.

Illustration 117

g03770396

1. Remove 1. Remove the bolts and washers (1) from crankshaft rear seal (4).


2. Remove 2. Remove crankshaft rear seal (4) from crankshaft (2) and flywheel housing (3).


3. Remove 3. Remove O-ring seal (5). 4. If 4. If the crankshaft is installed with a crankshaft wear sleeve, sleeve, use a suitable suitable tool in order to remove the crankshaft wear sleeve from the crankshaft. Ensure that the crankshaft and the flywheel housing are not damaged. i05986469

Crankshaft Rear Seal Rear Seal - Install Installation Procedure



UENR4511-01


Note: If Note: If the crankshaft rear seal, O-ring seal, and the shipping sleeve are separated, these components should not be used. 1. Lubricate 1. Lubricate O-ring seal (5) with clean engine oil. Install the O-ring seal to crankshaft rear seal (4). 2. Position 2. Position crankshaft rear seal (4) and the shipping sleeve over crankshaft (2). Push the crankshaft rear seal into place. Pushing the crankshaft rear seal into place will dislodge the shipping sleeve. Do not remove the shipping sleeve until bolts (1) are installed. 3. Install 3. Install new bolts and washers (1) hand tight. 4. Tigh 4. Tighten ten bolts (2) to a torque torque of 12 N·m (106 lb in) in numerical sequence, shown in Illustration 119 . 119 . End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install” for the correct procedure. i05986311

Flywheel Housing - Remove and Install Illustration 118

g03770396

Removal Procedure Table 26 Required Tools Tools

Illustration 119

Tool ool


A

-

Part Description Guide Studs M12 x 1.75 by 5 inches

Qty 2

g03770476

Tightening sequence for the bolts Note: Leave Note: Leave the shipping sleeve in place to install the crankshaft rear seal. The crankshaft rear seal must be installed dry.


70

UENR4511-01


Start By: a. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan Remove and Install” for the correct procedure. b. Remove the electric starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install” for the correct procedure. c. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove and Install” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the product product.. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.


2. Remove 2. Remove crankshaft rear seal (3). Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove” for the correct procedure. 3. Attach 3. Attach a suitable lifting device to flywheel housing (2). The weight of flywheel flywheel housing (1) is approximately approximately 25 25 kg (55 lb). 4. Remove 4. Remove bolts (1) from Positions (X). Install Tooling (A) to Positions (X). 5. Remove 5. Remove the remaining bolts (1). Use the lifting device to remove flywheel housing (2) from the cylinder block. 6. Inspect 6. Inspect the dowels in the cylinder block. Do not remove the dowels unless the dowels are damaged.

Installation Procedure Table 27 Required Tools Tools Tool ool


A

-

B

CH10879

Part Description

Qty

Guide Bolts M12 x 1.75 by 5 inches

2

Sealant

1

Contaminants may cause rapid wear and shortened component life. 1. Use 1. Use a suitable lifting device and cribbing to support the rear of the engine. engine.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the mating surfaces of the flywheel housing and the cylinder block are clean and free from damage.

Illustration 120

g03784594

Typical example


UENR4511-01


Illustration 121

g03784594

Illustration 122

g03784600

Illustration 123

g03785114

Typical example

Tightening sequence for flywheel housing bolts 2. Apply 2. Apply Tooling (B) to the rear face of the cylinder block. Ref to Illustration 122 Illustration 122 for for the correct application position. Note: The Note: The flywheel housing must be installed within 10 minutes of applying Tooling (B). 3. Install 3. Install Tooling (A) to Positions (X) in the cylinder block. 4. Attach 4. Attach a suitable lifting device to flywheel housing (2). The weight of the flywheel housing housing is approximately approximately 25 25 kg (55 lb).


72

UENR4511-01


5. Use 5. Use the lifting device to align flywheel housing (2) with Tooling (A). 6. Install 6. Install flywheel housing (2) to the cylinder block. 7. Install 7. Install bolts (1). Remove Tooling (A). Install the remaining bolts. 8. Tigh 8. Tighten ten bolts (1) to a torque of 100 100 N·m (74 lb ft). Tighten the bolts in the sequence that is shown in Illustration 123 Illustration 123 . . 9. Install 9. Install crankshaft rear seal (3). Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Install” for the correct procedure. 10. Use 10. Use a suitable suitable lifting device to raise the rear of the engine and remove cribbing. End By: a. Install the engine engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install” for the correct procedure. Illustration 124

b. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove and Install” for the correct procedure. c. Install the electric starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install” for the correct procedure. i06542630

Vibration Damper and Damper and Pulley Remove and Install

g06015666

Typical example 1. Use 1. Use a suitable tool to prevent the crankshaft from turning. Remove bolts (1) and thrust block (2) from the assembly of crankshaft vibration damper (3). 2. Attach 2. Attach a suitable lifting device to the assembly of crankshaft vibration damper (3). Remove the assembly of crankshaft vibration damper. The weight of the assembly of crankshaft vibration damper is approximate approximately ly 50 kg (110 (110 lb). 3. Remove 3. Remove the crankshaft front seal. Refer to Disassembly and Assembly, “Crankshaft Front Seal - Remove” for the correct procedure.

Start By: a. Remove the v-belts. Refer to Disassembly and Assembly, “V-Belts - Remove and Install” and refer to Disassembly and Assembly, “Alternator Belt - Remove and Install” for the correct procedure.

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


UENR4511-01


Illustration 125

g06015673

Illustration 126

g06015673

Typical example

Typical example

4. If 4. If necessary, follow Step 4.a Step 4.a through through Step 4.c Step 4.c to to disassemble the assembly of crankshaft vibration damper (3).

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.c Step 2.c to to assemble the assembly of crankshaft vibration damper (3).

a.

Place the assembly assembly of of cranksh crankshaft aft vibratio vibration n damper (5) in a suitable support.

b.

Remove Remove bolts bolts (4).

c.

Remove Remove pulley pulley (5), damper (6) from from adapter adapter (7).


a.

Place adapter adapter (7) (7) in a suitable suitable support. support.

b.

Install damper (6) and and pulley pulley (7) (7) onto onto adapter adapter (7). Align the bolt hole in the damper and the pulley.

c.

Install bolts (4). Tighten Tighten the bolts bolts to a torque of 55 N·m N·m (41 lb lb ft).


NOTICE Thoroughly inspect the viscous damper for signs of leakage or for signs of a dented or damaged to the case. Either of these conditions can cause the weight to contact with the case. The weight contacting with the case can affect the viscous damper operation. 1. Ensure 1. Ensure that all the components of the assembly of the crankshaft vibration damper are free from wear or damage. Replace any component that is worn or damaged.

Illustration 127

g06015666

Typical example


74

UENR4511-01


3. Install 3. Install a new crankshaft front seal. Refer to Disassembly and Assembly, “Crankshaft Front Seal - Install” for the correct procedure.

Start By:

4. Attach 4. Attach a suitable lifting device to the assembly of crankshaft vibration damper (3). Install the assembly of crankshaft vibration damper. The weight of the assembly of crankshaft vibration damper is approximate approximately ly 50 kg (110 (110 lb). Ensure lb). Ensure that the crankshaft front seal is not damaged as the assembly of crankshaft vibration damper in installed. installed.

a. Remove the assembly of the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley Remove and Install” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids.

5. Install 5. Install thrust block (2) and bolts (1) to the assembly of crankshaft vibration damper (3). Hand tighten the bolts.

Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.

6. Use 6. Use a suitable tool to prevent the crankshaft from turning and tighten tighten bolts (1) to a torque of 160 N·m (118 lb ft).


End By:


a. Install the v-belts . Refer to Disassembly Disassembly and Assembly, “V-Belts - Remove and Install (Charging Alternator Drive Belts)” and refer to Disassembly and Assembly, “Alternator Belt Remove and Install” for the correct procedure. i05986329

Crankshaft Front Seal Remove Removal Procedure Table 28 Required Tools Tool ool A B


27610311 -

Part Description

Qty

Slide Hammer Puller

1

Drill Bit3 mm (0.118 (0.118 inch)

1 Illustration 128

g01276176

1. Apply 1. Apply clean grease to Tooling (B) in order to prevent any swarf that is generated from entering the engine. Carefully use Tooling (B) to drill three evenly spaced holes in crankshaft front seal (1). Note: Ensure Note: Ensure that the housing or the crankshaft is not damaged when drilling the front seal.


75

UENR4511-01


2. Alternate 2. Alternate between the drilled holes and use Tooling (A) to remove crankshaft front seal (1).

End By:

i05986328

Crankshaft Front Seal - Install

a. Install the assembly of the vibration damper and the pulley. Refer to Disassembly and Assembly, “Vibration Damper and Pulley Remove and Install” for the correct procedure. i05975647

Front Cover Cover - Remove


Removal Procedure

Table 29 Required Tools Tool ool C


T401072

Part Description Fr Front Seal Installer

Qty 1




Illustration 129

g01276301

1. Ensure 1. Ensure that the housing is clean, dry, and free from damage. 2. Use 2. Use Tooling (C) and install crankshaft front seal (1). Note: Do not lubricate the seal. The seal must be installed dry. dry.


76

UENR4511-01


Illustration 130

g03781156

Illustration 131

g03781156

Illustration 132

g03781238

1. Remove 1. Remove the nuts and bolts (3) and remove blanking plate (5). 2. Remove 2. Remove bolts (1) from front cover (2). Identify the positions of bolts of different length. Support the front cover as the bolts are removed. 3. Remove 3. Remove front cover (2) and gasket (4) (not shown). i05975648

Front Cover Cover - Install Installation Procedure

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components are free from wear or damage. If necessary, replace any component that is worn or damaged.


77

UENR4511-01


Start By: a. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) Remove” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, maintemaintenance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartme tment nt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regula regulation tions s and mandates.


Illustration 133

g03781240


Front cover tightening sequence 2. Clean 2. Clean the gasket surfaces of the front housing (6), front cover (2), and blanking plate (5). 3. Position 3. Position a new gasket (4) (not shown) onto front cover (2).

1. Set 1. Set the No. 1 piston to top center on the compression stroke. Refer to Testing and Adjusting, “ Finding Top Center Position for No. 1 Piston” for the correct procedure.

4. Install 4. Install front cover (2) and in stall bolts (1). Support the front cover as the bolts are installed. 5. Apply 5. Apply Tooling (B) to front housing (6) as shown in Illustration 132 Illustration 132 . . 6. Install 6. Install blanking plate (5) onto front housing (6). Install the nuts and bolts (3) hand tight. 7. Tighte 7. Tighten n bolts (1) for front cover (2) to a torque of 28 N·m (248 lb in) in the tightening tightening sequence sequence shown in Illustration 133 Illustration 133 . . 8. Tighten 8. Tighten the nuts and bolts (3) for blanking plate (5) to a toque of 100 100 N·m (74 lb ft). i05986299

Gear Group Gear Group (Front) - Remove Removal Procedure Table 30 Required Tools Tool ool A


27610275


Qty 1


78

UENR4511-01


5. If 5. If necessary, remove engine oil pump idler gear (5). Refer to Disassembly and Assembly, “Engine Oil Pump - Remove” for the correct procedure. 6. Remove 6. Remove thrust plate (9) from idler hub (9). Remove idler gear (6) from idler hub (9). 7. If 7. If necessary, follow Step 7.a Step 7.a through through Step 7.b Step 7.b in in order to remove bushing (8) from idler gear (7). a.


b.

Use Tooling Tooling (A) and and a suitable suitable press press to remove bushing bushing (8) from idler gear (7).

8. If 8. If necessary, remove crankshaft gear (5). Refer to Disassembly and Assembly, “Crankshaft Gear Remove and Install” for the correct procedure. i05986298

Gear Group Gear Group (Front) - Install Installation Procedure Table 31 Required Tools Tools Illustration 134

g03781421

Tool ool A


27610275


Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components of the gear group are free from wear or damage. Refer to Specifications, “Gear Group (Front)” for the correct information. Replace any component that is not within specification.

Illustration 135

g03781425

2. Make 2. Make temporary mark on each of idler gear (4) and crankshaft gear (5) for installation purposes. 3. Remove 3. Remove bolts (1) and bolt (2). Remove retaining plate (3). 4. Remove 4. Remove idler gear assembly (4) from the cylinder block.


UENR4511-01


bushing is correctly located into the idler gear. 3. If 3. If necessary, install crankshaft gear (5). Refer to Disassembly and Assembly, “Crankshaft Gear Remove and Install” for the correct procedure 4. Install 4. Install idler gear (7) to idler hub (9). Ensure that the idler gear is correctly orientated in the idler hub. Note: Ensure Note: Ensure that the idler gear is free to rotate on the idler hub. 5. Install 5. Install thrust plate (10) to idler hub (9). Ensure that the thrust plate is correctly positioned onto the idler hub. 6. Install 6. Install idler gear assembly (4) onto the cylinder block. block. Align the timing marks on the idler gear and crankshaft gear (5) as shown in Illustration 137 . 137 . Also align the bolt hole in the idler hub with the holes in the cylinder block. Illustration 136

g03781425

7. Install 7. Install retaining retaining plate (3) and bolts (1) and bolt (2). Ensure that the retaining plate is correctly orientated. 8. Tighte 8. Tighten n bolts (1) and bolt (2) to a torque of 70 N·m (52 lb ft). 9. Check 9. Check the end play for idler gear assembly (4). The end play for the gear assembly is 0.05 to 0.35 mm (0.002 to 0.014 0.014 inch). 10. If 10. If necessary, install engine oil pump idler gear (6). Refer to Disassembly and Assembly, “Engine Oil Pump - Install” for the correct procedure. 11. Calibrate 11. Calibrate the speed/timing sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor Calibrate ” for the calibration procedure.

Illustration 137

g03781421

Step 2.a through through Step 2.b Step 2.b in in 2. If 2. If necessary, follow Step 2.a order to install bushing bushing (8) to idler gear (7). a.


b.

Use Tooling Tooling (A) and a suitable suitable press press to install bushing bushing (8) to idler gear (7). Ensure that the


80

UENR4511-01


End By: a. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Install” for the correct procedure. i06543361

Housing (Front) - Remove Removal Procedure Start By: a. If necessary, remove the air compressor. Refer to Disassembly and Assembly, Air Compressor - Remove and Install for the correct procedure. b. Remove the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Remove” for the correct procedure. c. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove” for the correct procedure. d. Remove the speed timing sensor. Refer to Disassembly and Assembly, “Speed/Timing Sensor - Remove and Install” for the correct procedure.

Illustration 138

g03781615

Illustration 139

g03781617

e. Remove the V-Belt adjuster and the bracket. Refer to Disassembly and Assembly, “V-Belts Remove and Install” for the correct procedure. f. Remove the crankshaft front seal. Refer to Disassembly and Assembly, “Crankshaft Front Seal - Install” for the correct procedure. g. Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan Remove and Install” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regula regulatio tions ns and mandates.


1. Remove 1. Remove bolt (1) from bracket (2). Position the bracket away from cover (5). 2. Remove 2. Remove bolts (3) and bolts (4) from front cover (5). Identify the positions of bolts of different length. Support the front cover as the bolts are removed. 3. Remove 3. Remove front housing (5) from the cylinder block.


UENR4511-01


4. Inspect 4. Inspect dowel (6) and dowel (7) for damage. If necessary, remove the dowels from the cylinder block.

3. Install 3. Install Tooling (A) in Positions (X) of the cylinder block.

i06543363

Housing (Front) - Install Installation Procedure Table 32 Required Tools Part Description

Qty

Tool ool


A

-

Guide Studs (1/2 - 13 UNC by 6 inch)

2

B

-

Loctite 598 Black High Performance RTV Silicone Gasket Maker

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components are free from wear or damage. If necessary, replace any component that is worn or damaged.

Illustration 140

g03781618

2. If 2. If necessary, install dowel (6) and dowel (7) to the cylinder block.


82

UENR4511-01


Illustration 143

g03781620

Front housing tightening sequence 4. Clean 4. Clean the gasket surfaces of the cylinder block and front housing (5).

Illustration 141

g03781615

5. Apply 5. Apply Tooling (B) to front housing (5) as shown in Illustration 142 Illustration 142 . . 6. Position 6. Position front housing (5) over Tooling (A) and install the front housing to the cylinder block. Ensure Tooling (B) is not damaged as the front housing is installed. 7. Install 7. Install bolts (3) and bolts (4) from front cover (5). Identify the positions of bolts of different length. Support the front cover as the bolts are install. 8. Tighten 8. Tighten bolts (3) and bolts (4) for front housing (5) to a torque of 28 N·m (248 lb in) in the tightening tightening sequence shown in Illustration 143 Illustration 143 . . 9. Position 9. Position bracket (2) onto cover (5).Install bolt (1) to the bracket. Tighten the bolts to a torque of 55 N·m N·m (41 lb lb ft).

Illustration 142

g03781619


UENR4511-01


End By: a. Install the unit injector hydraulic pump. Refer to Disassembly and Assembly, “Unit Injector Hydraulic Pump - Install” for the correct procedure. b. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Install” for the correct procedure. c. Install the speed timing sensor. Refer to Disassembly and Assembly, “Speed/Timing Sensor - Remove and Install” for the correct procedure. d. Install the crankshaft front seal. Refer to Disassembly and Assembly, “Crankshaft Front Seal - Install” for the correct procedure. e. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install” for the correct procedure. f. Install the V-Belt adjuster and the bracket. Refer to Disassembly and Assembly, “V-Belts Remove and Install” for the correct procedure. g. If necessary, install the air compressor. Refer to Disassembly and AssemblyAir Compressor - Remove and Install for the correct procedure. Illustration 144

g03758497

i05986446

Crankcase Breather Breather - Remove

1. Loosen 1. Loosen hose clamp (4) and disconnect hose assembly (5) from crankcase breather (1).

and Install

2. Remove 2. Remove bolt (1) from crankcase breather (1). Remove the breather from cylinder block cover (7).

Removal Procedure

3. Remove 3. Remove O-ring seal (6) (not shown).



4. Remove 4. Remove sealing washer (3) (not shown) from bolt (1). 5. If 5. If necessary, remove the nut and bolt (8) from clip (9). Remove hose assembly (5) from the bracket.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components of the crankcase breather breather are free from wear or damage.


84

UENR4511-01


10. Tighte 10. Tighten n the nut and bolt (8) to a torque of 28 N·m (248 lb in). Ensure that clip (9) is not strained as the nut and bolt is tightened. i05986481

Cylinder Block Cover Remove and Install Removal Procedure Start By: a. Remove the electronic control module. Refer to Disassembly and Assembly, “Electronic Control Module - Remove and Install” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, maintemaintenance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartme tment nt or disass disassemembling any component containing fluids. Illustration 145

g03758497

2. Inspect 2. Inspect and clean crankcase breather (1). Refer to Operation and Maintenance Manual, “Engine Crankcase Breather - Clean” for the correct procedure. 3. If 3. If necessary, position hose assembly (5) and clip (9) onto the bracket. Ensure that the hose assembly and the clip are correctly positioned onto the bracket.

Dispos Dispose e of all fluids fluids accord according ing to local local regula regulation tions s and mandates.


4. Install 4. Install the nut and bolt (8) to clip (9). Tighten the nut and bolt hand tight. 5. Install 5. Install a new O-ring seal (6) (not shown) onto crankcase breather (1). 6. Install 6. Install crankcase breather (1) onto cylinder block cover (7). Install a new sealing washer washer (3) (not shown) shown) onto bolt (2). Loosely install the bolt to the crankcase breather. 7. Connect 7. Connect hose assembly (5) to crankcase breather (1). 8. Tigh 8. Tighten ten bolt (2) to a torque of 15 N·m (133 lb in). 9. Tighte 9. Tighten n hose clamp (4) to a torque of 7 N·m (62 lb in).


UENR4511-01


Illustration 146

g03770738

Illustration 147

g03770536

1. Loosen 1. Loosen hose clamp (4) and disconnect hose assembly (5) from crankcase breather (1).

6. Loosen 6. Loosen tube nut (11) from connection (10) for tube assembly (12).

2. Remove 2. Remove bolt (1) from crankcase breather (1). Remove the breather from cylinder block cover (7).

7. Disconnect 7. Disconnect tube nut (13) from elbow connection (14) for tube assembly (12).

3. Remove 3. Remove O-ring seal (6) (not shown). 4. Remove 4. Remove sealing washer (3) (not shown) from bolt (1). 5. Remove 5. Remove the nut and bolt (8) from clip (9). Remove hose assembly (5) from the bracket.

8. Cut 8. Cut cable straps (15) from the clips. 9. Disconnect 9. Disconnect harness assembly (18) from engine oil pressure sensor (17) (not shown). Position the harness assembly away from cylinder block cover (7). 10. Remove 10. Remove bolts (16) from cylinder block cover (7). Support the cylinder block cover as the bolts are removed. 11. Remove 11. Remove cylinder block cover (7) from the cylinder block. 12. Remove 12. Remove gasket (19) (not shown).


86

UENR4511-01


Illustration 148

g03772745

13. If 13. If necessary, follow Step 2.a Step 2.a through through Step 2.d Step 2.d in in order to disassemble cylinder block cover (7). a.

Make temporary temporary marks on elbow elbow connection connection (14) and cylinder block cover (7) for installation purposes.

b.

Loosen Loosen lock lock nut nut (20) (20) on on elbow elbow connec connection tion (14). Remove the elbow connection from cylinder block cover (7).

c.

Remove Remove O-ring O-ring seal (21) from elbow connection (14).

d.

Remove Remove engine engine oil oil pressure pressure sensor sensor (17) from connection (23). Remove O-ring seal (22).

e.

Remove Remove connecti connection on (23) (23) from from cylinde cylinderr block block cover (7).

f.

Remove Remove O-ring O-ring seal (24) from connection connection (24).

Installation Procedure NOTICE Keep all parts clean from contaminants.

Illustration 149

g03772745

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.f Step 2.f in in order to assemble cylinder block cover (7). a.

Install a new O-ring seal (24) onto onto connec connection tion (23).

b.

Install connection connection (23) to cylinder cylinder block block cover cover (7). Tighten the connection to a torque of 30 N·m (266 lb lb in).

c.

Install a new new O-ring O-ring seal seal (22) to connecti connection on (23). Install engine oil pressure sensor (17) to the connection. Tighten the engine oil pressure pressure sensor to a torque of 10 N·m (89 lb in).

d.

Install a new new O-ring O-ring seal seal (21) to elbow elbow connection (14).

e.

Install elbow connection connection (14) to cylinder cylinder block block cover (7) and align with temporary makes. Tighten lock nut (20) hand tight.

f.

Tighten Tighten lock lock nut (20) on elbow connec connection tion (14) (14) to a torque of 65 65 N·m (48 lb ft). Ensure Ensure that the elbow connection does not move as the locking nut is tightened

Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure all component for the cylinder block cover and the breather are free from wear or damage. Replace any component that is worn or damaged.


UENR4511-01


3. Position 3. Position a new gasket (19) (not shown) onto cylinder block cover (7). Ensure that the gasket is correctly orientated. 4. Install 4. Install cylinder block cover (7) onto the cylinder block. Loosely connect tube nut (13) to elbow connection (14) for tube assembly (12). 5. Install 5. Install bolts (16) to cylinder cylinder block cover (7) hand tight. Support the cylinder block cover as the bolts are installed. 6. Tig 6. Tighten hten bolts (16) (16) to a torque of 28 N·m (248 lb in) in a numerical sequence that is shown in Illustration 151 Illustration 151 . . 7. Tighten 7. Tighten tube nut (11) and tube nut (13) for connection (10) and elbow connection (14) hand tight. Ensure that tube assembly (12) is not strained as the tube nuts are tightened. 8. Tighten 8. Tighten tube nut (11) and tube nut (13) to a torque of 130 N·m (96 lb ft). Use a suitable suitable tooling to hold hold elbow connection (14) and connection (10) as the tube nuts are tightened. 9. Connect 9. Connect harness assembly (18) to engine oil pressure sensor (17) (not shown). Illustration 150

g03770536

10. Install 10. Install new cable straps (15) to the clips. Note: Ensure Note: Ensure that the cable straps meet the Original Equipment Manufacture (OEM) specification.

Illustration 151

g03770720

Tightening sequence for the cylinder block cover


88

UENR4511-01


End By: a. Install the electronic control module. Refer to Disassembly and Assembly, “ Electronic Control Module - Remove and Install” for the correct procedure. i05986458

Valve Mechanism Cover -Remove and Install Removal Procedure NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.

Illustration 152

g03770738

11. Position 11. Position hose assembly (5) and clip (9) onto the bracket. Ensure that the hose assembly and the clip are correctly positioned onto the bracket.


12. Install 12. Install the nut and bolt (8) to clip (9). Tighten the nut and bolt hand tight. 13. Install 13. Install a new O-ring seal (6) (not shown) onto crankcase breather (1). 14. Install 14. Install crankcase breather (1) onto cylinder block cover (7). Install a new sealing washer (3) (not shown) shown) onto bolt (2). Loosely install the bolt to the crankcase breather. 15. Connect 15. Connect hose assembly (5) to crankcase breather (1). 16. Connect 16. Connect hose assembly (5) to crankcase breather (1). 17. Tigh 17. Tighten ten bolt (2) to a torque of 15 N·m (133 lb in). 18. Tighte 18. Tighten n hose clamp (4) to a torque of 7 N·m (62 lb in). 19. Tighte 19. Tighten n the nut and bolt (8) to a torque of 28 N·m (248 lb in). Ensure that clip (9) is not strained strained as the nut and bolt is tightened.


UENR4511-01


Illustration 153

g03782599

Illustration 154

g03782600

Valve mechanism cover tightening sequence 1. Loosen 1. Loosen bolts (1) and bolts (2) in the reverse numerical tightening sequence. Refer to the Illustration 154 Illustration 154 . . Note the position of different types of bolts for installation purposes. 2. Remove 2. Remove valve mechanism cover (3) from valve mechanism base (4).



Part Description

Qty

A

-

Loctite 5940 Black RTV Silicone Sealant

1

3. Remove 3. Remove seal (5) (not shown).


90

UENR4511-01



Illustration 155

g03782599

Illustration 156

g03782600

Valve mechanism cover tightening sequence 1. Apply 1. Apply Tooling (A) to both sides of seal (5) (not shown).

2. Install 2. Install seal (5) (not shown) to the recess of valve mechanism cover (3). Ensure that the seal is correctly installed to the recess of the valve mechanism cover.


UENR4511-01


3. Position 3. Position valve mechanism cover (3) onto valve mechanism base (4). Ensure that the valve mechanism cover is correctly orientated onto the valve mechanism base. 4. Install 4. Install bolts (1) and bolts (2) to valve mechanism cover (3). Ensure that the different types of bolts are installed into the correct position. 5. Tighte 5. Tighten n bolts (1) and bolts (2) to a torque of 20 N·m (177 lb in).Tighten in).Tighten the bolts bolts in the sequence that is shown in Illustration 156 . 156 . i05986459

Valve Mechanism Cover Base Remove and Install Removal Procedure

Illustration 157

g03783103

Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regula regulatio tions ns and mandates.


1. Disconnect 1. Disconnect harness assembly (1) from all electronic unit injectors (2). 2. Remove 2. Remove Allen head bolts (3) and bolt (4) from harness assembly (1). 3. Disconnect 3. Disconnect harness assembly (7) from connection (8) on valve mechanism cover base (5). 4. Disconnect 4. Disconnect harness assembly (9) from atmospheric pressure sensor (10). 5. Remove 5. Remove bolts (4), the washers, and the springs from valve mechanism cover base (5). 6. Remove 6. Remove valve mechanism cover base (5) from the cylinder head. Ensure that the harness assembly is not damaged as the valve mechanism cover base is removed. 7. Remove 7. Remove seal (6) (not shown). 8. If 8. If necessary, remove atmospheric pressure sensor (10) from valve mechanism cover base (5). Refer to Disassembly and Assembly, “Atmospheric Pressure Sensor - Remove and Install”for the correct procedure.



Part Description

Qty

A

-

Loctite 5940 Black RTV Silicone Sealant

1


92

UENR4511-01


NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that valve mechanism cover base and the cylinder cylinder head are clean and free from wear or damage.

Illustration 158

Illustration 159

g03783103

g03783099

Valve mechanism base tightening sequence


UENR4511-01


2. If 2. If necessary, install atmospheric pressure sensor (10) to valve mechanism cover base (5). Refer to Disassembly and Assembly, “Atmospheric Pressure Sensor - Remove and Install”for the correct procedure.

End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure.

3. Apply 3. Apply Tooling (A) to both sides of seal (6) (not shown). 4. Install 4. Install seal (5) (not shown) to the recess of valve mechanism base (5). Ensure that the seal is correctly installed to the recess of the valve mechanism cover. 5. Position 5. Position valve mechanism base(5) onto the cylinder head. Ensure that the harness assembly is not damaged as the valve mechanism cover base is installed. 6. Install 6. Install the springs, the washers, and bolts (4) to valve mechanism cover base (5). Hand tighten the bolts in a numerical sequence that is shown in Illustration 159 Illustration 159 . . 7. Tigh 7. Tighten ten bolts (4) to a torque torque of 28 N·m (248 lb in). Tighten the bolts in a numerical sequence that is shown in Illustration 159 Illustration 159 . . 8. Connect 8. Connect harness assembly (1) to all electronic unit injectors (2). 9. Install 9. Install new Allen head bolts (3) and a new bolt (4) to harness assembly (1).

i05986456

Rocker Arm and Shaft Remove Removal Procedure Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Place 1. Place identification marks on each of the rocker arms in order to identify the correct location for installation.

10. Tighte 10. Tighten n Allen head bolts (3) to a torque of 28 N·m (248 lb in). Tighten Tighten bolt (4) to a torque of 12 N·m (106 lb in). Note: Ensure Note: Ensure that the clips for the harness assembly are not strained as the Allen head bolts and the bolt are tightened. 11. Connect 11. Connect harness assembly (7) to connection (8) on valve mechanism cover base (5). 12. Connect 12. Connect harness assembly (9) to atmospheric pressure sensor (10).

Illustration 160

g03781764

2. Loosen 2. Loosen all nuts (4) on the rocker arm. Loosen Loosen all adjustment screws (2). Ensure that all adjusters are fully unscrewed.


94

UENR4511-01


3. Remove 3. Remove bolts (1) and rocker shaft assembly (6). Remove the rocker shaft assembly from the cylinder head. 4. Make 4. Make temporary marks on push rods (5). Remove the push rods from the engine. 5. Make 5. Make temporary marks on valve bridges (2). Remove the valve bridges from the valves. i05986454

Rocker Arm - Disassemble Disassembly Procedure Start By: a. Remove the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Place Note: Place an identification mark on each of the components of the rocker shaft for installation purposes.


UENR4511-01


Illustration 161

g03781883

5. If 5. If necessary, remove plugs (6) from rocker shaft (1). Personal injury can result from being struck by parts propelled by a released spring force.

i05986453

Make Make sure sure to wear wear all all nece necess ssar ary y prot protec ecti tive ve equipment.

Rocker Arm Rocker Arm - Assemble

Follow the recommended procedure and use all recommended tooling to release the spring force.

Assembly Procedure

1. Remove 1. Remove stand (10), inlet rocker arm (9), spring (8), and exhaust rocker arm (7) from rocker shaft (1). 2. If 2. If necessary, remove nut (1) from adjuster (3). Remove the adjuster from exhaust rocker arm (7). 3. If 3. If necessary, remove nut (2) from adjuster (4). Remove the adjuster adjuster from inlet rocker arm (9). 4. Repeat 4. Repeat Step 1 Step 1 through through Step 3 Step 3 in in order to remove the remaining components from the rocker shaft.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Lubricate 1. Lubricate all components of the rocker arm shaft with clean engine oil.


96

UENR4511-01


Illustration 162

g03781883

End By: Impr Improp oper er asse assemb mbly ly of part parts s that that are are spri spring ng loaded can cause bodily injury. To prevent possible injury, follow the established assem ssembl bly y proce rocedu dure re and and wear wear prot prote ectiv ctive e equipment. 2. If 2. If necessary, use a suitable tool to install plugs (6) to rocker shaft (1).

a. Install the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install” for the correct procedure. i05986455

Rocker Arm Rocker Arm and Shaft - Install Installation Procedure

3. If 3. If necessary, install adjuster (3) to exhaust rocker arm (7). Install nut (1) to the adjuster. 4. If 4. If necessary, install adjuster (4) to inlet rocker arm (9). Install nut (2) to the adjuster.


5. Install 5. Install exhaust rocker arm (7), spring (8), inlet rocker arm (9), and stand (10) to rocker rocker shaft (1).


6. Repeat 6. Repeat Step 1 Step 1 through through Step 5 Step 5 in in order to install the remaining components to the rocker shaft.


UENR4511-01


Illustration 163

g03781764

Illustration 164

g03781781

Rocker shaft bolts tightening sequence 1. Clean 1. Clean push rods (5). Inspect the push rods for wear and damage. Replace any push rods that are worn or damaged.

Note: Ensure Note: Ensure that the push rods are installed in the original location. Ensure that the ball end of each push rod is correctly seated in the valve lifters.

2. Lubricat 2. Lubricate e to both ends of push rods (5). Install the push rods into the engine with clean engine oil.


98

UENR4511-01


3. Clean 3. Clean valve bridges (2). Inspect the valve bridges for wear and damage. Replace any valve bridges that are worn or damaged. NOTICE Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine.

Start By: a. Remove the air cleaner and the bracket. Refer to Disassembly and Assembly, “Air Cleaner Remove and Install” for the correct procedure. b. Remove the fan drive. Refer to Disassembly and Assembly, “Fan Drive - Remove” for the correct procedure. c. Remove the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove” for the correct procedure.

4. Install 4. Install valve bridges (2) onto the valves. Note: Install Note: Install used valve bridges in the original location and in the original orientation. Ensure that the valve bridges are correctly seated on the valves. New valve bridges may be installed in either orientation. 5. Position 5. Position rocker shaft (4) on the cylinder head. Install bolts (1) hand tight. 6. Tighten 6. Tighten bolts (1) in the sequence shown. Tighten bolts (1) to a torque torque of 100 N·m N·m (74 lb ft). 7. Lubricate 7. Lubricate each of the bottom faces of the rocker arms with clean engine oil. 8. Position 8. Position rocker arm adjustment screws (3) into each push rods (5). Note: Ensure Note: Ensure that the adjusting are correctly seated in ends of the push rods. 9. Adjust 9. Adjust the valve lash of the rocker arms. Tighten nuts (4) to a torque of 30 N·m (266 lb in) after the engine valve lash has been adjusted. Refer to Testing and Adjusting, “Engine Valve Lash Inspect/Adjust” for the correct procedure. End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure. i05986349

d. Remove the valve mechanism cover base. Refer to Disassembly and Assembly, “Valve Mechanism Cover Base - Remove and Install” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perfor performan mance ce of inspec inspection tion,, maintemaintenance, nance, testin testing, g, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartme tment nt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regula regulation tions s and mandates.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn 1. Turn the fuel supply to the OFF position. 2. If 2. If necessary, remove the coolant out tube assembly for the thermostats housing and the radiator. Refer to the Original Equipment Manufacture (OEM) for the correct procedure. 3. If 3. If necessary, remove the tube assembly from the turbocharger out connection and the air to air charge cooler. Refer to the OEM for the correct procedure.

Cylinder Head Cylinder Head - Remove

4. If 4. If necessary, remove the tube assembly from the inlet manifold connection and the air to air charge cooler. Refer to the OEM for the correct procedure.

Removal Procedure

5. If 5. If necessary, remove the OEM exhaust tube assembly from the exhaust elbow. Refer to the OEM for the correct procedure.



T401089

Part Description Link Bracket

Qty

6. If 6. If necessary, remove the radiator support brackets. Refer to the OEM for the correct procedure.

2


UENR4511-01


7. Drain 7. Drain the coolant coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change” for the correct procedure.

Illustration 166

g03773233

17. Disconnect 17. Disconnect tube nut (16) and tube nut (23). Remove the hose assembly from the turbocharger (17) and the connection on the engine oil cooler. Illustration 165

g03773232

8. Remove 8. Remove bolt (1) and spacer (2) from the alternator adjusting link. 9. Remove 9. Remove bolts (9) and remove bracket (10). Support the bracket as the bolts are removed. 10. Disconnect 10. Disconnect hose assembly (11) from the connection on the cylinder head. 11. Disconnect 11. Disconnect the hose assembly from connection (15) on the cylinder head.

18. Remove 18. Remove O-ring seal (17) (not shown) and O-ring seal (25) (not shown). 19. Remove 19. Remove bolts (20) and bolts (21). Remove tube assemble (23). 20. Remove 20. Remove gasket (19) (not shown) and gasket (22) (not shown). 21. Loosen 21. Loosen hose clamp (26) for hose assembly (27). Ensure that the hose clamp is sufficiently loosened in order to allow the hose assembly assembly to be disconnected from the thermostat housing.

12. Disconnect 12. Disconnect harness assembly (3) from coolant temperature sensor (4) (not shown). 13. Disconnect 13. Disconnect harness assembly (5) from inlet manifold pressure sensor (6) (not shown). 14. Disconnect 14. Disconnect harness assembly (7) from inlet manifold temperature sensor (8) (not shown). 15. Disconnect 15. Disconnect harness assembly (12) from rail pressure sensor (13) (not shown). 16. Make 16. Make temporary marks for all cable strap (14) on the harness assemble for installation purposes. Cut the cable straps and position the harness assemble away from the cylinder head.


100

UENR4511-01


Illustration 167

g03773235

Illustration 168

g03773237

Sequence for tightening the bolts for the cylinder head


UENR4511-01


Illustration 169

g03773696

Sequence for tightening the bolts for the cylinder head 22. Gradually 22. Gradually loosen bolts (28) and bolts (29) in the reverse numerical sequence. Refer to the Illustration 168 Illustration 168 and and 169 169 . . 23. Remove 23. Remove bolts (28) and bolts (29) from the cylinder head (30).


102

UENR4511-01


28. Remove 28. Remove gasket (32) and O-ring seal (33). i05986340

Cylinder Head Cylinder Head - Install Installation Procedure Table 36 Required Tools Tools Tool ool A


B C

Illustration 170

g03773234

Part Description

Qty

Link Bracket

2

-

Guide Studs M16 x 2.00 by 200 mm

2

CV60889

Anti-Seize Compound

1

T401089


Illustration 171

g03773785

24. Attach 24. Attach Tooling (A) and a suitable lifting device onto cylinder head (30). The weight of the cylinder head is approximate approximately ly 181 kg (400 lb). 25. Use 25. Use the suitable lifting device to remove cylinder head (30) from cylinder block (35). 26. Place 26. Place cylinder head (30) on a suitable surface. Note: Use caution in order not to damage the tips of the injectors. 27. Note 27. Note the position of dowel (31) and dowel (34) in cylinder block (35).


UENR4511-01



g03773845

g03774253

1. Inspect 1. Inspect dowel (31) and dowel (34) for damage. If necessary, replace the dowels in the cylinder block. 2. Install 2. Install Tooling (B) to cylinder block (35). 3. Align 3. Align a new gasket (32) with dowel (31), dowel (34), and Tooling (B). 4. Install 4. Install the new O-ring seal (33) to the recess recess in cylinder block (35). Ensure that the O-ring is correctly seated into the recess. 5. Attach 5. Attach Tooling (A) and a suitable lifting device onto cylinder head (28). The weight of the cylinder head is approximately approximately 181 181 kg (400 lb). 6. Use 6. Use the suitable lifting device to lift cylinder head (30).

Illustration 173

g03773234

7. Use 7. Use Tooling (B) to align cylinder head (30) with cylinder block (35). Install the cylinder head to the cylinder block. Ensure block. Ensure that the hose assembly for the thermostat housing is correctly located onto the water pump connection. 8. Apply 8. Apply Tooling (C) to the threads of bolts (28) and bolts (29). 9. Install 9. Install bolts (28) and bolts (29) to cylinder head (30). 10. Remove 10. Remove Tooling (B) from the cylinder block (35). Install remaining bolts (28) to cylinder head (29).


104

UENR4511-01


Illustration 175

g03774253

Illustration 176

g03773237

Sequence for tightening the bolts for the cylinder head


UENR4511-01


Illustration 177

g03773696

Sequence for tightening the bolts for the cylinder head 11. Follow 11. Follow Step 11.a Step 11.a through through Step 11.g Step 11.g to to tighten bolts (28) according to the following procedure a.

Tighten Tighten bolts bolts (28) (28) in a numerical numerical sequence sequence that is shown in Illustration 176 Illustration 176 to to a torque of 130 N·m N·m (96 lb ft).

b.


c.

Place a mark on bolts bolts (28) (28) and and cylinder cylinder head (27). Turn the bolts through an additional 90 degrees in the numerical Sequence shown in Illustration 176 Illustration 176 . .

d.

Fully Fully loosen loosen bolts bolts (28). (28).

e.


f.

Tighten Tighten bolts bolts (28) in a numerical numerical sequence sequence that is shown in Illustration 176 Illustration 176 to to a torque of 130 N·m N·m (96 lb ft).

g.

Place a mark on bolt bolt (28) (28) and cylinder cylinder head head (30). Turn the bolts through an additional 90 degrees in the numerical Sequence shown in Illustration 176 Illustration 176 . .

12. Tighten 12. Tighten bolts (29) in a numerical sequence that is shown in Illustration 177 Illustration 177 to to a torque of 28 N·m (248 lb in).

Illustration 178

g03773233

13. Tighten 13. Tighten hose clamp (26) for hose assembly (27) to a torque torque of 7 N·m (62 lb in). in). 14. Position 14. Position a new gasket (19) (not shown) and a new gasket (22) (not shown) onto tube assemble (23). 15. Position 15. Position tube assembly (23) onto turbocharger (18) and the cylinder block. Install bolts (20) and bolts (21) hand tight. 16. Tighte 16. Tighten n bolts (20) and bolts (21) to a torque of 28 N·m (248 lb in).


106

UENR4511-01


17. Install 17. Install a new O-ring seal (17) (not shown) and a new O-ring seal (25) (not shown) to the connections on turbocharger (18) the engine oil cooler. Ensure that the O-ring seals are correctly installed into the connections. 18. Install 18. Install the hose assembly onto the turbocharger (17) and the connection on the engine oil cooler. Tighten Tighten tube nut (16) and tube nut (23) to a torque of 45 N·m (33 lb ft). Ensure Ensure that that the hose assembly is not strained or come into contact with other engine components

27. Connect 27. Connect harness assembly (12) to rail pressure sensor (13) (not shown). 28. Install 28. Install all new cable strap (14) onto the harness assemble. Ensure that the new cable straps are installed in the original position. Note: Ensure Note: Ensure that the cable straps meet Original Equipment Manufacture (OEM) specification. 29. If 29. If necessary, install the coolant out tube assembly for the thermostats housing and the radiator. Refer to the OEM for the correct procedure. 30. If 30. If necessary, install the tube assembly to the turbocharger out connection and the air to air charge cooler. Refer to the OEM for the correct procedure. 31. If 31. If necessary, install the tube assembly to the inlet manifold connection and the air to air charge cooler. Refer to the OEM for the correct procedure. 32. If 32. If necessary, install the OEM exhaust tube assembly to the exhaust elbow. Refer to the OEM for the correct procedure. 33. If 33. If necessary, install the radiator support brackets. Refer to the OEM for the correct procedure. 34. Fill 34. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change” and Operation and Maintenance Manual, “Capacities (Refill)”.

Illustration 179

g03773232

35. Turn 35. Turn the fuel supply to the ON position.

19. Position 19. Position bracket (10) onto cylinder head. Install bolts (9) hand tight. Support the bracket bracket as the bolts are installed . 20. Loosely 20. Loosely install install bolt (1) and spacer spacer (2) to the alternator adjusting link. 21. Tigh 21. Tighten ten bolts (9) (9) to a torque of 100 N·m (74 lb ft). 22. Connect 22. Connect hose assembly (11) to the connection on the cylinder head. Tighten the tube nut for the hose assembly assembly to a torque of 30 N·m (266 lb in). 23. Connect 23. Connect the hose assembly to connection (15) on the cylinder head. Tighten the tube nut for the hose assembly assembly to a torque of 30 N·m (266 lb in). 24. Connect 24. Connect harness assembly (3) to coolant temperature sensor (4) (not shown). 25. Connect 25. Connect harness assembly (5) to inlet manifold pressure sensor (6) (not shown). 26. Connect 26. Connect harness assembly (7) to inlet manifold temperature sensor (8) (not shown).


UENR4511-01


End By: a. Install the valve mechanism cover base. Refer to Disassembly and Assembly, “Valve Mechanism Cover Base - Remove and Install” for the correct procedure. b. Install the rocker arm and shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install” for the correct procedure. c. Install the fan drive. Refer to Disassembly and Assembly, “Fan Drive - Install” for the correct procedure. d. Install the air cleaner and the bracket. Refer to Disassembly and Assembly, “Air Cleaner Remove and Install” for the correct procedure. i05986452

Lifter Group - Remove and Install Illustration 180

g03778321

Typical example

Removal Procedure Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head Remove” for the correct procedure.

1. Use 1. Use a suitable tool to remove valve lifter (2) from the cylinder block. Note: Make Note: Make a temporary mark on each lifter in order to identify the lifter of installation purposes. 2. Remove 2. Remove guide spring (1) from valve lifter (2). 3. Repeat 3. Repeat Step 1 Step 1 through through Step 2 Step 2 for for the remaining lifters.

Personal injury can result from being struck by parts propelled by a released spring force.


Make Make sure sure to wear wear all all nece necess ssar ary y prot protec ecti tive ve equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.


Personal injury can result from being struck by parts propelled by a released spring force. Make Make sure sure to wear wear all all nece necess ssar ary y prot protec ecti tive ve equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components are clean and free from wear or damage. Replace any components that are worn or damaged.


108

UENR4511-01


Start By: a. Remove the rocker arm and the shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Remove” for the correct procedure. b. Remove the lifter from the cylinder block. Refer to Disassembly and Assembly, “Lifter GroupRemove and Install” for the correct procedure. c. Remove the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 181

g03778321

Typical example 2. Install 2. Install new guide spring (1) to valve lifter (2). 3. Lubricate 3. Lubricate the roller pin with clean engine oil prior to installation. Note: Ensure Note: Ensure that rollers are free to rotate. 4. Install 4. Install valve lifter (2) to the cylinder block. Ensure that used lifters are installed in the correct location. 5. Repeat 5. Repeat Step 2 Step 2 through through Step 4 Step 4 in in order to install the remaining lifters. End By: a. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install” for the correct procedure. i05986442

Camshaft - Remove Removal Procedure Table 37 Required Tools Tool ool A


CH11148

Part Description Engine Turning Tool

Qty 1


UENR4511-01


Illustration 183

g03750417

1. Use 1. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center. Refer to System Operation, Testing and Adjusting, “Finding Top Center Position for No.1 Piston” for the correct procedure. 2. Ensure 2. Ensure that the timing marks on camshaft gear (2) and idler gear (1) are aligned. 3. Remove 3. Remove bolts (3) from thrust plate (4). 4. Remove 4. Remove thrust plate (4) from camshaft (5). Illustration 182

g03750318

NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed. 5. Use 5. Use a suitable tool to remove camshaft (5) from the cylinder block. Ensure that camshaft bearings (6) are not damaged as the camshaft is removed.


110

UENR4511-01


6. If 6. If necessary, remove camshaft gear (2) from the camshaft. Refer to Disassembly and Assembly, “Camshaft “Camshaft Gear - Remove Remove and Install” Install” for the correct procedure. i05986441

Camshaft - Install Installation Procedure Table 38 Required Tools Tool ool A


CH11148 21825617

Part Description

Qty

Engine Turning Tool

1

Dial Gauge

1

Magnetic Base and Stand

1

B -

Illustration 184

g03750280

Illustration 185

g03750277


NOTICE


UENR4511-01


Do not damage the lobes or the bearings when the camshaft is removed or installed.

NOTICE When installing the camshaft, make sure the number one one cylin cylinde derr is at top top cent center er of the the comp compres ressi sion on stroke with the timing bolt installed in the flywheel. The camshaft camshaft timing timing is very very importa important. nt. The timing mark on the camshaft drive gear must line up with the timing mark on the idler gear. Refer to the Specifications Manual for more information. Note: During Note: During the installation of the camshaft, rotate the camshaft in both directions in order to prevent binding in the camshaft bearing bores. 1. If 1. If necessary, install camshaft gear (2) to the camshaft. Refer to Disassembly and Assembly, “Camshaft “Camshaft Gear - Remove Remove and Install” Install” for the correct procedure. 2. If 2. If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center. Refer to Testing and Adjusting, “Finding Top Center Position for No 1 Piston” for the correct procedure. 3. Lubricate 3. Lubricate camshaft (7) lobes and camshaft bearing journals wit h a clean lubricating engine oil. Apply clean lubricating engine oil onto camshaft bearings (6). 4. Carefully 4. Carefully install camshaft (7) to the cylinder block. Ensure that camshaft bearings (6) are not damaged as the camshaft is installed.

End By: a. Install the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install” for the correct procedure. b. Install the lifter to the cylinder cylinder block. Refer to Disassembly and Assembly, “Lifter GroupRemove and Install” for the correct procedure. c. Install the rocker arm and the shaft. Refer to Disassembly and Assembly, “Rocker Arm and Shaft - Install” for the correct procedure. d. Calibrate the speed/timing sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor - Calibrate” for the correct procedure. i05986445

Camshaft Gear - Remove and Install Removal Procedure Start By: a. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

5. Align 5. Align the timing marks on camshaft gear (2) and idler gear (1) are aligned. 6. Install 6. Install thrust plate (4) to camshaft (5). 7. Install 7. Install bolts (3) to thrust plate (4). Tighten Tighten the bolts to a torque of 28 28 N·m (248 lb in). in). 8. Use 8. Use Tooling (B) to check that the maximum permissible end play for a worn camshaft is 0.46 mm (0.018 inch). inch). The maximum permissibl permissible e end play for a new camshaft camshaft is 0.13 ± 0.08 mm (0.005 ± 0.003 inch).


112

UENR4511-01


1. Wrap 1. Wrap camshaft (2) with a protective covering, in order to prevent damage to the camshaft the lobes or the bearings surfaces. 2. Use 2. Use a suitable press to remove camshaft (2) from camshaft gear (1). 3. If 3. If necessary, remove key (3) from camshaft (2).



A

-

Part Description

Qty

Hot Plate

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the camshaft gear, the camshaft, and the key are clean and free from wear and damage.

Illustration 186

g03756138

Illustration 188

g03756238

2. If 2. If necessary, install key (3) to camshaft (2). Illustration 187

g03756140

NOTICE Do not allow the camshaft to fall to the floor when pressing it from the drive gear. Also make sure that the camshaft lobes do not catch on the press plates.

3. Position 3. Position camshaft (2) into the vertical position. Ensure that the camshaft is correctly supported. 4. Use 4. Use Tooling (A) to raise the temperature of the camshaft camshaft gear up to a temperature temperature of 177 °C (350 °F). Note: The temperature of the camshaft gear must not exceed 177 177 °C (350 °F) during installatio installation. n.


UENR4511-01


5. Align 5. Align key (3) with the keyway keyway (4) in camshaft gear (1). Install the camshaft gear onto the camshaft. Ensure that the camshaft gear is correctly seated onto the camshaft. End By: a. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Install” for the correct procedure. i05986489

Camshaft Bearings - Remove Illustration 189

Removal Procedure

g00633159

1. Use 1. Use Tooling (A) to remove the camshaft bearings from the cylinder block.



Part Description

Qty

T401074

Camshaft Bearing Tool Group

1

i05986491

Camshaft Bearings - Install

Start By: a. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove” for the correct procedure. b. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing- Remove and Install” for the correct procedure.



Part Description

Qty

T401074

Camshaft Bearing Tool Group

1

Note: Note Note: Note the oil hole orientation in each camshaft bearing prior to removal for assembly purposes.





NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids.

NOTICE Camshaft bearings must be installed into their correct posi positi tion on.. Fail Failur ure e to do so will will resu result lt in engi engine ne damage.

Dispos Dispose e of all fluids fluids accordi according ng to local local regula regulatio tions ns and mandates.


114

UENR4511-01


2. Use 2. Use Tooling (A) to install camshaft bearing (2), camshaft bearing (3), and camshaft bearing (4) that are behind the front camshaft bearing. Install the camshaft bearings to the correct depths. Refer to Illustration 190 Illustration 190 and and refer to Step 1 Step 1.. Orientate the camshaft bearings so that oil holes (5) in the camshaft bearings are located at the tops of the bores in the cylinder block and camshaft bearing joints (6) are positioned as shown in Illustration Ill ustration 191 . 191 .

Illustration 190

g03753876

Illustration 192

Illustration 191

g03753878

g03753896

3. Use 3. Use Tooling (A) to install front camshaft bearing (4). Carefully Carefully align oil hole (8) in the oil gallery gallery in the cylinder block. Orientate joint (7) as shown in Illustration 192 Illustration 192 . .

1. Refer 1. Refer to Illustration 190 Illustration 190 for for the locations locations of the camshaft bearings. (1) Installation Dimension (A) for camshaft bearing (1) . . . . . . . . . . . 816.5 ± 0.8 mm ((32.15 ± 0.03 inch)) (2) Installation Dimension (B) for camshaft bearing (2) . . . . . . . . . . . 536.5 ± 0.8 mm ((21.12 ± 0.03 inch)) (3) Installation Dimension (C) for camshaft bearing (3) . . . . . . . . . . . 294.5 ± 0.8 mm ((11.59 ± 0.03 inch)) (4) Installation Dimension (D) for camshaft bearing (4) . . . . . . . . . . 0.50 ± 0.25 mm ((0.020 ± 0.010 inch))


UENR4511-01


End By: a. Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install” for the correct procedure. b. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Install” for the correct procedure. i05986417

Engine Oil Pan - Remove and Install Removal Procedure

Hot Hot oil oil and and comp compon onen ents ts can can caus cause e pers person onal al injury. Do not not allo allow w hot hot oil or comp compon onen ents ts to conta contact ct skin.


Illustration 193

g03779396

1. Open 1. Open drain valve (4) and drain the engine oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Engine Oil Change” for the correct procedure. 2. Support 2. Support the assembly of engine oil pan (1). 3. Remove 3. Remove bolts (2) and remove assembly of engine oil pan (1). 4. Remove 4. Remove gasket (3).

Dispos Dispose e of all fluids fluids accord according ing to local local regula regulatio tions ns and mandates.


Illustration 194

g03779397

5. If 5. If necessary, follow Step 5.a Step 5.a through through Step 5.d Step 5.d in in order to disassemble the assembly of engine oil pan (1).


116

UENR4511-01


a.

Make temporary temporary marks marks on tube tube assembly assembly (6) for assembly purposes.

b.

Loosen Loosen nut nut (5) and remove remove tube assembl assembly y (6) from engine oil pan (1).

c.

Make temporary temporary marks marks on drain valve (4) for for assembly purposes. Loosen locking nut (8) and remove the drain valve from engine oil pan (1).

d.

Remove Remove O-ring O-ring seal seal (7) (not shown) shown) from drain drain valve (4)

Installation Procedure Table 42 Required Tools Tool ool


Part Description

Qty

A

-

Loctite 598 Black High Performance RTV Silicone Gasket Maker

-

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all components of the engine oil pan are free from wear or damage. If necessary, replace any component that is worn or damaged.

Illustration 195

g03779397

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.d Step 2.d in in order to assemble the assembly of engine oil pan (1). a.

Install a new O-ring seal (7) (not (not shown) shown) to drain valve (4). Install the drain valve to engine oil pan (1) and align with temporary marks.

b.

Tighten Tighten locking locking nut (8) (8) to a torque torque of 40 N·m N·m (30 lb ft). Use a suitable tool to hold the drain valve as the locking nut is tightened. Ensure that the drain valve is still aligned to the temporary marks.

c.

Install tube assembly assembly (6) (6) to engine engine oil pan pan (1). (1). Align tube assembly with temporary mar ks.

d.

Tight Tighten en nut nut (5) to to a torque torque of of 28 N·m N·m (248 lb in). Use a suitable suitable tool to hold the tube assembly as the nut is tightened. Ensure that the tube assembly is still aligned to the temporary marks.


UENR4511-01


Illustration 196

g03779396

Illustration 197

3. Clean 3. Clean the gasket surface of engine oil pan (1) and the cylinder block. Apply Tooling (A) to four areas on the sealing surface of the engine oil pan. The areas are Marked Location (Y).

g03779446

7. Tighten 7. Tighten the remaining bolts (2) starting in Position (Z) to a torque torque of 31 N·m (274 lb in) in a counterclockwise sequence.

4. Place 4. Place a new gasket (3) onto engine oil pan (1). 5. Install 5. Install assembly of engine oil pan (1). Install bolts (2) to the assembly assembly of engine oil pan hand tight. 6. Tighte 6. Tighten n four bolts (2) in Position Position (X) to a torque of 31 N·m (274 lb lb in).


118

UENR4511-01


8. Fill 8. Fill the engine with engine oil to the correct level level and if necessary, replace the engine oil filter. Refer to Operation and Maintenance Manual, “Engine Oil - Change” and Operation and Maintenance Manual, “Capacities (Refill)” for the correct procedure. i05986450

Cylinder Liner Cylinder Liner -- Remove Removal Procedure Table 43 Required Tools Tool ool A


GE50001

Part Description Cylinder Pack Puller

Qty 1

Start By:

Illustration 198

g03785157

Illustration 199

g03774280

a. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove” for the correct procedure. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspection tion,, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before opening opening any compartment compartment or disassemdisassembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regula regulatio tions ns and mandates.


1. Use 1. Use Tooling (A) to remove cylinder liners (1) from the cylinder block. 2. Remove 2. Remove O-ring seal (2) from cylinder liners (1).


UENR4511-01


3. If 3. If necessary, repeat Step 1 Step 1 through through Step 2 Step 2 in in order to remove the remaining cylinder lines. i05986449

Cylinder Liner Cylinder Liner -- Install Installation Procedure Table 44 Required Tools Tool ool B C


GE50000

-

Part Description

Qty

Cylinder Liner Installer

1

Delphi Lockheed Rubber Grease

1


Illustration 200

g03774280

Illustration 201

g03785150

Contaminants may cause rapid wear and shortened component life. 1. Check 1. Check the cylinder liner projection. Refer to Testing and Adjusting, “Cylinder Liner Projection - Inspect” for the correct procedure.

2. Apply 2. Apply Tooling (C) to O-ring seal (2). Install the Oring seal in the machined groove on cylinder liner (1). 3. Lubricate 3. Lubricate the lower portion of cylinder liner (1) with clean engine oil. Ensure that the corresponding crankshaft throw is at the bottom center. Use Tooling (B) to install cylinder liner (1). 4. If 4. If necessary, repeat Step 2 through 2 through Step 3 Step 3 in in order to install the remaining cylinder lines.


120

UENR4511-01


End By: a. Install the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install” for the correct procedure.

2. Remove 2. Remove bolt (1) and remove piston cooling jet (2) from the cylinder block.


Required Tools i05986308

Piston Cooling Jets - Remove and Install

Tool ool A


CH11148

Part art Desc Descri ript ptiion Engine Turning Tool

Qty 1


Removal Procedure


Table 45



CH11148

Part Desc Descri rip ptio tion Engine Turning Tool

Qty Qty 1

Start By: a. 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 203

g03781732

1. Use 1. Use Tooling (A) to rotate the crankshaft in order to gain access to piston cooling jet (2). Note: Engine Note: Engine damage may occur if the piston cooling jet is not install ed correctly. Install the piston cooling jet by hand. 2. Position 2. Position piston cooling jet (2) in the cylinder block. Ensure that the piston cooling jet is flush with the cylinder block. Install bolt (1). Tighten the bolt to a torque of of 28 N·m (248 lb in).

Illustration 202

g03781732

1. Use 1. Use Tooling (A) to rotate the crankshaft in order to gain access to piston cooling jet (2).


UENR4511-01


End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install” for the correct procedure. i05986482

Pistons and Connecting Rods - Remove Removal Procedure Table 47 Required Tools Tool ool A


CH11148


Qty 1

Start By:

Illustration 204

g03781739

Illustration 205

g03781740

a. Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head Remove” for the correct procedure. b. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove” for the correct procedure. c. Remove the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Use 1. Use Tooling (A) to turn the crankshaft until two of the connecting rod caps are at the bottom center. 2. Inspect 2. Inspect connecting rod (3) and connecting rod cap (1) for the correct identification mark. Connecting rod (3) and connecting rod cap (1) should have an etched number on the side that is toward the camshaft. The number should match the cylinder number. if necessary mark connecting rod (3) and connecting rod cap (1).


122

UENR4511-01


Note: This Note: This engine has fractured connecting rods. Fractured connecting rods must be handled with care. Use a soft faced hammer in order to tap the connecting rod cap, if necessary. 3. Loosen 3. Loosen connecting rod cap bolts (2). Remove connecting rod cap bolts (2). 4. Remove 4. Remove connecting rod cap (1) from connecting (3). 5. Remove 5. Remove the lower half of connecting rod bearing (5) from connecting rod cap (1). 6. Push 6. Push the piston and connecting rod assembly (3) away from the crankshaft. Remove the upper half of connecting rod bearing (4) from connecting rod (3). 7. Remove 7. Remove the piston and connecting rod assembly (3) from the cylinder liner. i05986434

Illustration 206

g03781749

Illustration 207

g03781750

Pistons and Connecting Rods - Disassemble Disassembly Procedure Table 48 Required Tools Part Description

Qty

Tool ool


A

-

Piston Ring Expander

1

B

-

Retaining Ring Pliers

1

Start By: a. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: This Note: This engine has fractured connecting rods. Fractured connecting rods must be handled with care. When possible, the connecting rod assembly should be kept bolted together in order to protect protect the fractured surface when the connecting rod is out of the engine. 1. Use 1. Use Tooling (B) in order to remove circlips (3) from piston skirt (2). 2. Remove 2. Remove piston pin (4) and separate piston skirt (2) and piston crown (6) from connecting rod (1). 3. Inspect 3. Inspect bearings (7) in the piston crown (6).


UENR4511-01


4. Use 4. Use Tooling (A) to remove piston rings (5).

Illustration 208

NOTICE Verify correct assembly of the pistons and the connecting rods. Ensure that the etched numbers on the rod and the rod cap are in the correct positions. The etch etched ed numb number er on the rod and and the the rod cap corr correespond to the cylinder in which it should be installed.

g03781751

NOTICE The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch. 5. Raise 5. Raise the temperature of connecting rod (1) along Length (X). The maximum distance of Length (X) is 83.0 mm (3.27 inch). inch). Length (X) should should raise the temperature from 175° to 260°C (347 to 500°F) in order to assemble bearing. 6. Remove 6. Remove old bearing (8) and install a new bearing (8) at the same time.

Illustration 209

g03781750

Illustration 210

g03781749

7. The 7. The bearing split line must be within 5 degrees of one of the locations that are indicated by the arrows. i05986433

Pistons and Connecting Rods - Assemble Assembly Procedure Table 49 Required Tools Part Description

Qty

Tool ool


A

-

Piston Ring Expander

1

B

-

Retaining Ring Pliers

1


Note: This Note: This engine has fractured connecting rods. Fractured connecting rods must be handled with care. Hold the connecting rod in a soft jawed vise. Then assemble the piston pin to the connecting rod, the piston skirt, and the piston crown.


124

UENR4511-01


1. Check 1. Check the clearance between the ends of piston rings (5). Refer to Specifications, “Piston and Rings” for the correct information. 2. Use 2. Use Tooling (A) to install the oil control piston ring. The ends of the spring should be rotated 180 degrees degrees from the ring end gap. 3. Use 3. Use Tooling (A) to install the intermediate piston ring with the side marked UP-2 toward the top of the piston. “

NOTICE The joint between the connecting rod and the connecting rod cap is produced by fracturing. The connecting rod assembly must be handled with care in order to avoid damage to the mating surfaces. The connec connectin ting g rod assembly assembly must must be replac replaced ed if any damage occurs to the mating surfaces. New connecting rod assemb assemblies lies come with the connec connecting ting rod caps bolted on the connecting rod.

”

4. Use 4. Use Tooling (A) to install the top piston ring with the side marked UP-1 toward the top of the piston.

Use only a soft jawed vise to hold the connecting rod assemb assembly ly when when removi removing ng the connec connectin ting g rod cap bolts. Use only a soft faced hammer to tap the connecting rod cap when separating the connecting rod cap from the connecting rod.

5. Inspect 5. Inspect bearings (7) in piston crown (6). The piston crown must be replaced if the piston crown is worn or damaged.

Failure to use a soft jawed vise and a soft faced hammer mer may may resu result lt in dama damage ge to the the conn connec ectin ting g rod rod assembly.

“

”

6. Position 6. Position piston skirt (2) and piston crown (6) on connecting rod (1). Apply clean engine oil to pin (4) and install pin (4). Use Tooling (B) to install circlips (3). Ensure that circlips (3) are correctly in the grooves of piston skirt (2).

1. Apply 1. Apply clean engine oil to the pistons, the piston rings, and the cylinder bore.

End By: a. Install the pistons and connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Install” for the correct procedure. i05986473

Pistons and Connecting Rods - Install Illustration 211

Typical Example


2. Place 2. Place Tooling (B) over both fractured ends of the connecting rod.

Table 50



-

B C

CH11148

T401075

Part art Descr escrip ipti tion on

g00828435

Qty

Engine Turning Tool

1

Plastic Cap

2

Piston Ring Compressor

1

3. Position 3. Position the piston rings rings so that the end gaps are located 120 degrees from each other. Use Tooling (C) to compress the piston rings.



UENR4511-01


9. Apply 9. Apply clean engine oil to the surface of the lower half of connecting rod bearing (5). Install connecting rod cap (1) on connecting rod (3). Ensure that the number on connecting rod cap (1) matches the number on connecting rod (3). Ensure that the numbers are on the same side. 10. Install 10. Install new connecting rod cap bolts (2). Tighten connecting connecting rod cap bolts (2) to a torque of 50 N·m (37 lb ft). 11. Place 11. Place an index mark on each connecting rod cap bolt. Tighten each connecting rod cap bolt (2) for an additional 90 ± 5 degrees. 12. Use 12. Use Tooling (A) ensure that the installed connecting rod assembly has tactile side play. Rotate the crankshaft in order to ensure that there is no binding. End By: Illustration 212

g03781740

4. Position 4. Position the crankshaft throw at the bottom center position, install the piston and connecting rod assembly (3) into the cylinder liner. Ensure that the correct piston and connecting rod are in the corresponding cylinder with the identification mark on the connecting connecting rod on the side that is toward the camshaft.

a. Install the piston cooling cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install” for the correct procedure. b. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install” for the correct procedure. c. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install” for the correct procedure.

Note: The Note: The forged part number on the connecting rod must be installed toward the flywheel end of the engine. 5. Line 5. Line up the piston and connecting rod assembly (3) with the crankshaft. Use a soft faced hammer and tap the piston and connecting rod assembly into the cylinder bore. 6. Before 6. Before connecting rod (3) comes in contact with the crankshaft, remove Tooling (B) and install the upper half of connecting rod bearing (4). Ensure that the bearing tab engages with the slot in connecting rod (3). 7. Apply 7. Apply clean engine oil to the surface of the upper half of connecting rod bearing (4). Use a soft faced hammer in order to tap the piston and connecting rod assembly further into the cylinder bore while you guide connecting rod (3) onto the crankshaft. 8. Place 8. Place the lower half of connecting rod bearing (5) in corresponding connecting rod cap (1). Ensure that the bearing tab engages with the groove groove in connecting rod cap (1).

i05986479

Connecting Rod Bearings Remove Removal Procedure Table 51 Required Tools Tools Tool ool A


CH11148


Qty 1

Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


126

UENR4511-01


Note: Do Note: Do not damage damage the fractured faces of the connecting rod. Place a suitable protective cap on the ends of the connecting rod in order to prevent damage to the fractured faces of the connecting rod. i05986241

Connecting Rod Bearings Install Installation Procedure Illustration 213

g01139029

Table 52 Required Tools Tools

1. Use 1. Use Tooling (A) to turn the crankshaft until the connecting rod bearing caps are accessible. 2. Check 2. Check connecting rod (3) and connecting rod caps (1) for identification and for the location. 3. Remove 3. Remove bolts (2). Remove connecting rod cap (1) from connecting connecting rod (3). Remove the lower half of connecting rod bearing (5) from connecting rod cap (1). Note: This Note: This engine has fractured connecting rods. Fractured connecting rods must be handled with care. Use a soft faced hammer in order to tap the connecting rod cap, if necessary. Note: Do Note: Do not place the fractured fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap. 4. Push 4. Push connecting rod (3) away from the crankshaft. Remove the upper half of connecting rod bearing (4) from connecting rod (3).

Tool ool


A B

CH11148 21825607

Part Description

Qty

Engine Turning Tool

1

Degree Wheel

1


NOTICE The joint between the connecting rod and the connecting rod cap is produced by fracturing. The connecting rod assembly must be handled with care in order to avoid damage to the mating surfaces. The connec connectin ting g rod assembly assembly must must be replac replaced ed if any damage occurs to the mating surfaces. New connecting rod assemb assemblies lies come with the connec connecting ting rod caps bolted on the connecting rod. Use only a soft faced hammer to tap the connecting rod cap when separating the connecting rod cap from the connecting rod. Fail Failure ure to use use a soft soft faced faced hamm hammer er may may resul resultt in damage to the fractured surfaces of the connecting rod assembly. assembly. 1. Use 1. Use Tooling (A) to turn the crankshaft until the connecting rod bearing cap is accessible.


UENR4511-01


9. Ensure 9. Ensure that the installed connecting rod assembly has tactile side play. Use Tooling (A) to rotate the crankshaft in order to ensure that the crankshaft turns freely. End By: a. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install” for the correct procedure. i05986487

Illustration 214

g01139029

Note: Install Note: Install the connecting rod bearings dry when clearance checks are performed. Apply clean engine oil to the connecting rod bearings for final assembly. 2. Remove 2. Remove the protective caps from the end of the connecting rod and install the upper half of connecting rod bearing (4). Ensure that the bearing tab engages with the slot in connecting rod (3). 3. Pull 3. Pull the piston and connecting rod assembly onto the crankshaft.

Crankshaft Main Bearings Remove (Crankshaft in Position) Removal Procedure Table 53 Required Tools Tools Tool ool A


27610319

Part Description Bearing Tool

Qty 1

Start By:

4. Install 4. Install the lower half of connecting rod bearing (5) into connecting rod cap (1). Ensure that the bearing tab engages with the slot in connecting rod cap (1).

a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove” for the correct procedure.

Note: Do Note: Do not place the fractured fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap.

NOTICE This procedure must only be used to remove and install the main bearing shells with the crankshaft in position sition.. Main bearing bearing shells shells remova removall proced procedure ure and the instal installati lation on proced procedure ure must must be comple completed ted for each pair of main bearing shells before the next pair of main bearing shells are removed.

Note: Ensure Note: Ensure that the number on the connecting rod cap matches the number on the connecting rod. Make sure that both of the numbers are located on the same side.


5. Install 5. Install connecting rod cap (1) and connecting rod cap bolts (2).


6. Check 6. Check the bearing clearance. Refer to Disassembly and Assembly, “Bearing Clearance Check” for the correct procedure. 7. Tighten 7. Tighten connecting rod cap bolts (2) to a torque of 50 N·m N·m (37 lb lb ft). 8. Turn 8. Turn the bolts for an additional 90 ± 5 degrees degrees in a clockwise direction. Use Tooling (B) to achieve the correct final torque.


128

UENR4511-01


NOTICE If the crankshaft is turned in the wrong direction, the tab of the crankshaft main bearing will be pushed between the crankshaft and the cylinder block. this can cause damage to either or both the crankshaft and the cylinder block. 3. Install 3. Install Tooling (A) in the crankshaft journal. 4. Turn 4. Turn the crankshaft in order to remove the upper half of the crankshaft main bearing. Note: The Note: The upper main bearing shell has a groove and two oil holes. 5. Remove 5. Remove thrust washers (3) from number 6 main bearing in the cylinder block. i05986480

Crankshaft Main Bearings Install (Crankshaft in Position)

Illustration 215

g03769476



Part art Desc escript riptiion

Qty Qty

27610319

Bearing Tool

1

21825617

Dial Indicator

1


1

B -

NOTICE This procedure must only be used to remove and install the main bearing shells with the crankshaft in position. sition. Main Main bearing bearing shells shells remova removall proced procedure ure and the instal installati lation on procedu procedure re must must be comple completed ted for each pair of main bearing shells before the next pair of main bearing shells are removed.

NOTICE Keep all parts clean from contaminants. Illustration 216

g03769536

1. Remove 1. Remove bolts (1) and crankshaft main bearing cap (2). 2. Remove 2. Remove the lower half of the crankshaft main bearing from crankshaft main bearing cap (2).

Contaminants may cause rapid wear and shortened component life. Note: Place Note: Place clean engine oil on the crankshaft main bearings prior to assembly. Ensure that the tabs on the back side of the crankshaft crankshaft main bearings fit in the grooves of the crankshaft main bearing caps and the cylinder block.

Note: The Note: The lower main bearing shell is a plain bearing that has no oil holes.


UENR4511-01


4. Place 4. Place crankshaft main bearing caps (2) in position on the cylinder block and Install bolts (1). Evenly tighten the bolts in order to pull the caps into position. Ensure that the caps are correctly seated. Note: Do Note: Do not tap the main bearing caps into position as the bearing shells may be dislodged.

Illustration 217

g03769476

1. Use 1. Use Tooling (A) and install the upper halves of the crankshaft main bearings in the cylinder block. Do not put oil on the back of the crankshaft main bearing. Note: The Note: The upper main bearing shell has a groove and two oil holes. 2. Install 2. Install the lower halves of the crankshaft main bearings in crankshaft main bearing caps (2). Do not put oil on the back of the crankshaft main bearing.

Illustration 218

g03769536

5. Install 5. Install thrust washers (3) to number 6 main bearing in the cylinder block. 6. Repeat 6. Repeat Step 1 Step 1 through through Step 4 Step 4 in in order to install the remaining main bearing shell, main bearing caps, and bolts.

Note: The Note: The lower main bearing shell is a plain bearing that has no oil holes. NOTICE Cranks Crankshaf haftt main main bearing bearing caps caps should should be install installed ed with the part number toward the front of the engine. Crankshaft main bearing caps are to be identified by stamped numbers 1 through 7 that are located on the bottom surface of the bearing cap. The thrust plate is used on the number 6 main bearing. 3. Lubricate 3. Lubricate threads of bolts (1) and the washer face with clean engine oil or Molylube.


130

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Illustration 220

g03769518

Typical example

Illustration 219

g03769517

7. Follow 7. Follow Step 7.a Step 7.a thought thought Step 7.c Step 7.c to to tighten the bolts (1) for the crankshaft main bearing cap. a. b.

c.

Tighten Tighten each bolt (2) (2) to a torque torque of of 95 N·m (70 lb ft). Place an index index mark mark on each each bolt bolt (2). Tighten Tighten each bolt for an additional 90 ± 5 degrees degrees (1/4 turn). Rotate the cranksh crankshaft aft in order to ensure ensure that there is no binding.

8. Check 8. Check the crankshaft end play. Push the crankshaft toward the front of the engine. Install Tooling (B) to the cylinder block and the rear face of the crankshaft. Push the crankshaft toward the rear of the engine. Use Tooling (B) to measure the crankshaft end play. The permissible crankshaft end play is 0.21 0.21 ± 0.60 mm (0.0083 (0.0083 ± 0.024 inch). End By: a. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install” for the correct procedure. i05986448

Crankshaft - Remove Removal Procedure Table 55 Required Tools Tools Tool ool A


T401076

Part Description Bracket As

Qty 2


UENR4511-01


Start By: a. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) Remove” for the correct procedure. b. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install” for the correct procedure. c. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove” for the correct procedure. d. Remove the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 221

g03758636

1. Check 1. Check the connecting rod and connecting rod cap (3) for identification marks and for the location. Remove bolts (1) from connecting rod cap (3). Remove the connecting rod cap and connecting rod bearing (5) (not shown). Position the connecting rod (7) (not shown) down the cylinder bore. Repeat Step 1 Step 1 for for the remaining connecting rod caps. Note: Ensure that the crankshaft bearing surfaces are not damaged as the remaining connecting rod caps are removed. 2. Check 2. Check the cylinder block and main bearing cap (4) for identification marks and for the location. Remove bolts (2) from main bearing bearing cap (4). Remove the main bearing cap and lower main bearing (6) (not shown). Repeat Step 1 Step 1 for for the remaining the main bearing caps. Note: The Note: The lower main bearing shell is a plain bearing that has no oil holes.


132

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7. If 7. If necessary, remove the crankshaft gear. Refer to Disassembly and Assembly, “Crankshaft Gear Remove and Install” for the correct procedure. i05986447

Crankshaft - Install Installation Procedure Table 56 Required Tools Tools Tool ool A


T401076 21825617

B -

Part Description

Qty

Bracket As

2

Dial Indicator

1


1


g03758637

3. Attach 3. Attach Tooling (A) and a suitable lifting device to crankshaft (7). The weight of the crankshaft is approximately approximately 79 79 kg (175 lb). 4. Remove 4. Remove crankshaft (8) from the cylinder block. 5. For 5. For number No. 7 main bearing, remove two thrust washers (9) from the cylinder block. 6. Remove 6. Remove upper main bearing shell (10) from the cylinder block. Note: The Note: The upper main bearing shell has a groove and two oil holes.

NOTICE Ensure that the crankshaft crankshaft main bearing tabs engage with the grooves in the block and the crankshaft crankshaft main bearing cap. 1. Clean 1. Clean the crankshaft and inspect the crankshaft for wear and damage. Refer to Specifications, “Crankshaft” for more information. If necessary, replace the crankshaft or recondition the crankshaft. 2. If 2. If necessary, install the crankshaft gear. Refer to Disassembly and Assembly, “Crankshaft Gear Remove and Install” for the correct procedure. 3. Ensure 3. Ensure that parent bores for bearing shells in the cylinder block are clean. Ensure that the threads for the main bearing bolts in the cylinder cylinder block are clean and free from damage. 4. Clean 4. Clean the main bearing shells. Inspect the main bearing shells and the thrust washers for wear and damage. If necessary, replace the main bearing shells. Note: If Note: If the main bearing shells are replaced, check whether oversize main bearing shells were previously installed.


UENR4511-01


Illustration 223

g03758637

Illustration 224

g03758636

5. Install 5. Install upper main bearing shell (9) into the cylinder block. Ensure that the locating tabs for the upper rear main bearing shells are seated in the slots in the cylinder block.

10. Install 10. Install main bearing shells (6) into main bearing caps (4). Ensure that the locating locating tabs for the lower main bearing shells are correctly seated into the slots in the bearing caps.

Note: The Note: The upper main bearing shell has a groove and two oil holes.

Note: The Note: The lower main bearing shells are plain bearings that do not have oil holes.

6. Lubricate 6. Lubricate upper main bearing shells (9) with clean engine oil.

11. Lubricate 11. Lubricate main bearing shells (6) and lubricate the journals of the crankshaft with clean engine oil. Install main bearing cap (4) to the cylinder block.

7. Attach 7. Attach Tooling (A) and a suitable lifting device to crankshaft (7). The weight of the crankshaft is approximately approximately 79 79 kg (175 lb). 8. Use 8. Use the suitable lifting device to install crankshaft (7) to the cylinder block. Ensure block. Ensure that the crankshaft bearing surfaces are not damaged as the crankshaft is installed. 9. Apply 9. Apply clean engine oil to thrust washers (8). Install the thrust washers to number No. 7 main bearing.

Note: Ensure Note: Ensure the correct location and orientation of the main bearing caps. The locating tabs for the upper and the lower main bearing shells should be on the same side of the engine. 12. Lubricate 12. Lubricate the threads of bolts (2) with clean engine oil. Lubricate the underside of the heads of bolts (2) with clean engine oil. 13. Install 13. Install bolts (2) to main bearing cap (4). Evenly tighten tighten the bolts in order to pull the caps into position. Ensure that the caps are correctly seated. Repeat Step 10 Step 10 through through Step 13 Step 13 to to install remaining main bearing shells, main bearing cap, and bolts. Note: Do Note: Do not tap the main bearing caps into position position as the bearing shells may be dislodged.


134

UENR4511-01


14. Lubricate 14. Lubricate the connecting rod bearings with clean engine oil. Ensure that the connecting rod bearings are correctly locating tabs connecting rod (7) (not shown) and the connecting rod cap(3). 15. Position 15. Position connecting rod (7) (not shown) onto crankshaft. 16. Lubricate 16. Lubricate connecting rod bearing (5) (not shown) with clean engine oil. Install connecting rod cap (3) to connecting rod (7) (not shown). Ensure that the identification marks are correctly positioned. 17. Install 17. Install bolts (1) to connecting rod cap (3) and evenly tighten tighten the bolts in order to pull the connecting rod cap into position. Repeat Step 14 through Step 17 Step 17 to to install remaining connecting rod bearing, connecting rod cap, and bolts. 18. Rotate 18. Rotate the crankshaft in order to ensure that there is no binding.


UENR4511-01


Illustration 225

g03765878

Illustration 226

g03761077

Tightening sequence for the main bearing cap bolts 19. Follow 19. Follow Step 19.a Step 19.a thought thought Step 19.c Step 19.c to to tighten the bolts (2) for the crankshaft main bearing caps. a.

Tighten Tighten each each bolt bolt (2) (2) to a torque of 95 N·m (70 lb ft) in the numerical sequence sequence that is shown in Illustration 226 Illustration 226 . .

b.

Place an an index index mark on each each bolt bolt (2). Tighten Tighten each bolt for an additional 90 ± 5 degrees degrees (1/4 turn) in the numerical sequence that is shown in Illustration 226 Illustration 226 . .


136

UENR4511-01


c.

Rotate the cranksh crankshaft aft in order to ensure ensure that that there is no binding.

Illustration 228

g03767476

Typical example

Illustration 227

g03761076

21. Check 21. Check the crankshaft end play. Push the crankshaft toward the front of the engine. Install Tooling (B) to the cylinder block and the rear face of the crankshaft. Push the crankshaft toward the rear of the engine. Use Tooling (B) to measure the crankshaft end play. The permissible crankshaft end play is 0.21 ± 0.60 0.60 mm (0.0083 (0.0083 ± 0.024 inch).

20. Follow 20. Follow Step through Step to tighten bolts (1) for the connecting rod caps. a.

Tighten Tighten each each bolt bolt (1) (1) to a torque of 50 N·m (36.87800 lb ft).

b.

Place an index index mark mark on on each each bolt. bolt. Tighten Tighten each bolt for an additional 90 ± 5 degrees degrees (1/4 turn).

c.

Ensure that the installe installed d connec connecting ting rod assembly has tactile side play. Rotate the crankshaft crankshaft in order to ensure ensure that there is no binding.


UENR4511-01


End By:

Start By:

a. Install the piston cooling jets. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove” for the correct procedure.

a. Remove the crankshaft. Refer to Disassembly and Assembly, “Crankshaft - Remove” for the correct procedure.

b. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install” for the correct procedure. c. Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install” for the correct procedure. d. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Install” for the correct procedure. i06031074

Crankshaft Gear - Remove and Install Removal Procedure Table 57

Illustration 229

g03781900


Part art Num Number ber

Part Description

Qty

1. Make 1. Make temporary marks on crankshaft gear (2) for installation purposes.

-

Bearing Puller

1

-

Screw

1

2. Use 2. Use Tooling (A) in order to remove crankshaft gear (2) from crankshaft (1).

-

Crossblock

1

3. If 3. If necessary, remove key (3) from crankshaft (1).

-

Puller Leg

2


A

Table 58 Required Tools Tools Tool ool


B

-

Part Description Hot Plate

Qty 1

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


138

UENR4511-01


End By: a. Install the crankshaft. Refer to Disassembly and Assembly, “Crankshaft - Remove” for the correct procedure. i05980323

Bearing Clearance - Check Measurement Procedure Table 59 Required Tools Tools Tool

Illustration 230

g03781900

2. If 2. If necessary, install a new key (3) to crankshaft (1).

Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin. Note: The Note: The crankshaft crankshaft gear may be a sliding fit on the crankshaft or an interference fit on the crankshaft. 3. Use 3. Use Tooling (B) to heat crankshaft gear (2) to 150° ± 50°C 50°C (302° ± 90°F). 90°F). 4. Align 4. Align the keyway on crankshaft gear (2) with key (3) in the crankshaft. Install crankshaft gear (2) to crankshaft (1). Ensure that the crankshaft gear is correctly orientated.


Part Description

Qty

-

Plastigauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch)

1

-

Plastigauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch)

1

-

Plastigauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)

1

-

Plastigauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)

1

A

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Perkins 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 Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft crankshaft journals journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).


UENR4511-01


NOTICE Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces. The technician must use Tooling (A) correctly. The following points must be remembered: • Ensure that the the backs backs of the bearings bearings and and the bores are clean and dry. • Ensure that the the bearing bearing locking locking tabs tabs are properly properly seated in the tab grooves. • The cranksh crankshaft aft must must be free free of oil oil at the contact contact points of Tooling (A). 1. Put 1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap. Note: Do Note: Do not allow Tooling (A) to extend over the edge of the bearing. 2. Use 2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact impact wrench. Be careful not to dislodge the bearing when the cap is installed. Note: Do Note: Do not turn the crankshaft when Tooling (A) is installed. 3. Carefully 3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 231 Illustration 231 . .

Illustration 231

Note: When 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. i06546597

Refrigerant Compressor Remove and Install Removal Procedure Note: Cleanliness Note: Cleanliness is an important factor. Cleaning of the exterior of the component before the disassembly procedure procedure is carried out will help to prevent prevent dirt from entering the internal mechanism. NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.

g01152855

Typical Example 4. Remove 4. Remove all of Tooling (A) before you install the bearing cap.


140

UENR4511-01


Pers Person onal al injur injury y can can resu result lt from from cont contac actt with with refrigerant. Cont Contac actt with with refr refrig iger eran antt can can caus cause e fros frostt bite. bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slow Slowly ly loose loosen n the the fittin fitting. g. If the the syste system m is still still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use Use a cert certifi ified ed reco recove very ry and and recy recycl clin ing g cart cart to properly remove the refrigerant from the air conditioning system. Note: Put Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. Plugging all lines helps to prevent fluid loss and helps to keep contaminants from entering the system.

Illustration 232

g06018824

Typical example of a refrigerant compressor (ports may vary) 2. Disconnect 2. Disconnect the hose assemblies from port (1) and port (2). Refer to the Original Equipment Manufacture (OEM) for the correct procedure. Note: Cap Note: Cap the hose assemblies with new caps. Plugs the ports in the refrigerant compressor with new plugs. 3. Disconnect 3. Disconnect harness assembly (3) from refrigerant compressor (4).

1. Turn 1. Turn the battery disconnect switch to the OFF position.


UENR4511-01


Illustration 233

g06018465

4. Remove 4. Remove the alternator belt. Refer to Disassembly and Assembly, “Alternator Belts - Remove and Install” for the correct procedure. 5. Remove 5. Remove bolts (6) and bolts (7) from refrigerant compressor (4). Note: Support Note: Support the weight of the refrigerant compressor on removal of the bolts.

Illustration 234

g06018830

7. If 7. If necessary, follow Step 7.a Step 7.a through through Step 7.b Step 7.b to to remove bracket (5) for the refrigerant compressor from the cylinder block. a.

Remove bolts (8) from bracket bracket (5). (5).

b.

Remove bracket bracket (5) from the the water water pump.


6. Remove 6. Remove refrigerant compressor (4) from bracket (5).

Illustration 235

g06018830

1. If 1. If necessary, follow Step 1.a Step 1.a through through Step 1.c Step 1.c to to install bracket (5) for the refrigerant compressor to the cylinder block.


142

UENR4511-01


a.

Ensure that bracket bracket (5) is clean and free free from from wear and damage. If necessary, replace the bracket.

b.

Position Position bracket bracket (5) onto onto the the water water pump. Install bolts (8) and hand tighten the bolts.

c.

Tighten Tighten bolts bolts (8) (8) to a torque torque of of 55 N·m (41 lb ft).

Illustration 237

g06018824

Typical example of a refrigerant compressor (ports may vary) 6. Connect 6. Connect harness assembly (3) to refrigerant compressor (4).

Illustration 236

g06018465

2. Position 2. Position refrigerant compressor (4) onto bracket (5). Note: Support Note: Support the weight of the refrigerant compressor. 3. Install 3. Install bolts (6) and bolts (7) to refrigerant refrigerant compressor (4). 4. Tighte 4. Tighten n bolts (6) and bolts (7) to a torque of 28 N·m N·m (21 lb lb ft). 5. Install 5. Install the alternator belt. Refer to Disassembly and Assembly, “Alternator Belts - Remove and Install” for the correct procedure.

7. Remove 7. Remove the caps from hose assemblies and remove the plugs from the ports of the refrigerant compressor. Connect the hose assemblies to port (1) and port (2) . Refer to the OEM for the correct procedure. 8. Turn 8. Turn the battery disconnect switch to the ON position. i05986439

Atmospheric Pressure Sensor - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


UENR4511-01


Illustration 238

g03750177

1. Cut 1. Cut cable strap (3) from harness assembly (1). 2. Disconnect 2. Disconnect harness assembly (1) from atmospheric pressure sensor (2). 3. Remove 3. Remove atmospheric pressure sensor (2). 4. Remove 4. Remove O-ring seal (4) (not shown) from atmospheric pressure sensor (2).

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

Illustration 239

g03750177

1. Install 1. Install a new O-ring seal (4) (not shown) shown) onto atmospheric pressure sensor (2). 2. Install 2. Install atmospheric pressure sensor (2). Tighten the atmospheric pressure sensor to a torque of 10 N·m (89 lb lb in). 3. Connect 3. Connect harness assembly (1) to atmospheric pressure sensor (2). 4. Install 4. Install a new cable strap (3) to harness assembly (1). Note: Ensure Note: Ensure that the cable strap meets Original Equipment Manufacture (OEM) specifications. i05986323

Coolant Temperature Sensor Sensor Remove and Install Removal Procedure NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.


144

UENR4511-01


1. Drain 1. Drain the coolant into a suitable container for storage or for disposal. Drain the coolant to a level that is below the coolant temperature sensor. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change” for the correct procedure.


Illustration 241

g03758478

1. Install 1. Install a new O-ring seal (3) (not shown) to coolant temperature sensor (1). Illustration 240

g03758478

2. Disconnect 2. Disconnect harness assembly (2) from coolant temperature sensor (1). 3. Remove 3. Remove coolant temperature sensor (1) from the cylinder head. 4. Remove 4. Remove O-ring seal (3) (not shown) from Remove coolant temperature sensor (1) from the cylinder head.

2. Install 2. Install coolant temperature sensor (1) to the cylinder head. Tighten the coolant temperature sensor sensor to a torque of 20 N·m N·m (177 lb in). 3. Connect 3. Connect harness assembly (2) to coolant temperature sensor (1). 4. Fill 4. Fill the cooling system. Refer to Operation and Maintenance Manual, “Cooling System Coolant (ELC) - Change” for the correct procedure. i05986418

Engine Oil Pressure Sensor Sensor Remove and Install Removal Procedure NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.


UENR4511-01



Illustration 243

g03779490

1. Install 1. Install a new O-ring seal (1) (not shown) shown) onto the adapter.

Illustration 242

g03779490

1. Disconnect 1. Disconnect harness assembly (3) from engine oil pressure sensor (2).

2. Install 2. Install engine oil pressure sensor (2). Tighten the engine oil pressure pressure sensor to a torque of 10 N·m (89 lb in). 3. Connect 3. Connect harness assembly (1) to engine oil pressure sensor (2).

2. Remove 2. Remove engine oil pressure sensor (2).

i05986440

3. Remove 3. Remove O-ring seal (1) (not shown) from the adapter.

Fuel Pressure Sensor Sensor -


Remove and Install


Removal Procedure NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.



146

UENR4511-01


Illustration 244

g03777571

Illustration 245

g03777571

Typical example

Typical example

1. Slide 1. Slide the locking tab into the unlocked position. Disconnect harness assembly (1) from fuel pressure sensor (2).

1. Install 1. Install a new O-ring seal (3) on fuel pressure sensor (2).

2. Remove 2. Remove fuel pressure sensor (2) from fuel filter base (4). 3. Remove 3. Remove O-ring seal (3) from fuel pressure sensor (2).


2. Install 2. Install fuel pressure sensor (2) to fuel filter base (4). Tighten the fuel pressure sensor to a torque of 10 N·m (89 lb lb in). 3. Connect 3. Connect harness assembly (1) to fuel pressure sensor (2). Slide the locking tab into the locked position. i06543397

Fuel Pressure Sensor Sensor Remove and Install (Option 2) Removal Procedure NOTICE Care Care must must be taken to ensure ensure that fluids are concontained tained during during perform performanc ance e of inspec inspectio tion, n, mainte mainte-nance, nance, testing testing,, adjust adjusting ing and repair repair of the produc product. t. Be prepared to collect the fluid with suitable containers before before openin opening g any compar compartmen tmentt or disass disassemembling any component containing fluids. Dispos Dispose e of all fluids fluids accord according ing to local local regulati regulations ons and mandates.


UENR4511-01



Illustration 247

g06016208

Typical example 1. Install 1. Install a new O-ring seal (4) (not shown) shown) on elbow connection (5). Illustration 246

g06016208

Typical example 1. Cut 1. Cut cable strap (2). 2. Slide 2. Slide the locking tab into the unlocked position. Disconnect harness assembly (1) from fuel pressure sensor (3). 3. Remove 3. Remove fuel pressure sensor (3) from elbow connection (5).

2. Install 2. Install fuel pressure sensor (3) to elbow connection (5). Tighten the fuel pressure sensor to a torque of 10 N·m (89 lb lb in). 3. Connect 3. Connect harness assembly (1) to fuel pressure sensor (3). Slide the locking tab into the locked position. 4. Secure 4. Secure harness assembly (1) with a new cable strap (2). i05986297

4. Remove 4. Remove O-ring seal (4) (not shown) from elbow connection (5).

Fuel Temperature Sensor Sensor -


Remove and Install




148

UENR4511-01



Illustration 249

g03777560

Typical example 1. Install 1. Install a new O-ring seal (4) to fuel temperature temperature sensor (2). Illustration 248

g03777560

Typical example 1. Disconnect 1. Disconnect harness assembly (1) from fuel temperature sensor (2). 2. Use 2. Use a deep socket socket in order to remove fuel temperature sensor (2) from fuel filter base (3).

2. Install 2. Install fuel temperature sensor (2) to the fuel filter base (3). Use a deep socket socket to tighten the fuel temperature temperature sensor to a torque of 20 N·m (15 lb ft). 3. Connect 3. Connect harness assembly (1) to fuel temperature sensor (2). i06031075

3. Remove 3. Remove O-ring seal (4) from fuel temperature sensor (2).

Injection Actuation Pressure


Sensor Sensor - Remove and Install




UENR4511-01


4. If 4. If necessary, follow Step 2.a Step 2.a through through Step 2.c Step 2.c in in order to remove elbow connection (4).


a.

Make temporary temporary marks marks on elbow elbow connection connection (4).

b.

Loosen Loosen locking locking nut (5) and and remove remove elbow connection (4) from the cylinder head.

c.


Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that all the components are free from wear or damage. Replace any component that is worn or damaged.

Illustration 250

g03781887

Illustration 251

g03781888

1. Disconnect 1. Disconnect harness assembly (1) from injection actuation pressure sensor (2). 2. Use 2. Use a suitable tool to remove injection actuation pressure sensor (2) from elbow connection (4). 3. Remove 3. Remove O-ring seal (1) (not shown).


150

UENR4511-01


3. Install 3. Install a new O-ring seal (1) (not shown) shown) to injection actuation pressure sensor (2). 4. Use 4. Use a suitable tool to install injection actuation pressure sensor (2) to elbow connection (4). Tighten the injection actuation pressure sensor to a torque of 20 20 N·m (177 lb in). in). 5. Connect 5. Connect harness assembly (1) to injection actuation pressure sensor (2). i06544818

Speed/Timing Sensor Remove and Install Removal Procedure Start By: Illustration 252

g03781888

a. If necessary, remove the air compressor. Refer to Disassembly and Assembly, Air Compressor - Remove and Install for the correct procedure.

Removal Procedure

Illustration 253

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2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.c Step 2.c in in order to install elbow connection (4). a.

Install Install a new new O-ring O-ring seal seal (6) (6) (not shown) shown) to elbow connection (4).

b.

Install Install elbow elbow connectio connection n (4) to the cylinder cylinder head and align with temporary marks.

c.

Tighten Tighten locking locking nut (5) (5) to a torque of 30 N·m (266 lb in). Ensure that the elbow connection remains align after the locking nut is tightened.

Illustration 254

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Typical example


UENR4511-01


1. Disconnect 1. Disconnect harness assemblies (2) from speed/ timing sensors (1). 2. Remove 2. Remove bolt (5), washer (4), and bracket (3).

1. Apply 1. Apply Tooling (A) to new O-ring seals (6) prior to installation. Install new O-ring seals (6) to speed/ timing sensors (1).

Note: Make Note: Make a note of the orientation of the bracket.

2. Install 2. Install speed/timing sensors (1) to the front housing.

3. Carefully 3. Carefully remove speed/timing sensors (1) from the front housing.

3. Install 3. Install bolt (5) to washer(4). Position bracket (3) to the front housing. Install bolt (5) to bracket bracket (3).

4. Remove 4. Remove the O-ring seals (6) from speed/timing sensors (1).

4. Tigh 4. Tighten ten bolt (5) to a torque of 28 N·m (248 lb in).


5. Connect 5. Connect harness assemblies (2) onto speed/timing sensors (1).

Table 60

End By: Required Tools

Tool ool


A

-

Part Description Loctite 575

Qty 1

a. If necessary, install the air compressor. Refer to Disassembly and Assembly, Air Compressor - Remove and Install for the correct procedure. i05986307


Inlet Manifold Temperature


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

Illustration 255

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Typical example


152

UENR4511-01


Illustration 256

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Illustration 257

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1. Disconnect 1. Disconnect harness assembly (2) from inlet manifold temperature sensor (1).

1. Install 1. Install a new O-ring seal (3) to inlet manifold temperature sensor (1).

2. Use 2. Use a deep socket to remove inlet manifold temperature sensor (1).

2. Use 2. Use a deep socket to install inlet manifold temperature sensor (1). Tighten the inlet manifold temperature temperature sensor to a torque of 20 N·m (15 lb ft).

3. Remove 3. Remove O-ring seal (3) from inlet manifold temperature sensor (1).


3. Connect 3. Connect harness assembly (2) to inlet manifold temperature sensor (1).


i05986301

Inlet Manifold Pressure Sensor - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.


UENR4511-01



Illustration 258

Illustration 259

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Illustration 260

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Illustration 261

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g03781629

1. Cut 1. Cut cable strap (2) from harness assembly (1). 2. Disconnect 2. Disconnect harness assembly (1) from inlet manifold pressure sensor (3). 3. Use 3. Use a suitable suitable tool to remove inlet manifold manifold pressure sensor (3) from adapter (5) in the cylinder head. 4. Remove 4. Remove O-ring seal (4) (not shown) from adapter (5). 5. If 5. If necessary, remove adapter (5) from the cylinder head. Remove O-ring seal (6) (not shown).

1. If 1. If necessary, install a new O-ring seal (6) (not shown) shown) to adapter adapter (5). Install Install the adapter adapter to the cylinder head. Tighten the adapter to a torque of 40 N·m N·m (30 lb lb ft). 2. Install 2. Install a new O-ring seal to adapter adapter (5).


154

UENR4511-01


3. Use 3. Use a suitable tool to install inlet manifold pressure sensor sensor (1) to adapter (5) in the cylinder head. Tighten the inlet manifold pressure sensor to a torque of of 10 N·m (89 lb in). in). 4. Connect 4. Connect harness assembly (1) to inlet manifold pressure pressure sensor (1). Install a cable strap (2) to the harness assembly. assembly. Note: Ensure Note: Ensure that the cable strap meets Original Equipment Manufacture (OEM) specifications. i05986200

V-Belts - Remove and Install (Charging Alternator Drive Belts) Removal Procedure 1. If 1. If necessary, remove the engine fan guards. Refer to the Original Equipment Manufacture (OEM) for the correct procedure. Note: Mark Note: Mark the direction of rotation of the belt if the belt is to be reused. reused.

Illustration 263

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Typical example 2. Loosen 2. Loosen bolt (1) and bolt (2). Loosen nut (3). 3. Loosen 3. Loosen bolt (4). Loosen nut (5) and nut (6). 4. Remove 4. Remove alternator belts (7).

Installation Procedure 1. Ensure 1. Ensure that the pulleys are clean. Ensure that the pulleys pulleys are free from dirt and build up from the old belts.

Illustration 262

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Typical example

Illustration 264

g03778317

Typical example


UENR4511-01


9. If 9. If necessary, install the engine fan guards. Refer to the OEM for the correct procedure. i05986217

V-Belts - Remove and Install (Water Pump Drive Belt) Removal Procedure Start By: a. Remove the V-Belts for the charging alternator. Refer to Disassembly and Assembly, “V-Belts Remove and Install (Charging Alternator Drive Belts)” for the correct procedure.

Illustration 265

g03778318

Typical example

1. If 1. If necessary, remove the engine fan guards. Refer to the Original Equipment Manufacture (OEM) for the correct procedure. 2. Mark 2. Mark the direction of rotation of the belt if the belt is to be reused. reused.

2. Position 2. Position alternator belts (7). Used belts should be installed in the original direction of rotation. 3. Adjust 3. Adjust nut (5) and nut (6) in order to increase increase or decrease the tension of belts (7). Refer to Operation and Maintenance Manual, “Belts Inspect/Adjust/Replace” for the correct tension. 4. With 4. With the correct applied tension on belts (7), tighten nut (5) and nut (6) securely. 5. Tigh 5. Tighten ten bolt (1) to a torque of 89 N·m (65 lb ft). 6. Tigh 6. Tighten ten bolt (2) to a torque of 89 N·m (65 lb ft). 7. Tighte 7. Tighten n the bolt and nut (3) to a torque of 89 N·m (65 lb ft). 8. Tigh 8. Tighten ten bolt (4) to a torque of 100 100 N·m (73 lb ft).

Illustration 266

g03777627

Typical example 3. Loosen 3. Loosen bolt (2) and bolt (4). 4. If 4. If necessary, install a 1/2" square drive tool into Hole (X) in plate (3) in order to adjust pulley assembly assembly (1). From the front of the engine, turn the tool in a clockwise direction. 5. Remove 5. Remove belt (5).


156

UENR4511-01


6. Release 6. Release the pressure on the 1/2" square drive tool and remove the 1/2" square drive tool from Hole (X).

7. If 7. If the engine has guards, install the guards. Refer to the OEM for the correct procedure. procedure. i06544870


Alternator Belt Alternator Belt - Remove and Install Removal Procedure 1. If 1. If the engine has guards, remove the guards. Refer to the Original Equipment Manufacture (OEM) for the correct procedure. Note: Mark Note: Mark the direction of rotation of the alternator belt if the belt will be reused.

Illustration 267

g03777627

Typical example 1. Ensure 1. Ensure that the pulleys are clean. Ensure that the pulleys pulleys are free from dirt and build up from the old belt. 2. Install 2. Install a 1/2" square drive tool into Hole (X) in plate (3). 3. Position 3. Position belt (5). Ensure that the belt is centered on all pulleys. A used belt should be installed in the original direction of rotation. Note: The Note: The ribs on the belt must be located into the grooves of all pulleys.

Typical example

4. From 4. From the front of the engine, turn the 1/2" square drive tool in a clockwise direction direction in order to adjust pulley assembly (1).

2. Install 2. Install a 1/2" square drive tool into Hole (X) in tensioner tensioner (2). From the front of the engine, turn the tool in a clockwise direction.

5. Release 5. Release the pressure on the 1/2" square drive tool until the belt is tensioned. Remove the 1/2" square drive tool from Hole (X).

3. Remove 3. Remove alternator belt (1).

6. With 6. With the correct tension on the belt, tighten bolt (2) and bolt (4). Tighten bolts to a torque of 28 N·m (248 lb in).

Illustration 268

g06016831

4. Release 4. Release the pressure on the 1/2" square drive tool and remove the 1/2" square drive tool from Hole (X).


UENR4511-01



6. If 6. If the engine has guards, install the guards. Refer to the OEM for the correct procedure. procedure. i06547498

Idler Pulley - Remove and Install (Grooved Idler Pulley) Removal Procedure Start By: a. Remove the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt Remove and Install”. NOTICE Keep all parts clean from contaminants. Illustration 269

g06016831


Typical example 1. Ensure 1. Ensure that the belt tensioner, pulleys, and all guide rollers are clean. Ensure that the pulleys and guide rollers are free from dirt and build up from the old belt. 2. Ensure 2. Ensure that all components of the belt tensioner, pulleys, and guide rollers are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. Refer to Disassembly and Assembly, “Belt Tensioner - Remove and Install” for the correct procedure. Refer to Disassembly and Assembly, “Idler Pulley (Grooved Idler Pulley) - Remove and Install” for the correct procedure. 3. Install 3. Install a 1/2" square drive tool into Hole (X) in tensioner tensioner (2). From the front of the engine, turn the tool in a clockwise direction. 4. Position 4. Position alternator belt (1). Ensure that the alternator belt is centered on all pulleys. A used alternator belt should be installed in the original direction of rotation. Note: The Note: The ribs on the alternator alternator belt must be located located into the grooves of all pulleys.

Illustration 270

g06019350

1. Make 1. Make a temporary mark on idler pulley (2) to identify the correct orientation and the position. 2. Loosen 2. Loosen bolt (1) and remove idler pulley (2).

5. Release 5. Release the pressure on the 1/2" square drive tool until the alternator belt is tensioned. Remove the 1/2" square drive tool from Hole (X).


158

UENR4511-01



2. Remove 2. 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. 1. Ensure 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.

Illustration 272

g06019025

3. Make 3. Make a temporary mark on belt tensioner (3) to identify the correct orientation and the position. 4. Loosen 4. Loosen bolt (2) sufficiently to remove belt tensioner (3) from mounting bracket (1). 5. Remove 5. Remove belt tensioner (3) from mounting bracket (1). Illustration 271

g06019350

2. Position 2. Position idler pulley (2) onto bracket (3). Tighten bolt (1) hand tight. 3. Tigh 3. Tighten ten bolt (3) to a torque of 55 N·m (41 lb ft). End By:

Installation Procedure 1. Ensure 1. Ensure that all components of the belt tensioner are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

a. Install the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”. i06547445

Belt Tensioner - Remove and Install Removal Procedure 1. If 1. If the engine has guards, remove the guards. Refer to the Original Equipment Manufacture (OEM) for the correct procedure.


UENR4511-01


Illustration 273

g06019025

Illustration 274

g03780756

Illustration 275

g03780757

2. Position 2. Position belt tensioner (3) on mounting bracket (1). Tighten bolt (2) finger tight. 3. Tigh 3. Tighten ten bolt (2) to a torque of 55 N·m (41 lb ft). 4. Install 4. Install the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install.” for the correct procedure. 5. If 5. If the engine has guards, install the guards. Refer to the OEM for the correct procedure. procedure. i05986264

Fan - Remove and Install Removal Procedure 1. If 1. If necessary, remove the engine fan guards. Refer to the Original Equipment Manufacture (OEM) for the correct procedure.

2. Remove 2. Remove bolts (2) from fan assembly (1). Support the fan assembly as the bolts are removed. Note: Ensure Note: Ensure that the radiator is protected during removal of the fan assembly. 3. Remove 3. Remove fan assembly (1). Note orientation of the fan assembly for installation purposes. 4. If 4. If necessary, follow Step 4.a Step 4.a through through Step 4.e Step 4.e in in order to remove adapter (4). a.

Remove V-belts V-belts belts (7). Refer to Disassembly and Assembly, “V-Belts -


160

UENR4511-01


Remove and Install (Charging Alternator Drive Belts)” for the correct procedure. b.

Remove Remove bolts bolts (3) (3) from from adapter adapter (4). Support Support the fan adapter as the bolts are removed.

c.

Remove Remove fan adapter adapter (4) (4) from pulley (6).

d.

If necessa necessary ry,, remove remove pulley pulley (6) from from the fan drive assembly. assembly.

e.

Remove Remove O-ring O-ring seal (5) (not shown). shown).

f.

Install V-belts V-belts belts belts (7). (7). Refer Refer to Disassembly Disassembly and Assembly, “V-Belts - Remove and Install (Charging Alternator Drive Belts)” for the correct procedure

Installation Procedure 1. Ensure 1. Ensure that all the components components are free wear or damage. If necessary replace any component that is worn or damaged.

Illustration 277

g03780756

3. Install 3. Install fan assembly (1). Ensure that the fan assembly is orientated. 4. Install 4. Install bolts (2) to fan assembly (2). Support the fan assembly as the bolts are installed. Note: Ensure Note: Ensure that the radiator is protected during installation of the fan assembly. 5. Tig 5. Tighten hten bolts (2) (2) to a torque of 55 N·m (41 lb ft).

Illustration 276

g03780757

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.f Step 2.f in in order to install adapter (4). a.

If necessary necessary,, install install pulley pulley (6) to the fan drive drive assembly. Ensure that the bolt holes are aligned.

b.

Install Install a new O-ring seal (5) (not (not shown). shown).

c.

Install Install fan adapter adapter (4) onto pulley (5) and and align align the bolt holes.

d.

Install Install bolts bolts (3) to adapter adapter (4). Support Support the fan fan adapter as the bolts are installed.

e.

Tighten Tighten bolts bolts (3) (3) to a torque torque of 47 N·m N·m (416 lb in).

6. If 6. If necessary, install the engine fan guards. Refer to the OEM for the correct procedure. i05986429

Fan Drive - Remove Removal Procedure 1. Remove 1. Remove the fan. Refer to Disassembly and Assembly, Assembly, “Fan - Remove and Install” for the correct procedure.


UENR4511-01


b.

Remove bolt (6) and and spacer spacer (5) from from the the alternator adjusting bracket.

c.

Remove bolts (4) from from bracket bracket (3). Support Support the bracket as the bolts are removed.

d.

Remove bracket bracket (3) from the the cylinder cylinder head. i05986426

Fan Drive - Disassemble Disassembly Procedure Table 61 Required Tools Tools Tool ool A Illustration 278


27610275


Qty 1

g03780784

2. Make 2. Make temporary marks on fan drive (2) and bracket (3) for installation purposes. 3. Remove 3. Remove bolts (1) from fan drive (2). Support the fan drive as the bolts are removed.

Start By: a. Remove the fan drive. Refer to Disassembly and Assembly, “Fan Drive - Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants.

4. Remove 4. Remove fan drive (2) from bracket (3).


Illustration 279

g03780787

5. If 5. If necessary, follow Step 5.a Step 5.a through through Step 5.d Step 5.d in in order to remove bracket (3). a.

If necessa necessary ry,, remove remove the the Original Original Equipme Equipment nt Manufacture (OEM) radiator support brackets. Refer to the OEM for the correct procedure.


162

UENR4511-01


Illustration 280

g03780800

1. Place 1. Place the fan drive assembly in a suitable support. 2. Remove 2. Remove bolt (13) and washer (14).


3. Remove 3. Remove plate (12) and bearing (11). 4. Remove 4. Remove hub assembly (9) and pulley (3). 5. Remove 5. Remove spacer (5) from hub assembly (9) 6. Use 6. Use a suitable suitable tool to remove remove seal (4) from hub assembly (9). Remove bearing (6) and spacer (8). 7. Position 7. Position hub assembly (9) on a suitable press. Use Tooling (A) and the press to remove bearing cup (7) and bearing cup (10) from the hub assembly (9). 8. If 8. If necessary, remove spring pin (2) from shaft (1). i05986425

Fan Drive - Assemble Assembly Procedure Table 62 Required Tools Tool ool A B


27610275 -

Part Description

Qty

Driver Gp

1

Bearing Lubricant

1


UENR4511-01


Illustration 281

g03780800

1. If 1. If necessary, install spring pin (2) to shaft (1). 2. Position 2. Position hub assembly (9) on a suitable press. Use Tooling (A) and the press to install bearing cup (7) and bearing cup (10) to hub assembly(9). Ensure that the bearing cups are correctly seated into the hub assembly. assembly. 3. Apply 3. Apply Tooling (B) to bearing (6). Install the bearing into hub assembly(9). 4. Use 4. Use a suitable suitable tool to install install seal (4) to hub assembly (9). Ensure that the seal is correctly installed. Install spacer (8) to seal (4). 5. Apply 5. Apply Tooling (B) to shaft (1). 6. Position 6. Position pulley (3) onto hub assembly (9). Ensure that the pulley is correctly orientated on the hub assembly. 7. Install 7. Install pulley (3) and hub assembly (9) onto shaft (1). Install shaft (1). 8. Install 8. Install plate (12) to shaft (1). Ensure that the hole in plate is correctly located into the spring pin. 9. Install 9. Install washer (14) and bolt (13). Tighten the bolt to a torque of 100 N·m (74 lb ft). Ensure that that the hub assembly (9) rotate freely and with no binding.


164

UENR4511-01


End By: a. Install the fan drive. Refer to Disassembly and Assembly, “Fan Drive - Install” for the correct procedure. i05986427

Fan Drive - Install Installation Procedure

Illustration 283

g03780784

2. Position 2. Position fan drive (2) onto bracket (3) and align with temporary marks. 3. Install 3. Install bolts (1) to fan drive (2). Support the fan drive as the bolts are removed. 4. Tigh 4. Tighten ten bolts (1) to a torque torque of 100 N·m (74 lb ft). 5. Install 5. Install the fan. Refer to Disassembly and Assembly, Assembly, “Fan - Remove and Install” for the correct procedure. Illustration 282

i05986352

g03780787

1. If 1. If necessary, follow Step 1.a Step 1.a through through Step 1.e Step 1.e in in order to install bracket (3). a.

Position Position bracket bracket (3) onto onto the cylinder cylinder head. head.

b.

Install Install bolts bolts (4) to bracket bracket (3). Support Support the bracket as the bolts are install.

c.

Tighten Tighten bolts bolts (4) (4) to a torque torque of 55 N·m N·m (41 lb ft).

d.

Install Install bolt (6) and and spacer spacer (5) (5) to the the alternato alternator r adjusting bracket.

e.

If necessa necessary ry,, install install the the Original Original Equipme Equipment nt Manufacture (OEM) radiator support brackets. Refer to the OEM for the correct procedure.

Electronic Control Module Remove and Install Removal Procedure 1. If 1. If a replacement Electronic Control Module (ECM) is to be installed, the replacement replacement ECM must be programmed with the correct information. Refer to Troubleshooting Guide, “ECM - Replace” for the correct procedure. 2. Turn 2. Turn the battery disconnect switch to the OFF position.


UENR4511-01


Illustration 284

g03776658

3. Cut 3. Cut cable strap (1), cable strap (3), cable strap (5), and cable strap (7). 4. Loosen 4. Loosen Allen head screw (9) until harness assembly (4) can be disconnected from the ECM (11). 5. Position 5. Position harness assemblies (4) away from ECM (11). 6. Loosen 6. Loosen Allen head screw (10) until Original Equipment Manufacture (OEM) harness assembly (6) can be disconnected from the ECM (11). 7. Position 7. Position OEM harness assembly (4) away from ECM (11).

Illustration 285

g03776676

10. If 10. If necessary, follow Step 2.c Step 2.c through through Step 10.c Step 10.c in in order to disassemble ECM (11). a.

Remove spacers spacers (17) (17) and isolator isolator mounts mounts (18) (18) from ECM (11).

b.

Remove bolt (14) (not shown) shown) and and bracket bracket (13).

c.

Remove bolt (16) and bracket bracket (16). (16).

Installation Procedure 1. Ensure 1. Ensure that all components for the ECM are free from wear or damage. Replace any component that is worn or damaged.

8. Remove 8. Remove bolts (12) and the washers from ECM (11) ensure that ground strap (2) is not damaged as the bolts are removed. Remove brackets (8). Support the ECM as the bolts are removed. removed. 9. Remove 9. Remove ECM (11) from the cylinder block.


166

UENR4511-01


Illustration 286

g03776676

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.d Step 2.d in in order to assemble ECM (11).

Illustration 287

g03776658

a.

Install Install isolator isolator mounts mounts (18) (18) to ECM ECM (11). (11). Install Install spacers (17) to the isolator mounts.

3. Position 3. Position electronic control module (4) onto the cylinder block. Install the washers and bolts (12) and brackets (8) to ECM (11). Support the ECM as the bolts are installed. Ensure that the brackets are installed into the correct positions.

b.

Position Position bracket bracket (13) onto onto ECM ECM (11). (11). Install Install bolt (14) (not shown) hand tight. Ensure that the bracket is correctly orientated.

4. Tig 4. Tighten hten bolts (12) (12) to a torque of 28 N·m (248 lb in) . Ensure that ground strap (2) is not damaged damaged as the bolts are tightened.

c.

Position Position bracket bracket (15) onto onto ECM ECM (11). (11). Install Install bolt (16) (not shown) hand tight. Ensure that the bracket is correctly orientated.

5. Position 5. Position harness assemblies (4) onto ECM (11).

Tighten Tighten bolt bolt (16) and bolt bolt (14) (not shown) shown) to a torque of 6.5 N·m (57 lb in). in).

Note: Care Note: Care must be taken in order to avoid damage to the connector pins during installation of the harness assembly. assembly.

d.

6. Tighten 6. Tighten Allen head screw (9) until harness assembly (4) is connected onto ECM (11).

7. Position 7. Position OEM harness assembly (4) onto ECM (11). 8. Tighten 8. Tighten Allen head screw (10) until harness assembly (6) is connected onto ECM (11). Note: Care Note: Care must be taken in order to avoid damage to the connector pins during installation of the harness assembly. assembly. 9. Tighten 9. Tighten Allen head bolt (9) and Allen head screw (10) to a torque torque of 6 N·m (53 lb in). 10. Install 10. Install new cable strap (1), cable strap (3), cable strap (5), and cable strap (7) to the harness harness assemblies. 11. Turn 11. Turn the battery disconnect switch to the ON position.


UENR4511-01


12. If 12. If new ECM has been installed, programmed the new ECM configuration data. Refer to Troubleshooting Guide, “ECM - Replace” for the correct procedure. i05986315

Alternator Alternator - Remove and Install Removal Procedure Start By: a. Remove the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace” for the correct procedure.

Personal injury can result from failure to disconnect the battery. Firs First, t, disc discon onne nect ct the nega negativ tive e batte battery ry cable cable.. Then, disconnect the positive battery cable. A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn 1. Turn the battery disconnect switch to the OFF position.

Illustration 288

g03749697

2. Remove 2. Remove the guard from the radiator in order to gain access to alternator (3). Refer to the Original Equipment Manufacture (OEM) for the correct procedure. 3. Place 3. Place identification marks on all of the harness assemblies. Disconnect the harness assemblies from alternator (3). 4. Remove 4. Remove bolt (1) and spacer (2) from the alternator belt adjuster. 5. Remove 5. Remove the nut and bolt (5) and bolt (7). Support the alternator alternator (3) as the nut and bolt and the bolt are removed. 6. Remove 6. Remove alternator (3) from bracket (6). 7. If 7. If necessary, remove pulley (4) from alternator (3).


168

UENR4511-01


Illustration 289

g03749720

8. If 8. If necessary, follow Step 2.c Step 2.c through through Step 8.c Step 8.c to to remove bracket (6). a.

Remove Remove the spacer spacer and and bolts bolts (9) (9) and and the the spacer and bolt (10) from bracket (6).

b.

Remove Remove bracket bracket (6) from from the water pump.

c.

If necessary necessary,, remove remove ring dowels (8) from the water pump.

Illustration 290

g03749720

2. If 2. If necessary, follow Step 2.a Step 2.a through through Step 2.d Step 2.d to to install bracket (5). a.

If necessary necessary,, install install ring dowels (7) from the water pump. Ensure that the ring dowels are correctly seated into the water pump.

b.

Install bracket bracket (5) from the water pump. Ensure that the bracket is correctly seated onto ring dowels (7).


c.


Install the spacer spacer and and bolts (8) and the spacer spacer and bolt (9) to bracket bracket (5).

d.

Tighten Tighten bolts bolts (8) (8) and bolt (9) to a torque torque of 55 N·m (41 lb lb ft).

Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the alternator and the bracket are free from wear or damage. Replace any component that is worn or damaged.


UENR4511-01


10. Turn 10. Turn the battery disconnect switch to the ON position. i06547272

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

Illustration 291

g03749697

3. If 3. If necessary, install pulley (4) on alternator (3). Install the nut and tighten the nut to a torque of 127 N·m N·m (94 lb lb ft). 4. Position 4. Position alternator (3) onto bracket (6). 5. Install 5. Install the nut and bolt (5) and bolt (7). Support the alternator alternator (3) as the nut and bolt and the bolt are installed. 6. Install 6. Install bolt (1) and spacer (2) to the alternator alternator belt adjuster. 7. Connect 7. Connect the harness assemblies from alternator (3). Tighten Tighten the nut to a torque of 4 N·m (35 lb in).

Personal injury can result from failure to disconnect the battery. Firs First, t, disc discon onne nect ct the the nega negativ tive e batte battery ry cabl cable. e. Then, disconnect the positive battery cable. A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn 1. Turn the battery disconnect switch to the OFF position.

Tighten Tighten the nut to a torque of 18 N·m (159 lb in). 8. Install 8. Install the belt. Refer to Operation and Maintenance Manual, “Belts - Inspect/Replace” for the correct procedure. 9. Tighte 9. Tighten n the nut and bolt (5), bolt (7), and bolt (1) to a torque of 55 N·m (41 lb ft). ft).


170

UENR4511-01


6. Remove 6. Remove alternator (4) from the alternator brackets. 7. If 7. If necessary, remove pulley (8) from alternator (4).

Illustration 292

g06018866

2. Remove 2. Remove the guard from the radiator to gain access to alternator (4). Refer to the Original Equipment Manufacture (OEM) for the correct procedure. 3. Place 3. Place identification marks on all the harness assemblies. Disconnect the harness assemblies from alternator (4). 4. Remove 4. Remove bolts (1), washers washers (2), and nuts (3) from the alternator bracket.

Illustration 294

g06018886

8. Follow 8. Follow Step 9 Step 9 through through Step 12 Step 12 to to remove bracket (9) and bracket (14). 9. Remove 9. Remove bolts (10) and washers (11) from bracket (9). 10. Remove 10. Remove bracket (9). 11. Remove 11. Remove bolts (12) and washers (13) from bracket (14). 12. Remove 12. Remove bracket (14).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure 1. Ensure that the alternator and the brackets are free from wear or damage. Replace any component that is worn or damaged.

Illustration 293

g06018875

5. Remove 5. Remove nut (7), washers (6) and bolt (5). Support the alternator alternator (4) as the nut and bolt and the bolt are removed.


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Illustration 295

g06018886

Illustration 296

g06018875

Illustration 297

g06018866

2. Position 2. Position bracket (14). Install washers (13) and bolts (12) finger tight. 3. Position 3. Position bracket (9). Install washers (11) and bolts (10) finger tight.

4. If 4. If necessary, install pulley (8) on alternator (4). Install the nut and tighten the nut to a torque of 127 N·m N·m (94 lb ft). 5. Position 5. Position alternator (4) onto bracket (14). 6. Install 6. Install bolt (7), washers washers (6), and nut (5). Support Support the alternator alternator (3) as the nut and bolt and the bolt are installed. 7. Install 7. Install bolts (1), washers (2) and nuts (3) to bracket (9). 8. Connect 8. Connect the harness assemblies to alternator (4).


172

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Tighten Tighten bolts (10) and bolts (12) to a torque of 55 N·m N·m (41 lb lb ft). Tighten Tighten nut (5) and nuts (3) to a torque of 105 N·m (77 lb ft). 9. Install 9. Install the belt. Refer to Disassembly and Assembly, Assembly, “Alternator “ Alternator Belt - Remove and Install” for the correct procedure. 10. Turn 10. Turn the battery disconnect switch to the ON position. i05986351

Electric Starting Motor Remove and Install Removal Procedure Table 63

Illustration 298

g03774291

Illustration 299

g03774290



A

-

Part Description Lifting Sling

Qty 2

Personal injury can result from failure to disconnect the battery. Firs First, t, disc discon onne nect ct the nega negativ tive e batte battery ry cable cable.. Then, disconnect the positive battery cable. A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire. 1. Turn 1. Turn the battery disconnect switch to the OFF position.

2. Place 2. Place identification marks on all harness assembly that is connected to electric starting motor (4) and the solenoid 3. Disconnect 3. Disconnect harness assembly (1). 4. Remove 4. Remove nut (2) and remove the earth strap. 5. Remove 5. Remove nut (3) and remove the cables. 6. Attach 6. Attach Tooling (A) and a suitable lifting device to electric starting motor (4). The weight of electric starting starting motor (1) is approximately approximately 44 kg (97 lb). 7. Remove 7. Remove bolts (5) from electric starting starting motor (4).


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8. Use 8. Use the suitable lifting device to remove electric starting motor (1). 9. Remove 9. Remove O-ring seal (6) (not shown). 10. Remove 10. Remove Tooling (A) and the suitable lifting device from electric starting motor (4).

Installation Procedure 1. Ensure 1. Ensure that all components for the electric starting motor are free from wear or damage. damage. Replace any component that is worn or damaged.

Illustration 300

g03774291

Illustration 301

g03774290

2. Attach 2. Attach Tooling (A) and a suitable lifting device to electric starting motor (4). The weight of electric starting starting motor (1) is approximately approximately 44 kg (97 lb). 3. Install 3. Install a new O-ring seal (6) (not shown) shown) onto electric starting motor (4). Ensure that the O-ring seal is correctly installed onto the electric starting motor. 4. Use 4. Use the suitable lifting device to install electric starting motor (1). 5. Install 5. Install bolts (5) to electric starting motor (4) hand tight.


174

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6. Remove 6. Remove Tooling (A) and the suitable lifting device from electric starting motor (4). 7. Tigh 7. Tighten ten bolts (5) to a torque torque of 215 N·m (159 lb ft). 8. Connect 8. Connect harness assembly (1). 9. Install 9. Install the earth strap onto electric starting motor (4) and install nut (2). Tighten the nut to a torque of 25 N·m (221 lb in). Ensure Ensure that the earth strap strap is not strained as the nut is tightened. 10. Install 10. Install the cables onto electric starting motor (4) and install nut (3). Tighten Tighten the nut to a torque of 25 N·m (221 lb in). Ensure Ensure that the cables cables are not strained as the nut is tightened.

Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnect nected ed unde underr pres pressu sure re it can can caus cause e pers person onal al injury. 1. Remove 1. Remove the air pressure from the air tank and drain the coolant from the cooling system. Refer to Operation and Maintenance Manual for the correct procedure.

11. Turn 11. Turn the battery disconnect switch to the ON position. i06544850

Air Compressor Air Compressor -- Remove and Install Removal Procedure

Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnecte nected d unde underr pres pressu sure re it can can caus cause e pers person onal al injury.



Illustration 302

g01028440

2. Disconnect 2. Disconnect hose assembly (1) and hose assembly (3) from the air compressor. 3. Disconnect 3. Disconnect hose assembly (2) and hose assembly (4) from the air compressor. 4. Attach 4. Attach a suitable suitable lifting device to the air compressor. The weight of the air compressor is approximatel approximately y 23 kg (51 lb). 5. Remove 5. Remove the mounting bracket for the air compressor by using the following procedure:

Dispos Dispose e of all fluids fluids accord according ing to local local regula regulatio tions ns and mandates. Note: Put Note: Put identification marks on all hoses, on all hose assemblies and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies helps to prevent fluid loss and also helps to keep contaminants from entering the system.


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A

-

Part Description Loctite 242

Qty 1


Illustration 303

g01028442

a.

Remove Remove bolts bolts (5) (5) that that fasten fasten the mountin mounting g bracket to the air compressor.

b.

Remove Remove bolts bolts (6) (6) that that fasten fasten the mountin mounting g bracket to the cylinder block. Remove the mounting bracket for the air compressor.

Illustration 305

g01028444

1. Install 1. Install a suitable lifting device to the air compressor. The weight of the air compressor is approximatel approximately y 23 kg (51 lb). 2. Inspect 2. Inspect the condition of the integral seal. Replace the integral seal, if necessary. Install the integral seal between air compressor (8) and the timing gear housing. 3. Position 3. Position air compressor (8) in the front housing. Ensure that the drive gear engages correctly with the gear in the front housing. Illustration 304

g01028444

6. Remove 6. Remove bolts (7), air compressor (8), and the integral seal from the timing gear housing.

4. Apply 4. Apply Tooling (A) to the threads of bolts (7). Install bolts (7). Tighten Tighten bolts (7) to a torque of 100 ± 20 N·m N·m (75 ± 15 lb lb ft). 5. Install 5. Install the mounting bracket for the air compressor by using the following procedure:


176

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Illustration 306

g01028442 Illustration 307

a.

Position Position the bracket bracket for the air air compress compressor or and install bolts (5) and bolts (6) finger tight.

NOTICE A loose compressor bracket can lead to a broken front cover and can damage the front gear train of the engine. b.

Tighten Tighten bolts bolts (5) (5) to a torque torque of of 60 ± 12 N·m (44 ± 9 lb ft). Tighten bolts (6) to a torque of 60 ± 12 N·m (44 ± 9 lb ft). Remove Remove the suitable lifting device and Tooling (A).

g01028440

6. Connect 6. Connect hose assembly (4) to the air compressor. Connect the clip that holds hose assembly (4) to the air compressor, if necessary. Tighten the bolt that holds the clip for the oil hose assembly assembly to a torque of 28 28 ± 7 N·m (21 ± 5 lb ft). 7. Connect 7. Connect hose assembly (1) and hose assembly (3) to the air compressor. 8. Connect 8. Connect hose assembly (2) to the air compressor. 9. Fill 9. Fill the cooling system with coolant to the correct level. Refer to the Operation and Maintenance Manual for the correct filling procedure.


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177 Index Section

Index A Air Cleaner - Remove and Install ...... ... ...... ...... ...... ...... ...... ...... ..... ..27 27 Installation Procedure ......................................28 ......................................28 Remova Removall Proced Procedure ure ......................................... .........................................27 27 Air Compressor - Remove and Install ...... ... ...... ...... ...... ...... ... 174 Installation Procedure ....................................175 ....................................175 Remova Removall Proced Procedure ure ....................................... .......................................174 174 Alternator - Remove and Install . ...... ... ...... ...... ...... ...... ...... ...... .....167 Installation Procedure ....................................168 ....................................168 Remova Removall Proced Procedure ure ....................................... .......................................167 167 Alternator - Remove and Install (High Mounted Alternator). ...... ... ...... ...... ...... ...... ... ...... ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...169 169 Installation Procedure ....................................170 ....................................170 Remova Removall Proced Procedure ure ....................................... .......................................169 169 Alternator Belt - Remove and Install ...... ... ...... ...... ...... ...... ..... ..156 156 Installation Procedure ....................................157 ....................................157 Remova Removall Proced Procedure ure ....................................... .......................................156 156 Atmospheric Pressure Sensor - Remove and Instal Installl ............................................................. .............................................................142 142 Installation Procedure ....................................143 ....................................143 Remova Removall Proced Procedure ure ....................................... .......................................142 142

Installation Procedure ....................................137 ....................................137 Remova Removall Proced Procedure ure ....................................... .......................................137 137 Crankshaft Main Bearings - Install (Crankshaft in Positio Position)...................................................... n)......................................................128 128 Installation Procedure ....................................128 ....................................128 Crankshaft Main Bearings - Remove (Crankshaft in Position)....................................127 Position)....................................127 Remova Removall Proced Procedure ure ....................................... .......................................127 127 Crankshaft Rear Seal - Install...............................68 Install...............................68 Installation Procedure ......................................68 ......................................68 Crankshaft Crankshaft Rear Seal - Remove Remove ..... ...... ...... ...... ....68 ....68 Remova Removall Proced Procedure ure ......................................... .........................................68 68 Cylinder Block Cover - Remove and Install............ 84 Installation Procedure ......................................86 ......................................86 Remova Removall Proced Procedure ure ......................................... .........................................84 84 Cylind Cylinder er Head Head - Install Install .......................................102 ....................................... 102 Installation Procedure ....................................102 ....................................102 Cylind Cylinder er Head Head - Remove...................................... Remove......................................98 98 Remova Removall Proced Procedure ure ......................................... .........................................98 98 Cylind Cylinder er Liner Liner - Install........................................ Install........................................119 119 Installation Procedure ....................................119 .................................... 119 Cylind Cylinder er Liner - Remove Remove .................................... ....................................118 118 Remova Removall Proced Procedure ure ....................................... .......................................118 118

B Bearing Bearing Clearanc Clearance e - Check Check ................................138 ................................138 Measurement Measurement Procedure Procedure ...... ...... ...... ...... ...... ..138 ..138 Belt Tensioner - Remove and Install.................... 158 Installation Procedure ....................................158 ....................................158 Remova Removall Proced Procedure ure ....................................... .......................................158 158 C Camsha Camshaft ft - Instal Installl .............................................. ..............................................1 110 Installation Procedure .................................... 110 Camsha Camshaft ft - Remove Remove ..........................................108 .......................................... 108 Remova Removall Proced Procedure ure ....................................... .......................................108 108 Camsha Camshaft ft Bearing Bearings s - Instal Installl ................................ 113 Installation Procedure .................................... 113 Camshaft Bearings - Remove ............................ 113 Remova Removall Proced Procedure ure ....................................... .......................................1 113 Camshaft Camshaft Gear Gear - Remove Remove and Install Install ...... ...... ...... 11 ...... 111 1 Installation Procedure .................................... 112 Remova Removall Proced Procedure ure ....................................... ....................................... 11 111 1 Connecting Rod Bearings - Install.......................126 Install....................... 126 Installation Procedure ....................................126 ....................................126 Connecting Rod Bearings - Remove................... 125 Remova Removall Proced Procedure ure ....................................... .......................................125 125 Coolant Temperature Sensor - Remove and Instal Installl ............................................................. .............................................................143 143 Installation Procedure ....................................144 ....................................144 Remova Removall Proced Procedure ure ....................................... .......................................143 143 Crankcase Crankcase Breather Breather - Remove and and Install ...... ...... . 83 Installation Procedure ......................................83 ......................................83 Remova Removall Proced Procedure ure ......................................... .........................................83 83 Cranks Crankshaf haftt - Instal Installl ............................................ ............................................132 132 Installation Procedure ....................................132 ....................................132 Cranks Crankshaf haftt - Remove Remove......................................... .........................................130 130 Remova Removall Proced Procedure ure ....................................... .......................................130 130 Crankshaft Crankshaft Front Seal - Install Install ..... ...... ...... ...... ...... .75 Installation Procedure ......................................75 ......................................75 Crankshaft Front Seal - Remove ..........................74 .......................... 74 Remova Removall Proced Procedure ure ......................................... .........................................74 74 Crankshaft Gear - Remove and Install ................ 137

D Disassembly and Assembly Section .......................5 ....................... 5 E Electric Electric Starting Motor Motor - Remove and Install Install ...... .. 172 Installation Procedure ....................................173 ....................................173 Remova Removall Proced Procedure ure ....................................... .......................................172 172 Electronic Electronic Control Module - Remove and Install. .. 164 Installation Procedure ....................................165 ....................................165 Remova Removall Proced Procedure ure ....................................... .......................................164 164 Electronic Electronic Unit Injector Injector - Install Install ...... ..... ...... ...... ......19 ......19 Installation Procedure ......................................19 ......................................19 Electronic Unit Injector - Remove..........................17 Remove..........................17 Remova Removall Proced Procedure ure ......................................... .........................................17 17 Electronic Electronic Unit Unit Injector Injector Sleeve Sleeve - Install Install ...... ...... ......23 ...... 23 Installation Procedure ......................................23 ......................................23 Electronic Unit Injector Sleeve - Remove .............. 21 Remova Removall Proced Procedure ure ......................................... .........................................21 21 Engine Lifting Bracket - Remove and Install .......... 60 Installation Procedure ......................................61 ......................................61 Remova Removall Proced Procedure ure ......................................... .........................................60 60 Start Start By.................................. .........................60 .........................60 Engine Oil Filter Base and Oil Cooler - Install ........ 43 Installation Procedure ......................................43 ......................................43 Engine Oil Filter Base and Oil Cooler - Remove..... 41 Remova Removall Proced Procedure ure ......................................... .........................................41 41 Engine Oil Pan - Remove and Install................... 115 Installation Procedure ....................................116 .................................... 116 Remova Removall Proced Procedure ure ....................................... .......................................115 115 Engine Oil Pressure Sensor - Remove and Instal Installl ............................................................. .............................................................144 144 Installation Procedure ....................................145 ....................................145 Remova Removall Proced Procedure ure ....................................... .......................................144 144 Engine Oil Pump - Assemble................................49 Assemble................................49 Assembly Procedure ...... ... ...... ...... ...... ... ...... ... ...... ...... ...... ...... ...... ...... .....49 Engine Engine Oil Pump Pump - Disass Disassemb emble le ...........................47 ...........................47 Disassembly Procedure ...................................47 ...................................47


178

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Index Section

Engine Oil Pump - Install......................................51 Install......................................51 Installation Procedure ......................................51 ......................................51 Engine Engine Oil Pump - Remove.................................. Remove..................................46 46 Remova Removall Proced Procedure ure ......................................... .........................................46 46 Engine Engine Support (Front) (Front) - Remove and Install ...... ...62 ... 62 Installation Procedure ......................................63 ......................................63 Remova Removall Proced Procedure ure ......................................... .........................................62 62 Engine Support (Front) - Remove and Install (Option (Option 2) ................... ...................................... ......................................64 64 Installation Procedure ......................................65 ......................................65 Remova Removall Proced Procedure ure ......................................... .........................................64 64 Exhaust Elbow - Remove and Install..................... 35 Installation Procedures.....................................35 Procedures.....................................35 Remova Removall Proced Procedure ure ......................................... .........................................35 35 Exhaust Manifold - Remove and Install ................. 32 Installation Procedure ......................................33 ......................................33 Remova Removall Proced Procedure ure ......................................... .........................................32 32

Remova Removall Proced Procedure ure ........................................... ...........................................5 5 Fuel Temperature Sensor - Remove and Install ... 147 Installation Procedure ....................................148 ....................................148 Remova Removall Proced Procedure ure ....................................... .......................................147 147 G Gear Gear Group Group (Front) (Front) - Instal Installl .................................. ..................................78 78 Installation Procedure ......................................78 ......................................78 Gear Group (Front) - Remove ..............................77 ..............................77 Remova Removall Proced Procedure ure ......................................... .........................................77 77 H Housing (Front) - Install .......................................81 .......................................81 Installation Procedure ......................................81 ......................................81 Housing (Front) - Remove....................................80 Remove....................................80 Remova Removall Proced Procedure ure ......................................... .........................................80 80

F Fan - Remove Remove and Install.. Install.. .................................159 .................................159 Installation Procedure ....................................160 ....................................160 Remova Removall Proced Procedure ure ....................................... .......................................159 159 Fan Drive Drive - Assemb Assemble le ........................................ ........................................162 162 Assembly Procedure ...... ... ... ...... ... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..162 162 Fan Drive - Disassemble....................................161 Disassemble.................................... 161 Disassembly Procedure .................................161 ................................. 161 Fan Drive Drive - Instal Installl .............................................. ..............................................164 164 Installation Procedure ....................................164 ....................................164 Fan Drive Drive - Remove Remove ..........................................160 ..........................................160 Remova Removall Proced Procedure ure ....................................... .......................................160 160 Flywhe Flywheel el - Install Install ................................................. .................................................66 66 Installation Procedure ......................................66 ......................................66 Flywhe Flywheel el - Remove Remove.............................................. ..............................................65 65 Remova Removall Proced Procedure ure ......................................... .........................................65 65 Flywheel Housing - Remove and Install.................69 Install................. 69 Installation Procedure ......................................70 ......................................70 Remova Removall Proced Procedure ure ......................................... .........................................69 69 Front Front Cover - Install............................................. Install.............................................76 76 Installation Procedure ......................................76 ......................................76 Front Front Cover Cover - Remove Remove ......................................... .........................................75 75 Remova Removall Proced Procedure ure ......................................... .........................................75 75 Fuel Filter Base - Assemble .................................10 .................................10 Assembly Procedure ...... ... ... ...... ... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....10 Fuel Filter Base - Assemble (Option 2).................. 11 Assembly Procedure ...... ... ... ...... ... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....11 Fuel Filter Base - Disassemble...............................8 Disassemble...............................8 Disassembly Procedure .....................................8 .....................................8 Fuel Filter Base - Disassemble (Option 2) ...............9 ............... 9 Disassembly Procedure .....................................9 .....................................9 Fuel Fuel Filter Base - Instal Installl ....................................... .......................................11 11 Installation Procedure ......................................11 ...................................... 11 Fuel Filter Base - Install (Option 2)........................13 2)........................13 Installation Procedure ......................................13 ......................................13 Fuel Filter Base - Remove......................................6 Remove......................................6 Remova Removall Proced Procedure ure ........................................... ...........................................6 6 Fuel Filter Filter Base Base - Remove Remove (Option (Option 2) ...... ...... ...... ....7 ....7 Remova Removall Proced Procedure ure ........................................... ...........................................7 7 Fuel Pressure Pressure Sensor - Remove and Install...... ... 145 Installation Procedure ....................................146 ....................................146 Remova Removall Proced Procedure ure ....................................... .......................................145 145 Fuel Pressure Sensor - Remove and Install (Option (Option 2) ................... .................................... ....................................146 146 Installation Procedure ....................................147 ....................................147 Remova Removall Proced Procedure ure ....................................... .......................................146 146 Fuel Priming Pump - Remove and Install.................5 Install.................5 Installation Procedure ........................................5 ........................................5

I Idler Pulley - Remove and Install (Grooved Idler Pulley Pulley)) ............................................................ ............................................................157 157 Installation Procedure ....................................158 ....................................158 Remova Removall Proced Procedure ure ....................................... .......................................157 157 Important Important Safety Information Information ...... ...... ..... ...... ...... .....2 .....2 Injection Actuation Pressure Sensor - Remove and Instal Installl ....................................................... .......................................................148 148 Installation Procedure ....................................149 ....................................149 Remova Removall Proced Procedure ure ....................................... .......................................148 148 Inlet and Exhaust Valve Guides - Remove and Instal Installl ............................................................... ...............................................................40 40 Installation Procedure ......................................40 ......................................40 Remova Removall Proced Procedure ure ......................................... .........................................40 40 Inlet and Exhaust Valve Springs - Remove and Instal Installl ............................................................... ...............................................................36 36 Installation Procedure ......................................37 ......................................37 Remova Removall Proced Procedure ure ......................................... .........................................36 36 Inlet and Exhaust Valves Valves - Remove Remove and Install..... Install..... .. 38 Installation Procedure ......................................39 ......................................39 Remova Removall Proced Procedure ure ......................................... .........................................38 38 Inlet Manifold Pressure Sensor - Remove and Instal Installl ............................................................. .............................................................152 152 Installation Procedure ....................................153 ....................................153 Remova Removall Proced Procedure ure ....................................... .......................................152 152 Inlet Manifold Temperature Sensor - Remove and Instal Installl ....................................................... .......................................................151 151 Installation Procedure ....................................152 ....................................152 Remova Removall Proced Procedure ure ....................................... .......................................151 151 L Lifter Group - Remove Remove and and Install Install ...... ...... ...... .....107 ..... 107 Installation Procedure ....................................107 ....................................107 Remova Removall Proced Procedure ure ....................................... .......................................107 107 P Piston Cooling Jets - Remove and Install ............ 120 Installation Procedure ....................................120 ....................................120 Remova Removall Proced Procedure ure ....................................... .......................................120 120 Pistons Pistons and Connecting Connecting Rods - Assemble. Assemble. ...... .... 123 Assembly Procedure ...... ... ...... ...... ...... ... ...... ... ...... ...... ...... ...... ...... ..... ..123 123 Pistons Pistons and Connecting Connecting Rods - Disassemble Disassemble ..... . 122 Disassembly Procedure .................................122 ................................. 122


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179 Index Section

Pistons and Connecting Rods - Install................. 124 Installation Procedure ....................................124 ....................................124 Pistons Pistons and Connecting Connecting Rods Rods - Remove ...... ...... . 121 Remova Removall Proced Procedure ure ....................................... .......................................121 121 R Refrigerant Compressor - Remove and Install ..... 139 Installation Procedure ....................................141 ....................................141 Remova Removall Proced Procedure ure ....................................... .......................................139 139 Rocker Rocker Arm - Assemb Assemble le ....................................... .......................................95 95 Assembly Procedure ...... ... ... ...... ... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....95 Rocker Arm - Disassemble...................................94 Disassemble...................................94 Disassembly Procedure ...................................94 ...................................94 Rocker Arm and Shaft - Install..............................96 Install..............................96 Installation Procedure ......................................96 ......................................96 Rocker Rocker Arm and Shaft - Remove Remove ..........................93 ..........................93 Remova Removall Proced Procedure ure ......................................... .........................................93 93

Assembly Procedure ...... ... ...... ...... ...... ... ...... ... ...... ...... ...... ...... ...... ...... .....54 Water Pump - Disassemble..................................53 Disassemble..................................53 Disassembly Procedure ...................................53 ...................................53 Water Water Pump - Install................... Install................... .........................56 .........................56 Installation Procedure ......................................56 ......................................56 Water Water Pump - Remove Remove ........................................52 ........................................52 Remova Removall Proced Procedure ure ................................... ................................... 52 52 – –53 53 Water Separator and Fuel Filter (Primary) Remove Remove and Install Install ............................................ ............................................14 14 Installation Procedure ......................................15 ......................................15 Remova Removall Proced Procedure ure ......................................... .........................................14 14 Water Temperature Regulator - Remove and Instal Installl ............................................................... ...............................................................57 57 Installation Procedure ......................................58 ......................................58 Remova Removall Proced Procedure ure ......................................... .........................................57 57

S Speed/Tim Speed/Timing ing Sensor - Remove and Install.. ...... . 150 Installation Procedure ....................................151 ....................................151 Remova Removall Proced Procedure ure ....................................... .......................................150 150 T Table able of Conten Contents ts .................................................. ..................................................3 3 Turbocharger - Install ..........................................30 ..........................................30 Installation Procedure ......................................30 ......................................30 Turbocharger - Remove.......................................29 Remove.......................................29 Remova Removall Proced Procedure ure ......................................... .........................................29 29 U Unit Injector Hydraulic Pump - Install ....................25 .................... 25 Remova Removall Proced Procedure ure ......................................... .........................................25 25 Unit Injector Hydraulic Pump - Remove.................24 Remove................. 24 Remova Removall Proced Procedure ure ......................................... .........................................24 24 V V-Belts - Remove and Install (Charging Alternator Drive Belts) ...... ... ... ...... ... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..154 154 Installation Procedure ....................................154 ....................................154 Remova Removall Proced Procedure ure ....................................... .......................................154 154 V-Belts - Remove and Install (Water Pump Drive Drive Belt)....................................................... Belt).......................................................155 155 Installation Procedure ....................................156 ....................................156 Remova Removall Proced Procedure ure ....................................... .......................................155 155 Valve Mechanism Mechanism Cover - Remove and Install ...... . 88 Installation Procedure ......................................89 ......................................89 Remova Removall Proced Procedure ure ......................................... .........................................88 88 Valve Mechanism Cover Base - Remove and Instal Installl ............................................................... ...............................................................91 91 Installation Procedure ......................................91 ......................................91 Remova Removall Proced Procedure ure ......................................... .........................................91 91 Vibration Damper and Pulley - Remove and Instal Installl ............................................................... ...............................................................72 72 Installation Procedure ......................................73 ......................................73 Remova Removall Proced Procedure ure ......................................... .........................................72 72 W Water Water Pump - Assemb Assemble le ...................................... ......................................54 54


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Perkins 1506D Engine Manual

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