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Engine Parts
Disassembly and Assembly Section

Disassembly and Assembly


Section
i02748528

Fuel Priming Pump and Fuel


Filter Base - Remove and
Install

Removal Procedure g01324908


Illustration 1
Typical example
NOTICE
Care must be taken to ensure that fluids are contained 3. Drain fuel filter (4). Refer to Operation and
during performance of inspection, maintenance, test- Maintenance Manual, “Fuel System Primary
ing, adjusting and repair of the product. Be prepared to Filter/Water Seperator - Drain”.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 4. Disconnect harness assembly (1) from fuel
nent containing fluids. priming pump (2).

Dispose of all fluids according to local regulations and 5. Disconnect the tube assemblies (not shown) from
mandates. fuel filter base (3).

6. Remove bolts (5) and remove fuel filter base (3).


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

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

2. Position fuel filter base (3) on the mounting


bracket. Install bolts (5) to the fuel filter base.
Tighten the bolts to a torque of 35 N·m (26 lb ft).

3. Connect the tube assemblies for the fuel inlet and


the fuel outlet (not shown) to fuel filter base (3).

4. If necessary, install a new fuel filter (4) to fuel filter


base (3). Refer to Operation and Maintenance
Manual, “Fuel System Primary Filter/Water
Seperator - Drain”.

5. Connect harness assembly (1) to fuel priming


pump (2).

6. Turn the fuel supply to the ON position.

7. Turn the battery disconnect switch to the ON


position.

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


Operation and Maintenance Manual, “Fuel System Illustration 3
g01332971
- Prime”. Typical example

i02748531

Fuel Injection Lines - Remove


and Install
(Naturally Aspirated 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.

Dispose of all fluids according to local regulations and


mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened g01332972


component life. Illustration 4
Typical example

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

Note: Do not allow the unions to turn in the fuel


injection pump when the fuel line nuts are loosened.
Use two wrenches in order to disconnect the fuel
injection lines from the fuel injection pump.

6. Remove fuel injection lines (1).

7. Use suitable caps in order to plug the open ports


of the fuel injection pump immediately.

8. Disconnect tube assembly (6) from fuel return line


(2).

9. Remove banjo bolt (9) and sealing washers (10)


from fuel injection pump (5).

10. Remove bolt (11) and remove tube assembly (6).

11. Remove nuts (7) from fuel injectors (3). Remove


fuel return line (2) and sealing washers (8) from
fuel injectors (3).
g01332971
Illustration 5
12. Use suitable caps in order to plug the open ports Typical example
of the fuel injectors immediately.

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.

Contaminants may cause rapid wear and shortened


component life.

g01332972
Illustration 6
Typical example

1. Remove the caps from fuel injectors (3) and install


new sealing washers (8) to the fuel injectors.

Note: Washers (8) have two small holes. The position


of the holes is not important.

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KENR6241 7
Disassembly and Assembly Section

2. Position fuel return line (2) onto fuel injectors (3).


NOTICE
3. Install nuts (7) onto each fuel injector. Tighten the Keep all parts clean from contaminants.
nuts to a torque of 23 N·m (17 lb ft).
Contaminants may cause rapid wear and shortened
4. Position tube assembly (6) onto the engine. component life.
Loosely connect the tube assembly to fuel return
line (2).
Note: Place identification marks on all tube
5. Install banjo bolt (9) and new sealing washers (10) assemblies for installation. Plug all lines and tube
to fuel injection pump (5). assemblies in order to prevent contamination.

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).

7. Tighten banjo bolt (9) to a torque of 18 N·m


(13 lb ft). Tighten the nut to fuel return line (2) to a
torque of 20 N·m (15 lb ft).

8. Remove the caps from the fuel injection pump.


Install fuel injection lines (1) to fuel injection pump
(5) and to fuel injectors (3).

9. Use Tooling (A) to tighten the nuts on fuel injection


lines (1) to a torque of 30 N·m (22 lb ft).

Note: Do not allow the unions to turn in the fuel


injection pump when the fuel line nuts are tightened.

10. Connect hose (4) to tube assembly (6).

11. If necessary, tighten the dipstick tube (not shown)


to a torque of 9 N·m (80 lb in).

12. Turn the fuel supply to the ON position.

13. Prime the fuel system. Refer to Operation and


Maintenance Manual, “Fuel System - Prime” for
more information.

i02748529 g01332532
Illustration 7

Fuel Injection Lines - Remove Typical example

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.

Dispose of all fluids according to local regulations and


mandates.

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.

Contaminants may cause rapid wear and shortened


component life.

g01324910
Illustration 8
Typical example

2. If necessary, loosen the dipstick tube (not shown).

3. Disconnect fuel injection lines (1) from fuel


injectors (3).

4. Disconnect fuel injection lines (1) from fuel


injection pump (5).

Note: Do not allow the unions to turn in the fuel


injection pump when the fuel line nuts are loosened.
Use two wrenches in order to disconnect the fuel
injection lines from the fuel injection pump. Illustration 9
g01332532

Typical example
5. Remove clamps (4) and remove fuel injection
lines (1).

6. Use suitable caps in order to plug the open ports


of the fuel injection pump and the fuel injectors
immediately.

7. Disconnect tube assembly (6) from fuel injector


(3). Disconnect tube assembly (6) from fuel
injection pump (5). Remove bolts (7) and remove
tube assembly (6).

8. Remove hoses (2) from fuel injectors (3).

This document has been printed from SPI². Not for Resale
KENR6241 9
Disassembly and Assembly Section

i02748534

Fuel Injection Pump - Remove

Removal Procedure
Table 3
Required Tools
Part
Tool Number Part Description Qty
A - Combination Puller 1

Start By:

a. Remove the fuel injection lines. Refer to


Disassembly and Assembly, “Fuel Injection Lines
- Remove and Install”.

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.

2. Position tube assembly (6) onto the engine and


install bolts (7). Tighten the bolts to a torque of NOTICE
18 N·m (13 lb ft). Keep all parts clean from contaminants.

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).

5. Install clamps (4). Tighten the clamps securely.

6. Use Tooling (A) to tighten the nuts on fuel injection


lines (1) to a torque of 30 N·m (22 lb ft).

Note: Do not allow the unions to turn in the fuel


injection pump when the fuel line nuts are tightened.

7. If necessary, tighten the dipstick tube (not shown)


to a torque of 9 N·m (80 lb in).

8. Turn the fuel supply to the ON position.

9. Prime the fuel system. Refer to Operation and


Maintenance Manual, “Fuel System - Prime” for
more information.

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10 KENR6241
Disassembly and Assembly Section

g01335768 g01375471
Illustration 11 Illustration 13
Typical example Typical example

2. Remove bolts (4). 6. Loosen bolt (7).

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).

9. Remove the assembly of housing (5) and fuel


injection pump (6).

g01375914
Illustration 12
Timing marks on the gears

5. Ensure that Timing marks (X) on the teeth of the


gears are aligned or make temporary marks on
the gears for installation purposes.

g01335808
Illustration 14
Typical example

10. Remove O-ring seal (13) from housing (5).

11. Loosen nut (11).

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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.

13. If the original fuel injection pump will be installed,


mark the flange of fuel injection pump (6) and
housing (5). Remove nuts (15).

Note: Refer to Systems Operation, Testing and


Adjusting, “Fuel Injection Timing - Check” for the
correct method of setting the fuel injection pump
timing after installation.

14. Remove housing (5) from fuel injection pump (6).


Remove O-ring seal (14) from housing (5).

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).

Removal Procedure 4. Ensure that number one piston is at the top


center position on the compression stroke. Refer
Table 4 to Systems Operation, Testing and Adjusting,
“Finding Top Center Position for No. 1 Piston”.
Required Tools
Tool Part Number Part Description Qty
A - Combination Puller 1

Start By:

a. Remove the fuel injection lines. Refer to


Disassembly and Assembly, “Fuel Injection Lines
- Remove and Install”.

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.

Dispose of all fluids according to local regulations and


mandates.
g01366190
Illustration 16

NOTICE Typical example


Keep all parts clean from contaminants.
5. Remove bolts (8).
Contaminants may cause rapid wear and shortened
component life. 6. Remove plate (6) from front housing (5).

7. Remove O-ring seal (7) from plate (6).

This document has been printed from SPI². Not for Resale
12 KENR6241
Disassembly and Assembly Section

g01375914
Illustration 17
Timing marks on the gears

8. Ensure that Timing marks (X) on the teeth of the


gears are aligned or make temporary marks on
the gears for installation purposes.
g01375949
Illustration 19
Typical example

13. Remove O-ring seal (16) from housing (9).

14. Loosen nut (14).

Note: Do not remove the nut at this time.

15. Use Tooling (A) to loosen gear (15). Remove nut


(14) and gear (15).

16. If the original fuel injection pump will be installed,


mark the flange of fuel injection pump (2) and
housing (9). Remove nuts (18).

Note: Refer to Systems Operation, Testing and


Adjusting, “Fuel Injection Timing - Check” for the
correct method of setting the fuel injection pump
timing after installation.
g01375476
Illustration 18 17. Remove housing (9) from fuel injection pump (2).
Typical example Remove O-ring seal (17) from housing (9).

9. Loosen bolt (10).

10. Remove fasteners (11), bolt (13) and bracket (12).

11. Support fuel injection pump (2) and remove bolt


(10).

12. Remove the assembly of housing (9) and fuel


injection pump (2).

This document has been printed from SPI². Not for Resale
KENR6241 13
Disassembly and Assembly Section

i02748536 6. Install a new O-ring seal (16) to housing (9). Install


gear (15) to fuel injection pump (2). Install nut (14)
Fuel Injection Pump - Install finger tight.
(Fuel Injection Pumps With
a Water Heated Cold Start
Device)

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

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”.
g01375476
Illustration 21
Typical example

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.

5. Tighten nuts (18) to a torque of 18 N·m (13 lb ft).

This document has been printed from SPI². Not for Resale
14 KENR6241
Disassembly and Assembly Section

15. Fill the cooling system with coolant. Refer to


Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.

16. Adjust the fuel injection pump timing. Refer to


Systems Operation, Testing and Adjusting, “Fuel
Injection Timing - Check”.

End By:

a. Install the fuel injection lines. Refer to Disassembly


and Assembly, “Fuel Injection Lines - Remove
and Install”.

i02748535

Fuel Injection Pump - Install

g01366190
Illustration 23
Typical example
Installation Procedure

10. Install a new O-ring seal (7) to plate (6). NOTICE


Keep all parts clean from contaminants.
11. Position plate (6) on front housing (5). Install
bolts (8). Tighten the bolts to a torque of 18 N·m Contaminants may cause rapid wear and shortened
(13 lb ft). component life.

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

13. Install hose (3) to fuel injection pump (2). Tighten


the hose clamps securely.

14. Connect hoses (1) and (4) to fuel injection pump g01335808
Illustration 25
(2). Tighten the hose clamps securely.
Typical example

This document has been printed from SPI². Not for Resale
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.

4. Position housing (5) on fuel injection pump (6). 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 (15) finger tight.

5. Tighten nuts (15) to a torque of 18 N·m (13 lb ft).

6. Install a new O-ring seal (13) to housing (5). Install


gear (12) to fuel injection pump (6). Install nut (11)
finger tight.

g01335768
Illustration 28
Typical example

10. Install a new O-ring seal (3) to plate (2).

11. Position plate (2) on front housing (1). Install


bolts (4). Tighten the bolts to a torque of 18 N·m
(13 lb ft).

12. Tighten bolt (7) to a torque of 18 N·m (13 lb ft).


Tighten bolt (10) to a torque of 18 N·m (13 lb ft).
Tighten fasteners (8) to a torque of 35 N·m
g01375471
Illustration 26 (26 lb ft). Refer to Illustration 26.
Typical example
13. Adjust the fuel injection pump timing. Refer to
Systems Operation, Testing and Adjusting, “Fuel
Injection Timing - Check”.

End By:

a. Install the fuel injection lines. Refer to Disassembly


and Assembly, “Fuel Injection Lines - Remove
and Install”.

g01375914
Illustration 27
Timing marks on the gears

7. Install the assembly of housing (5) and fuel


injection pump (6) to the engine. Ensure that
Timing marks (X) on the teeth of the gears are in
the correct position. Install bolt (7) finger tight.

This document has been printed from SPI². Not for Resale
16 KENR6241
Disassembly and Assembly Section

i02748539 Installation Procedure


Fuel Injector - Remove and NOTICE
Install Keep all parts clean from contaminants.
(Naturally Aspirated Engines) Contaminants may cause rapid wear and shortened
component life.

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.

a. Remove the fuel injection lines. Refer to


Disassembly and Assembly, “Fuel Injection Lines
- Remove and Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

NOTICE
Care must be taken to ensure that fluids 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:

a. Install the fuel injection lines. Refer to Disassembly


and Assembly, “Fuel Injection Lines - Remove
and Install”.

i02748538

Fuel Injector - Remove and


Install
g01325773
(Turbocharged Engines)
Illustration 29
Typical example

1. Use a deep socket to remove fuel injectors (2) Removal Procedure


from the cylinder head.
Start By:
2. Remove seat washers (1).
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection Lines
- Remove and Install”.

This document has been printed from SPI². Not for Resale
KENR6241 17
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

NOTICE
Care must be taken to ensure that fluids 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.

3. Install fuel injectors (2) into the cylinder head.

4. Position clamps (4) onto fuel injectors (2) and


install bolts (3). Tighten bolts (3) to a torque of
22 N·m (16 lb ft).

End By:

a. Install the fuel injection lines. Refer to Disassembly


and Assembly, “Fuel Injection Lines - Remove
and Install”.

g01325781
Illustration 31 i02748540

1. Remove bolts (3) and clamps (4) from fuel Turbocharger - Remove
injectors (2).

2. Remove fuel injectors (2) from the cylinder head.

3. Remove seat washers (1).


Removal Procedure
NOTICE
Installation Procedure Keep all parts clean from contaminants.

NOTICE Contaminants may cause rapid wear and shortened


Keep all parts clean from contaminants. component life.

Contaminants may cause rapid wear and shortened


component life. NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
1. Clean the bores for the fuel injectors in the cylinder ing, adjusting and repair of the product. Be prepared to
head. Ensure that no debris enters the cylinders. collect the fluid with suitable containers before open-
Clean the fuel injectors. ing any compartment or disassembling any compo-
nent containing fluids.

Dispose of all fluids according to local regulations and


mandates.

This document has been printed from SPI². Not for Resale
18 KENR6241
Disassembly and Assembly Section

g01336694
Illustration 33
Typical example

1. Loosen hose clamps (6) and remove hose (4).


Plug the connection on the inlet manifold with a
suitable plug.

2. Remove bolts (5) and remove air pipe (3) from


turbocharger (1). Remove gasket (2).

3. Plug the opening in the inlet manifold and the


opening in the turbocharger with suitable plugs.
g01336699
Illustration 34
Typical example

g01337174
Illustration 35

4. Follow Steps 4.a through 4.c in order to remove


tube assembly (9) for the oil feed.

a. Remove tube clamp (17) that secures tube


assembly (9) to tube assembly (12). Note the
position of the clamp.

This document has been printed from SPI². Not for Resale
KENR6241 19
Disassembly and Assembly Section

b. Remove banjo bolt (14) and sealing washers


(15). Disconnect tube assembly (9) from
adapter (16) in the cylinder block.

Note: Do not allow adapter (16) to turn in the cylinder


block when the banjo bolt is loosened. Use two
wrenches in order to disconnect the tube assembly.

c. Remove banjo bolt (7) and sealing washers (8).


Remove tube assembly (9) from turbocharger
(1).

5. Follow Steps 5 through 5.c in order to remove the


tube assembly (12) for the oil drain.

a. Remove bolts (13). Disconnect tube assembly


(12) from turbocharger (1).

b. Remove joint (11).

c. If necessary, loosen the hose clips and remove


tube assembly (12) from the adapter in the
cylinder block.

6. Remove the double nuts (not shown) that secure


turbocharger (1) to the exhaust manifold.

7. Remove turbocharger (1) from the exhaust


manifold. Remove gasket (10).

8. Plug the oil supply and the oil drain ports in


the turbocharger and in the cylinder block with
suitable plugs.

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.

This document has been printed from SPI². Not for Resale
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).

Note: Do not allow adapter (16) to turn in the cylinder


block. Removal Procedure
Start By:

a. If the engine is equipped with a turbocharger,


remove the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Remove”.

Hot engine components can cause injury from


burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
g01337174
Illustration 37
NOTICE
10. Install clamp (17) to tube assemblies (9) and (12). Keep all parts clean from contaminants.
Tighten the fasteners securely.
Contaminants may cause rapid wear and shortened
component life.

g01333088
Illustration 39
Exhaust manifold from a naturally aspirated engine

1. Loosen bolts (1).


g01336694
Illustration 38
Typical example Note: In order to prevent distortion of the exhaust
manifold, Loosen the outer bolts first.

This document has been printed from SPI². Not for Resale
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)

NOTICE Removal Procedure


Keep all parts clean from contaminants.
Start By:
Contaminants may cause rapid wear and shortened
component life. a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection Lines
1. Ensure that the exhaust manifold is clean and - Remove and install”.
free from damage. Clean the joint surface of the
cylinder head. NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g01333101
Illustration 40
Exhaust manifold from a naturally aspirated engine

2. Install Tooling (A) to the cylinder head in positions


g01333458
(X). Illustration 41
Typical example
3. Position a new exhaust manifold gasket (3) onto
Tooling (A).

Note: Ensure that the exhaust manifold gasket is


correctly oriented.

4. Align exhaust manifold (2) with Tooling (A). Install


the exhaust manifold to the cylinder head.

5. Install bolts (1) finger tight.

6. Remove Tooling (A). Install the remaining bolts


(1) finger tight.

7. Tighten bolts (1) to a torque of 30 N·m (22 lb ft).

This document has been printed from SPI². Not for Resale
22 KENR6241
Disassembly and Assembly Section

g01333457 g01333458
Illustration 42 Illustration 43
Typical example Typical example

1. Loosen the hose clamps and disconnect the air


hose (not shown) from connection (3).

2. For naturally aspirated engines, disconnect the


hose for the crankcase breather (not shown) from
inlet manifold (1).

For turbocharged engines, remove the bolt that


secures the hose for the crankcase breather (not
shown) from the inlet manifold (1).

3. Remove bolts (6) from inlet manifold (1). Note the


position of any brackets that are retained by the
bolts for installation.
g01333457
Illustration 44
4. Remove inlet manifold (1) and gasket (5) from the Typical example
cylinder head.
2. If necessary, position a new gasket (2) and
5. If necessary, remove bolts (4) and remove connection (3) onto inlet manifold (1). Install
connection (3) from inlet manifold (1). Remove bolts (4). Tighten the bolts to a torque of 11 N·m
gasket (2). (97 lb in).

Installation Procedure Note: Ensure correct orientation of the connection.

3. Place a new gasket (5) in position on inlet manifold


NOTICE (1).
Keep all parts clean from contaminants.
4. Position inlet manifold (1) on the cylinder head.
Contaminants may cause rapid wear and shortened
component life. 5. Install bolts (6). Ensure that bolts of different
lengths are installed in the correct positions. Also
1. Ensure that all mating surfaces are clean and free ensure that any brackets that are retained by the
from debris. bolts are installed in the correct positions.

6. Tighten bolts (6) to a torque of 18 N·m (13 lb ft).

7. For naturally aspirated engines, connect the hose


for the crankcase breather (not shown) to inlet
manifold (1).

This document has been printed from SPI². Not for Resale
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

Inlet and Exhaust Valve


Springs - Remove and Install

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.

Note: Do not compress the spring so that the valve


Personal injury can result from being struck by spring retainer (2) touches the valve stem seal.
parts propelled by a released spring force.
c. Carefully rotate the crankshaft until the piston
Make sure to wear all necessary protective equip- touches the valve.
ment.
Note: Do not use excessive force to turn the
Follow the recommended procedure and use all crankshaft. The use of force can result in bent valve
recommended tooling to release the spring force. stems.

d. Continue to rotate the crankshaft and gradually


NOTICE release the pressure on Tooling (A) until the
Keep all parts clean from contaminants. piston is at the top center position. The valve
is now held in a position that allows the valve
Contaminants may cause rapid wear and shortened spring to be safely removed.
component life.
NOTICE
NOTICE Ensure that the valve spring is compressed squarely
Plug the apertures for the push rods in the cylinder or damage to the valve stem may occur.
head in order to prevent the entry of loose parts into
the engine.

This document has been printed from SPI². Not for Resale
24 KENR6241
Disassembly and Assembly Section

2. Use Tooling (A) in order to compress valve spring


(3). Remove valve keepers (1).

Note: Do not compress the valve spring so that the


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

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

4. Remove valve spring retainer (2) and remove


valve spring (3).

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.

5. Remove Tooling (A) and (B).


Improper assembly of parts that are spring loaded
can cause bodily injury.
Installation Procedure
To prevent possible injury, follow the established
Table 8 assembly procedure and wear protective equip-
Required Tools ment.
Part
Tool Number Part Description Qty NOTICE
A 21825666 Valve Spring Compressor 1 Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
B 27610235 Adapter 1

3. Install Tooling (A) and (B) in the appropriate


NOTICE position on the cylinder head in order to compress
Keep all parts clean from contaminants. the valve spring.
Contaminants may cause rapid wear and shortened 4. Apply sufficient pressure to Tooling (A) in order to
component life. install valve keepers (1).

Note: Do not compress the spring so that valve


NOTICE spring retainer (2) touches the valve stem seal.
Do not turn the crankshaft while the valve springs are
removed. Install the valve spring keepers.

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.

This document has been printed from SPI². Not for Resale
KENR6241 25
Disassembly and Assembly Section

2. Place a temporary identification mark on the


heads of the valves in order to identify the correct
position.
The valve spring keepers can be thrown from
the valve when the valve spring compressor is
Note: Do not stamp the heads of the valves.
released. Ensure that the valve spring keepers
Stamping or punching the heads of the valves could
are properly installed on the valve stem. To help
cause the valves to fracture.
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


6. Remove Tooling (A). Ensure that all of the valves parts propelled by a released spring force.
are secured in place by a valve spring and valve
keepers. Rotate the crankshaft through about Make sure to wear all necessary protective equip-
45 degrees in order to clear the piston from the ment.
valve. Lightly strike the top of the valve with a soft
hammer in order to ensure that the valve keepers Follow the recommended procedure and use all
are properly installed. recommended tooling to release the spring force.
End By:
NOTICE
a. Install the rocker shaft assembly. Refer to Ensure that the valve spring is compressed squarely
Disassembly and Assembly, “Rocker Shaft and or damage to the valve stem may occur.
Pushrod - Install”.

i02748545

Inlet and Exhaust Valves -


Remove and Install

Removal Procedure
Table 9
Required Tools
Tool Part Number Part Description Qty
Valve Spring
A 21825663 1
Compressor
B - Seal Remover 1

Start By: g01333469


Illustration 47

a. Remove the cylinder head assembly. Refer to Typical example


Disassembly and Assembly, “Cylinder Head -
Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Clean the bottom face of the cylinder head.


Check the depth of the valves below the face of
the cylinder head before the valve springs are
removed. Refer to Specifications, “Cylinder Head
Valves” for the correct dimensions.

This document has been printed from SPI². Not for Resale
26 KENR6241
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Clean all components of the cylinder head


assembly. Ensure that all ports, all coolant
passages and all lubrication passages in the
cylinder head are free from debris. Follow Steps
1.a through 1.e in order to inspect the components
of the cylinder head assembly. Replace any
components that are worn or damaged.

a. Inspect the cylinder head for wear and for


damage. Refer to Systems Operation, Testing
and Adjusting, “Cylinder Head Inspect”.

b. Inspect the valve seats for wear and for


g01333471 damage. Refer to Specifications, “Cylinder
Illustration 48
Head Valves” for further information.
Typical example
c. Inspect the valve guides for wear and for
3. Use Tooling (A) in order to compress the damage. Refer to Specifications, “Cylinder
appropriate valve spring (3). Remove valve Head Valves” and Systems Operation, Testing
keepers (1). and Adjusting, “Valve Guide - Inspect” for
further information.
Note: Do not compress the valve spring so that valve
spring retainer (2) touches valve stem seal (4). d. Inspect the valves for wear and for damage.
Refer to Specifications, “Cylinder Head Valves”.
4. Remove Tooling (A).
e. Inspect the valve springs for the correct length.
5. Remove valve spring retainer (2). Remove valve Refer to Specifications, “Cylinder Head Valves”.
spring (3).

6. Remove valve (5).

7. Use Tooling (B) to remove valve stem seal (4).

8. Repeat Steps 3 through 7 in order to remove the


remaining inlet and exhaust valves.

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

This document has been printed from SPI². Not for Resale
KENR6241 27
Disassembly and Assembly Section

2. Use Tooling (C) to install new valve stem seals (4)


onto each of the valve guides.

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”.

This document has been printed from SPI². Not for Resale
28 KENR6241
Disassembly and Assembly Section

i02748546 1. Use Tooling (A) to remove engine oil filter (6)


from engine oil filter base (5). Refer to Operation
Engine Oil Filter Base - and Maintenance Manual, “Engine Oil and Filter
Remove and Install - Change”.

2. Mark the orientation of engine oil filter base (5) for


installation. Remove bolt (2).
Removal Procedure Note: The engine oil filter base can be oriented in
different positions.
Table 11
Required Tools 3. Remove bolt (4) and remove engine oil filter base
(5) from the cylinder block. Plug the oil galleries in
Tool Part Number Part Description Qty
the cylinder block with suitable plugs.
A - Strap Wrench 1
4. Remove O-ring seal (1) from engine oil filter base
(5).
NOTICE
Keep all parts clean from contaminants. 5. Remove O-ring seal (3) from bolt (4).
Contaminants may cause rapid wear and shortened
component life. Installation 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
opening any compartment or disassembling any com-
ponent containing fluids.

Dispose of all fluids according to local regulations and


mandates.

g01333853
Illustration 53
Typical example

1. Ensure that the engine oil filter base is clean and


free from damage. Clean the mating surfaces of
the cylinder block.

2. Install a new O-ring seal (1) to engine oil filter


base (5). Install a new O-ring seal (3) to bolt (4).

3. Position engine oil filter base (5) against the


cylinder block. Install bolt (4) finger tight.
g01333853
Illustration 52
Typical example
4. Ensure the correct orientation of engine oil filter
base (5). Install bolt (2) finger tight.

Note: The engine oil filter base can be oriented in


different positions.

This document has been printed from SPI². Not for Resale
KENR6241 29
Disassembly and Assembly Section

5. Tighten bolt (4) to a torque of 50 N·m (37 lb ft).


Tighten bolt (2) to a torque of 11 N·m (97 lb in).

6. Install a new engine oil filter (6). Refer to Operation


and Maintenance Manual, “Engine Oil and Filter -
Change” for the correct procedure.

i02748547

Engine Oil Cooler - Remove

Removal Procedure
Start By:

a. Remove the fuel injection lines. Refer to


Disassembly and Assembly, “Fuel Injection Lines
- Remove”.
g01361343
Illustration 54
NOTICE Typical example
Keep all parts clean from contaminants.
3. For turbocharged engines, remove crankcase
Contaminants may cause rapid wear and shortened breather (2). Refer to Disassembly and Assembly,
component life. “Crankcase Breather - Remove and Install”.

NOTICE 4. Remove dipstick tube (1).


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.

Dispose of all fluids according to local regulations and


mandates.

1. Drain the coolant from the cooling system into


a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change” for the correct
procedure.

2. Drain the engine lubricating oil into a suitable


container for storage or disposal. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for the procedure.

This document has been printed from SPI². Not for Resale
30 KENR6241
Disassembly and Assembly Section

i02748549

Engine Oil Cooler - Install

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g01333881
Illustration 55
Typical example

5. Gradually loosen bolts (11). Note the position of


any brackets that are secured by the bolts.

6. Support the assembly of engine oil cooler (3).


Remove bolts (11) and remove the assembly of
engine oil cooler (3) from the cylinder block.

7. Remove joint (5).

8. Remove O-ring seals (4) from the recesses in the


cylinder block.
g01333881
Illustration 56
9. If necessary, follow Steps 9.a through 9.d in order Typical example
to disassemble the engine oil cooler.
1. If necessary, follow Steps 1.a through 1.e in order
a. Remove nuts (8). to assemble the engine oil cooler.

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).

This document has been printed from SPI². Not for Resale
KENR6241 31
Disassembly and Assembly Section

c. Install cooler matrix (6) to cover (7). End By:

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”.

e. Install joint (9) and plate (10).


i02748550

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.

4. Install two bolts (11) to the upper corners of the


assembly of engine oil cooler (3). Install a new Removal Procedure
joint (5) to the assembly of engine oil cooler (3).
Table 12
5. Install the assembly of engine oil cooler (3) to the
cylinder block. Install the remaining bolts (11). Required Tools
Part
Note: Ensure that any brackets that are secured by Tool Number Part Description Qty
the bolts are installed in the correct location. -
A Strap Wrench 1
6. Tighten bolts (11) evenly to a torque of 18 N·m
(13 lb ft). NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

NOTICE
Care must be taken to ensure that fluids 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.

Dispose of all fluids according to local regulations and


mandates.

g01361343
Illustration 57
Typical example

7. Install dipstick tube (1).

8. For turbocharged engines, install crankcase


breather (2). Refer to Disassembly and Assembly,
“Crankcase Breather - Remove and Install”.

9. Fill the cooling system to the correct level.


Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change” for the correct
procedure.

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.

This document has been printed from SPI². Not for Resale
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:

a. Remove the engine oil pan. Refer to Disassembly


and Assembly, “Engine Oil Pan - Remove and
Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

This document has been printed from SPI². Not for Resale
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.

Dispose of all fluids according to local regulations and


mandates.

1. If the engine is equipped with a balancer, remove


the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove”.

g01334433
Illustration 61
Typical example

2. Install a new sealing washer (2) to engine oil


bypass valve (1).

3. Install engine oil bypass valve (1) to the cylinder


block. Tighten the engine oil bypass valve to a
torque of 69 N·m (51 lb ft).

4. If the engine is equipped with a balancer, install


the balancer. Refer to Disassembly and Assembly,
“Balancer - Install”.

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).

3. Remove sealing washer (2). i02748553

Engine Oil Pump - Remove


Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Removal Procedure
Contaminants may cause rapid wear and shortened
Start By:
component life.
a. Remove the front housing. Refer to Disassembly
1. Inspect the components of the engine oil bypass and Assembly, “Housing (Front) - Remove and
valve for wear or damage. Check the valve and Install”.
the valve seat for an abnormal contact pattern.
Check the spring for weakness or damage. If NOTICE
necessary, replace the engine oil bypass valve. Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

This document has been printed from SPI². Not for Resale
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.

Contaminants may cause rapid wear and shortened


component life.

g01334869
Illustration 63

1. Ensure that bushing (8) is free from wear or


damage. Refer to Specifications, “Engine Oil
g01334537
Illustration 62 Pump” for more information. If necessary, replace
the bushing.
1. Remove nut (5) and washer (4).

2. Remove gear (3) from the shaft of engine oil pump


(1).

3. Remove bolts (6) and remove engine oil pump (1)


from the cylinder block.

4. Remove O-ring seal (2).

This document has been printed from SPI². Not for Resale
KENR6241 35
Disassembly and Assembly Section

i02748555

Water Pump - Remove and


Install

Removal Procedure
Start By:

a. If the engine is equipped with a fan, remove


the fan. Refer to Disassembly and Assembly,
“Fan - Remove and Install”. If the engine is not
equipped with a fan, remove the V-belt. Refer to
Disassembly and Assembly, “V-belts - Remove
and Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

NOTICE
Care must be taken to ensure that fluids 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).

7. Use Tooling (A) to check the backlash between


oil pump gear (3) and the idler gear. Ensure that
the backlash is within specified values. Refer to
Specifications, “Gear Group (Front)” for further
information.

End By:

a. Install the front housing. Refer to Disassembly and


Assembly, “Housing (Front) - Remove and Install”.

This document has been printed from SPI². Not for Resale
36 KENR6241
Disassembly and Assembly Section

1. Ensure that the mating surfaces of the water pump


and the cylinder block are clean and free from
damage. If the cover was removed, ensure that
the mating surfaces of the cover are clean and
free from damage.

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

3. Loosen the hose clamp and disconnect hose (1)


from water pump (2).

4. Remove bolts (4) and remove water pump (2). Do


not remove bolts (5) at this time.

Note: If necessary, gently tap the water pump with a


soft faced hammer in order to loosen the water pump. Illustration 68
g01335213

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.

NOTICE 5. Connect the hose (not shown) to the water pump


Keep all parts clean from contaminants. inlet and tighten the hose clamp.

Contaminants may cause rapid wear and shortened


component life.

This document has been printed from SPI². Not for Resale
KENR6241 37
Disassembly and Assembly Section

6. Fill the cooling system with coolant. Refer to


Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.

End By:

a. If the engine is equipped with a fan, install the


fan. Refer to Disassembly and Assembly, “Fan -
Remove and Install”. If the engine is not equipped
with a fan, install the V-belt. Refer to Disassembly
and Assembly, “V-belts - Remove and Install”.

i02748556

Water Temperature Regulator


Housing - Remove and Install

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life. Illustration 69
g01335249

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).

5. Remove bolts (7) and remove water temperature


1. Drain the coolant from the cooling system into regulator housing (6) from the cylinder head.
a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, 6. Remove joint (5).
“Cooling System Coolant - Change” for the correct
procedure.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Inspect the water temperature regulator for


wear, damage and correct operation. Refer
to Systems Operation,Testing and Adjusting,
“Water Temperature Regulator - Test” for more
information. If necessary, replace the water
temperature regulator.

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.

6. Position a new joint (3) and outlet connection (2)


onto water temperature regulator housing (6).

7. Install bolts (1). Tighten the bolts to 18 N·m


(13 lb ft).

8. Connect hose (8) to water temperature regulator


housing (6). Tighten the hose clamps securely.

9. Fill the cooling system with coolant to the correct


level. Refer to Operation and Maintenance
Manual, “Cooling System Coolant -Change” for
the correct procedure.

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.

Contaminants may cause rapid wear and shortened


component life.

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).

3. Remove two bolts (1) from Positions (X) on the


flywheel. Always wear protective gloves when handling
parts that have been heated.
4. Install Tooling (A) in positions (X) on the flywheel.

5. Remove the remaining bolts (1) and remove


flywheel (2).

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.

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


temperature of 150°C (302°F) prior to
installation.

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

Crankshaft Rear Seal - Remove


and Install

Removal Procedure
Table 16
Required Tools
Tool Part Number Part Description Qty
g01335288
Illustration 75
A - Drill Bit (4.10 mm) 1
Typical example

B 27610311 Slide Hammer Puller 1


2. Thoroughly clean the flywheel housing. Inspect
the crankshaft rear seal for leaks. If there are any
oil leaks replace the crankshaft rear seal. Refer Start By:
to Disassembly and Assembly, “Crankshaft Rear
Seal - Remove and Install”. a. Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove”.
3. Ensure that the dowels are installed to the
crankshaft. Install Tooling (A) to positions (X) in
the crankshaft. NOTICE
Care must be taken to ensure that fluids are contained
4. Install a suitable lifting device to flywheel (2). The during performance of inspection, maintenance, test-
weight of the flywheel is approximately 23 kg ing, adjusting and repair of the product. Be prepared to
(50 lb). collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
5. Align flywheel (2) with Tooling (A). Install the nent containing fluids.
flywheel to the crankshaft.
Dispose of all fluids according to local regulations and
Note: Ensure the correct orientation of the flywheel mandates.
on the crankshaft.
NOTICE
6. Install bolts (1) finger tight. Keep all parts clean from contaminants.
7. Remove Tooling (A) and install the two remaining Contaminants may cause rapid wear and shortened
bolts (1). component life.
8. Remove the lifting device from the flywheel.

9. Use a suitable tool to prevent flywheel (2) from


rotating. Tighten bolts (1) to a torque of 83 N·m
(61 lb ft).

10. Check the concentricity of the flywheel. Refer


to Systems Operation, Testing and Adjusting,
“Flywheel - Inspect”.

This document has been printed from SPI². Not for Resale
KENR6241 41
Disassembly and Assembly Section

1. Ensure that the flange of the crankshaft and the


inside of the flywheel housing are clean and free
of damage. It is possible to reclaim a crankshaft
flange that has a worn seal surface, or a damaged
seal surface by installing a wear sleeve. Refer to
Disassembly and Assembly, “Crankshaft Wear
Sleeve (Rear) - Remove and Install” for more
information.

g01335312
Illustration 76
Typical example

1. Use Tooling (A) to drill three evenly spaced holes


in crankshaft rear seal (2).

2. Use Tooling (B) to carefully remove crankshaft


rear seal (2) from flywheel housing (1). Alternate
g01335312
the position of Tooling (B) from one hole to another Illustration 77
hole. This will allow you to evenly remove the Typical example
crankshaft rear seal from the flywheel housing.

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

NOTICE 2. Apply a thin coat of clean engine oil to the lip of


Keep all parts clean from contaminants. crankshaft rear seal (2).

Contaminants may cause rapid wear and shortened 3. Use Tooling (C) in order to install crankshaft rear
component life. seal (2), as follows:

a. Align the locator with the dowels in crankshaft


(3). Install the locator to the crankshaft. Ensure
the correct orientation of the locator.

Note: Check that the installer will slide freely over


the locator.

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.

c. Assemble the installer to the locator and install


the bolt and the washer. Ensure that the face
of the installer with the deep counterbore is
toward crankshaft rear seal (2).

d. Tighten the bolt until the installer bottoms out


on the locator in order to pull crankshaft rear
seal (2) into flywheel housing (1).

e. Remove Tooling (C).

End By:

a. Install the flywheel. Refer to Disassembly and g01384938


Assembly, “Flywheel - Install”. Illustration 79

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


i02748560 wear sleeve (1) from crankshaft (2).
Crankshaft Wear Sleeve (Rear)
Installation Procedure
- Remove and Install
Table 19
Required Tools
Tool Part Number Part Description Qty
Removal Procedure
27610266 Oil Seal Installer 1
Table 18
27610345 Oil Seal Locator 1
Required Tools
27610346 Bolt 1
Part B
Tool Part Description Qty 28710476 Hard Washer 1
Number
A - Puller 1 Bolt
27610266 (M12 x 1.25 by 20 2
mm)
Start By:

a. Remove the crankshaft rear seal. Refer to NOTICE


Disassembly and Assembly, “Crankshaft Rear Keep all parts clean from contaminants.
Seal - Remove and Install”.
Contaminants may cause rapid wear and shortened
NOTICE component life.
Keep all parts clean from contaminants.
Note: Wear sleeves are used to reclaim worn seal
Contaminants may cause rapid wear and shortened surfaces or damaged seal surfaces. Wear sleeves
component life. are not original equipment. The wear sleeve is
supplied with a crankshaft rear seal that has a larger
internal diameter than a standard crankshaft rear
seal. A standard crankshaft rear seal cannot be used
if a wear sleeve is installed.

1. Ensure that the crankshaft is thoroughly clean and


dry. Remove any areas of raised damage.

This document has been printed from SPI². Not for Resale
KENR6241 43
Disassembly and Assembly Section

2. Lubricate the inner surface of the crankshaft wear i02748561


sleeve with clean engine oil.
Flywheel Housing - Remove
and Install

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).

e. Remove Tooling (A). 1. Support the engine.

End By:

a. Install the new crankshaft rear seal that was


supplied with the crankshaft wear sleeve. Refer
to Disassembly and Assembly, “Crankshaft Rear
Seal - Remove and Install”.

This document has been printed from SPI². Not for Resale
44 KENR6241
Disassembly and Assembly Section

7. Remove joint (1).

8. Remove crankshaft rear seal (4) from flywheel


housing (2).

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.

g01335374 Contaminants may cause rapid wear and shortened


Illustration 81
component life.
Typical example

1. Ensure that the mating surfaces of the cylinder


block and the flywheel housing are clean and free
from damage.

g01366220
Illustration 82
Typical example

2. Remove two bolts (5) from positions (X) on


flywheel housing (2).

3. Install Tooling (A) to positions (X) on flywheel


housing (2).

4. Attach a suitable lifting device to flywheel


housing (2). The weight of the flywheel housing is Illustration 83
g01335383
approximately 32 kg (71 lb).
Typical example

5. Remove the remaining bolts (5).


2. Inspect dowels (3) in the cylinder block. If
necessary, replace the dowels.
6. Carefully remove flywheel housing (2) from dowels
(3) and from the cylinder block.

Note: If necessary, tap the flywheel housing with a


soft faced hammer in order to separate the flywheel
housing from the cylinder block.

This document has been printed from SPI². Not for Resale
KENR6241 45
Disassembly and Assembly Section

i02748562

Crankshaft Pulley - Remove


and Install

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).

10. Remove the lifting device.

11. Use Tooling (B) to check the alignment of the


flywheel housing with the crankshaft. Refer
to Systems Operation, Testing and Adjusting,
“Flywheel Housing - Inspect”.

12. Install a new crankshaft rear seal (4). Refer to


Disassembly and Assembly, “Crankshaft Rear
Seal - Install”.

End By:

a. Install the flywheel. Refer to Disassembly and


Assembly, “Flywheel - Install”.

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

2. Use Tooling (A) in order to loosen nut (3).

Note: Do not remove the nut at this time.

3. Install Tooling (B) to crankshaft pulley (2). Use


Tooling (B) to loosen the crankshaft pulley.
Remove Tooling (B).

4. Remove nut (3) and remove crankshaft pulley (2).


g01368691
5. If necessary, remove woodruff key (1) from Illustration 87
crankshaft (4). 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).

4. Use a suitable method to prevent the crankshaft


NOTICE from rotating.
Keep all parts clean from contaminants.
5. Install nut (3). Tighten the nut to a torque of
Contaminants may cause rapid wear and shortened 490 N·m (361 lb ft).
component life.
End By:

a. Install the V-belt. Refer to Disassembly and


Assembly, “V-belts - Remove and Install”.

This document has been printed from SPI². Not for Resale
KENR6241 47
Disassembly and Assembly Section

i02748563 Installation Procedure


Crankshaft Front Seal - Table 25

Remove and Install Required Tools


Part
Tool Number Part Description Qty
Seal Installer Stud 1
Removal Procedure
C 27610268 Washer 1
Table 24
Required Tools Seal Installer Sleeve 1
Tool Part Number Part Description Qty
A - Drill Bit (4.10 mm) 1 NOTICE
Keep all parts clean from contaminants.
B 27610311 Slide Hammer Puller 1
Contaminants may cause rapid wear and shortened
Start By: component life.

a. Remove the crankshaft pulley. Refer to


Disassembly and Assembly, “Crankshaft Pulley
- Remove and Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

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

1. Ensure that the bore in front housing (1) and the


nose of the crankshaft are clean and free from
damage.

2. Lubricate the outside diameter of a new crankshaft


front seal (2) with clean engine oil.

3. Position crankshaft front seal (2) in the bore of


front housing (1).

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:

a. Install the crankshaft pulley. Refer to Disassembly


and Assembly, “Crankshaft Pulley - Remove and
Install”.

i02748564

Front Cover - Remove and


Install

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life. g01335768
Illustration 91
Typical example

1. Ensure that the mating surface of front housing (1)


and plate (2) are clean and free from damage.

2. Install a new O-ring seal (3) to plate (2).

3. Position plate (2) onto front housing (1).

4. Install bolts (4) and tighten to 18 N·m (13 lb ft).

i02748565

Idler Gear - Remove and Install

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.

Contaminants may cause rapid wear and shortened


component life.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Dispose of all fluids according to local regulations and


mandates.

1. Ensure that number one piston is at the top


center position on the compression stroke. Refer
g01337783
to Systems Operation, Testing and Adjusting, Illustration 93
“Finding Top Center Position for No. 1 Piston”. Typical example

4. Remove bolt (2), washer (3), and plate (4).

5. Remove idler gear (5) from shaft (1).

g01337345
Illustration 92
Alignment of timing marks

2. Ensure that timing marks (X) on the gears are


g01337810
aligned. Refer to Illustration 92. Illustration 94
Extracting the shaft from the cylinder block
Alternatively, make temporary timing marks on the
gears in order to show alignment. 6. If necessary, follow Steps 6.a and 6.b in order to
remove shaft (1).
3. Loosen the nuts on all rocker arms. Unscrew the
adjusters on all rocker arms until all valves are a. Make a temporary mark on the cylinder block
fully closed. in order to show the position of oil hole (Y).

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.

Contaminants may cause rapid wear and shortened


component life.

g01337345
Illustration 96
Alignment of timing marks

4. Lubricate shaft (1) with clean engine oil. Position


idler gear (5) onto shaft (1). Ensure that timing
marks (X) on the gears are aligned. Refer to
Illustration 96.

5. Lubricate the bearing surface of plate (4) with


clean engine oil. Install plate (4), washer (3), and
bolt (2).

Note: Ensure that the bearing surface of the plate


Illustration 95
g01364486 is toward the idler gear.
Typical example
6. Tighten bolt (2) to a torque of 34 N·m (25 lb ft).
1. If necessary, follow Steps 1.a and 1.b in order to
install shaft (1). 7. Use a feeler gauge in order to check the end play
of idler gear (2). Refer to Specifications, “Gear
a. Align oil hole (Y) on shaft (1) with the temporary Group (Front)” for more information.
mark on the cylinder block.
8. Use Tooling (B) in order to inspect the backlash
b. Use a soft faced hammer and a hard wooden of the gear group. Refer to Systems Operation,
drift to install shaft (1) into the cylinder block. Testing and Adjusting, “Gear Group - Inspect”.

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

Housing (Front) - Remove and


Install

Removal Procedure
Start By:

a. Remove the fan. Refer to Disassembly and


Assembly, “Fan - Remove and Install”.

b. Remove the alternator. Refer to Disassembly and


Assembly, “Alternator - Remove and Install”.

c. Remove the crankshaft pulley. Refer to


Disassembly and Assembly, “Crankshaft Pulley
- Remove and Install”.
g01349330
Illustration 97
d. Remove the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install”. Typical example

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).

Note: Avoid damage to crankshaft front seal (3)


NOTICE
when the front housing is removed.
Keep all parts clean from contaminants.
3. Remove joint (5).
Contaminants may cause rapid wear and shortened
component life.
Note: It is not necessary to remove dowels (1).

NOTICE Installation Procedure


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- NOTICE
ing, adjusting and repair of the product. Be prepared to Keep all parts clean from contaminants.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Contaminants may cause rapid wear and shortened
nent containing fluids. component life.
Dispose of all fluids according to local regulations and
mandates.

This document has been printed from SPI². Not for Resale
52 KENR6241
Disassembly and Assembly Section

d. Install the alternator. Refer to Disassembly and


Assembly, “Alternator - Remove and Install”.

e. Install the fan. Refer to Disassembly and


Assembly, “Fan - Remove and Install”.

i02748568

Front Plate - Remove

Removal Procedure
Start By:

a. Remove the fuel injection pump. Refer to


Disassembly and Assembly, “Fuel Injection Pump
- Remove”.

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.

3. Install a new joint (5) to plate (6). Ensure that the


joint is correctly seated on dowels (1).

4. Align front housing (4) with dowels (1). Install the


front housing to plate (6).

Note: Ensure that the crankshaft front seal is not


damaged when the front housing is installed.

5. Install bolts (2). Tighten the bolts to a torque of


18 N·m (13 lb ft).

End By: Illustration 99


g01365310

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”.

c. Install the crankshaft pulley. Refer to Disassembly


and Assembly, “Crankshaft Pulley - 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

Front Plate - Install

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g01365310
Illustration 102

5. Position gear (1) onto the shaft of engine oil pump


(4). Ensure that the gear is aligned with the flat on
the shaft. Install washer (2) and nut (3). Tighten
the nut to a torque of 33 N·m (24 lb ft).

6. If necessary, Install the bracket for the alternator


(not shown) to plate (7).

This document has been printed from SPI². Not for Resale
54 KENR6241
Disassembly and Assembly Section

End By:

a. Install the camshaft. Refer to Disassembly and


Assembly, “Camshaft - Remove and Install”.

b. Install the idler gear. Refer to Disassembly and


Assembly, “Idler Gear - Remove and Install”.

c. Install the fuel injection pump. Refer to


Disassembly and Assembly, “Fuel Injection Pump
- Install”.

i02748570

Crankcase Breather - Remove


and Install
(Turbocharged Engines)

g01344989
Illustration 103
Removal Procedure Typical example

NOTICE 1. Loosen the hose clamp and disconnect hose (3)


Keep all parts clean from contaminants. from crankcase breather (1).
Contaminants may cause rapid wear and shortened 2. Loosen the hose clamp and disconnect hose (4)
component life. from crankcase breather (1).

3. Remove bolts (2) and remove crankcase breather


NOTICE
(1).
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 Installation Procedure
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- NOTICE
nent containing fluids. Keep all parts clean from contaminants.

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

Valve Mechanism Cover -


Remove and Install

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

NOTICE
Care must be taken to ensure that fluids 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

3. Remove bolts (7). Remove valve mechanism


cover (8) from the cylinder head.

4. Remove seal (9) from valve mechanism cover (8).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Thoroughly clean the valve mechanism cover.


Clean the mating surfaces of the cylinder head.

g01336694
Illustration 108
Typical example

6. If the engine is equipped with a turbocharger,


follow Steps 6.a through 6.c in order to install the
air pipe.

a. Remove the plugs from the inlet manifold and


from the turbocharger.

b. Position a new joint (2) and air pipe (3) onto


turbocharger (1). Install bolts (5). Tighten the
bolts to a torque of 18 N·m (13 lb ft).

c. Install hose (4) and tighten hose clamps (6)


securely.
g01345049
Illustration 107
i02748572
2. Install a new seal (9) to valve mechanism cover
(8). Rocker Shaft and Pushrod -
Note: Ensure that the joint is fully seated into the Remove
groove of the valve mechanism cover.

3. Place valve mechanism cover (8) in position on


the cylinder head. Removal Procedure
4. Install bolts (7). Tighten the bolts to a torque of Start By:
12 N·m (106 lb in).
a. Remove the valve mechanism cover. Refer to
5. Connect hose (10) to valve mechanism cover (8) Disassembly and Assembly, “Valve Mechanism
and tighten the hose clamp. Cover - Remove and Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

This document has been printed from SPI². Not for Resale
KENR6241 57
Disassembly and Assembly Section

i02748573

Rocker Shaft - Disassemble

Disassembly Procedure
Table 28
Required Tools
Part
Tool Number Part Description Qty
A - Retaining Ring Pliers 1

Start By:

a. Remove the rocker shaft and pushrods. Refer to


Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
g01345395
Illustration 109
Typical example

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.

Note: Damage to the rocker shaft may occur if the


NOTICE
long bolts are loosened first. To avoid distortion
Keep all parts clean from contaminants.
of the rocker shaft assembly, each bolt should be
loosened by a quarter of a turn at one time. Repeat
Contaminants may cause rapid wear and shortened
the procedure until all bolts are loosened.
component life.
4. Remove bolts (3).

5. Remove rocker shaft assembly (2) from the


cylinder head.

6. Place temporary identification marks on pushrods


(4) and pads (6).

Note: Identification will ensure that the pushrods and


pads can be reinstalled in the correct position. Do not
interchange the positions of used pushrods or pads.

7. Remove pushrods (4) from the cylinder head.


Remove pads (6) from the valve stems.

This document has been printed from SPI². Not for Resale
58 KENR6241
Disassembly and Assembly Section

i02748575

Rocker Shaft - Assemble

Assembly Procedure
Table 29
Required Tools
Part
Tool Number Part Description Qty
A - Retaining Ring Pliers 1

1. Ensure that all components are clean and free


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

Note: Ensure that all oil holes are free from


blockages.

2. Lubricate all of the components with clean engine


oil before assembly.
g01345402
Illustration 110

1. Make an identification mark on each rocker arm


assembly in order to show the location. Note the
mark at position (X) for installation purposes.

Note: The components must be reinstalled in the


original location. Do not interchange components.

2. Use Tooling (A) to remove retaining rings (8).

3. Remove rocker arm assembly (5).

4. Remove pedestal (6) from rocker shaft (3).

5. Remove rocker arm assembly (7).

6. Remove spring (4).

7. Repeat Steps 3 through 6 in order to remove the


remaining rocker arm assemblies from rocker
shaft (3).

8. If necessary, remove nuts (1) and adjusters


(2) from the rocker arms. Make a temporary
identification mark on each adjuster in order to
show the location.
g01345402
Illustration 111
Note: The components must be reinstalled in the
original location. Do not interchange components. 3. If necessary, install nuts (1) and adjusters (2) to
rocker arm assemblies (5) and (7). If the original
adjusters are reused, ensure that the adjusters
are installed in the original positions.

This document has been printed from SPI². Not for Resale
KENR6241 59
Disassembly and Assembly Section

4. Use Tooling (A) to install retaining ring (8) to the


front end of rocker shaft (3). The front end of the
rockershaft is identified by the mark at Position
(X). Ensure that the mark at position (X) is upward.

5. Install rocker arm assembly (5) to rocker shaft (3).

6. Install bracket (6) to rocker shaft (3).

Note: Ensure correct orientation of the bracket. Refer


to Illustration 111.

7. Install rocker arm assembly (7) to rocker shaft (3).

Improper assembly of parts that are spring loaded


can cause bodily injury.

To prevent possible injury, follow the established


assembly procedure and wear protective equip- g01345395
ment. Illustration 112
Typical example

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.

5. Install bolts (3) to the rocker shaft. Tighten the


bolts to a torque of 15 N·m (11 lb ft). Begin at
Installation Procedure the center of the rocker shaft assembly and work
outward.
NOTICE
Keep all parts clean from contaminants. Note: Damage to the rockershaft may occur if the
short bolts are tightened first.
Contaminants may cause rapid wear and shortened
component life. 6. Install bolts (5) to the rocker shaft. Tighten the
bolts to a torque of 15 N·m (11 lb ft).

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

Cylinder Head - Remove

Removal Procedure
Table 30
Required Tools
Tool Part Number Part Description Qty
A - Lifting Bracket 2

Start By:

a. Remove the exhaust manifold. Refer to


Disassembly and Assembly, “Exhaust Manifold
- Remove and Install”.
g01362487
Illustration 113
b. Remove the fuel injectors. Refer to Disassembly Typical example
and Assembly, “Fuel Injectors - Remove and
Install”. 2. Disconnect hose (2) from water temperature
regulator housing (1).
c. Remove the glow plugs. Refer to Disassembly
and Assembly, “Glow Plugs - Remove and Install”. 3. Remove breather hose (4).

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.

Contaminants may cause rapid wear and shortened


component life.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the 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

9. Note the position of dowels (8) in the cylinder


block. Do not remove the dowels unless the
dowels are damaged.

g01346253
Illustration 115

5. Gradually loosen cylinder head bolts (5) in reverse


numerical order to the sequence that is shown in
Illustration 114. This will prevent distortion of the
cylinder head.

6. Remove cylinder head bolts (5) from cylinder head


(6).

7. Attach Tooling (A) and a suitable lifting device to


cylinder head (6). Carefully lift the cylinder head
off the cylinder block. The weight of the cylinder
head is approximately 34 kg (75 lb).

Note: Do not use a lever to separate the cylinder


head from the cylinder block. Take care not to
damage the machined surfaces of the cylinder head
during the removal procedure. Avoid contamination
of the cylinder bores with coolant or with debris.
g01346658
Illustration 117

NOTICE Typical example


Place the cylinder head on a surface that will not
scratch the face of the cylinder head. 10. If necessary, remove bolts (11) and remove lifting
bracket (10). Remove joint (9).

8. Remove gasket (7). 11. If necessary, remove water temperature regulator


housing (1). Refer to Disassembly and Assembly,
“Water Temperature Regulator Housing - Remove
and Install”.

This document has been printed from SPI². Not for Resale
62 KENR6241
Disassembly and Assembly Section

i02748578

Cylinder Head - Install

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.

2. Inspect the mating surface of the cylinder head for


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

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

7. Use Tooling (A) and a suitable lifting device to lift


cylinder head (6). The weight of the cylinder head
is approximately 34 kg (75 lb). Align cylinder head
(6) with Tooling (B) and install the cylinder head to
the cylinder block.

Note: Ensure that the cylinder head is correctly


seated on dowels (8).

8. Remove Tooling (B).

g01362487
Illustration 123
Typical example

g01346700 13. If necessary, install water temperature regulator


Illustration 121
housing (1). Refer to Disassembly and Assembly,
“Water Temperature Regulator Housing - Remove
9. Clean cylinder head bolts (5). Inspect the threads
and Install”.
of the bolts. Use Tooling (C) in order to check the
bolts. The bolts must be renewed if there is any
14. Connect hose (2) to water temperature regulator
visual reduction in the diameter over area (X).
housing (1).
10. Lubricate the threads and the shoulder of cylinder
15. If necessary, install inlet manifold (3). Refer to
head bolts (5) with clean engine oil before
Disassembly and Assembly, “Inlet Manifold -
installation.
Remove and Install”.
11. Install cylinder head bolts (5) to cylinder head (6).
16. Install breather hose (4).

17. Install the rocker shaft and pushrods. Refer to


Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”.

18. Fill the cooling system with coolant. Refer to


Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.

End By:

a. Install the glow plugs. Refer to Disassembly and


Assembly, “Glow Plugs - Remove and Install”.
g01001090
Illustration 122
b. Install the fuel injectors. Refer to Disassembly and
The cylinder head tightening sequence
Assembly, “Fuel Injectors - Remove and Install”.
12. Tighten cylinder head bolts (5) in numerical order c. Install the exhaust manifold. Refer to Disassembly
to the sequence that is shown in Illustration 122. and Assembly, “Exhaust Manifold - Remove and
Tighten the cylinder head bolts to a torque of Install”.
118 N·m (87 lb ft).

This document has been printed from SPI². Not for Resale
64 KENR6241
Disassembly and Assembly Section

i02748579 3. Repeat Steps 1 and 2 in order to remove the


remaining lifters.
Lifter Group - Remove and
Install Installation Procedure
Table 33
Required Tools
Removal Procedure Tool Part Number Part Description Qty
Table 32 A - Telescoping Magnet 1
Required Tools
Part NOTICE
Tool Number Part Description Qty Keep all parts clean from contaminants.
A - Telescoping Magnet 1
Contaminants may cause rapid wear and shortened
component life.
Start By:

a. If the engine is equipped with a balancer, remove NOTICE


the balancer. Refer to Disassembly and Assembly, It is strongly recommended that all lifters should be
“Balancer - Remove”. If the engine is not equipped replaced when a new camshaft is installed.
with a balancer, remove the engine oil pan. Refer
to Disassembly and Assembly, “Engine Oil Pan
1. Clean the lifters. Follow Steps 1.a through 1.c in
- Remove and Install”.
order to inspect the lifters. Replace lifters that are
worn or damaged.
b. Remove the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove and Install”.
a. Inspect the seat of the pushrod in the lifter for
visual wear or damage.
NOTICE
Keep all parts clean from contaminants. b. Inspect the shank of the lifter for wear or
damage. Refer to Specifications, “Lifter Group”
Contaminants may cause rapid wear and shortened for more information.
component life.
c. Inspect the face of the lifter that runs on the
camshaft for visual wear or damage.

2. If the crankshaft is installed, rotate the crankshaft


to access to the cylinder block in order to install
lifters (1).

3. Lubricate lifters (1) with clean engine oil.

g01343537
Illustration 124
Typical example

1. If the crankshaft is installed, rotate the crankshaft


in order to gain access to lifters (1).

2. Use Tooling (A) to remove lifters (1).


g01343537
Illustration 125
Note: Make a temporary identification mark on each
Typical example
lifter in order to identify the correct location.

This document has been printed from SPI². Not for Resale
KENR6241 65
Disassembly and Assembly Section

4. Use Tooling (A) to install lifters (1) to the cylinder


block. Ensure that used lifters are installed in the
correct location.

Note: The lifters should be free to rotate.

5. Repeat Steps 2 through 4 in order to install the


remaining lifters.

End By:

a. Install the camshaft. Refer to Disassembly and


Assembly, “Camshaft - Remove and Install”.

b. If the engine is equipped with a balancer, install g01349741


the balancer. Refer to Disassembly and Assembly, Illustration 126
“Balancer - Install”. If the engine is not equipped Typical example
with a balancer, install the engine oil pan. Refer
to Disassembly and Assembly, “Engine Oil Pan 4. Ensure that gears (2) and (3) are marked in order
- Remove and Install”. to show alignment. Refer to Illustration 126.

Note: Identification will ensure that the camshaft can


i02748580 be installed in the original position.
Camshaft - Remove and Install 5. Remove bolts (1).

Removal Procedure
Start By:

a. Remove the front housing. Refer to Disassembly


and Assembly, “Housing (Front) - Remove and
Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened g01350309


component life. Illustration 127
Typical example

1. The engine should be mounted on a suitable


stand and placed in the inverted position. NOTICE
Do not damage the lobes or the bearings when the
2. Rotate the crankshaft so that number one piston camshaft is removed or installed.
is at the top center position on the compression
stroke. Refer to Systems Operation, Testing and 6. Carefully remove camshaft assembly (4) from the
Adjusting, “Finding Top Center Position for No.1 cylinder block.
Piston”.
7. If necessary, remove the camshaft gear. Refer to
3. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Camshaft Gear.-
Disassembly and Assembly, “Rocker Shaft and Remove and Install”.
Pushrod - Remove”.
Installation Procedure
Table 34
Required Tools
Part
Tool Number Part Description Qty
A 21825617 Dial Indicator Group 1

This document has been printed from SPI². Not for Resale
66 KENR6241
Disassembly and Assembly Section

4. Install bolts (1). Tighten the bolts to a torque of


NOTICE 12 N·m (106 lb in).
Keep all parts clean from contaminants.
5. Use Tooling (A) to check the backlash between
Contaminants may cause rapid wear and shortened gears (2) and (3). Ensure that the backlash for
component life. the gears is within specified values. Refer to the
Specifications, “Gear Group (Front)” for further
information.
1. Ensure that the camshaft assembly is clean and
free from wear or damage. If necessary, install 6. Use Tooling (A) to check the end play for camshaft
the camshaft gear. Refer to Disassembly and gear (3). Ensure that the end play is within
Assembly, “Camshaft Gear.- Remove and Install”. specified values. Refer to the Specifications,
“Camshaft” for further information.
2. Lubricate the camshaft assembly with clean
engine oil prior to installation. 7. Lubricate the teeth of the gears with clean engine
oil.

End By:

a. Install the front housing. Refer to Disassembly and


Assembly, “Housing (Front) - Remove and Install”.

b. Install the rocker shaft and pushrods. Refer to


Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”.

i02748582

Camshaft Gear - Remove and


Illustration 128
g01349741
Install
Typical example

Removal Procedure
Start By:

a. Remove the camshaft assembly from the engine.


Refer to Disassembly and Assembly, “Camshaft
- Remove and Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


Illustration 129
g01350309 component life.
Typical example

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

3. Carefully install camshaft assembly (4) to the


cylinder block. Ensure that the timing marks on
gears (2) and (3) are in alignment and that the
mesh of the gears is correct. Refer to Illustration
128.

This document has been printed from SPI². Not for Resale
KENR6241 67
Disassembly and Assembly Section

Always wear protective gloves when handling


parts that have been heated.

3. Raise the temperature of camshaft gear (1). Align


the camshaft gear with woodruff key (3) and install
the camshaft gear to camshaft (4).

End By:

a. Install the camshaft assembly to the engine.


Refer to Disassembly and Assembly, “Camshaft
g01350917 - Remove and Install”.
Illustration 130

1. Place the camshaft assembly on a suitable i02748583


support. Use a press to remove camshaft gear (1)
from camshaft (4). Engine Oil Pan - Remove and
Install
2. Remove thrust plate (2) and woodruff key (3) from
camshaft (4). Note the orientation of the thrust
plate for installation.
Removal Procedure for the Engine
Installation Procedure
Oil Pan
NOTICE
Keep all parts clean from contaminants. NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life. Contaminants may cause rapid wear and shortened
component life.

1. Ensure that all components of the camshaft


assembly are clean and free from damage. 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.

Dispose of all fluids according to local regulations and


mandates.

g01350917
Illustration 131

2. Install woodruff key (3) and thrust plate (2) to


camshaft (4).

Note: Ensure that the machined face of the thrust


plate is toward the camshaft.

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.

2. Remove sealing washer (2) from oil drain plug (3).

3. Remove bolts (4) from engine oil pan (1).

4. Carefully separate engine oil pan (1) from the


cylinder block.

Note: Avoid damage to the engine oil pan during


removal.

Removal Procedure for the Oil


Strainer
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life. g01347461
Illustration 134
The oil strainer for engines that are equipped with a balancer

1. Remove bolts (7).

2. Remove oil strainer (6).

3. Remove O-ring seal (5) from oil strainer (6).

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

1. Clean all mating surfaces thoroughly. POWERPART


A 21826038 1
Silicon Adhesive
POWERPART
B 21820117 Threadlock and 1
Nutlock

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Ensure that the engine oil pan is clean and free


from damage. Clean the mating surface of the
cylinder block.

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

2. Install a new O-ring seal (5) to oil strainer (6).

3. Install oil strainer (6) and install bolts (7).

This document has been printed from SPI². Not for Resale
70 KENR6241
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

NOTICE
Care must be taken to ensure that fluids 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”.

3. Ensure that bolts (4) are clean and dry. Apply


Tooling (B) to the threads of the bolts.

4. Position engine oil pan (1) onto the cylinder block


and install bolts (4).

5. Tighten bolts (4) to a torque of 11 N·m (97 lb in).

6. Install a new sealing washer (2) to oil drain plug


(3).

7. Install oil drain plug (3) to engine oil pan (1).


Tighten the oil drain plug to a torque of 39 N·m
(29 lb ft).

8. Fill the engine oil pan to the correct level. Refer to


Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for the correct procedure.

i02748584

Balancer - Remove

Removal Procedure g01344508


Illustration 139
Start By:
Note: If the balancer will be disassembled, loosen
a. Remove the engine oil pan and remove the oil bolts (4) before the balancer is removed from the
strainer. Refer to Disassembly and Assembly, engine.
“Engine Oil Pan - Remove and Install”.
2. Support the weight of the balancer. The balancer
weighs approximately 23 kg (51 lb). Remove bolts
(3) and remove balancer (1) from the engine.

This document has been printed from SPI². Not for Resale
KENR6241 71
Disassembly and Assembly Section

3. Do not remove dowels (2) unless the dowels are


damaged.

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.

Contaminants may cause rapid wear and shortened


component life.

g01344665
Illustration 142
Timing marks

1. Remove bolts (4) and washers (5). Use Tooling


(A) in order to remove gears (6). Ensure that
balancer shaft (10) is protected from damage.

Note: Gears (6) have different Markings (X). Refer


to Illustration 142. Identify the position of the gears
for installation.

2. Remove keys (7). Use Tooling (B) in order to


remove retaining rings (8).

g01344515
Illustration 140

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72 KENR6241
Disassembly and Assembly Section

1. Ensure that all components of the balancer are


clean and free from damage.

g01344533
Illustration 143

3. Carefully tap the assembly of bearing (9) and


balancer shaft (10) forward until the shaft is clear
of bushing (11). Refer to Illustration 143.

4. Use Tooling (A) in order to remove bearing (9)


from balancer shaft (10).

Note: Ensure that the balancer shaft is protected


from damage.

5. Slide balancer shaft (10) back through bushing


(11) until the shaft is clear of the balancer.

6. If necessary, use Tooling (C) in order to remove Illustration 144


g01344574
bushing (11) from balancer (1).
2. If new bushing (11) is installed to the balancer,
i02748588 follow Steps 2.a and 2.b.

Balancer - Assemble a. Align oil holes (Z) in bushing (11) to drilling (Y)
in balancer (1).

b. Use Tooling (C) to install bushing (11) to


Assembly Procedure balancer (1). Ensure that the oil holes (Z) are
correctly aligned to drilling (Y).
Table 37
Required Tools
Part
Qty
Tool Number Part Description
B - Retaining Ring Pliers 1
C 27610275 Bearing Installer Group 1
POWERPART
D 21820117 1
Threadlock and Nutlock

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

This document has been printed from SPI². Not for Resale
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.

Contaminants may cause rapid wear and shortened


component life.

This document has been printed from SPI². Not for Resale
74 KENR6241
Disassembly and Assembly Section

g01344971
Illustration 149
Alignment of the timing marks

2. Align dowels (2) with the holes in the cylinder


block. Align mark 1,1 on gear (6) to mark 1 on
crankshaft gear (12). Refer to Illustration 149.
Illustration 147
g01344665 Position balancer (1) on the engine. The balancer
weighs approximately 23 kg (51 lb).
Timing marks

3. Install bolts (3). Tighten the bolts to a torque of


30 N·m (22 lb ft).

4. Use Tooling (F) in order to check the backlash


between gears (6). Refer to Specifications, “Gear
Group (Front)”.

5. Use Tooling (F) in order to check the


backlash between gears (6) and (12). Refer to
Specifications, “Gear Group - Front” for further
information.

End By:

a. Install the engine oil pan. Refer to Disassembly


and Assembly, “ Engine Oil Pan - Remove and
Install”.

i02748590

Pistons and Connecting Rods


- Remove

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

Start By: Note: Use tape or rubber tubing on the connecting


rod bolts to protect the crankshaft journals from
a. Remove the cylinder head. Refer to Disassembly damage.
and Assembly, “Cylinder Head - Remove”.
7. Carefully push the piston and the connecting rod
b. Remove the engine oil pan and remove the oil assembly out of the cylinder bore. Lift the piston
strainer. Refer to Disassembly and Assembly, out of the top of the cylinder block.
“Engine Oil Pan - Remove and Install”.
8. Repeat Steps 2 through 7 in order to remove the
NOTICE remaining pistons and connecting rods.
Keep all parts clean from contaminants.
i02748591
Contaminants may cause rapid wear and shortened
component life. Pistons and Connecting Rods
- Disassemble
1. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove”.

2. Rotate the crankshaft until the piston that is being


Disassembly Procedure
removed is at the bottom center position. Table 40

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:

a. Remove the pistons and connecting rods. Refer


to Disassembly and Assembly, “Piston and
Connecting Rods - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g01352319
Illustration 150

4. The connecting rod and the connecting rod cap


have matching numbers (X) on the side. Note
the location of the connecting rod for installation.
If necessary, make a temporary mark on the
connecting rod and the connecting rod cap in
order to identify the cylinder number.

5. Remove nuts (2).

6. Remove connecting rod cap (1) from the Illustration 151


g01359107
connecting rod.
(X) Number
(Y) Number

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76 KENR6241
Disassembly and Assembly Section

2. Place the piston and connecting rod assembly on


a suitable surface with the connecting rod upward.
Use Tooling (A) in order to remove retaining rings
(4).

3. Remove piston pin (3) and connecting rod (1) from


piston (2).

Note: If the piston pin cannot be removed by hand,


heat the piston to a temperature of 45 ± 5 °C
(113 ± 9 °F). Do not use a torch to heat the piston.

g01359108
Illustration 152

(X) Number
(Y) Number

1. Make a temporary mark on the components of


the piston and connecting rod assembly. This will
ensure that the components of each piston and
connecting rod assembly can be reinstalled in
the original cylinder. Note the correct orientation
of the connecting rod in relation to the piston.
Number (X) and number (Y) must be on the same g00829406
Illustration 154
side. Refer to Illustration 151. Do not interchange
components.

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).

8. Repeat Steps 1 through 7 in order to disassemble


the remaining pistons and connecting rods.

i02748593

Pistons and Connecting Rods


- Assemble

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

2. If necessary, use Tooling (C) and a suitable press (X) Number


to install piston pin bearing (12) into connecting (Y) Number
rod (1). Ensure that oil hole (Z) in the piston pin
bearing is aligned with the oil hole at the top of
the connecting rod.

g01359108
Illustration 161

(X) Number
(Y) Number

4. Place piston (2) on a suitable surface with the


crown downward. Ensure the correct orientation
of the connecting rod in the piston. Number
(X) and number (Y) must be on the same side.
Refer to Illustration 160 or Illustration 161. Install
connecting rod (1) and piston pin (3) to the piston.

Note: If the piston pin cannot be installed by hand,


heat the piston to a temperature of 45 ± 5 °C
(113 ± 9 °F). Do not use a torch to heat the piston.
g01311807
Illustration 159 5. Use Tooling (A) in order to install retaining rings
Typical example (4) to the piston pin bore in piston (2).

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

b. Use Tooling (B) to install oil control ring (7) over


the spring.

Note: Ensure that the central wire is 180 degrees


from the ring gap.

c. Use Tooling (B) to install intermediate


compression ring (6) into the second groove in
the piston. The letter “T” and the chamfer on
the inner face of the ring must be upward.
g01351357
Illustration 162
Piston from a turbocharged engine d. Use Tooling (B) to install top compression ring
(5) into the top groove in the piston. The letter
“T” must be upward.

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

e. Align the piston ring gaps to the positions that


are shown in Illustration 165.

This document has been printed from SPI². Not for Resale
80 KENR6241
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Ensure that the assemblies of the pistons and


connecting rods are clean and free from damage.

2. Apply clean engine oil to the cylinder bore, to the


piston rings, to the outer surface of the piston and
to the connecting rod bearings.

Note: Install the connecting rod bearings dry


when clearance checks are performed. Refer to
Disassembly and Assembly, “Bearing Clearance -
Check”. Apply clean engine oil to the connecting rod
bearings during final assembly.

g01362961 3. Rotate the crankshaft until the crankshaft pin


Illustration 166
is in the bottom center position. Lubricate the
Typical example crankshaft pin with clean engine oil.
7. Install the upper half of connecting rod bearing
(8) to connecting rod (1).

8. Install the lower half of connecting rod bearing (9)


to connecting rod cap (10).

9. Repeat Steps 2 through 8 in order to assemble


the remaining pistons and connecting rods.

End By:

a. Install the pistons and connecting rods. Refer


to Disassembly and Assembly, “Piston and
Connecting Rods - Install”.
g01352295
Illustration 167
i02748594 Piston from a turbocharged engine

Pistons and Connecting Rods


- Install

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

This document has been printed from SPI². Not for Resale
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

Note: Use tape or rubber tubing on the connecting


rod bolts to protect the crankshaft pin from damage.
Connecting Rod Bearings -
Ensure that the piston and the connecting rod Remove
assembly are installed in the correct cylinder.
(Connecting rods in position)

Removal Procedure
Start By:

a. Remove the engine oil pan and remove the oil


strainer. Refer to Disassembly and Assembly,
“Engine Oil Pan - Remove and Install”.

b. If the engine is equipped with a balancer, remove


the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.
g01352319
Illustration 169
Typical example Note: If all connecting rod bearings require
replacement, the procedure can be carried out on
6. Remove the tape or rubber tubing on the two cylinders at the same time. The procedure can
connecting rod bolts. Install connecting rod cap be carried out on the following pairs of cylinders.
(1). 1 with 4 and 2 with 3. Ensure that both pairs
of the connecting rod bearings are installed
Note: Ensure that number (X) on the connecting before changing from one pair of cylinders to
rod cap matches number (X) on the connecting rod. another pair of cylinders.. Refer to Disassembly
Ensure that the numbers are on the same side. and Assembly, “Connecting Rod Bearings - Install”
for the correct procedure.
7. Install nuts (2). Tighten the nuts to a torque of
54 N·m (40 lb ft).

8. Ensure that the installed connecting rod assembly


has tactile side play. Rotate the crankshaft in order
to ensure that there is no binding.

9. Repeat Steps 2 through 8 in order to install the


remaining pistons and connecting rods.

This document has been printed from SPI². Not for Resale
82 KENR6241
Disassembly and Assembly Section

i02748597

Connecting Rod Bearings -


Install
(Connecting rods in position)

Installation Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

1. Inspect the pins of the crankshaft for damage.


Refer to Specifications, “Connecting Rod Bearing
Journals” for more information. If the crankshaft
Illustration 170
g01361963 is worn or damaged, replace the crankshaft or
Typical example recondition the crankshaft. Refer to Disassembly
and Assembly, “Crankshaft - Remove” and
Note: The connecting rod and the connecting rod Disassembly and Assembly, “Crankshaft - Install”.
cap have matching numbers at position (X). Note the
location of the connecting rod cap (5) for installation. 2. Ensure that the connecting rod bearings are clean
and free from wear or damage. If necessary,
1. Rotate the crankshaft until the piston is at the replace the connecting rod bearings.
bottom center position. Remove nuts (6) and
remove connecting rod cap (5) from connecting
rod (1).

2. Remove lower connecting rod bearing (4) from


connecting rod cap (5).

Note: Use tape or rubber tubing on connecting rod


bolts (2) in order to protect the crankshaft journals.
The sharp edges of the connecting rod bolts could
damage the crankshaft journals.

3. Carefully push connecting rod (1) into the cylinder


bore. Remove upper connecting rod bearing (3)
from the connecting rod.

g01361963
Illustration 171
Typical example

3. Clean the bearing surface of connecting rod (1)


and connecting rod cap (5).

4. Install upper connecting rod bearing (3) to


connecting rod (1). Lubricate the bearing surface
of the connecting rod bearing with clean engine oil.

This document has been printed from SPI². Not for Resale
KENR6241 83
Disassembly and Assembly Section

Note: Use tape or rubber tubing on connecting rod i02748598


bolts (2) in order to protect the crankshaft journals.
The sharp edges of the connecting rod bolts could Crankshaft Main Bearings -
damage the crankshaft journals. Remove and Install
5. Carefully pull connecting rod (1) against the (Crankshaft in position)
crankshaft pin.

6. Install lower connecting rod bearing (4) to


connecting rod cap (5). Removal Procedure
7. Lubricate the pin of the crankshaft and lubricate Start By:
lower connecting rod bearing (4) with clean engine
oil. a. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
NOTICE “Balancer - Remove”. If the engine is not equipped
When the connecting rod caps are installed, ensure with a balancer, remove the oil strainer. Refer to
that the identification marks are aligned. Disassembly and Assembly, “Engine Oil Pan -
Remove and Install”.
8. Ensure that the numbers at position (X) on b. Remove the flywheel housing. Refer to
connecting rod cap (5) and on connecting rod (1) Disassembly and Assembly, “Flywheel Housing
match. Install connecting rod cap (5). - Remove and Install”.
9. Install nuts (6). Tighten the nuts evenly to a torque
of 54 N·m (40 lb ft). NOTICE
This procedure must only be used to remove and in-
10. Repeat Steps 2 through 9 for the remaining stall the main bearing shells with the crankshaft in po-
connecting rod bearings. sition.

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:

a. If the engine is equipped with a balancer, Install


the balancer. Refer to Disassembly and Assembly,
“Balancer - Install”.

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

This document has been printed from SPI². Not for Resale
Worldwide Parts Source LLC Phone 269 673 2313
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.

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.

g01353517
Illustration 175
Typical example

5. Push out upper main bearing (6) with a suitable


tool from the side opposite the locating tab.
Carefully rotate the crankshaft while you push on
the bearing. Remove upper main bearing (6) from
the cylinder block. Keep the bearings together.

Note: Do not damage the machined surfaces of the


crankshaft during removal of the upper main bearing.
g01353478 The upper main bearing has a groove and two oil
Illustration 173
holes.
Number five main bearing cap

3. For number five main bearing cap, remove lower Installation Procedure
thrust washers (4) and remove seals (3).
Table 43

Note: It is not possible to remove the upper thrust Required Tools


washer from the cylinder block with the crankshaft Tool Part Number Part Description Qty
in position. If the upper thrust washer requires
removal, the crankshaft must be removed. Refer to POWERPART
Disassembly and Assembly, “Crankshaft - Remove”. A 218260238 Silicone Sealant 1
Adhesive
B 27610013 Seal Installer 1
C 21825617 Dial Indicator Group 1

NOTICE
This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in po-
sition.

The removal procedure and the installation procedure


must be completed for each pair of main bearing shells
before the next pair of main bearing shells are re-
moved.
g01353475
Illustration 174
Number five main bearing cap

4. Remove lower main bearing (5) from main bearing


cap (2). Keep the main bearing and the main
bearing cap together.

This document has been printed from SPI². Not for Resale
KENR6241 Worldwide Parts Source LLC Phone 269 673 2313 Engine Parts

4. Install lower main bearing (5) into main bearing


NOTICE cap (2). Ensure that the locating tab for the lower
Keep all parts clean from contaminants. main bearing is correctly seated into the slot in
the bearing cap.
Contaminants may cause rapid wear and shortened
component life. Note: The lower main bearing is a plain bearing that
has no oil holes.
1. Ensure that the main bearings are clean and free
from wear or damage. If necessary, replace the
main bearings.

2. Clean the journal of the crankshaft. Inspect the


journal of the crankshaft for damage. If necessary,
replace the crankshaft or recondition the
crankshaft. Refer to Disassembly and Assembly,
“Crankshaft - Remove” for more information.

g01353916
Illustration 178
Number five main bearing cap

5. For number five main bearing cap, follow Steps


5.a through 5.c in order to install the lower thrust
washers (4) to the main bearing cap.

Note: It is not possible to install the upper thrust


washer to the cylinder block with the crankshaft in
g01353517 position. If the upper thrust washer requires removal
Illustration 176
and installation, the crankshaft must be removed.
Typical example Refer to Disassembly and Assembly, “Crankshaft -
Remove”.
3. Lubricate the crankshaft journal and the upper
main bearing (6) with clean engine oil. Slide the a. Ensure that lower thrust washers (4) are clean
upper main bearing into position between the and free from wear or damage. If necessary,
crankshaft journal and the cylinder block. Ensure replace the thrust washers. Lubricate the thrust
that the locating tab for the upper main bearing is washers with clean engine oil.
correctly seated in the slot in the cylinder block.
b. Install lower thrust washers (4) to main bearing
Note: The upper main bearing has a groove and two cap (2). Ensure that holes (X) in the thrust
oil holes. washers are aligned with dowels (Y) in the
main bearing cap. Ensure that the grooves in
the thrust washers face toward the crankshaft.

g01353475
Illustration 177
Number five main bearing cap

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Worldwide Parts Source LLC Phone 269 673 2313 Engine Parts
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).

6. Lubricate the crankshaft journal and the lower


main bearing with clean engine oil. Install main
bearing cap (2) to the cylinder block. Ensure the
correct orientation of the main bearing cap. The
locating tab for the upper and the lower bearing
should be on the same side of the engine.

g01353474
Illustration 182
Typical example

9. Lubricate the threads of bolts (1) with clean engine


oil. Lubricate the underside of the heads of the
bolts with clean engine oil.

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.

This document has been printed from SPI². Not for Resale
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”.

b. If the engine is equipped with a balancer, remove


the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove”. If the engine is not equipped
with a balancer, remove the oil strainer. Refer to
Disassembly and Assembly, “Engine Oil Pan -
Remove and Install”.

c. Remove the flywheel housing. Refer to


Disassembly and Assembly, “Flywheel Housing
- Remove and Install”.

d. Remove the front plate. Refer to Disassembly and


Assembly, “Front Plate - Remove”.
g01359530
Illustration 183
Typical example NOTICE
If the crankshaft has been reground or if the crankshaft
13. Check the crankshaft end play. Refer to has been replaced, the height of the piston above the
Specifications, “Crankshaft” for more information. cylinder block must be inspected. It is necessary to
Push the crankshaft toward the front of the engine. remove the cylinder head in order to inspect the height
Install Tooling (C). Push the crankshaft toward the of the piston above the cylinder block.
rear of the engine in order to measure the end
play.
NOTICE
End By: Keep all parts clean from contaminants.

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.

2. If necessary, remove the cylinder head. Refer


i02748599 to Disassembly and Assembly, “Cylinder Head -
Remove”. Remove the pistons and connecting
Crankshaft - Remove rods. Refer to Disassembly and Assembly,
“Pistons and Connecting Rods - Remove”.

If the cylinder head, the pistons and the


Removal Procedure connecting rods have not been removed, remove
the connecting rod caps. Refer to Disassembly
Table 44 and Assembly, “Connecting Rod Bearings
Required Tools - Remove”. Carefully push the piston and
connecting rod assemblies into the cylinder bores.
Part
Tool Number Part Description Qty
A - Lifting Sling 1

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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

8. Remove upper main bearings (7). Keep the upper


main bearings and the upper thrust washer with
the respective main bearing caps.

For number five main bearing, remove the upper


thrust washer from the rear of the cylinder block.

g01359992 Note: The upper main bearings have a groove and


Illustration 185
two oil holes.
Number five main bearing cap

6. Remove lower main bearings (4) from main


bearing caps (2). Keep the main bearings and the
main bearing caps together.

For number five main bearing cap, remove lower


thrust washers (5) and remove seals (6).

Note: The lower main bearings are plain bearings


with no oil holes.

This document has been printed from SPI². Not for Resale
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.

6. Lubricate upper thrust washer (8). Install the upper


Note: The engine should be mounted on a suitable thrust washer to the rear of the cylinder block with
stand and placed in the inverted position. the oil grooves toward the outside. Ensure that
holes (X) in the thrust washer are aligned with
1. Clean the crankshaft and inspect the crankshaft dowels (Y) in the cylinder block.
for wear or damage. Refer to Specifications,
“Crankshaft” for more information. If necessary, 7. Lubricate upper bearings (7) with clean engine oil.
replace the crankshaft or recondition the
crankshaft.

2. Ensure that the parent bores for the crankshaft


bearings in the cylinder block are clean. Ensure
that the threads for the bearing bolts in the cylinder
block are clean and free from damage.

3. Clean the crankshaft bearings and the thrust


washers. Inspect the bearings and the thrust
washers for wear or damage. If necessary, replace
the bearings and the thrust washers.

Note: If the crankshaft bearings are replaced, check


whether oversize bearings were previously installed.
If the thrust washers are replaced, check whether Illustration 189
g01359996
oversize thrust washers were previously installed. Typical example

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).

Note: Do not damage any of the finished surfaces on


the crankshaft. Do not damage the bearings.

This document has been printed from SPI². Not for Resale
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.

b. Install lower thrust washers (5) to main bearing


cap (2). Ensure that holes (X) in the thrust
washers are aligned with dowels (Y) in the
main bearing cap.

g01359531
Illustration 192
Typical example

12. Inject a small quantity of Tooling (A) into the two


grooves in number five main bearing cap. Position
new seals (3) in the grooves. Ensure that rounded
edges of the seals are outward. Push the first
25 mm (1 inch) of the seal into the grooves by
hand.

This document has been printed from SPI². Not for Resale
KENR6241 91
Disassembly and Assembly Section

g01359530
Illustration 195
Typical example

18. Check the crankshaft end play. Refer to


Specifications, “Crankshaft” for more information.
Push the crankshaft toward the front of the engine.
Illustration 193
g01354238 Install Tooling (A). Push the crankshaft toward the
rear of the engine in order to measure the end
Typical example
play.
13. Use Tooling (B) in order to push seals (3) fully 19. If the crankshaft has been replaced or the
into the grooves. crankshaft has been reconditioned, inspect
the height of the pistons above the cylinder
block. Refer to Systems Operation, Testing
and Adjusting, “Piston Height - Inspect” for
more information. First install the pistons and
connecting rods. Refer to Disassembly and
Assembly, “Pistons and Connecting Rods - Install”.
Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install”.

If the crankshaft has not been replaced or the


crankshaft has not been reconditioned, install the
connecting rod caps. Refer to Disassembly and
Assembly, “Connecting Rod Bearings - Install”.

g01353474 End By:


Illustration 194
Typical example a. Install the front plate. Refer to Disassembly and
Assembly, “Front Plate - Install”.
14. Lubricate the threads of bolts (1) with clean
engine oil. Lubricate the underside of the heads b. Install the flywheel housing. Refer to Disassembly
of the bolts with clean engine oil. and Assembly, “Flywheel Housng - Remove and
Install”.
15. Install bolts (1) to main bearing caps (2). Evenly
tighten the bolts in order to pull the main bearing c. If the engine has a balancer, install the balancer.
caps into position. Ensure that the caps are Refer to Disassembly and Assembly, “Balancer -
correctly seated. Install”. If the engine does not have a balancer,
install the oil strainer and install the engine oil pan.
Note: Do not tap the main bearing caps into position Refer to Disassembly and Assembly, “Engine Oil
as the bearing may be dislodged. Pan - Install”.
16. Tighten bolts (1) to a torque of 103 N·m (76 lb ft). d. Install the rocker shaft and pushrods. Refer to
Disassembly and Assembly, “Rocker Shaft and
17. Rotate the crankshaft in order to ensure that there Push Rod - Install”.
is no binding.

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92 KENR6241
Disassembly and Assembly Section

i02748602 4. If necessary, remove the keys (not shown) from


crankshaft (2).
Crankshaft Gear - Remove and
Install Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Removal Procedure
Contaminants may cause rapid wear and shortened
Table 46 component life.
Required Tools
Tool Part Number Part Description Qty
A - Combination Puller 1

Start By:

a. Remove the idler gear. Refer to Disassembly and


Assembly, “Idler Gear - Remove and Install”.

Note: In this procedure, the crankshaft gear is


removed with the crankshaft in the engine.

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. Align the keyway in crankshaft gear (1) with the


keys in crankshaft (2). Install crankshaft gear (1).
Ensure that the crankshaft gear is seated squarely
against the crankshaft.

4. 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”.

5. If the engine is equipped with a balancer, install


the balancer. Refer to Disassembly and Assembly,
“Balancer - Install”.
g01343991
Illustration 196
Typical example End By:

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”.

This document has been printed from SPI². Not for Resale
KENR6241 93
Disassembly and Assembly Section

i02748526 • Ensure that the bearing locking tabs are properly


seated in the tab grooves.
Bearing Clearance - Check
• The crankshaft must be free of oil at the contact
points of Tooling (A).

Measurement Procedure 1. Put a piece of Tooling (A) on the crown of the


bearing that is in the cap.
Table 47
Required Tools Note: Do not allow Tooling (A) to extend over the
edge of the bearing.
Part
Tool Number Part Description Qty 2. Use the correct torque-turn specifications in order
Plastic Gauge (Green) to install the bearing cap. Do not use an impact
- 0.025 to 0.076 mm 1 wrench. Be careful not to dislodge the bearing
(0.001 to 0.003 inch) when the cap is installed.
Plastic Gauge (Red) Note: Do not turn the crankshaft when Tooling (A)
- 0.051 to 0.152 mm 1
is installed.
(0.002 to 0.006 inch)
A
Plastic Gauge (Blue) 3. Carefully remove the cap, but do not remove
- 0.102 to 0.229 mm 1 Tooling (A). Measure the width of Tooling (A)
(0.004 to 0.009 inch) while Tooling (A) is in the bearing cap or on the
Plastic Gauge (Yellow) crankshaft journal. Refer to Illustration 198.
- 0.230 to 0.510 mm 1
(0.009 to 0.020 inch)

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

Note: Perkins does not recommend the checking of


the actual clearances of the bearing shells particularly
on small engines. This is because of the possibility
of obtaining inaccurate results and of damaging the
bearing shell or the journal surfaces. Each Perkins
bearing shell is quality checked for specific wall
thickness.

Note: The measurements should be within


specifications and the correct bearings should Illustration 198
g01152855

be used. If the crankshaft journals and the bores Typical Example


for the block and the rods were measured during
disassembly, no further checks are necessary. 4. Remove all of Tooling (A) before you install the
However, if the technician still wants to measure the bearing cap.
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with Note: When Tooling (A) is used, the readings can
small diameters if clearances are less than 0.10 mm sometimes be unclear. For example, all parts of
(0.004 inch). Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
NOTICE within the specification range. Refer to Specifications
Lead wire, shim stock or a dial bore gauge can dam- Manual, “Connecting Rod Bearing Journal” and
age the bearing surfaces. Specifications Manual, “Main Bearing Journal” for the
correct clearances.
The technician must be very careful to use Tooling (A)
correctly. The following points must be remembered:

• Ensure that the backs of the bearings and the


bores are clean and dry.

This document has been printed from SPI². Not for Resale
94 KENR6241
Disassembly and Assembly Section

i02748603 Installation Procedure


Coolant Temperature Sensor - Table 48

Remove and Install Required Tools


Tool Part Number Part Description Qty
POWERPART
A 21820122 1
Pipe Sealant
Removal Procedure
NOTICE 1. Ensure that the coolant temperature sensor is
Keep all parts clean from contaminants. clean and free from damage.

Contaminants may cause rapid wear and shortened


component life.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Dispose of all fluids according to local regulations and


mandates. g01343990
Illustration 200
Typical example
1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
2. Apply a thin layer of Tooling (A) to the threads of
to Operation and Maintenance Manual, “Cooling
coolant temperature sensor (1).
System Coolant - Change”.
3. Install coolant temperature sensor (1) into the
cylinder head. Tighten the coolant temperature
sensor to a torque of 11 N·m (97 lb in).

4. Connect the harness assembly (not shown) to


coolant temperature sensor (1).

5. Fill the cooling system to the correct level. Refer


to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.

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.

Contaminants may cause rapid wear and shortened


component life.

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.

Dispose of all fluids according to local regulations and


mandates.

g01343988
Illustration 202
Typical example

2. Apply a thin layer of Tooling (A) to the threads of


engine oil pressure sensor (1).

3. Install engine oil pressure sensor (1) to the


cylinder block. Use a deep socket in order to
tighten the engine oil pressure sensor to a torque
of 11 N·m (97 lb in).

g01343988 4. Connect the harness assembly (not shown) to


Illustration 201
engine oil pressure sensor (1).
Typical example

1. Remove the harness assembly (not shown) from i02748605


engine oil pressure sensor (1).
Glow Plugs - Remove and
2. Use a deep socket in order to remove engine oil
pressure sensor (1) from the cylinder block.
Install

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.

NOTICE 1. Turn the battery disconnect switch to the OFF


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

1. Ensure that the engine oil pressure sensor is


clean and free from damage.

This document has been printed from SPI². Not for Resale
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).

NOTICE 5. Turn the battery disconnect switch to the ON


Keep all parts clean from contaminants. position.

Contaminants may cause rapid wear and shortened


component life.

1. Ensure that the threads of the glow plugs are clean


and free from damage. Replace any damaged
glow plugs.

This document has been printed from SPI². Not for Resale
KENR6241 97
Disassembly and Assembly Section

i02748606

V-Belts - Remove and Install

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

g01343666
Illustration 208
Typical example

1. Install V-belt (3) onto the pulleys.

Note: A used V-belt should be installed in the original


direction of rotation.

2. Adjust the tension of V-belt (3) by moving the


alternator away from the engine. Use Tooling (A)
in order to achieve the correct belt tension. Refer
to Specifications, “Belt Tension Chart” for more
information.
g01343666
Illustration 207 3. Tighten bolts (1), and (2) to a torque of 11 N·m
Typical example (97 lb in). Tighten bolt (4), to a torque of 35 N·m
(26 lb ft).
1. Loosen bolts (1), (2) and (4). Slide the alternator
toward the engine.
i02748608

2. Remove V-belt (3). Fan - Remove and Install


Note: Mark the direction of rotation if the V-belt will
be reused.
Removal Procedure
Installation Procedure
Start By:
Table 51
Required Tools a. Remove the V-Belt. Refer to Disassembly and
Tool Part Number Part Description Qty
Assembly, “V-Belts - Remove and Install”.

A - Belt Tension Gauge 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

This document has been printed from SPI². Not for Resale
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

Alternator - Remove and Install

Removal Procedure
Start By:

a. Remove the V-Belt. Refer to Disassembly and


Assembly, “V-Belts - Remove and Install”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened


component life.

This document has been printed from SPI². Not for Resale
KENR6241 99
Disassembly and Assembly Section

1. Turn the battery disconnect switch to the OFF Installation Procedure


position.

2. Make temporary identification marks on the


connections of the harness assembly.

g01343570
Illustration 212
Typical example

1. Position alternator (3) on bracket (6) and install


g01343570
Illustration 211 bolt (5) finger tight.
Typical Example
2. Install bolt (1) and washer (2) finger tight.
3. Disconnect the harness assembly from alternator
(3). 3. Install the V-belt. Refer to Disassembly and
assembly, “V-belts - Remove and Install” for the
4. Loosen bolt (4). Remove bolt (1) and washer (2) correct procedure.
from alternator (3).
4. Tighten bolts (1) and (4) to a torque of 11 N·m
5. Remove bolt (5) from alternator (3). Remove the (97 lb in). Tighten bolt (5) to a torque of 35 N·m
alternator from alternator bracket (6). (26 lb ft).

5. Connect the harness assembly to alternator (3).

6. Turn the battery disconnect switch to the ON


position.

This document has been printed from SPI². Not for Resale
Worldwide Parts Source LLC Phone 269 673 2313
100 Engine Parts
Disassembly and Assembly Section

i02748611 Installation Procedure


Electric Starting Motor -
Remove and Install

Removal Procedure

Accidental engine starting can cause injury or


death to personnel working on the equipment.

To avoid accidental engine starting, disconnect g01343546


Illustration 214
the battery cable from the negative (−) battery ter-
minal. Completely tape all metal surfaces of the Typical example
disconnected battery cable end in order to prevent
contact with other metal surfaces which could ac- 1. If necessary, install studs (2).
tivate the engine electrical system.
2. Align electric starting motor (1) to studs (2). Install
Place a Do Not Operate tag at the Start/Stop switch the electric starting motor.
location to inform personnel that the equipment is
being worked on. 3. Install nuts (3). Tighten the nuts to a torque of
35 N·m (26 lb ft).
1. Disconnect the battery. 4. Connect the harness assemblies to the electric
starting motor. Refer to Specifications, “Electric
2. Make temporary identification marks on the Starting Motor” for the tightening torques of the
harness assemblies that are connected to the terminal nuts.
electric starting motor. Disconnect the harness
assemblies from the electric starting motor. 5. Connect the battery.

g01343546
Illustration 213
Typical example

3. Remove nuts (3) from electric starting motor (1).

Note: Support the weight of the electric starting


motor as the nuts are removed.

4. Remove electric starting motor (1).

5. If necessary, remove studs (2).

This document has been printed from SPI². Not for Resale

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