KENR6226-01 April 2008 Disassembly and Assembly 402D-403D-404D Industrial Engine GG (Engine) GH (Engine) GJ (Engine) GK (Engine) GL (Engine) GM (Engine) GN (Engine) GP (Engine) GQ (Engine) GS (Engine) SAFETY.CAT.COM This document has been printed from SPI².
Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
KENR6226-01 Table of Contents Disassembly and Assembly Section Fuel Filter Base - Remove and Install (403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines) ..................... 4 Fuel Filter Base - Remove and Install (402D-05 and 403D-07 Engines) ................................................. 5 Fuel Transfer Pump - Remove and Install (Mechanical Fuel Transfer Pump) .............................................
Disassembly and Assembly Section KENR6226-01 Disassembly and Assembly Section i02959949 Fuel Filter Base - Remove and Install (403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines) Removal Procedure NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
KENR6226-01 5 Disassembly and Assembly Section i02645711 Fuel Filter Base - Remove and Install (402D-05 and 403D-07 Engines) Removal Procedure NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. Illustration 2 g01302737 Typical example 2. If necessary, install new rubber olives (not shown) onto tube assemblies (3).
Disassembly and Assembly Section Illustration 3 KENR6226-01 g01303701 Illustration 4 g01303701 Typical example Typical example 2. Loosen hose clamps (3) and disconnect hoses (4). 2. Align fuel filter base (2) with the mounting bracket. Install bolt (1). Tighten the bolt to a torque of 25 N·m (18 lb ft). 3. If necessary, remove fuel filter element (5). Refer to Operations and Maintenance Manual, “Fuel System Filter - Replace”. 4.
KENR6226-01 7 Disassembly and Assembly Section i02645722 Fuel Transfer Pump - Remove and Install (Mechanical Fuel Transfer Pump) Removal Procedure NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
Disassembly and Assembly Section KENR6226-01 i02645719 Fuel Transfer Pump - Remove and Install (Electrical Fuel Transfer Pump) Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Illustration 6 g01326306 Typical example 1.
KENR6226-01 9 Disassembly and Assembly Section 4. Loosen hose clamps (4) and (5). Disconnect hoses (6) and (7). 5. Remove bolts (2) and remove electric transfer pump (3). Installation Procedure 1. Ensure that the electric transfer pump is clean and free from damage. If necessary, replace the electric transfer pump. i02959953 Fuel Injection Lines - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Disassembly and Assembly Section Illustration 9 KENR6226-01 g01326550 Typical example 2. Disconnect nuts (1) for fuel injection lines (2) from the fuel injectors. 3. Disconnect nuts (1) for fuel injection lines (2) from the fuel injection pump. Illustration 10 4. Remove fuel injection lines (2) from the engine as a unit. 7. Remove nuts (5) from fuel injectors (7). 5. Use suitable caps in order to plug the open ports of the fuel injection pump immediately.
KENR6226-01 11 Disassembly and Assembly Section NOTICE Do not let the tops of fuel injectors turn when the fuel line nuts are loosened or tightened. The fuel injectors will be damaged if the top of the injector turns in the body. The 402D-05, 403D-07, 403D-11 and 404D-15 engines have a flexible fuel return hose. For engines with a flexible fuel return hose, connect the fuel return hose to the fuel injection pump. 4. Tighten nuts (5) to a torque of 27 N·m (20 lb ft).
Disassembly and Assembly Section KENR6226-01 For 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines, tighten the union nuts (1) to a torque of 23 N·m (17 lb ft). 9. Turn the fuel supply to the ON position. 10. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for more information. i02645718 Fuel Shutoff Solenoid Remove and Install 2. Disconnect electrical connection (3) from the harness assembly (not shown).
KENR6226-01 13 Disassembly and Assembly Section i02959957 Fuel Injection Pump - Remove and Install Removal Procedure Start By: a. Remove the fuel shutoff solenoid. Refer to Disassembly and Assembly, “Fuel Shutoff Solenoid - Remove and Install”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
Disassembly and Assembly Section KENR6226-01 Note: Record the thickness of each shim and the number of shims for reassembly. The fuel injection timing is determined by the thickness of the shim pack that is between the fuel injection pump and the mounting face on the cylinder block. Refer to Specifications, “Fuel Injection Pump” for more information. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
KENR6226-01 15 Disassembly and Assembly Section End By: 1. Use a deep socket to remove fuel injector (1) from the cylinder head. a. Install the fuel shutoff solenoid. Refer to Disassembly and Assembly, “Fuel Shutoff Solenoid - Remove and Install”. 2. Remove seat washers (2) from the cylinder head. i02959963 Fuel Injector - Remove and Install Note: 402D-05 and 403D-07 engines have two seat washers. The seat washers are different diameters.
Disassembly and Assembly Section KENR6226-01 Note: 402D-05 and 403D-07 engines have two seat washers. The seat washers are different diameters. The 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines have one seat washer. 3. Apply a bead of Tooling (A) to the first two threads of the fuel injector that engage into the cylinder head. The bead should have a diameter of 2 mm (0.08 inch) and a length of 6 mm (0.25 inch).
KENR6226-01 17 Disassembly and Assembly Section 3. Remove banjo bolt (2) and washers (3). Remove the fasteners and the spacers (not shown) for tube clips (6). Remove bolts (14) and remove tube assembly (13) from the cylinder block. Remove O-ring seal (12). 4. Remove bolts (8) and disconnect tube assembly (10) from the turbocharger. Remove joint (7). If necessary, remove bolts (9) and remove tube assembly (10) from the cylinder block. Remove joint (11). 5.
Disassembly and Assembly Section 5. Ensure that tube assemblies (10) and (13) are clean and free from damage. If necessary, replace the tube assemblies. 6. If necessary, position a new joint (11) and tube assembly (10) onto the cylinder block. Install bolts (9). Tighten the bolts finger tight. Position a new joint (7) on tube assembly (10). Align tube assembly (10) to the bottom of the turbocharger. Install bolts (8). Tighten the bolts finger tight.
KENR6226-01 19 Disassembly and Assembly Section 5. If necessary, remove exhaust manifold studs (2) from cylinder head (1). Note: On three cylinder engines and four cylinder engines, tighten the inner bolts first. Installation Procedure End By: NOTICE Keep all parts clean from contaminants. a. If the engine is equipped with a turbocharger, install the turbocharger. Refer to Disassembly and Assembly, “ Turbocharger, Remove and Install”. Contaminants may cause rapid wear and shortened component life.
Disassembly and Assembly Section KENR6226-01 NOTICE Install suitable plugs to the inlet ports of the cylinder head in order to prevent the entry of loose parts into the engine. NOTICE Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine. Note: The removal procedure is similar for the two cylinder, the three cylinder and the four cylinder engines.
KENR6226-01 21 Disassembly and Assembly Section Installation Procedure Table 4 Improper assembly of parts that are spring loaded can cause bodily injury.
Disassembly and Assembly Section KENR6226-01 i02959973 NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur. Inlet and Exhaust Valves Remove and Install Removal Procedure Table 5 Required Tools Tool Part Number A 21825663 Part Description Valve Spring Compressor Qty 1 Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Remove”. NOTICE Keep all parts clean from contaminants.
KENR6226-01 23 Disassembly and Assembly Section 5. Remove valve spring retainer (2). Remove valve spring (3). 6. Remove valve (5). 7. Remove valve stem seal (4). 8. Repeat Steps 3 to 7 for the remaining valves.
Disassembly and Assembly Section KENR6226-01 4. Install valve spring (3) to the cylinder head. Position valve spring retainer (2) onto valve spring (3). Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur. 6.
KENR6226-01 25 Disassembly and Assembly Section 4. Remove oil line (1) from the engine. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 34 g01304820 Typical example 1. Loosen nut (2) that attaches the clip on oil line (1) to the fuel injection pump. 2. Remove banjo bolt (3) and remove washers (4) from the cylinder block. Illustration 36 g01304820 Typical example 1. Place oil line (1) on the engine.
Disassembly and Assembly Section KENR6226-01 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants.
KENR6226-01 27 Disassembly and Assembly Section Note: Make a temporary mark in order to show the orientation of the oil cooler for installation. 6. Remove O-ring seal (6) from oil cooler (3). i02645679 Engine Oil Relief Valve Remove and Install Installation Procedure Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the oil cooler is clean and free from damage. Clean the mating surfaces of the cylinder block.
Disassembly and Assembly Section KENR6226-01 Installation Procedure i02645678 Engine Oil Pump - Remove NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Removal Procedure Start By: a. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
KENR6226-01 29 Disassembly and Assembly Section Idler Hub Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Remove C-clip (9) that retains idler gear (3) on idler hub (1). 2. Remove the following items from idler hub (1): Illustration 44 g01320621 • Collar (8) Typical example • Spring (7) 1.
Disassembly and Assembly Section KENR6226-01 i02960005 Engine Oil Pump - Install 3. Use a hammer in order to strike the guide plate of Tooling (A). Drive idler hub (1) into the cylinder block until the guide plate contacts the front of the cylinder block. 4. Remove Tooling (A).
KENR6226-01 31 Disassembly and Assembly Section • Collar (8) Refer to Illustration 48. 6. Install retaining ring (9) on idler hub (1). Illustration 50 Illustration 49 g01305805 Typical example Improper assembly of parts that are spring loaded can cause bodily injury. g01320625 Checking end play by using a feeler gauge 7. Use a feeler gauge in order to measure the end play of the engine oil pump. Refer to Specifications, “Engine Oil Pump”. 8. If the oil strainer was removed, follow Steps 8.
Disassembly and Assembly Section KENR6226-01 i02960013 Water Pump - Remove and Install (403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines) Removal Procedure Start By: Illustration 52 g01304930 Typical example 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”. NOTICE Keep all parts clean from contaminants.
KENR6226-01 33 Disassembly and Assembly Section Installation Procedure Note: The alternator bracket on some engines is secured by two bolts. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the mating surfaces of the water pump and the cylinder block are clean and free from damage. 5. For engines that have an alternator bracket that is secured by one bolt, tighten fasteners (7) to a torque of 10 N·m (89 lb in).
Disassembly and Assembly Section KENR6226-01 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component 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.
KENR6226-01 35 Disassembly and Assembly Section i02645789 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 59 g01308309 Typical example 2. Install a new joint (6) to the cylinder head. If the water pump has a spacer, install spacer (5) and install a new joint (4) to the cylinder head. 3. Place water pump (1) in position and install fasteners (7).
Disassembly and Assembly Section KENR6226-01 6. If necessary, remove the water temperature regulator. Refer to Disassembly and Assembly , “ Water Temperature Regulator - Remove and Install”. Installation Procedure NOTICE Keep all parts clean from contaminants. i02645783 Water Temperature Regulator Remove and Install (402D-05 and 404D-07 Engines) Removal Procedure Contaminants may cause rapid wear and shortened component life. 1.
KENR6226-01 37 Disassembly and Assembly Section Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 2. Remove bolts (6) and nuts (5). 3. Remove outlet connection (4). 4. Remove joint (3). 5. Remove water temperature regulator (2) and spring (1). Installation Procedure Illustration 63 g01326174 Typical example NOTICE Keep all parts clean from contaminants.
Disassembly and Assembly Section KENR6226-01 i02960059 Water Temperature Regulator Remove and Install (403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines) Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 64 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
KENR6226-01 39 Disassembly and Assembly Section i02645699 Flywheel - Remove Removal Procedure Table 9 Required Tools Tool Part Number A - Lifting Bracket 1 B - Guide Stud (M10 x 1.25 mm by 80mm) 2 Part Description Qty Start By: Illustration 65 g01327027 Typical example 3. Install water temperature regulator (4) to water temperature regulator housing (5).
Disassembly and Assembly Section KENR6226-01 2. Remove two bolts (1) from positions (X) on the flywheel. i02645696 Flywheel - Install 3. Install Tooling (B) in positions (X) on the flywheel. 4. Remove the remaining bolts (1) and remove flywheel (2). Note: On some three cylinder engines, a roll pin is located between the crankshaft and the flywheel. 5. Inspect ring gear (3) and flywheel (2) for wear or damage. If the ring gear or the flywheel is worn or damaged, use new parts for replacement.
KENR6226-01 41 Disassembly and Assembly Section b. Heat ring gear (3) in an oven to a maximum temperature of 150°C (302°F) prior to installation. Note: Do not use a torch to heat the ring gear. c. Ensure that the orientation of ring gear (3) is correct and quickly install the ring gear onto flywheel (2). 9. Remove Tooling (A) and the lifting device from the flywheel. End By: a. Install the electric starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”.
Disassembly and Assembly Section KENR6226-01 g01305376 Illustration 70 Illustration 71 g01305365 Typical example Typical example 1. Remove bolts (3) and remove the flywheel housing or back plate (2) from the cylinder block. Refer to Disassembly and Assembly, “Flywheel Housing Remove and Install” for more information. 1. Ensure that the mating surface of cylinder block (5) and the flywheel housing or back plate (2) are clean and free from damage. Inspect dowels (4).
KENR6226-01 43 Disassembly and Assembly Section For 402D-05 and 403D-07 engines, tighten the bolts to a torque of 15 N·m (11 lb ft). For 403D-11 and 404D-15 engines, tighten the bolts to a torque of 50 N·m (37 lb ft). For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten the bolts to a torque of 25 N·m (19 lb ft). 2. Insert a thin blade between crankshaft wear sleeve (1) and crankshaft (2) below the scored line. The crankshaft wear sleeve will separate along the line. 3.
Disassembly and Assembly Section KENR6226-01 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: The two cylinder, the three cylinder and the four cylinder engines have different flywheel housings. The removal procedure is similar for all models. 1. Support the engine. Illustration 74 g01318215 Sectional view of the crankshaft, the wear sleeve and the installation tool 2. Install a suitable lifting device to the flywheel housing.
KENR6226-01 45 Disassembly and Assembly Section i02645702 Flywheel Housing - Remove and Install (Engines with Flywheel Housing and Back Plate) Removal Procedure Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”. NOTICE Keep all parts clean from contaminants. Illustration 76 g01326595 Typical example 1. Ensure that the mating surfaces of flywheel housing (2) are clean and free from damage. Inspect the crankshaft rear seal (3) for leaks.
Disassembly and Assembly Section Illustration 78 KENR6226-01 g01305649 Illustration 79 g01305649 Illustration 80 g01326591 Typical example 3. Remove bolts (3) and (4) that fasten flywheel housing (8) to the cylinder block. 4. Remove bolts (6) on each side of the cylinder block. These bolts fasten flywheel housing (8) to the cylinder block. 5. Remove bolts (1) that fasten back plate (2) to flywheel housing (8). 6.
KENR6226-01 47 Disassembly and Assembly Section 6. Remove the lifting device from the flywheel housing. 7. Install bolts (3) and (4) that fasten flywheel housing (8) to the cylinder block. 8. Tighten the fasteners to a torque of 25 N·m (19 lb ft). End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”. i02961010 Crankshaft Pulley - Remove and Install Illustration 82 g01305772 2. Install Tooling (A) to crankshaft pulley (2).
Disassembly and Assembly Section KENR6226-01 For 403D-11 and 404D-15 engines, tighten nut (5) to a torque of 123 N·m (91 lb ft). For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten nut (5) to a torque of 304 N·m (224 lb ft). End By: a. Install the V-belt to the engine. Refer to Disassembly and Assembly, “V Belts Remove and Install”. i02645666 Crankshaft Front Seal Remove and Install Removal Procedure Illustration 84 g01310976 Typical example Table 14 1. Use a 4 mm (0.
KENR6226-01 49 Disassembly and Assembly Section Note: This is an alternative procedure to remove the crankshaft front oil seal. This procedure may be used if the front housing has been removed from the engine. 1. Use a suitable mandrel and a press in order to remove the oil seal from the front cover. Ensure that the front cover is supported in order to prevent damage to the cover while the oil seal is being removed. i02645726 Housing (Front) - Remove Removal Procedure Start By: a.
Disassembly and Assembly Section KENR6226-01 i02902054 Housing (Front) - Disassemble Disassembly Procedure Start By: a. Record the governor settings. Refer to Systems Operation, Testing and Adjusting, “Govener Adjust” b. Remove the engine front housing. Refer to Disassembly and Assembly, “Housing (Front) Remove”. Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment.
KENR6226-01 51 Disassembly and Assembly Section Illustration 90 g01357689 7. If the engine is equipped with an angleich unit, remove angleich unit (10) from lever assembly (7). Illustration 88 g01354631 Typical example 2. Remove bolts (5) and remove the assembly of throttle control (1) from front housing (3). 3. Remove joint (6). Illustration 91 g01357693 Typical example Illustration 89 g01357717 Typical example 4. Remove shaft (9) from front housing (3). 5.
Disassembly and Assembly Section KENR6226-01 Note: The position of fuel screw (16) controls the emissions of the engine. Do not remove the fuel screw unless a different front housing will be installed. Do not adjust the fuel screw. Refer to Systems Operation, Testing and Adjusting, “Governor” for further information. 12. If necessary, remove cap (21), locknut (20) and sealing washer (19) from front housing (3). Remove fuel screw (16).
KENR6226-01 53 Disassembly and Assembly Section d. Install a new emissions label to front housing (3). 2. Install a new sealing washer (18) to spring assembly (17). Loosely install spring assembly (17) to front housing (3). Illustration 94 g01358537 Typical example Illustration 96 g01357727 Typical example 3. Place lever assembly (11) in position in front housing (3) and install shaft (15). Note: Ensure the correct orientation of the lever assembly.
Disassembly and Assembly Section KENR6226-01 5. Connect spring (12) to front housing (3). Refer to Illustration 96. 8. Place lever assembly (7) in position in front housing (3) and install shaft (9). Tighten the shaft to a torque of 16 N·m (142 lb in). Note: Ensure the correct orientation of the lever assembly. Illustration 98 g01357689 6. If the engine is equipped with an angleich unit, follow Steps 6.a and 6.b in order to install the angleich unit. a.
KENR6226-01 55 Disassembly and Assembly Section 12. If the position of stop (16) has been altered, the stop must be reset. Refer to Systems Operation, Testing and Adjusting, “Governor” for the correct procedure. 13. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) Install” for more information. 14. Set the position of the spring assembly (17). Refer to Illustration 95.
Disassembly and Assembly Section KENR6226-01 10. If the engine is equipped with a turbocharger, connect the hose to connection (1). End By: a. Install the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install”. b. Install the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump - Install”. i02970280 Crankcase Breather - Remove and Install (Turbocharged Engines) Removal Procedure NOTICE Keep all parts clean from contaminants.
KENR6226-01 57 Disassembly and Assembly Section b. Remove screws (9) and carefully remove plate (10). c. Remove gauze (8) from valve mechanism cover (7). Installation Procedure Table 17 Required Tools Tool Part Number A 27610296 Part Description Torque Wrench Qty 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Make sure that the components of the breather assembly are installed correctly.
Disassembly and Assembly Section 1. Clean all parts and inspect all parts. Replace any parts that are worn or damaged. Ensure that the cavity for the breather in the valve mechanism cover is clean. Ensure that vent hole in adapter (5) and the vent hole in cover (2) are free from restriction. 2. If necessary, follow Steps 2.a through 2.d in order to install the gauze for the breather. a. Install gauze (8) to valve mechanism cover (7). b.
KENR6226-01 59 Disassembly and Assembly Section Installation Procedure Table 18 Required Tools Tool Part Number A 27610296 Part Description Torque Wrench Qty 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Make sure that the components of the breather assembly are installed correctly. Engine damage may occur if the breather assembly is not working properly.
Disassembly and Assembly Section KENR6226-01 2. If necessary, follow Steps 2.a through 2.d in order to install the gauze for the breather. a. Install gauze (6) to valve mechanism cover (7). b. Position plate (9) on valve mechanism cover (7) and install screws (8). c. Tighten screws (8) to a torque of 1.5 N·m (13 lb in). d. Install valve mechanism cover (7). Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure.
KENR6226-01 61 Disassembly and Assembly Section 3. Remove bolts (4) from valve mechanism cover (7). 2. If necessary, install the crankcase breather. Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install” for more information. Note: Loosen the bolts evenly in order to avoid distortion of the valve mechanism cover. 3. Install a new joint (9) to valve mechanism cover (7). 4. Remove valve mechanism cover (7) from base (8). Remove joint (9) from valve mechanism cover (7). 4.
Disassembly and Assembly Section KENR6226-01 i02645767 Rocker Shaft and Pushrod Remove Note: Identification will ensure that the pushrods and the caps can be reinstalled in the original positions. Do not interchange the positions of used pushrods or caps. 5. Remove pushrods (6) from the cylinder head. Remove caps (5) from the valve stems. Removal Procedure Start By: a. Remove the engine oil line. Refer to Disassembly and Assembly, “Engine Oil Line - Remove and Install”. b.
KENR6226-01 63 Disassembly and Assembly Section i02645756 Rocker Shaft - Disassemble (402D-05, 403D-07, 403D-11 and 404D-15 Engines) Disassembly Procedure Start By: a. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Make a temporary identification mark on each rocker arm assembly in order to show the location.
Disassembly and Assembly Section 3. On 403D-07, 403D-11 and 404D-15 engines, remove screw (9). Note: Screw (9) is not used on 402D-05 engines. 4. In order to remove rocker shaft (8), install a suitable bolt into the end of the rocker shaft. Use the bolt to pull the rocker shaft from base (10). KENR6226-01 i02961065 Rocker Shaft - Assemble (403D-15, 403D-15T,403D-17, 404D-22, 404D-22T and 404D-22TA Engines) Personal injury can result from being struck by parts propelled by a released spring force.
KENR6226-01 65 Disassembly and Assembly Section • Rocker arm (3) 7. Repeat Steps 5 and 6 in order to install the remaining components. 8. Ensure that rocker shaft (6) is fully engaged into base (8). Check that recesses (X) on the rocker shaft are aligned with holes (Y) in the base. End By: a. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install”.
Disassembly and Assembly Section KENR6226-01 • Rocker arm (3) 6. Repeat Steps 5 and 4 in order to install the remaining components. 7. For 403D-07, 403D-11 and 404D-15 engines, Apply Tooling (A) to the first two threads of screw (9). Install screw (9) in hole (Y) in the base. Note: Ensure that Tooling (A) is allowed to contaminate the oil gallery in the rocker shaft. 8. Install a new O-ring seal (7) to plug (6). 9. Install plug (6) to base (10). Tighten the plug to a torque of 15 N·m (11 lb ft).
KENR6226-01 67 Disassembly and Assembly Section 2. Install a new joint (7) to the base of rocker shaft assembly (3). 8. Adjust the valve lash. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash Inspect/Adjust” for the correct procedure. End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. b. Install the engine oil line. Refer to Disassembly and Assembly, “Engine Oil Line- Remove and Install”.
Disassembly and Assembly Section KENR6226-01 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component 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 for disposal.
KENR6226-01 69 Disassembly and Assembly Section 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. NOTICE Place the cylinder head on a surface that will not scratch the face of the cylinder head. 5. Remove the cylinder head gasket.
Disassembly and Assembly Section KENR6226-01 Note: Ensure that the cylinder head is correctly positioned onto dowels (3). 9. Remove Tooling (A). 10. Install bolts (1) to cylinder head (2). Illustration 127 g01317471 Typical example 5. Ensure that the new cylinder head gasket (4) is the same thickness as the cylinder head gasket that was previously removed. The thickness of the cylinder head gasket is indicated by the number that is shown at position (X).
KENR6226-01 For 403D-07 engines, tighten bolts (1) to a torque of 37 N·m (27 lb ft). Use the numerical sequence that is shown in Illustration 130. For 403D-11 engines, tighten bolts (1) to a torque of 51 N·m (38 lb ft). Use the numerical sequence that is shown in Illustration 130. For 403D-15, 403D-15T and 403D-17 engines, tighten bolts (1) to a torque of 101 N·m (75 lb ft). Use the numerical sequence that is shown in Illustration 130.
Disassembly and Assembly Section KENR6226-01 2. Repeat Step 1 for the remaining lifters. i02963920 Camshaft - Remove Installation Procedure NOTICE Keep all parts clean from contaminants. Removal Procedure Contaminants may cause rapid wear and shortened component life. NOTICE It is strongly recommended that all lifters should be replaced when a new camshaft is installed. Start By: a. Remove the lifters. Refer to Disassembly and Assembly, “Lifter Group - Remove and Install”. b.
KENR6226-01 73 Disassembly and Assembly Section For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, remove bolt (2). Rotate camshaft gear (4) in order to align the access hole in the camshaft gear with bolt (1). Remove bolt (1). 4. Remove camshaft retainer (5). 5.
Disassembly and Assembly Section KENR6226-01 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 138 g01326129 Typical example 2. Lubricate the nose of camshaft (1) with clean engine oil. Use a suitable press to install bearing (3) to the camshaft. Illustration 137 g01326129 Typical example 1. Use Tooling (A) to remove gear (5) from camshaft (1). Note: Ensure that the bearing is installed in the correct orientation.
KENR6226-01 75 Disassembly and Assembly Section 1. Ensure that the assembly of the camshaft is clean and free from damage. 2. Lubricate the bearings of the camshaft with clean engine oil. Illustration 139 g01311416 Typical example Illustration 141 g01311411 Typical example Note: 402D-05, 403D-07, 403D-11, and 404D-15 engines have a different camshaft retainer and different fasteners to 403D-15, 403D-15T, 403D-17, 404D-22,404D-22T and 404D-22TA engines.
Disassembly and Assembly Section KENR6226-01 b. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Install”. i02645675 Engine Oil Pan - Remove and Install 1. Remove drain plugs (5) from engine oil pan (2). Drain the engine oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Oil Filter Change” for the correct procedure. 2. Remove sealing washers (3) from drain plugs (5). 3. Remove bolts (4) from engine oil pan (2). 4.
KENR6226-01 77 Disassembly and Assembly Section 4. Install drain plugs (5) and sealing washers (3) to oil pan (2). Tighten the drain plugs to a torque of 34 N·m (25 lb ft). 5. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil Filter Change” for the correct procedure. i02645749 Pistons and Connecting Rods - Remove Removal Procedure Table 23 Required Tools Tool Part Number A 27610274 Part Description Qty Ridge Reamer 1 Start By: a.
Disassembly and Assembly Section KENR6226-01 Note: Make an identification mark underneath the piston on the pin boss in order to identify the position on the piston for installation. Always mark the front pin boss. 6. Keep connecting rod bearings (3) with the respective connecting rod (4) and cap (2). 7. Repeat Steps 1 through 6 in order to remove the remaining pistons and connecting rods.
KENR6226-01 Illustration 148 79 Disassembly and Assembly Section g01311809 4. Place the piston on a suitable surface with the crown upward. Use Tooling (B) in order to remove compression rings (5) and (6), and oil control ring (7) from piston (2). Note: Identify the orientation of the piston rings for installation. Illustration 149 g01311837 Typical example 5. Remove nuts (11) and connecting rod cap (10) from connecting rod (1). 6.
Disassembly and Assembly Section KENR6226-01 i02645739 Pistons and Connecting Rods - Assemble Assembly Procedure Table 25 Required Tools Tool Part Number A - Retaining Ring Pliers 1 B - Ring Expander 1 Part Description Qty Illustration 151 g00829406 Typical example b. Use Tooling (B) to install oil control ring (7) over the spring. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1.
KENR6226-01 Illustration 152 81 Disassembly and Assembly Section g01311807 g01311837 Illustration 153 Typical example Typical example 3. Lubricate the bush in connecting rod (1) and lubricate the bore for the piston pin in piston (2) with clean engine oil. 6. Install the upper half of connecting rod bearing (8) to connecting rod (1). 4. Place the piston on a suitable surface with the crown downward. Install connecting rod (1) and piston pin (3) to piston (2).
Disassembly and Assembly Section KENR6226-01 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. If the connecting rod caps were temporarily installed, remove the connecting rod caps. If necessary, thoroughly clean all of the components. 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.
KENR6226-01 83 Disassembly and Assembly Section i02645659 Connecting Rod Bearings Remove (Connecting rods in position) 1. Rotate the crankshaft until the piston is at the 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). 3. Carefully push connecting rod (1) into the cylinder bore. Remove upper connecting rod bearing (3) from the connecting rod. Removal Procedure Start By: a.
Disassembly and Assembly Section KENR6226-01 For 403D-11 and 404D-15 engines, tighten nuts (4) to a torque of 32 N·m (24 lb ft). For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten nuts (4) to a torque of 52 N·m (38 lb ft). 9. Ensure that the installed connecting rod assembly has tactile side play. Carefully rotate the crankshaft in order to ensure that there is no binding.
KENR6226-01 85 Disassembly and Assembly Section Note: The identification marks must face the right hand side of the engine for the correct installation. 9. Repeat Steps 2 through 8 for the installation of the remaining connecting rod bearings. End By: a. Install the oil supply tube. Refer to Disassembly and Assembly, “Crankshaft - Install”. b. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install”.
Disassembly and Assembly Section KENR6226-01 4. Remove main bearings (4) and (5) from the main bearing caps. Keep the main bearings with the respective bearing caps. 5. Do not remove dowels (8) from the main bearing caps. Crankshaft Bearing (Front) Table 27 Required Tools Illustration 159 Tool Part Number A 27610275 Part Description Qty Driver 1 g01327056 Illustration 161 g01327066 1. Use Tooling (A) to remove crankshaft bearing (9) from the cylinder block.
KENR6226-01 87 Disassembly and Assembly Section 4. Install lower main bearing (5) to lower main bearing cap (6). Ensure that the locating tab for the main bearing is seated in the slot in the main bearing cap. Note: The lower bearing is a plain bearing that has oil holes. 5. Lubricate main bearings (4) and (5) with clean engine oil. 6. Position the upper half of main bearing cap (2) in position on the crankshaft. Position the lower half of main bearing cap (6) in position on the crankshaft.
Disassembly and Assembly Section KENR6226-01 c. Remove the engine oil pump and the suction pipe. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”. d. Remove the pistons and the connecting rods. Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. The engine should be mounted in a suitable stand with the rear end upward. Illustration 164 g01485933 1.
KENR6226-01 89 Disassembly and Assembly Section g01311527 Illustration 166 Illustration 167 g01311527 Typical example Typical example 4. Attach a suitable lifting device (3) to crankshaft assembly (4). 3. Attach a suitable lifting device (3) to crankshaft assembly (4). Lubricate the front journal of the crankshaft with clean engine oil. 5. Carefully lift crankshaft assembly (4) from the cylinder block. If necessary, gently tap the nose of the crankshaft with a soft faced hammer.
Disassembly and Assembly Section 4. Align the holes in the crankshaft assembly for bolts (2) with the holes in the cylinder block. Align the holes in the crankshaft assembly for allen head screws (1) with the holes in the cylinder block. Carefully lower the crankshaft assembly (4) into the cylinder block. If necessary, gently tap the rear of the crankshaft with a soft faced hammer. 5. Remove lifting device (3) from crankshaft assembly (4). 6. Install allen head screws (1) finger tight.
KENR6226-01 91 Disassembly and Assembly Section • Ensure that the backs of the bearings and the bores are clean and dry. • Ensure that the bearing locking tabs are properly seated in the tab grooves. • The crankshaft must be free of oil at the contact points of Tooling (A). 1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap. Note: Do not allow Tooling (A) to extend over the edge of the bearing. 2. Use the correct torque-turn specifications in order to install the bearing cap.
Disassembly and Assembly Section KENR6226-01 Installation Procedure i02645660 Table 31 Required Tools Tool A Part Number 21820122 Part Description Qty POWERPART Pipe Sealant Coolant Temperature Switch Remove and Install (402D-05 and 403D-07 Engines) 1 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Inspect the coolant temperature switch for damage and correct operation.
KENR6226-01 93 Disassembly and Assembly Section Installation Procedure i02645676 Engine Oil Pressure Switch Remove and Install Table 32 Required Tools Tool A Part Number 21820122 Part Description Qty POWERPART Pipe Sealant 1 Removal Procedure 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.
Disassembly and Assembly Section KENR6226-01 1. Disconnect the harness assembly (not shown) from engine oil pressure switch (1). 2. If engine oil pressure switch (1) is located in the valve mechanism cover, remove the engine oil pressure switch from the valve mechanism cover. g01307450 Illustration 175 Typical example 3. If engine oil pressure switch (1) is located in the cylinder block follow Steps 3.a through 3.c in order to remove the engine oil pressure switch. g01307413 a.
KENR6226-01 95 Disassembly and Assembly Section a. Install engine oil pressure switch (1) to adapter (4). Tighten the engine oil pressure switch to a torque of 23 N·m (17 lb ft). Note: If a used engine oil pressure switch is installed, apply a thin layer of Tooling (A) to the threads of the engine oil pressure switch. b. Position new washers (3) onto oil line (2) and install the assembly of engine oil pressure switch (1) and adapter (4) to the cylinder block. c.
Disassembly and Assembly Section KENR6226-01 i02645773 V-Belts - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. If the engine is equipped with fan guards, remove the fan guards. Illustration 181 g01325726 Typical example 1. Check the condition of the V-belt . If the V-belt is worn or damaged, use a new V-belt for replacement. 2. Install V-belt (5) in position on the engine.
KENR6226-01 97 Disassembly and Assembly Section 2. Position pulley (4) and spacer (3) on water pump (5). Ensure that the bolt holes are aligned. 3. Install fan (2). Note: Ensure the correct orientation of the fan. 4. Install bolts (1) and tighten to a torque of 11 N·m (97 lb in). End By: a. Install the V-Belt. Refer to Disassembly and Assembly, “V-Belts - Remove and Install” . i02645653 Illustration 182 g01318055 Alternator - Remove and Install (65 Amp and 85 Amp Alternators) Typical example 1.
Disassembly and Assembly Section KENR6226-01 Installation Procedure Illustration 184 g01308285 Typical example 3. Disconnect the harness assembly (not shown) from alternator (5). 4. Remove bolt (4) and washer (3) from alternator (5). 5. Remove washer (7) and nut (6). Remove bolt (8) and alternator (5) from the mounting bracket. 6. If necessary, remove bolt (1) and remove adjusting link (2). Illustration 185 g01308285 Typical example 1.
KENR6226-01 99 Disassembly and Assembly Section i02645652 Installation Procedure Alternator - Remove and Install (55 Amp Alternator) 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. 1. Turn the battery disconnect switch to the OFF position. 2. Make temporary identification marks on the connections of the harness assembly.
Disassembly and Assembly Section KENR6226-01 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn the battery disconnect switch to the OFF position. 2. Make temporary identification marks on the connections of the harness assembly. Illustration 189 g01308278 Typical example 1. If necessary, install adjusting link (2) and install bolts (1). Tighten bolts (1) to a torque of 10 N·m (89 lb in). 2.
KENR6226-01 101 Disassembly and Assembly Section i02645650 Alternator - Remove and Install (14 Amp and 15 Amp Alternators) 6. If necessary, remove bolts (5) and remove adjusting link (2). Note: The adjusting link on some engines is secured by one bolt. Installation Procedure 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. 1.
Disassembly and Assembly Section KENR6226-01 i02645769 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 the battery cable from the negative (−) battery terminal.
KENR6226-01 103 Index Section Index A Alternator - Remove and Install (14 Amp and 15 Amp Alternators) ........................................................ 101 Installation Procedure ...................................... 101 Removal Procedure ......................................... 101 Alternator - Remove and Install (40 Amp Alternator) ............................................................ 99 Installation Procedure ...................................... 100 Removal Procedure .................
Index Section Engine Oil Relief Valve - Remove and Install ........ Installation Procedure ........................................ Removal Procedure ........................................... Exhaust Manifold - Remove and Install ................. Installation Procedure ........................................ Removal Procedure ........................................... KENR6226-01 27 28 27 18 19 18 F Fan - Remove and Install ...................................... 96 Installation Procedure ......
KENR6226-01 105 Index Section Rocker Shaft and Pushrod - Remove.................... 62 Removal Procedure ........................................... 62 T Table of Contents..................................................... 3 Turbocharger - Remove and Install ....................... 16 Installation procedure......................................... 17 Removal procedure............................................ 16 V V-Belts - Remove and Install ................................. Installation Procedure ..
Index Section KENR6226-01 This document has been printed from SPI².
KENR6226-01 107 Index Section This document has been printed from SPI².
Copyright © 2008 Perkins Engine Company Limited All Rights Reserved Printed in U. K. This document has been printed from SPI².
