Professional Documents
Culture Documents
Engine Parts
Disassembly and Assembly Section
Dispose of all fluids according to local regulations and 5. Disconnect the tube assemblies (not shown) from
mandates. fuel filter base (3).
Note: Put identification marks on all hose assemblies Contaminants may cause rapid wear and shortened
and on all tube assemblies for installation purposes. component life.
Plug all hose assemblies and tube assemblies.
This helps prevent fluid loss, and this helps to keep
contaminants from entering the system. 1. Ensure that the assembly of the fuel priming pump
and the fuel filter base is clean and free from
1. Turn the fuel supply to the OFF position. damage. If necessary, replace any components
that are damaged.
2. Turn the battery disconnect switch to the OFF
position.
g01324908
Illustration 2
Typical example
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KENR6241 5
Disassembly and Assembly Section
i02748531
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
NOTICE
Keep all parts clean from contaminants.
Note: Place identification marks on all tube 3. Disconnect hose (4) from tube assembly (6).
assemblies for installation. Plug all lines and tube
assemblies in order to prevent contamination. 4. Disconnect fuel injection lines (1) from fuel
injectors (3).
1. Turn the fuel supply to the OFF position.
5. Disconnect fuel injection lines (1) from fuel
2. If necessary, loosen the dipstick tube (not shown). injection pump (5).
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6 KENR6241
Disassembly and Assembly Section
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 27610294 Injector Pipe Nut Tool 1
NOTICE
Keep all parts clean from contaminants.
g01332972
Illustration 6
Typical example
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KENR6241 7
Disassembly and Assembly Section
6. Install bolt (11). Tighten the bolt to a torque of 1. Turn the fuel supply to the OFF position.
11 N·m (97 lb in).
i02748529 g01332532
Illustration 7
and Install
(Turbocharged Engines)
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
This document has been printed from SPI². Not for Resale
8 KENR6241
Disassembly and Assembly Section
Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 27610294 Injector Pipe Nut Tool 1
NOTICE
Keep all parts clean from contaminants.
g01324910
Illustration 8
Typical example
Typical example
5. Remove clamps (4) and remove fuel injection
lines (1).
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KENR6241 9
Disassembly and Assembly Section
i02748534
Removal Procedure
Table 3
Required Tools
Part
Tool Number Part Description Qty
A - Combination Puller 1
Start By:
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
g01324910
ing any compartment or disassembling any compo-
Illustration 10 nent containing fluids.
Typical example
Dispose of all fluids according to local regulations and
1. Install hoses (2) to fuel injectors (3). mandates.
3. Connect tube assembly (6) to fuel injectors (3). Contaminants may cause rapid wear and shortened
Connect tube assembly (6) to fuel injection pump component life.
(5).
1. Ensure that number one piston is at the top
4. Remove the caps from fuel injectors and from the center position on the compression stroke. Refer
fuel injection pump. Loosely install fuel injection to Systems Operation, Testing and Adjusting,
lines (1) to fuel injection pump (5) and to fuel “Finding Top Center Position for No. 1 Piston”.
injectors (3).
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10 KENR6241
Disassembly and Assembly Section
g01335768 g01375471
Illustration 11 Illustration 13
Typical example Typical example
3. Remove plate (2) from front housing (1). 7. Remove fasteners (8), bolt (10) and bracket (9).
4. Remove O-ring seal (3) from plate (2). 8. Support fuel injection pump (6) and remove bolt
(7).
g01375914
Illustration 12
Timing marks on the gears
g01335808
Illustration 14
Typical example
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KENR6241 11
Disassembly and Assembly Section
Note: Do not remove the nut at this time. 1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
12. Use Tooling (A) to loosen gear (12). Remove nut to Operation and Maintenance Manual, “Cooling
(11) and gear (12). System Coolant - Change” for more information.
i02748532
g01366198
Fuel Injection Pump - Remove Illustration 15
Typical example
(Fuel Injection Pumps With
a Water Heated Cold Start 2. Loosen the hose clamps and disconnect hoses (1)
and (4) from fuel injection pump (2).
Device)
3. Loosen the hose clamps and remove hose (3)
from fuel injection pump (2).
Start By:
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
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12 KENR6241
Disassembly and Assembly Section
g01375914
Illustration 17
Timing marks on the gears
This document has been printed from SPI². Not for Resale
KENR6241 13
Disassembly and Assembly Section
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01375914
Illustration 22
Timing marks on the gears
Illustration 20
g01375949 7. Install the assembly of housing (9) and fuel
injection pump (2) to the engine. Ensure that
Typical example
Timing marks (X) on the teeth of the gears are in
the correct position. Install bolt (10) finger tight.
2. Ensure that the mating surfaces of housing (9)
and fuel injection pump (2) are clean and free 8. Position bracket (12) on fuel injection pump (2).
from damage. Install fasteners (11) and bolt (13) finger tight.
3. Install a new O-ring seal (17) to housing (9). 9. Tighten nut (14) to a torque of 90 N·m (66 lb ft).
Refer to Illustration 20.
4. Position housing (9) on fuel injection pump (2). If
the original fuel injection pump is installed, ensure
that the appropriate marks on the flange of the
fuel injection pump and the housing are aligned.
Install nuts (18) finger tight.
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14 KENR6241
Disassembly and Assembly Section
End By:
i02748535
g01366190
Illustration 23
Typical example
Installation Procedure
12. Tighten bolt (10) to a torque of 18 N·m (13 lb ft). 1. Ensure that number one piston is at the top
Tighten bolt (13) to a torque of 18 N·m (13 lb ft). center position on the compression stroke. Refer
Tighten fasteners (11) to a torque of 35 N·m to Systems Operation, Testing and Adjusting,
(26 lb ft). Refer to Illustration 21. “Finding Top Center Position for No. 1 Piston”.
g01366198
Illustration 24
Typical example
14. Connect hoses (1) and (4) to fuel injection pump g01335808
Illustration 25
(2). Tighten the hose clamps securely.
Typical example
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KENR6241 15
Disassembly and Assembly Section
2. Ensure that the mating surfaces of housing (5) 8. Position bracket (9) on fuel injection pump (6).
and fuel injection pump (6) are clean and free Install fasteners (8) and bolt (10) finger tight.
from damage.
9. Tighten nut (11) to a torque of 90 N·m (66 lb ft).
3. Install a new O-ring seal (14) to housing (5). Refer to Illustration 25.
g01335768
Illustration 28
Typical example
End By:
g01375914
Illustration 27
Timing marks on the gears
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16 KENR6241
Disassembly and Assembly Section
Removal Procedure 1. Clean the bore for the fuel injector in the cylinder
head. Ensure that no debris enters the cylinder.
Start By: Clean the threads on the body of the fuel injector.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Illustration 30
g01325773
ing, adjusting and repair of the product. Be prepared to
Typical example
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. 2. Install new seat washers (1) into the bore for the
fuel injector in the cylinder head.
Dispose of all fluids according to local regulations and
mandates. 3. Install fuel injectors (2) into the cylinder head. Use
a deep socket to tighten fuel injectors (2) to a
torque of 59 N·m (44 lb ft).
End By:
i02748538
This document has been printed from SPI². Not for Resale
KENR6241 17
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. g01325781
Illustration 32
Dispose of all fluids according to local regulations and Typical example
mandates.
2. Install new seat washers (1) to the bores for the
fuel injectors in the cylinder head.
End By:
g01325781
Illustration 31 i02748540
1. Remove bolts (3) and clamps (4) from fuel Turbocharger - Remove
injectors (2).
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18 KENR6241
Disassembly and Assembly Section
g01336694
Illustration 33
Typical example
g01337174
Illustration 35
This document has been printed from SPI². Not for Resale
KENR6241 19
Disassembly and Assembly Section
g01336699
i02748541 Illustration 36
Typical example
Turbocharger - Install
2. Clean the mating surface of the exhaust manifold.
Install a new gasket (10) over the studs. Apply
Tooling (A) to the studs.
Installation Procedure
3. Position turbocharger (1) onto the exhaust
Table 5 manifold and install the double nuts. Tighten the
nuts to a torque of 18 N·m (13 lb ft).
Required Tools
Part Note: Do not allow the lower nuts to turn when the
Tool Number Part Description Qty upper nuts are tightened.
A CV60889 Anti-Seize Compound 1
4. Ensure that tube assemblies (9) and (12) are
clean and free from damage. If necessary, replace
NOTICE the tube assemblies.
Keep all parts clean from contaminants.
5. Remove the plugs from the ports in the
Contaminants may cause rapid wear and shortened turbocharger and from the cylinder block.
component life.
6. If necessary, install the lower end of tube assembly
(12) to the adapter in the cylinder block. Position a
1. Ensure that the turbocharger is clean and free new joint (11) onto tube assembly (12). Connect
from damage. Inspect the turbocharger for the tube assembly to turbocharger (1) and install
wear. Refer to Systems Operation, Testing and bolts (13). Tighten the bolts to a torque of 9 N·m
Adjusting, “Turbocharger - Inspect” for more (80 lb in). If necessary, tighten the hose clips.
information. If the turbocharger is worn, the
complete turbocharger must be replaced.
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20 KENR6241
Disassembly and Assembly Section
7. Lubricate the bearings of turbocharger (1) with 11. Position a new joint (2) and air pipe (3) onto
clean engine oil through the oil inlet port. Rotate turbocharger (1). Install bolts (5). Tighten the bolts
the shaft of the turbocharger in order to distribute to a torque of 18 N·m (13 lb ft).
the lubricant.
12. Remove the plugs from the connection on the
8. Install new sealing washers (8) and banjo bolt (7) inlet manifold and from the turbocharger. Install
to tube assembly (9). Position tube assembly (9) hose (4) and tighten hose clamps (6) securely.
onto turbocharger (1). Tighten the banjo bolt finger
tight. Install new sealing washers (15) and banjo
i02748542
bolt (14) to tube assembly (9). Connect the tube
assembly to adapter (16) in the cylinder block. Exhaust Manifold - Remove
9. Tighten banjo bolts (7) and (14) to a torque of and Install
16 N·m (12 lb ft).
g01333088
Illustration 39
Exhaust manifold from a naturally aspirated engine
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KENR6241 21
Disassembly and Assembly Section
2. Remove bolts (1) and remove exhaust manifold Note: Tighten the center bolts first.
(2) from the cylinder head.
End By:
3. Remove gasket (3).
a. If the engine is equipped with a turbocharger,
install the turbocharger. Refer to Disassembly and
Installation Procedure Assembly, “Turbocharger - Install”.
Table 6
Required Tools i02748543
Tool Part Number Part Description Qty Inlet Manifold - Remove and
A -
Guide Stud
(M8 x 1.25 by 100 2
Install
mm)
g01333101
Illustration 40
Exhaust manifold from a naturally aspirated engine
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22 KENR6241
Disassembly and Assembly Section
g01333457 g01333458
Illustration 42 Illustration 43
Typical example Typical example
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KENR6241 23
Disassembly and Assembly Section
For turbocharged engines, install the bolt that Note: The following procedure should be adopted in
secures the hose for the crankcase breather (not order to remove the valve springs when the cylinder
shown) to the inlet manifold (1). Tighten the bolt head is installed to the engine. Refer to Disassembly
to a torque of 11 N·m (97 lb in). and Assembly, “Inlet and Exhaust Valves - Remove
and Install” for the procedure to remove the valve
8. Connect the air hose (not shown) to connection springs from a cylinder head that has been removed
(3) and tighten the hose clamps securely. from the engine.
End By: Note: Ensure that the appropriate piston is at the top
center position before the valve spring is removed.
a. Install the fuel injection lines. Refer to Disassembly Failure to ensure that the piston is at the top center
and Assembly, “Fuel Injection Lines - Remove position may allow the valve to drop into the cylinder
and install”. bore.
i02748544
Removal Procedure
Table 7
Required Tools
Part g01358696
Tool Number Part Description Qty Illustration 45
Typical example
A 21825666 Valve Spring Compressor 1
B 27610235 Adapter 1 1. Follow Steps 1.a through 1.d in order to position
the appropriate piston at top center.
Start By:
a. Install Tooling (A) and (B) in position on the
cylinder head in order to compress a valve
a. Remove the rocker shaft assembly. Refer to
spring for the appropriate piston.
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
b. Use Tooling (A) in order to compress valve
spring (3) and open the valve slightly.
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24 KENR6241
Disassembly and Assembly Section
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
g01358696
Illustration 46
Note: If all valve springs require replacement the Typical example
procedure can be carried out on two cylinders at the
same time. The procedure can be carried out on 2. Install valve spring (3) onto the cylinder head.
the following pairs of cylinders. 1 with 4 and 2 with Position valve spring retainer (2) onto valve spring
3. Ensure that all of the valve springs are installed (3).
before changing from one pair of cylinders to another
pair of cylinders.
1. Inspect the valve springs for the correct length. 5. Carefully release the pressure on Tooling (A).
Refer to Specifications, “Cylinder Head Valves ”.
Note: Ensure that the valve keepers are correctly
seated.
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KENR6241 25
Disassembly and Assembly Section
i02748545
Removal Procedure
Table 9
Required Tools
Tool Part Number Part Description Qty
Valve Spring
A 21825663 1
Compressor
B - Seal Remover 1
NOTICE
Keep all parts clean from contaminants.
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26 KENR6241
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Installation Procedure
Table 10
Required Tools
Tool Part Number Part Description Qty
Valve Spring
A 21825663 1
Compressor
27610261 Seal Installer 1
C
27610262 Valve Guide Driver 1
g01333472
Illustration 49
Typical example
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KENR6241 27
Disassembly and Assembly Section
g01333469
Illustration 51
Typical example
g01333471
Illustration 50
Typical example 5. Use Tooling (A) in order to compress valve spring
(3). Install valve keepers (1).
3. Lubricate the stem of valve (5) with clean engine
oil. Install valve (5) in the appropriate position in Note: Do not compress the spring so that valve
the cylinder head. Check the depth of the valve spring retainer (2) touches valve stem seal (4).
below the face of the cylinder head. Refer to
Systems Operation, Testing and Adjusting, “Valve
Depth - Inspect” for more information.
The valve spring keepers can be thrown from
4. Install valve spring (3) to the cylinder head. the valve when the valve spring compressor is
Position valve spring retainer (2) onto valve spring released. Ensure that the valve spring keepers
(3). 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.
Personal injury can result from being struck by
parts propelled by a released spring force. 6. Remove Tooling (A).
Make sure to wear all necessary protective equip- 7. Repeat Steps 3 to 6 for the remaining valves.
ment.
8. Place the cylinder head on a suitable support.
Follow the recommended procedure and use all Ensure that the heads of the valves are not
recommended tooling to release the spring force. obstructed. Gently strike the top of the valves
with a soft hammer in order to ensure that valve
keepers (1) are properly installed.
NOTICE
Ensure that the valve spring is compressed squarely
End By:
or damage to the valve stem may occur.
a. Install the cylinder head assembly. Refer to
Disassembly and Assembly, “Cylinder Head -
Install”.
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28 KENR6241
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
g01333853
Illustration 53
Typical example
This document has been printed from SPI². Not for Resale
KENR6241 29
Disassembly and Assembly Section
i02748547
Removal Procedure
Start By:
This document has been printed from SPI². Not for Resale
30 KENR6241
Disassembly and Assembly Section
i02748549
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01333881
Illustration 55
Typical example
b. Remove cooler matrix (6) from cover (7). a. Ensure that cooler matrix (6) is clean and free
from damage. Ensure that cover (7) is clean
c. Remove O-ring seals (12) and (13). and free from damage.
d. Remove plate (10) and joint (9) from cover (7). b. Position new O-ring seals (12) and (13) onto
cover (7).
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KENR6241 31
Disassembly and Assembly Section
d. Install nuts (8). Tighten the nuts to a torque of a. Install the fuel injection lines. Refer to Disassembly
18 N·m (13 lb ft). and Assembly, “Fuel Injection Lines - Install”.
2. Clean the mating surface of the cylinder block. Engine Oil Relief Valve -
3. Install new O-ring seals (4) to the recesses in the Remove and Install
cylinder block.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01361343
Illustration 57
Typical example
10. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for the correct procedure.
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32 KENR6241
Disassembly and Assembly Section
g01334417 g01334417
Illustration 58 Illustration 59
Typical example Typical example
1. If necessary, use Tooling (A) in order to remove 1. Install a new sealing washer (1) to engine oil relief
engine oil filter (3). Refer to Operation and valve (2).
Maintenance Manual, “Engine Oil and Filter -
Change”. 2. Install engine oil relief valve (2) to the cylinder
block. Tighten the engine oil relief valve to a
2. Remove engine oil relief valve (2). torque of 49 N·m (36 lb ft).
3. Remove sealing washer (1). 3. If necessary, install a new engine oil filter (3). Refer
to Operation and Maintenance Manual, “Engine
Oil and Filter - Change” for the correct procedure.
Installation Procedure
NOTICE i02748551
Keep all parts clean from contaminants.
Engine Oil Bypass Valve -
Contaminants may cause rapid wear and shortened Remove and Install
component life.
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI². Not for Resale
KENR6241 Worldwide Parts Source LLC Phone 269 673 2313 Engine Parts
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01334433
Illustration 61
Typical example
End By:
g01334433
Illustration 60
a. Install the engine oil pan. Refer to Disassembly
Typical example and Assembly, “Engine Oil Pan - Remove and
Install”.
2. Remove engine oil bypass valve (1).
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34 KENR6241
Disassembly and Assembly Section
i02748554
NOTICE
Care must be taken to ensure that fluids are contained
Engine Oil Pump - Install
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Installation Procedure
nent containing fluids.
Table 13
Dispose of all fluids according to local regulations and Required Tools
mandates.
Tool Part Number Part Description Qty
A 21825617 Dial Indicator Group 1
NOTICE
Keep all parts clean from contaminants.
g01334869
Illustration 63
This document has been printed from SPI². Not for Resale
KENR6241 35
Disassembly and Assembly Section
i02748555
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
g01334537
Illustration 64 during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
2. Ensure that engine oil pump (1) is clean and free collect the fluid with suitable containers before open-
from wear or damage. Refer to Specifications, ing any compartment or disassembling any compo-
“Engine Oil Pump” for more information. If nent containing fluids.
necessary, replace the engine oil pump.
Dispose of all fluids according to local regulations and
3. Install a new O-ring seal (2) to engine oil pump mandates.
(1). Lubricate the rotors of the engine oil pump
with clean engine oil. 1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
4. Align engine oil pump (1) with dowels (7). Install to Operation and Maintenance Manual, “Cooling
the engine oil pump to the cylinder block. System Coolant - Change” for more information.
5. Install bolts (6). Tighten the bolts to a torque of 2. Loosen the hose clamp and disconnect the hose
11 N·m (97 lb in). (not shown) from the water pump inlet.
6. Position oil pump gear (3) onto the shaft of engine
oil pump (1). Ensure that the oil pump gear is
aligned with the flat on the shaft. Install washer (4)
and nut (5). Tighten the nut to a torque of 33 N·m
(24 lb ft).
End By:
This document has been printed from SPI². Not for Resale
36 KENR6241
Disassembly and Assembly Section
g01335205
Illustration 67
g01335213
Illustration 65
2. If necessary, align a new joint (6) and cover (7)
with the holes in water pump (2). Install bolts (5).
Tighten the bolts to a torque of 10 N·m (89 lb in).
g01335205
Illustration 66
5. Remove joint (3). 3. Place water pump (2) in position and install bolts
(4). Ensure that bolts of different lengths are
6. If necessary, remove bolts (5), and remove cover installed in the correct positions. Tighten bolts (4)
(7). Remove joint (6). to a torque of 18 N·m (160 lb in).
Installation Procedure 4. Connect hose (1) and tighten the hose clamp.
This document has been printed from SPI². Not for Resale
KENR6241 37
Disassembly and Assembly Section
End By:
i02748556
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Typical example
NOTICE
Care must be taken to ensure that fluids are contained 2. Remove bolts (1) and remove outlet connection
during performance of inspection, maintenance, test- (2).
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 3. Remove joint (3) and remove water temperature
ing any compartment or disassembling any compo- regulator (4). Note the orientation of the water
nent containing fluids. temperature regulator for installation.
Dispose of all fluids according to local regulations and 4. Loosen the hose clamp and disconnect hose (8)
mandates. from water temperature regulator housing (6).
This document has been printed from SPI². Not for Resale
38 KENR6241
Disassembly and Assembly Section
2. Ensure that the mating surfaces of the outlet 5. Install water temperature regulator (4) to water
connection, the water temperature regulator temperature regulator housing (6). Ensure the
housing and the cylinder head are clean and free correct orientation of the water temperature
from damage. regulator.
i02748557
Flywheel - Remove
Removal Procedure
Table 14
Required Tools
Tool Part Number Part Description Qty
g01335249
Illustration 70 Guide Stud
Typical example A - (M12 x 1.25 by 100 2
mm)
3. Position bolts (7) and a new joint (5) onto water
temperature regulator housing (6). Start By:
4. Position water temperature regulator housing a. Remove the starting motor. Refer to Disassembly
(6) onto the cylinder head. Tighten bolts (7) to a and Assembly, “Electric Starting Motor - Remove
torque of 18 N·m (13 lb ft). and Install”.
NOTICE
Keep all parts clean from contaminants.
g01335282
Illustration 71
Orientation of the water temperature regulator
This document has been printed from SPI². Not for Resale
KENR6241 39
Disassembly and Assembly Section
i02748558
Flywheel - Install
Installation Procedure
Table 15
Required Tools
Tool Part Number Part Description Qty
Guide Stud
A - (M12 x 1.25 by 100 2
g01335288 mm)
Illustration 72
Typical example
NOTICE
1. Make a temporary mark in order to show the Keep all parts clean from contaminants.
orientation of the flywheel on the crankshaft.
Contaminants may cause rapid wear and shortened
2. Install a suitable lifting device to flywheel (2). The component life.
weight of the flywheel is approximately 23 kg
(50 lb).
g01369129
Illustration 74
Typical example
Illustration 73
g01360927 1. If the ring gear was removed, follow Steps 1.a
through 1.c in order to install ring gear (3) to
Typical example
flywheel (2).
6. Inspect ring gear (3) and flywheel (2) for wear or a. Identify the orientation of the new ring gear in
damage. If the ring gear or the flywheel is worn or order to install the ring gear correctly onto the
damaged, use new parts for replacement. flywheel.
7. To remove ring gear (3) from flywheel (2), place Note: The chamfered side of gear teeth (Y) must
the flywheel on a suitable support. Use a hammer face toward the starting motor when the flywheel is
and a punch in order to remove the ring gear from installed. This will ensure the correct engagement of
the flywheel. the starting motor.
This document has been printed from SPI². Not for Resale
40 KENR6241
Disassembly and Assembly Section
Note: Do not use a torch to heat the ring gear. End By:
c. Ensure that the orientation of ring gear (3) is a. Install the starting motor. Refer to Disassembly
correct and quickly install the ring gear onto and Assembly, “Electric Starting Motor - Remove
flywheel (2). and Install”.
i02748559
Removal Procedure
Table 16
Required Tools
Tool Part Number Part Description Qty
g01335288
Illustration 75
A - Drill Bit (4.10 mm) 1
Typical example
This document has been printed from SPI². Not for Resale
KENR6241 41
Disassembly and Assembly Section
g01335312
Illustration 76
Typical example
Installation Procedure
Table 17
Required Tools
Tool Part Number Part Description Qty
27610266 Oil Seal Installer 1
27610345 Oil Seal Locator 1
27610346 Bolt 1
C
28710476 Hard Washer 1
Bolt Illustration 78
g01368204
27610347 (M12 x 1.25 by 20 2
Sectional view of the crankshaft rear seal, the crankshaft and the
mm)
installation tool
Contaminants may cause rapid wear and shortened 3. Use Tooling (C) in order to install crankshaft rear
component life. seal (2), as follows:
This document has been printed from SPI². Not for Resale
42 KENR6241
Disassembly and Assembly Section
b. Carefully slide crankshaft rear seal (2) over the Note: Wear sleeves are used to reclaim worn seal
locator until the crankshaft rear seal contacts surfaces or damaged seal surfaces. Wear sleeves
the rear of crankshaft (3). are not original equipment. The wear sleeve is
supplied with a crankshaft rear seal that has a larger
Note: Ensure that the lip of the crankshaft rear seal internal diameter than a standard crankshaft rear
that is spring loaded is facing toward the flywheel seal. A standard crankshaft rear seal cannot be used
housing. if a wear sleeve is installed.
End By:
This document has been printed from SPI². Not for Resale
KENR6241 43
Disassembly and Assembly Section
Removal Procedure
Table 20
Required Tools
Part
Tool Number Part Description Qty
Guide Stud
Illustration 80
g01377790 A - (M10 x 1.25 by 100 2
mm)
Sectional view of the crankshaft, the wear sleeve and the
installation tool
Start By:
3. Use Tooling (A) in order to install the crankshaft
wear sleeve, as follows: a. Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove”.
a. Align the locator with the dowels in crankshaft
(2). Install the locator to the crankshaft. Ensure
NOTICE
the correct orientation of the locator.
Keep all parts clean from contaminants.
Note: Check that the installer will slide freely over
Contaminants may cause rapid wear and shortened
the locator.
component life.
b. Carefully slide crankshaft wear sleeve (3) over
the locator until the crankshaft wear sleeve NOTICE
contacts the rear of crankshaft (2). Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
c. Assemble the installer to the locator and install ing, adjusting and repair of the product. Be prepared to
the bolt and the washer. Ensure that the face collect the fluid with suitable containers before open-
of the installer with the deep counterbore is ing any compartment or disassembling any compo-
toward crankshaft wear sleeve (3). nent containing fluids.
d. Tighten the bolt until the installer bottoms out Dispose of all fluids according to local regulations and
on the locator in order to pull crankshaft wear mandates.
sleeve (3) onto crankshaft (2).
End By:
This document has been printed from SPI². Not for Resale
44 KENR6241
Disassembly and Assembly Section
Installation Procedure
Table 21
Required Tools
Tool Part Number Part Description Qty
Guide Stud
A - (M10 x 1.25 by100 2
mm)
B 21825617 Dial Indicator Group 1
NOTICE
Keep all parts clean from contaminants.
g01366220
Illustration 82
Typical example
This document has been printed from SPI². Not for Resale
KENR6241 45
Disassembly and Assembly Section
i02748562
Removal Procedure
Table 22
Required Tools
Tool Part Number Part Description Qty
g01335381
A 27610267 Socket 1
Illustration 84
B - Puller Group 1
3. Install Tooling (A) to the cylinder block.
Start By:
4. Install a new joint (1) to the cylinder block.
a. Remove the V-belt. Refer to Disassembly and
5. Install a suitable lifting device to flywheel housing Assembly, “V-belts - Remove and Install”.
(2). The weight of the flywheel housing is
approximately 32 kg (71 lb).
NOTICE
6. Use the lifting device to align flywheel housing (2) Keep all parts clean from contaminants.
with Tooling (A). Install the flywheel housing to the
cylinder block. Contaminants may cause rapid wear and shortened
component life.
7. Install bolts (5) finger tight.
1. Use a suitable method to prevent the crankshaft
8. Remove Tooling (A). Install the remaining bolts (5). from rotating.
9. Tighten bolts (5) to a torque of 35 N·m (26 lb ft).
End By:
g01335388
Illustration 85
Typical example
This document has been printed from SPI². Not for Resale
46 KENR6241
Disassembly and Assembly Section
g01335508
Illustration 86
Typical example
Installation Procedure 1. Ensure that the threads of crankshaft (4) and nut
(3) are clean and free from damage. If necessary,
Table 23 install woodruff key (1) to the crankshaft.
Required Tools
2. Apply a continuous bead of Tooling (C) around
Tool Part Number Part Description Qty the threads of crankshaft (4) at position (X)
approximately 10 mm (0.4 inch) from the shoulder
POWERPART
of the crankshaft.
Silicon RTV Sealing
C 1861108 1
and Jointing
Compound 3. Install pulley (2) to crankshaft (4).
This document has been printed from SPI². Not for Resale
KENR6241 47
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
NOTICE
Ensure that the main lip is used in order to remove the
crankshaft front seal. Do not damage the edge of the
housing for the crankshaft front seal. Illustration 89
g01335757
Typical example
NOTICE
Ensure that the lip of the crankshaft front seal that is
g01335759 spring loaded is facing toward the inside of the front
Illustration 88
housing and that it is square with the bore of the hous-
Typical example ing for the crankshaft front seal.
1. Use Tooling (A) to drill three evenly spaced holes
in crankshaft front seal (2). 4. Use Tooling (C) to install crankshaft front seal (2)
into front housing (1).
2. Use Tooling (B) to carefully remove crankshaft
front seal (2). Alternate the position of Tooling (B) 5. Remove Tooling (C) and check for correct
from one hole to another hole. This will allow you installation of crankshaft front seal (2).
to evenly remove the crankshaft front seal from
front housing (1). 6. Apply clean engine oil to the lip of crankshaft front
seal (2).
This document has been printed from SPI². Not for Resale
48 KENR6241
Disassembly and Assembly Section
End By:
i02748564
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
i02748565
Removal Procedure
Table 26
g01335768
Illustration 90 Required Tools
Typical example Part
Tool Number Part Description Qty
1. Remove bolts (4).
A 27610269 Idler Shaft Puller 1
2. Remove plate (2) from front housing (1).
Start By:
3. Remove O-ring seal (3) from plate (2).
a. Remove the front housing. Refer to Disassembly
Installation Procedure and Assembly, “Housing (Front) - Remove and
Install”.
NOTICE
b. Remove the valve mechanism cover. Refer to
Keep all parts clean from contaminants.
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI². Not for Resale
KENR6241 49
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01337345
Illustration 92
Alignment of timing marks
Note: Failure to ensure that ALL adjusters are fully b. Use Tooling (A) to extract shaft (1) from the
unscrewed can result in contact between the valves cylinder block.
and pistons.
Installation Procedure
Table 27
Required Tools
Tool Part Number Part Description Qty
B 21825617 Dial Indicator Group 1
This document has been printed from SPI². Not for Resale
50 KENR6241
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g01337345
Illustration 96
Alignment of timing marks
Note: Install shaft (1) squarely into the cylinder block. 9. Lightly lubricate all of the gears with clean engine
Ensure that oil hole (Y) is aligned with the temporary oil.
mark and that the shoulder on the shaft is seated
against the face of the cylinder block. 10. Install the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Remove and
2. Ensure that plate (4) and idler gear (5) are clean Install”.
and free from wear or damage. If necessary,
replace any components that are worn or 11. Adjust the engine valve lash. Refer to Systems
damaged. Operation, Testing and Adjusting, “Engine Valve
Lash - Inspect/Adjust”.
3. Ensure that number one piston is at the top
center position on the compression stroke. Refer End By:
to Systems Operation, Testing and Adjusting,
“Finding Top Center Position for No. 1 Piston”. a. Install the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
This document has been printed from SPI². Not for Resale
KENR6241 51
Disassembly and Assembly Section
i02748567
Removal Procedure
Start By:
e. Remove the engine oil pan. Refer to Disassembly 1. Remove bolts (2).
and Assembly, “Engine Oil Pan - Remove and
Install”. 2. Remove front housing (4) from plate (6).
This document has been printed from SPI². Not for Resale
52 KENR6241
Disassembly and Assembly Section
i02748568
Removal Procedure
Start By:
Illustration 98
g01349330 b. Remove the idler gear. Refer to Disassembly and
Assembly, “Idler Gear - Remove and Install”.
Typical example
c. Remove the camshaft. Refer to Disassembly and
1. Ensure that front housing (4) and the nose of the Assembly, “Camshaft - Remove and Install”.
crankshaft are clean and free from damage. Clean
the mating surface of plate (6).
NOTICE
2. Inspect crankshaft front seal (3) for wear or Keep all parts clean from contaminants.
damage. If necessary, replace the crankshaft
front seal. Refer to Disassembly and Assembly, Contaminants may cause rapid wear and shortened
“Crankshaft Front Seal - Remove and Install”. component life.
Apply clean engine oil to the lip of the crankshaft
front seal.
a. Install the engine oil pan. Refer to Disassembly 1. Remove nut (3) and washer (2).
and Assembly, “Engine Oil Pan - Remove and
Install”. 2. Remove gear (1) from the shaft of engine oil pump
(4).
b. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install”.
This document has been printed from SPI². Not for Resale
KENR6241 53
Disassembly and Assembly Section
g01365307 g01365307
Illustration 100 Illustration 101
Typical example Typical example
3. Remove bolts (5). 1. Ensure that plate (7) and the mating surface of the
cylinder block are clean and free from damage.
4. Remove plate (7) from the cylinder block. Ensure that dowels (6) are located in the cylinder
block.
5. Remove joint (8).
2. Install a new joint (8) to the cylinder block.
Note: It is not necessary to remove dowels (6).
3. Align plate (7) with dowels (6) and install the plate
6. If necessary, remove the bracket for the alternator to the cylinder block.
(not shown) from plate (7).
4. Install bolts (5). Tighten the bolts to a torque of
12 N·m (106 lb in).
i02748569
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01365310
Illustration 102
This document has been printed from SPI². Not for Resale
54 KENR6241
Disassembly and Assembly Section
End By:
i02748570
g01344989
Illustration 103
Removal Procedure Typical example
Dispose of all fluids according to local regulations and Contaminants may cause rapid wear and shortened
mandates. component life.
This document has been printed from SPI². Not for Resale
KENR6241 55
Disassembly and Assembly Section
g01344989 g01336694
Illustration 104 Illustration 105
Typical example Typical example
1. Connect hose (4) to crankcase breather (1) and 1. If the engine is equipped with a turbocharger,
tighten the hose clamp. follow Steps 1.a through 1.c in order to remove
the air pipe.
2. Position crankcase breather (1) and install bolts
(2). Tighten the bolts to a torque of 18 N·m a. Loosen hose clamps (6) and remove hose (4).
(13 lb ft).
b. Remove bolts (5) and remove air pipe (3) from
3. Connect hose (3) to crankcase breather (1) and turbocharger (1). Remove gasket (2).
tighten the hose clamp.
c. Plug the opening in the inlet manifold and the
opening in the turbocharger with suitable plugs.
i02748571
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- g01345049
Illustration 106
nent containing fluids.
2. Loosen the hose clamp and disconnect hose (10)
Dispose of all fluids according to local regulations and from valve mechanism cover (8).
mandates.
This document has been printed from SPI². Not for Resale
56 KENR6241
Disassembly and Assembly Section
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01336694
Illustration 108
Typical example
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI². Not for Resale
KENR6241 57
Disassembly and Assembly Section
i02748573
Disassembly Procedure
Table 28
Required Tools
Part
Tool Number Part Description Qty
A - Retaining Ring Pliers 1
Start By:
1. Loosen the nuts and adjustment screws (1) on all Personal injury can result from being struck by
rocker arms. parts propelled by a released spring force.
2. Remove bolts (5). Make sure to wear all necessary protective equip-
ment.
3. Progressively loosen bolts (3). Begin at the ends
of the rocker shaft assembly and work toward the Follow the recommended procedure and use all
center. recommended tooling to release the spring force.
This document has been printed from SPI². Not for Resale
58 KENR6241
Disassembly and Assembly Section
i02748575
Assembly Procedure
Table 29
Required Tools
Part
Tool Number Part Description Qty
A - Retaining Ring Pliers 1
This document has been printed from SPI². Not for Resale
KENR6241 59
Disassembly and Assembly Section
8. Install spring (4) to rocker shaft (3). 2. Apply clean engine lubricating oil to both ends of
pushrods (4). Install the pushrods to the engine
9. Repeat Steps 5 through 8 in order to assemble with the cup upward. Ensure that the pushrods are
the remaining components of the rocker shaft installed correctly in the socket of the valve lifters.
assembly.
Note: If the pushrods have been used, ensure that
10. Use Tooling (A) to install retaining ring (8) to the the pushrods are installed in original positions.
rear end of rocker shaft (3).
3. Lubricate the top of the valve stems with clean
End By: engine oil. Install caps (6) to the valve stems.
a. Install the rocker shaft and pushrods. Refer to Note: If the caps have been used, ensure that the
Disassembly and Assembly, “Rocker Shaft and caps are installed in original positions.
Pushrod - Install”.
4. Install rocker shaft (2) to the cylinder head.
i02748576
Note: Ensure that the ends of adjustment screws (1)
Rocker Shaft and Pushrod - are correctly seated in ends of pushrods (4). Also
ensure that valve caps (6) are in position under the
Install rocker arms.
1. Ensure that all components are clean and free 7. Adjust the valve lash. Refer to Systems Operation,
from wear or damage. Refer to Specifications, Testing and Adjusting, “Engine Valve Lash -
“Rocker Shaft” for more information. Replace any Inspect/Adjust” for the correct procedure.
components that are worn or damaged.
This document has been printed from SPI². Not for Resale
60 KENR6241
Disassembly and Assembly Section
End By: 1. Drain the coolant from the cooling system into
a suitable container for storage or disposal.
a. Install the valve mechanism cover. Refer to Refer to Operation and Maintenance Manual,
Disassembly and Assembly, “Valve Mechanism “Cooling System Coolant - Change” for the correct
Cover - Remove and Install”. procedure.
i02748577
Removal Procedure
Table 30
Required Tools
Tool Part Number Part Description Qty
A - Lifting Bracket 2
Start By:
d. Remove the rocker shaft and pushrods. Refer to 4. If necessary, remove inlet manifold (3). Refer
Disassembly and Assembly, “Rocker Shaft and to Disassembly and Assembly, “Inlet Manifold -
Pushrod - Remove”. Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01001090
Illustration 114
Dispose of all fluids according to local regulations and The cylinder head tightening sequence
mandates.
This document has been printed from SPI². Not for Resale
KENR6241 61
Disassembly and Assembly Section
g01352734
Illustration 116
g01346253
Illustration 115
This document has been printed from SPI². Not for Resale
62 KENR6241
Disassembly and Assembly Section
i02748578
Installation Procedure
Table 31
Required Tools
Tool Part Number Part Description Qty
A - Lifting Bracket 2
Guide Stud
B - (M12 x 1.75 by 100 2
mm)
C - Straight Edge 1
NOTICE
Keep all parts clean from contaminants. Illustration 119
g01346658
Typical example
Contaminants may cause rapid wear and shortened
component life.
5. If necessary, install a new joint (9), lifting bracket
(10) and bolts (11) to cylinder head (6). Tighten
1. Thoroughly clean the mating surfaces of the the bolts to a torque of 11 N·m (97 lb in).
cylinder head and the cylinder block. Ensure that
there is no debris in the cylinder bores, the coolant
passages or the lubricant passages.
g01346253
Illustration 118
g01352861 Illustration 120
3. Inspect dowels (8) for damage. If necessary, 6. Align cylinder head gasket (7) with Tooling (B) and
replace the dowels in the cylinder block. install the cylinder head gasket onto the cylinder
block.
4. Install Tooling (B) to the cylinder block. Refer to
Illustration 118. Note: Ensure that the word UP on the cylinder head
gasket is upward.
This document has been printed from SPI². Not for Resale
KENR6241 63
Disassembly and Assembly Section
g01362487
Illustration 123
Typical example
End By:
This document has been printed from SPI². Not for Resale
64 KENR6241
Disassembly and Assembly Section
g01343537
Illustration 124
Typical example
This document has been printed from SPI². Not for Resale
KENR6241 65
Disassembly and Assembly Section
End By:
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI². Not for Resale
66 KENR6241
Disassembly and Assembly Section
End By:
i02748582
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
This document has been printed from SPI². Not for Resale
KENR6241 67
Disassembly and Assembly Section
End By:
g01350917
Illustration 131
This document has been printed from SPI². Not for Resale
68 KENR6241
Disassembly and Assembly Section
g01347462 g01347459
Illustration 132 Illustration 133
The oil strainer for engines without a balancer
1. Remove oil drain plug (3). Drain the engine oil into
a suitable container for storage or disposal.
This document has been printed from SPI². Not for Resale
KENR6241 69
Disassembly and Assembly Section
Installation Procedure for the Oil 4. Tighten bolts (7) to a torque of 18 N·m (13 lb ft).
Strainer
Installation Procedure for the
NOTICE Engine Oil Pan
Keep all parts clean from contaminants.
Table 35
Contaminants may cause rapid wear and shortened Required Tools
component life.
Tool Part Number Part Description Qty
NOTICE
Keep all parts clean from contaminants.
g01347459
Illustration 135
The oil strainer for engines without a balancer
g01347462
Illustration 137
g01347461
Illustration 136
The oil strainer for engines that are equipped with a balancer
This document has been printed from SPI². Not for Resale
70 KENR6241
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
g01347865
nent containing fluids.
Illustration 138
The pattern of application of sealant to the engine oil pan. Dispose of all fluids according to local regulations and
mandates.
2. Apply a continuous bead of Tooling (A) to the
mating surface of engine oil pan (1) on the inside
of the bolt holes. Refer to Illustration 138 for the 1. Ensure that number one piston is at the top
correct pattern of application. The bead of Tooling center position on the compression stroke. Refer
(A) should be approximately 2 mm (0.080 inch) to Systems Operation, Testing and Adjusting,
in diameter. “Finding Top Center Position for No. 1 Piston”.
i02748584
Balancer - Remove
This document has been printed from SPI². Not for Resale
KENR6241 71
Disassembly and Assembly Section
i02748586
Balancer - Disassemble
Disassembly Procedure
Table 36
Required Tools
Part g01344528
Illustration 141
Tool Number Part Description Qty
A - Combination Puller 1
B - Retaining Ring Pliers 1
C 27610275 Bearing Installer Group 1
NOTICE
Keep all parts clean from contaminants.
g01344665
Illustration 142
Timing marks
g01344515
Illustration 140
This document has been printed from SPI². Not for Resale
72 KENR6241
Disassembly and Assembly Section
g01344533
Illustration 143
Balancer - Assemble a. Align oil holes (Z) in bushing (11) to drilling (Y)
in balancer (1).
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI². Not for Resale
KENR6241 73
Disassembly and Assembly Section
g01344665
Illustration 146
Timing marks
7. Align gears (6) with keys (7) and install the gears
to balancer shafts (10). Ensure that the gears are
installed in the correct position.
g01344515
Illustration 145
Note: The gears have different Markings (X). The
3. Use Tooling (C) in order to press bearings (9) into right hand gear is marked 1,1 and 2,2. The left hand
balancer (1). gear is marked 2. Refer to Illustration 146.
Note: Do not press on the inner race of the bearing 8. Apply Tooling (D) to the threads of bolts (4). Install
as this could result in damage to the bearing. bolts (4) and washers (5). Tighten the bolts to a
torque of 33 N·m (24 lb ft).
4. Use Tooling (B) to install retaining rings (8).
i02748589
Note: Ensure that the retaining rings are fully located
into the grooves in the balancer. Balancer - Install
5. Lubricate balancer shafts (10) and bushing (11)
with clean engine oil. Carefully install the balancer
shafts to balancer (1). Installation Procedure
6. Install keys (7). Table 38
Required Tools
Tool Part Number Part Description Qty
F 21825617 Dial Indicator Group 1
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI². Not for Resale
74 KENR6241
Disassembly and Assembly Section
g01344971
Illustration 149
Alignment of the timing marks
End By:
i02748590
Removal Procedure
g01344983
Illustration 148
Table 39
1. Ensure that dowels (2) are seated in balancer (1). Required Tools
Ensure that marks 2,2 and 2 on gears (6) are
Tool Part Number Part Description Qty
aligned. Refer to Illustration 147.
A 27610274 Ridge Reamer 1
This document has been printed from SPI². Not for Resale
KENR6241 75
Disassembly and Assembly Section
3. Use Tooling (A) to remove the carbon ridge from Required Tools
the top inside surface of the cylinder bore. Tool Part Number Part Description Qty
A - Retaining Ring Pliers 1
B - Ring Expander 1
C 27610275 Driver Group 1
Start By:
NOTICE
Keep all parts clean from contaminants.
g01352319
Illustration 150
This document has been printed from SPI². Not for Resale
76 KENR6241
Disassembly and Assembly Section
g01359108
Illustration 152
(X) Number
(Y) Number
g01351357
Illustration 155
g01311807
Illustration 153
Typical example
This document has been printed from SPI². Not for Resale
KENR6241 77
Disassembly and Assembly Section
4. Place piston (2) on a suitable surface with the 7. Inspect piston pin bearing (12) for wear or
crown upward. Use Tooling (B) in order to remove damage. Refer to Specifications, “Pistons and
compression rings (5) and (6), and oil control ring Rings” for more information. If necessary, replace
(7) from the piston. connecting rod (1) or replace piston pin bearing
(12).
Note: Identify the orientation of the piston rings for
installation. If necessary, use Tooling (C) and a suitable press
to remove piston pin bearing (12) from connecting
rod (1).
i02748593
Assembly Procedure
Table 41
Required Tools
Tool Part Number Part Description Qty
g01362961
A - Retaining Ring Pliers 1
Illustration 156
Typical example
B - Ring Expander 1
C 27610275 Driver Group 1
5. If necessary, remove nuts (11) and connecting rod
cap (10) from connecting rod (1).
NOTICE
6. Remove the lower half of connecting rod bearing Keep all parts clean from contaminants.
(9) from connecting rod cap (10). Remove the
upper half of connecting rod bearing (8) from Contaminants may cause rapid wear and shortened
connecting rod (1). Keep the bearing shells component life.
together.
1. Ensure that all components are clean and free
NOTICE from wear or damage. If necessary, replace any
Removal of the piston pin bushing in the connecting components that are worn or damaged.
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more NOTICE
information refer to your authorized Perkins distribu- Removal of the piston pin bushing in the connecting
tor. rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins distribu-
tor.
g01351358
Illustration 157
This document has been printed from SPI². Not for Resale
78 KENR6241
Disassembly and Assembly Section
g01352211 g01359107
Illustration 158 Illustration 160
g01359108
Illustration 161
(X) Number
(Y) Number
3. Lubricate piston pin bearing (12) and lubricate Note: Ensure that the retaining rings are seated in
the bore for the piston pin in piston (2) with clean the grooves in the piston.
engine oil.
6. Follow Steps 6.a through 6.e in order to install the
piston rings to the piston.
This document has been printed from SPI². Not for Resale
KENR6241 79
Disassembly and Assembly Section
g00829406
Illustration 164
Piston from a turbocharged engine
g01352230
Illustration 163
Piston from a turbocharged engine g01359137
Illustration 165
a. Position the spring for oil control ring (7) into the The correct position of the piston ring gaps
oil ring groove in the piston. The central wire (AA) Ring gap of the top compression ring
must be located inside the end of the spring. (BB) Ring gap of the intermediate compression ring
(CC) Ring gap of the oil control ring
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80 KENR6241
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
End By:
Installation Procedure
Table 42
Required Tools
Tool Part Number Part Description Qty
B 21825491 Piston Ring Compressor 1
g01359137
Illustration 168
The correct position of the piston ring gaps
(AA) Ring gap of the top compression ring
(BB) Ring gap of the intermediate compression ring
(CC) Ring gap of the oil control ring
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KENR6241 Worldwide Parts Source LLC Phone 269 673 2313 Parts Source
4. Align the piston ring gaps to the positions that 10. If the engine is equipped with a balancer, install
are shown in Illustration 168. Install Tooling (B) the balancer. Refer to Disassembly and Assembly,
onto piston (3). Ensure that Tooling (B) is installed “Balancer - Install”.
correctly and that the piston can easily slide from
the tool. End By:
Note: Use tape or rubber tubing on the connecting a. Install the oil strainer and install the engine oil pan.
rod bolts to protect the crankshaft pin from damage. Refer to Disassembly and Assembly, “Engine Oil
Ensure that the piston and the connecting rod Pan - Remove and Install”.
assembly are installed in the correct cylinder.
b. Install the cylinder head. Refer to Disassembly
5. Carefully push the piston and the connecting rod and Assembly, “Cylinder Head - Install”.
assembly into the cylinder bore and onto the
crankshaft pin.
i02748595
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
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82 KENR6241
Disassembly and Assembly Section
i02748597
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01361963
Illustration 171
Typical example
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KENR6241 83
Disassembly and Assembly Section
Note: If all connecting rod bearings require The removal procedure and the installation procedure
replacement, the procedure can be carried out on must be completed for each pair of main bearing shells
two cylinders at the same time. The procedure can before the next pair of main bearing shells are re-
be carried out on the following pairs of cylinders. moved.
1 with 4 and 2 with 3. Ensure that both pairs
of the connecting rod bearings are installed NOTICE
before changing from one pair of cylinders to Keep all parts clean from contaminants.
another pair of cylinders. Refer to Disassembly
and Assembly, “Connecting Rod Bearings - Remove” Contaminants may cause rapid wear and shortened
for the correct procedure. component life.
11. Ensure that the installed connecting rod
assemblies have tactile side play. Carefully rotate 1. Ensure that the main bearing caps are marked for
the crankshaft in order to ensure that there is no the correct location and orientation.
binding.
End By:
b. Install the oil strainer and the engine oil pan. Refer
to Disassembly and Assembly, “Engine Oil Pan
- Remove and Install”.
g01353474
Illustration 172
Typical example
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84 Engine Parts
Disassembly and Assembly Section
2. Remove bolts (1). Remove main bearing cap (2) Note: The lower main bearing is a plain bearing that
from the cylinder block. has no oil holes.
g01353517
Illustration 175
Typical example
3. For number five main bearing cap, remove lower Installation Procedure
thrust washers (4) and remove seals (3).
Table 43
NOTICE
This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in po-
sition.
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KENR6241 Worldwide Parts Source LLC Phone 269 673 2313 Engine Parts
g01353916
Illustration 178
Number five main bearing cap
g01353475
Illustration 177
Number five main bearing cap
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86
Disassembly and Assembly Section
g01354237 g01354238
Illustration 179 Illustration 181
Typical example
c. Ensure that the recess in the cylinder block for
number five main bearing cap is clean and dry. 8. Use Tooling (B) in order to push seals (3) fully into
Apply a bead of Tooling (A) to the corners of the grooves.
the recess at positions (Z).
g01353474
Illustration 182
Typical example
g01359531 10. Install bolts (1) to main bearing cap (2). Evenly
Illustration 180
tighten the bolts in order to pull the main bearing
Typical example cap into position. Ensure that the main bearing
cap is correctly seated.
7. Inject a small quantity of Tooling (A) into the two
grooves in number five main bearing cap. Position For number five main bearing cap, Ensure that
new seals (3) in the grooves. Ensure that rounded the rear face of the main bearing cap is flush with
edges of the seals are outward. Push the first the rear face of the cylinder block.
25 mm (1 inch) of the seal into the grooves by
hand. Note: Do not tap the main bearing cap into position
as the bearing may be dislodged.
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KENR6241 87
Disassembly and Assembly Section
11. Tighten bolts (1) to a torque of 103 N·m (76 lb ft). Start By:
12. Rotate the crankshaft in order to ensure that there a. Remove the rocker shaft and pushrods. Refer to
is no binding. Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
a. If the engine is equipped with a balancer, install Contaminants may cause rapid wear and shortened
the balancer. Refer to Disassembly and Assembly, component life.
“Balancer - Install”. If the engine is not equipped
with a balancer, install the oil strainer and install
the engine oil pan. Refer to Disassembly and 1. The engine should be mounted on a suitable
Assembly, “Engine Oil Pan - Remove and Install”. stand and placed in the inverted position.
b. Install the flywheel housing. Refer to Disassembly Note: Use tape or rubber tubing on the connecting
and Assembly, “Flywheel Housing - Remove and rod bolts to protect the crankshaft journals from
Install”. damage.
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88 KENR6241
Disassembly and Assembly Section
g01359995 g01359996
Illustration 184 Illustration 186
3. Ensure that bearing caps (2) are marked for the 7. Attach a Tooling (A) and a suitable lifting device to
location and orientation. crankshaft (3). Carefully lift the crankshaft out of
the cylinder block. The weight of the crankshaft is
4. Remove bolts (1) from bearing caps (2). approximately 32 kg (70 lb).
5. Remove bearing caps (2) from the cylinder block. Note: Do not damage the finished surfaces on the
crankshaft.
Note: Number five main bearing cap must be
removed squarely from the cylinder block. Do not
twist the main bearing cap during removal as damage
may result.
g01359993
Illustration 187
Typical example
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KENR6241 89
Disassembly and Assembly Section
i02748601
Crankshaft - Install
Installation Procedure
Table 45
Required Tools
Tool Part Number Part Description Qty
POWERPART
A 21826038 Silicone Sealant 1
Adhesive g01360029
Illustration 188
B 27610013 Seal Installer 1 Typical example
C 21825617 Dial Indicator Group 1
5. Install upper bearings (7) to the cylinder block.
Ensure that the locating tabs for the upper
NOTICE bearings are seated in the slots in the cylinder
Keep all parts clean from contaminants. block.
Contaminants may cause rapid wear and shortened Note: The upper bearings have a groove and two
component life. oil holes.
4. Ensure that all of the lubrication passages are 8. Attach Tooling (A) and a suitable lifting device to
clean and free of debris. crankshaft (3). Carefully lift the crankshaft into
the cylinder block. The weight of the crankshaft is
approximately 32 kg (70 lb). Remove Tooling (A).
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90 KENR6241
Disassembly and Assembly Section
g01359992 g01354237
Illustration 190 Illustration 191
Number five main bearing cap
c. Apply a bead of Tooling (A) to the corners of
9. Install lower bearings (4) to main bearing caps the recess in the cylinder block at positions (Z).
(2). Ensure that the locating tabs for the lower
bearings are seated in the slots in the bearing 11. Lubricate the crankshaft journals and the lower
caps. main bearings with clean engine oil. Install main
bearing caps (2) to the cylinder block. Ensure the
Note: The lower bearings are plain bearing with no correct orientation of the main bearing caps. The
oil holes. locating tab for the upper and the lower bearing
should be on the same side of the engine.
10. For number five main bearing cap, follow Steps
10.a through 10.c in order to install the lower Note: For number five main bearing cap, ensure that
thrust washers (5) to the main bearing cap. the rear face of the main bearing cap is flush with the
rear face of the cylinder block.
a. Ensure that lower thrust washers (5) are clean
and free from wear or damage. If necessary,
replace the thrust washers. Lubricate the thrust
washers with clean engine oil.
g01359531
Illustration 192
Typical example
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KENR6241 91
Disassembly and Assembly Section
g01359530
Illustration 195
Typical example
This document has been printed from SPI². Not for Resale
92 KENR6241
Disassembly and Assembly Section
Start By:
NOTICE
Keep all parts clean from contaminants. Illustration 197
g01344011
Typical example
Contaminants may cause rapid wear and shortened
component life. 1. If necessary, install the keys (not shown) to
crankshaft (2).
1. Ensure that number one piston is at the top
center position on the compression stroke. Refer
to Systems Operation, Testing and Adjusting,
“Finding Top Center Position for No. 1 Piston”. Always wear protective gloves when handling
parts that have been heated.
2. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove”. 2. Raise the temperature of crankshaft gear (1) in an
oven to 100 °C (212 °F).
3. Use Tooling (A) to remove crankshaft gear (1) a. Install the idler gear. Refer to Disassembly and
from crankshaft (2). Assembly, “Idler Gear- Remove and Install”.
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KENR6241 93
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI². Not for Resale
94 KENR6241
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
i02748604
g01343990
Engine Oil Pressure Sensor -
Illustration 199
Typical example
Remove and Install
2. Disconnect the harness assembly (not shown)
from coolant temperature sensor (1).
Removal Procedure
3. Remove coolant temperature sensor (1) from the
cylinder head. NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI². Not for Resale
KENR6241 95
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01343988
Illustration 202
Typical example
Installation Procedure
Table 49
Removal Procedure
Required Tools NOTICE
Tool Part Number Part Description Qty Keep all parts clean from contaminants.
POWERPART Contaminants may cause rapid wear and shortened
A 21820122 1
Pipe Sealant component life.
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96 KENR6241
Disassembly and Assembly Section
g01343974 g01343974
Illustration 203 Illustration 205
Naturally aspirated engine Naturally aspirated engine
g01343965 g01343965
Illustration 204 Illustration 206
Turbocharged engine Turbocharged engine
2. Remove nuts (1) and bus bar (2). 2. Install glow plugs (3) to the cylinder head.
3. Use a deep socket in order to remove glow plugs 3. For naturally aspirated engines, use a deep socket
(3) from the cylinder head. in order to tighten the glow plugs to a torque of
18 N·m (13 lb ft).
Installation Procedure For turbocharged engines, use a deep socket
Table 50 in order to tighten the glow plugs to a torque of
25 N·m (18 lb ft).
Required Tools
Tool Part Number Part Description Qty 4. Position bus bar (2) onto glow plugs (3) and install
nuts (1). Use Tooling (A) to tighten the nuts to a
A 27610296 Torque Wrench 1 torque of 1.2 N·m (11 lb in).
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KENR6241 97
Disassembly and Assembly Section
i02748606
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
g01343666
Illustration 208
Typical example
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI². Not for Resale
98 KENR6241
Disassembly and Assembly Section
g01343637 g01343637
Illustration 209 Illustration 210
Typical example Typical example
1. Remove bolts (5) and plate (6). 2. Position fan pulley (3) onto water pump (4).
2. Remove fan (1). Note the orientation of the fan 3. If the engine is equipped with a spacer, position
for installation. spacer (2) onto pulley (3).
3. If the engine is equipped with a spacer, remove 4. Install fan (1), plate (6), and bolts (5).
spacer (2).
Note: Ensure that the fan is correctly oriented.
4. Remove pulley (3) from water pump (4).
5. Tighten bolts (5) to a torque of 18 N·m (13 lb ft).
Installation Procedure End By:
1. Ensure that all components are free from wear or
damage. If necessary, replace any components a. Install the V-Belt. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install”.
that are worn or damaged.
i02748609
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
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KENR6241 99
Disassembly and Assembly Section
g01343570
Illustration 212
Typical example
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100 Engine Parts
Disassembly and Assembly Section
Removal Procedure
g01343546
Illustration 213
Typical example
This document has been printed from SPI². Not for Resale