UENR0624-03 (en-us) January 2017 Disassembly and Assembly 854E-E34TA, 854F-E34T and 854FE34TA Industrial Engines JR (Engine) JS (Engine) JT (Engine) JV (Engine) This document has been printed from SPI2.
i06558969 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, including human factors that can affect safety. This person should also have the necessary training, skills and tools to perform these functions properly.
UENR0624-03 3 Table of Contents Table of Contents Disassembly and Assembly Section Inspection of Parts ................................................5 Fuel Priming Pump - Remove and Install ..............10 Flow Control Valve - Remove and Install ..............12 Fuel Filter Base - Remove and Install ...................13 Water Separator and Fuel Filter (Primary) - Remove and Install .........................................................17 Fuel Manifold (Rail) - Remove and Install ..............
UENR0624-03 Table of Contents Temperature Sensor (DPF) - Remove and Install . 183 Pressure Sensor (DPF) - Remove and Install ...... 184 Pressure Sensor (Exhaust Back Pressure) - Remove and Install ....................................................... 185 Inlet Manifold Temperature Sensor - Remove and Install ............................................................. 187 Inlet Manifold Pressure Sensor - Remove and Install .............................................................
UENR0624-03 Disassembly and Assembly Section Disassembly and Assembly Section i05293780 Inspection of Parts Reuse Guideline for the Flexible Exhaust Pipe This Information Element will address the following applications for the lines group - flex pipe: the installation, the handling and the reusability. The lines group - flex pipe is defined as the connection between the turbocharger diffuser outlet and the Clean Emissions Module (CEM) inlet.
UENR0624-03 Disassembly and Assembly Section Note: Care should be taken when handling the lines group. The slightest bump or drop can result in a misalignment of the bellows and a possible need for replacement. 5. Discard clamp assemblies (2) and (6). The clamp assemblies are a one time use part. Note: Steps 6 through 7 are only necessary if clamp (4) was loosened to remove the entire lines group.
UENR0624-03 Disassembly and Assembly Section Illustration 7 g02211913 Typical example Alignment wrap is not shown for photographic purposes. Illustration 5 g02231073 Typical example 1. Install new clamp (4) with the tightening assembly centered between reliefs (A). Do not torque the clamp until Step 12 Note: The end of the clamp must be flush with the end of the bellows assembly. 4. Prior to installation, position both ball clamp assemblies (2) and (6) onto the lines group. 5.
UENR0624-03 Disassembly and Assembly Section Illustration 9 g02211955 Illustration 11 g02239877 Typical example The photo is a cutaway view of the ball clamp assembly. Typical example Example of configuration with the bellows located near the CEM inlet 6. Verify that the cup of the ball joint (E) does not touch the radius of the ball (D). Position ball clamp (2) and loosely tighten ball clamp (2). 8. Repeat Step 6 and 7 for ball clamp (6).
UENR0624-03 9 Disassembly and Assembly Section Examples of Possible Misalignment and Results Illustration 13 Illustration 12 g01023261 Typical example Example of lateral misalignment Lateral misalignment is shown in Illustration 12 . Lateral misalignment on the exhaust bellows can lead to contact between liner and convolutions. The misalignment can cause premature failure. Lateral misalignment is identified by visually inspecting the convolutions on the bellows.
UENR0624-03 Disassembly and Assembly Section If damage has occurred to the edges of the bellow, the bellows must be replaced. i05268254 Fuel Priming Pump - Remove and Install Removal Procedure Table 1 Required Tools Illustration 14 g01016669 Typical example Example of damage to the convolutions Inspect the bellows for damage. The part should be discarded if damage to the convolutions is present. Illustration 14 shows that damage to the convolutions.
UENR0624-03 11 Disassembly and Assembly Section d. Remove O-ring seals (3) from connectors (2) and plugs (5). Installation Procedure (Mechanical Priming Pump) NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.
UENR0624-03 Disassembly and Assembly Section d. Install connectors (2) to fuel priming pump (4). e. Install plugs (5) to fuel priming pump (4). f. Tighten the plugs and the connectors to a torque of 20 N·m (14 lb ft). 3. Position fuel priming pump (4) on the mounting bracket. Install bolts (7) to the fuel priming pump . Tighten the bolts to a torque of 44 N·m (32 lb ft). 4. Remove the plugs from the plastic tube assemblies. Remove the caps from the connectors. 5.
UENR0624-03 13 Disassembly and Assembly Section 8. Use Tooling (A) in order to plug the fuel injection pump. 9. Remove O-ring seal (4) (not shown) and O-ring seal (5) (not shown). Note: Ensure that the Torx screws are tightened equally. Failure to ensure that the Torx screws are tightened equally will result in damage to the fuel injection pump. 9. Tighten the Torx head screws to a torque of 9 N·m (80 lb in). Installation Procedure 1. Ensure that all component at free from wear and damage.
UENR0624-03 Disassembly and Assembly Section NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.
UENR0624-03 15 Disassembly and Assembly Section Illustration 22 g03011038 12. If necessary, follow Step 1.c through Step 12.c in order to remove the bracket for secondary fuel filter. Illustration 21 g03011037 10. Remove cannister (8) from fuel filter base (3). Remove secondary filter (7). Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for the correct procedure. 11. Remove nuts (6) from fuel filter base (3). Remove the fuel filter base from the mounting bracket.
UENR0624-03 Disassembly and Assembly Section Illustration 23 g03011038 1. If necessary, follow Step 1.a through Step 1.c in order to install the bracket for secondary fuel filter. a. If necessary, install studs (9) to fuel filter bracket (10). Tighten studs (9) to a torque of 18 N·m (159 lb in). b. Position fuel filter bracket (10) onto the valve mechanism cover. Install bolts (11) to fuel filter bracket (10). c. Tighten bolts (11) to a torque of 25 N·m (221 lb in). Illustration 24 g03011037 2.
UENR0624-03 17 Disassembly and Assembly Section End By: a. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. i05268272 Water Separator and Fuel Filter (Primary) - Remove and Install Removal Procedure Table 4 Required Tools Illustration 25 g03011036 5. Remove the plugs from the plastic tube assemblies. Remove the caps from the ports in the fuel filter base.
UENR0624-03 Disassembly and Assembly Section Illustration 26 g03011667 3. Make temporary identification marks on plastic tube assemblies in order to show the correct position of the plastic tube assemblies. 4. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled. 5. Disconnect the plastic tube assembly from connecting (1). Use Tooling (A) in order to plug the plastic tube assemblies. Use Tooling (A) in order to cap connection (1). 6.
UENR0624-03 19 Disassembly and Assembly Section Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.
UENR0624-03 Disassembly and Assembly Section NOTICE Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system. 5. Remove plug from the plastic tube assembly. Remove cap from connecting (1) on primary fuel filter (4).
UENR0624-03 21 Disassembly and Assembly Section a. Release hose clamp (9) on plastic tube assembly (6). b. Disconnect plastic tube assembly (6) from the fuel manifold (2). c. Use Tooling (A) to cap the open port in fuel manifold (2) with a new cap. d. Remove seal (10). e. Use Tooling (A) to plug the open end of plastic tube assembly (6) with a new plug.
UENR0624-03 Disassembly and Assembly Section Note: Ensure that the plastic tube assembly is correctly orientated. d. Tighten hose clamp (9) securely. 3. Position fuel manifold (2) onto valve mechanism cover (3). Install bolts (1) to fuel manifold (2) finger tight. 4. Install new fuel injection lines finger tight. Refer to Disassembly and Assembly, “Fuel Injection Lines Install” for the installation procedure.
UENR0624-03 23 Disassembly and Assembly Section Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.
UENR0624-03 Disassembly and Assembly Section 8. If necessary, cut cable straps in order to remove the wiring harness assemblies. 9. Slide the locking tab for wiring harness assembly (15) into the unlocked position. Disconnect wiring harness assembly (15) from crankshaft position sensor (16). 10. Slide the locking tab for wiring harness assembly (17) into the unlocked position. Disconnect wiring harness assembly (17) from camshaft position sensor (18). 11.
UENR0624-03 25 Disassembly and Assembly Section 18. Remove bolt (26). Remove bracket (25) from the valve mechanism cover. 19. Clean the area around the nuts for fuel injection lines (12). Ensure that the area is free from contamination before beginning disassembly. 20. Use Tooling (B) in order to disconnect fuel injection line (12) from electronic unit injector (27). Note: It may be necessary to remove the front engine lifting eye in order to gain access to number one high-pressure pipe nut. 21.
UENR0624-03 Disassembly and Assembly Section 5. Remove the caps from the port of the electronic unit injector and from the appropriate port in fuel manifold (16). 6. Loosely connect the nuts at both ends of fuel injection line (12) to the electronic unit injector and to the appropriate port in fuel manifold (16). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold. 7.
UENR0624-03 27 Disassembly and Assembly Section Illustration 43 Illustration 41 g02699462 g02849446 13. Position bracket (19) onto the valve mechanism cover. Install bolts (20) and tighten the bolts to a torque of 25 N·m (221 lb in). 14. Install the fuel filter base mounting bracket (21) (not shown). Refer to Disassembly and Assembly, “Fuel Filter Base - Remove and Install” for the correct procedure. 15. Position the wiring harness assembly (11) over fuel injection lines (12). 16.
UENR0624-03 Disassembly and Assembly Section 23. Connect wiring harness assembly (17) to camshaft position sensor (18). Slide the locking tab for wiring harness assembly (17) into the locked position. 24. Install cable straps to the wiring harness assembly in the relevant positions. Ensure that the cable straps meet the OEM specifications. Note: Plug or cap all open ports with new plugs or caps. 1. If necessary, remove the diesel particulate filter mounting bracket.
UENR0624-03 29 Disassembly and Assembly Section 11. If necessary, install the diesel particulate filter mounting bracket. Refer to Disassembly and Assembly, “Support and Mounting (CEM) Remove and Install” for the correct procedure. Illustration 45 g02717358 2. Ensure that the NRS exhaust cooler is free from restriction and external damage. Ensure that the NRS exhaust cooler and tube assemblies are free from wear and damage.
UENR0624-03 Disassembly and Assembly Section End By: a. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. i05268287 Throttle Valve (Intake Air) Remove and Install (Rear Facing Inlet Elbow) Removal Procedure Illustration 47 g02906317 1. Loosen the hose clamp and disconnect the hose assembly from elbow (1). 2.
UENR0624-03 31 Disassembly and Assembly Section Illustration 48 g02906404 Illustration 49 g02906404 Illustration 50 g02906317 10. If necessary, remove adaptor (12) and sealing washer (11) from elbow (1). Installation Procedure Table 8 Required Tools Tool Part Number A - Part Description Technologic 15 Qty 1 1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged. This document has been printed from SPI2.
UENR0624-03 Disassembly and Assembly Section 13. Install the clamp to the air inlet hose and connect the air inlet hose to elbow (1). i05268292 Throttle Valve (Intake Air) Remove and Install (Side Facing Inlet Elbow) Removal Procedure Illustration 51 g02906277 2. If necessary, install studs (9). Refer to Disassembly and Assembly, “Inlet Manifold Remove and Install” for the correct procedure. 3.
UENR0624-03 33 Disassembly and Assembly Section 10. If necessary, remove adaptor (11) and sealing washer (10) from elbow (3). 11. If necessary, remove studs (13). Refer to Disassembly and Assembly, “Inlet Manifold Remove and Install” for the correct procedure. Installation Procedure Table 9 Required Tools Tool Part Number A - Part Description Technologic 15 Qty 1 1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged.
UENR0624-03 Disassembly and Assembly Section 5. Install throttle valve (2) onto studs (13). 6. Install gasket (12) onto studs (13). Illustration 55 g02909198 Illustration 57 g02909057 7. Install bolt (8) in Position (X) to elbow (3). Install elbow (3) onto studs (13) and tighten bolt (8) in Position (X) finger tight. Install remaining bolt (8). 8. Install nuts (9) to studs (13). 9. Tighten bolts (8) and nuts (9) to a torque of 10 N·m (89 lb in). 10.
UENR0624-03 35 Disassembly and Assembly Section Start By: a. Remove the fuel injection pump gear. Refer to Disassembly and Assembly, “Fuel Injection Pump Gear - Remove” for the correct procedure. Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
UENR0624-03 Disassembly and Assembly Section 16. If necessary, remove studs (9) from front housing (10). i05500629 Fuel Injection Pump - Install Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.
UENR0624-03 37 Disassembly and Assembly Section Illustration 60 g02937680 Illustration 62 g02709437 5. Remove the appropriate caps in order to install a new fuel injection line (7). Install new fuel injection line (7) to the fuel injection pump and to the fuel manifold. Refer to Disassembly and Assembly, “Fuel Injection Lines - Install” for the correct procedure. 6.
UENR0624-03 Disassembly and Assembly Section 13. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. i05268312 Fuel Injection Pump Gear Remove Removal Procedure Table 11 Required Tools Part Description Qty Tool Part Number A T400086 Timing Pin (Crankshaft) 1 B T400152 Timing Pin (Camshaft) 1 C - Snap-on PBS650 Small Pry Bar 1 Illustration 63 g02937156 Illustration 64 g02937157 Start By: a.
UENR0624-03 39 Disassembly and Assembly Section d. Rotate the engine until Hole (X) in the camshaft gear is aligned with Position (W) in the front housing. e. Install Tooling (B) through Position (W) and into Hole (X) in the camshaft gear. Illustration 65 g02934298 4. Follow Step 4.a through Step 4.c in order to install the crankshaft positioning tool. a. Remove plug (4) from Position (X) in the cylinder block. b. Remove O-ring seal (3) from plug (4). c.
UENR0624-03 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components are clean and free from wear of damage. If necessary, replace any components that are worn or damaged. 2. If Tooling (A) and Tooling (B) are not installed, install Tooling (A) and install Tooling (B). Refer to Disassembly and Assembly, “Fuel Injection Pump Gear - Remove” for the correct procedure.
UENR0624-03 41 Disassembly and Assembly Section Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove” for the correct procedure. Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
UENR0624-03 Disassembly and Assembly Section 4. Use Tooling (A) in order to cap electronic unit injector (3) immediately. Use Tooling (A) in order to plug hose assembly (2) immediately. 13. If necessary, remove studs (9) from the cylinder head. i05270671 5. Remove nut (4) and washer (8) from clamp (6). Note: Note the orientation of the washer. Electronic Unit Injector - Install 6.
UENR0624-03 43 Disassembly and Assembly Section 2. If a replacement electronic unit injector is installed, the correct seven digit injector code that is located in Position (A) must be programmed into the electronic control module. Refer to Troubleshooting, “Injector Code - Calibrate” for more information. Note: Record the seven digit injector code in Position (A) before the electronic unit injector is installed. 3. Ensure that the fuel inlet port of the electronic unit injector is capped.
UENR0624-03 Disassembly and Assembly Section 25. Turn the fuel supply to the ON position. 26. Turn the battery disconnect switch to the ON position. 27. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. i05270673 Turbocharger - Remove (Top Mounted Turbochargers) Removal Procedure Start By: Illustration 73 g02706897 15. Install a new O-ring seal (7) to the connection on hose assembly (2). 16.
UENR0624-03 45 Disassembly and Assembly Section 5. Remove hose clamp (7) from hose assembly (8). Disconnect hose assembly (8) from the wastegate actuator. 6. Remove bolts (12) from tube assembly (9). 7. Remove gasket (13) (not shown). 8. If necessary, follow Step 8.a through Step 8.d in order to remove tube assembly (9) from the cylinder block. a. Remove bolts (16) and position tube assembly (18) away from the oil cooler. b. Remove O-ring seal (15) (not shown) from tube assembly (18). c.
UENR0624-03 Disassembly and Assembly Section f. Remove gasket (27) (not shown). i05270674 Turbocharger - Remove (Side Mounted Turbochargers) Removal Procedure Start By: a. Remove the flexible exhaust pipe from the turbocharger. Refer to Disassembly and Assembly, “Flexible Exhaust Pipe - Remove and Install” for the correct procedure. NOTICE Keep all parts clean from contaminants. Illustration 77 g02868256 12. If necessary, follow Step 12.a through Step 12.
UENR0624-03 47 Disassembly and Assembly Section 5. Loosen the hose clamp on hose assembly (4). Disconnect hose assembly (4) from the turbocharger. 6. Loosen the hose clamp on hose assembly (6). Disconnect hose assembly (6) from the wastegate actuator. 7. Remove bolts (10) from tube assembly (9). 8. Remove gasket (7) (not shown). 9. If necessary, remove tube assembly (9) from the cylinder block. Remove O-ring seals (8) (not shown). Illustration 78 g02859585 Illustration 80 g02861996 10.
UENR0624-03 Disassembly and Assembly Section f. Remove gasket (23) (not shown). i05270677 Turbocharger - Install (Top Mounted Turbochargers) Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 81 g02862040 13. If necessary, follow Step 13.a through Step 13.f in order to remove boost pressure chamber cover (29). 1. Ensure that the turbocharger is clean and free from damage.
UENR0624-03 49 Disassembly and Assembly Section c. Install a new sealing washer (31) to banjo bolt (32). Install the banjo bolt assembly to hose assembly (26) and install the remaining sealing washer (31). Install hose assembly (26) to boost pressure chamber cover (33) finger tight. d. Install tube assembly (26) into clip (25). e. Install a new sealing washer (29) to banjo bolt (28). Install the banjo bolt assembly to hose assembly (8) and install the remaining sealing washer (28).
UENR0624-03 Disassembly and Assembly Section b. Install tube assembly (9) to the cylinder block. c. Install bolt (17) to tube assembly (9). Tighten the bolt to a torque of 25 N·m (221 lb in). d. Install O-ring seal (15) (not shown) to tube assembly (18). e. Install tube assembly (18) to the oil cooler assembly. Install bolts (16) to tube assembly (18). Tighten the bolts to a torque of 25 N·m (221 lb in). 12. Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port.
UENR0624-03 51 Disassembly and Assembly Section End By: a. Install the flexible exhaust pipe to the turbocharger. Refer to Disassembly and Assembly, “Flexible Exhaust Pipe - Remove and Install” for the correct procedure. i05270679 Turbocharger - Install (Side Mounted Turbochargers) Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 86 1. Ensure that the turbocharger is clean and free from damage.
UENR0624-03 Disassembly and Assembly Section Illustration 87 g02862480 Illustration 88 g02859585 Illustration 89 g02859796 4. Clean the gasket surfaces of exhaust manifold (19). If necessary, install studs (17) to exhaust manifold (19) and turbocharger (11). Tighten the studs to a torque of 15 N·m (133 lb in). 5. Position a new gasket (20) (not shown) onto turbocharger (11). 6. Position turbocharger (11) onto exhaust manifold (19) and install washers (16) and new nuts (15).
UENR0624-03 53 Disassembly and Assembly Section 10. Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant. 19. Connect the hose assemblies to the turbocharger inlet and the turbocharger outlet. Tighten the hose clamps securely. 11. If necessary, install a new sealing washer (13) onto connection (14). Install connection assembly (14) to the cylinder block.
UENR0624-03 Disassembly and Assembly Section 20. Install the flexible exhaust pipe to the turbocharger. Refer to Disassembly and Assembly, “Flexible Exhaust Pipe - Remove and Install” for the correct procedure. i05270685 Wastegate Solenoid - Remove and Install Removal Procedure Start By: a. Turn the battery disconnect switch to the OFF position. Illustration 92 g02720986 1. Disconnect harness assembly (4) from wastegate solenoid (5). 2.
UENR0624-03 Disassembly and Assembly Section 5. Position hose (8) onto the wastegate solenoid. Tighten hose clamp (9) securely. 6. Position hose (7) onto the wastegate solenoid. Tighten hose clamp (6) securely. 7. Position hose (3) onto the wastegate solenoid. Tighten hose clamp (2) securely. 8. Ensure that the hoses do not come into contact with any other engine components. 9. Connect harness assembly (4) to the wastegate solenoid. End By: a. Turn the battery disconnect switch to the ON position.
UENR0624-03 Disassembly and Assembly Section Note: Plug or cap all open ports with new plugs or caps. 1. If necessary, remove the diesel particulate mounting bracket. Refer to Disassembly and Assembly, “Support and Mounting (CEM) Remove and Install” for the correct procedure. Illustration 95 g02912798 Illustration 96 g02898616 This document has been printed from SPI2.
UENR0624-03 Disassembly and Assembly Section Installation Procedure Sulfuric Acid Burn Hazard may cause serious personal injury or death. The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact.
UENR0624-03 Disassembly and Assembly Section Note: Ensure that the bolts are installed into the correct position. 8. If necessary, install tube (19) to hose (16). Slide hose clamp (17) into position and tighten securely. 9. Install new O-ring seals (21) (not shown) to tube assembly (19). 10. Install tube assembly (19) to EGR valve (4). 11. Install bolt (18) and bolt (20) finger tight. Tighten the bolt 12. Tighten bolt (20) to a torque of 10 N·m (89 lb in). 13.
UENR0624-03 59 Disassembly and Assembly Section The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions. NOTICE The bellows must be supported at all times when the bellows are not installed in the application. Failure to support the bellows adequately could result in the failure of the bellows. Do not use power tools in order to disassemble or assemble any part of the flexible exhaust system.
UENR0624-03 Disassembly and Assembly Section Disassembly Procedure for the Flexible Exhaust Pipe Assembly 1. If any part of the flexible exhaust pipe assembly is damaged. Refer to Disassembly and Assembly, “Inspection of Parts” for more information. Illustration 102 g02354616 Typical example 2. Follow Steps 2.a through Step 2.d in order to remove the flexible exhaust as an assembly from the Clean Emission Module (CEM) and the turbocharger. a.
UENR0624-03 61 Disassembly and Assembly Section Assembly Procedure for the Flexible Exhaust Pipe Assembly a. If original bellows are to be reinstalled, place the internal area in Position (G) of the bellows on a suitable support. Use Tooling (A) in order to drill a pilot hole through the spot weld in Position (H) on clamp (7). Table 14 Required Tools Tool Part Number Part Description A - Drill Bit 3 mm (0.118 inch) Ø B - Drill Bit 6.5 mm (0.256 inch) Ø Qty 1 1 1.
UENR0624-03 Disassembly and Assembly Section Note: Ensure that the bellows are not subjected to any undue stress. i. Install tube assembly (6), align the tube assembly with the temporary marks on the bellows. Tighten clamp (7) hand tight. Installation Procedure for the Flexible Exhaust Pipe as an Assembly NOTICE Failure to reinstall the bellows into the original position will result in a failure of the bellows and possible emissions failure. 7.
UENR0624-03 63 Disassembly and Assembly Section 13. Cut cable straps from the suitable material that was encasing bellows (3) between Position (A) and Position (B). Remove the suitable material from bellows (3). i05270715 Exhaust Manifold - Remove and Install Removal Procedure Start By: a. Remove the turbocharger. Refer to Disassembly and Assembly, “Turbocharger Remove” for the correct procedure. Illustration 108 g02725206 This document has been printed from SPI2.
UENR0624-03 Disassembly and Assembly Section Illustration 109 g02725251 Tighten sequence of exhaust manifold 1. Remove tube assembly (1). Refer to Disassembly and Assembly, “Air Control Valve - Remove and Install” for the correct procedure. 2. Loosen nuts (5) in reverse numerical order. Refer to Illustration 109 . Note: Loosening the bolts in reverse numerical order will help prevent distortion of the exhaust manifold. 3. Remove nuts (5) and remove exhaust manifold (3) from the cylinder head. 4.
UENR0624-03 65 Disassembly and Assembly Section Installation Procedure 1. Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the gasket surface of the cylinder head. Illustration 110 g02725206 Illustration 111 2. If necessary, install studs (2) to exhaust manifold (3). Tighten the stud to a torque of 18 N·m (159 lb in). 3. Position a new exhaust manifold gasket (6) (not shown) onto studs (4).
UENR0624-03 Disassembly and Assembly Section Tighten the nuts to an initial torque of 10 N·m (89 lb in). Tighten the nuts to a final torque of 27 N·m (239 lb in). 6. Install tube assembly (1). Refer to Disassembly and Assembly, “Air Control Valve - Remove and Install” for the correct procedure. NOTICE Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF.
UENR0624-03 67 Disassembly and Assembly Section 8. Disconnect pressure sensor tube assembly (5) from the DPF. Note: Make temporary identification marks on the tube assembly for assembly purposes. 9. Disconnect pressure sensor tube assembly (7) from the DPF. Note: Make temporary identification marks on the tube assembly for assembly purposes. 10. Remove bolts (10) from clamps (11). Remove the clamps from the DPF in order to allow removal of the DPF. 11. Attach a suitable lifting device to the DPF .
UENR0624-03 Disassembly and Assembly Section The muffler, catalytic converter/muffler, and diesel particulate filter will become extremely hot during engine operation. A hot muffler, catalytic converter/muffler and diesel particulate filter can cause serious burns. Allow adequate cooling time before working on or near the muffler, catalytic converter/muffler and diesel particulate filter. NOTICE Do not strike any part of the assembly of the Diesel Particulate Filter (DPF).
UENR0624-03 69 Disassembly and Assembly Section Note: Make temporary identification marks on all connections for assembly purposes. 8. Disconnect pressure sensor tube assembly (7) from the DPF. Note: Make temporary identification marks on the tube assembly for assembly purposes. 9. Disconnect pressure sensor tube assembly (9) from the DPF. Note: Make temporary identification marks on the tube assembly for assembly purposes. 10. Remove bolts (8) from clamps (5).
UENR0624-03 Disassembly and Assembly Section Illustration 119 Illustration 117 g03022697 g03017439 3. If necessary, install the temperature sensors (3) and temperature sensor (9) into the DPF. Refer to Disassembly and Assembly, “Temperature Sensor (DPF) - Remove and Install” for the correct procedure. 4. Position a new V-band clamp onto flexible exhaust pipe (8). 5. Attach a suitable lifting device to the assembly of the Diesel Particulate Filter (DPF) (6).
UENR0624-03 71 Disassembly and Assembly Section 11. If a new DPF is being installed, the DPF must be aligned using flexible exhaust pipe (8) as the reference point. Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress. 12. Position the V-band clamp onto the DPF. Tighten the flexible exhaust pipe clamp. Refer to Disassembly and Assembly, “Flexible Exhaust Pipe - Remove and Install” for the correct procedure. 13.
UENR0624-03 Disassembly and Assembly Section 6. Use the suitable lifting device in order to install the DPF to mounting bracket (10). Ensure that the flexible exhaust pipe is correctly seated onto the turbocharger and DPF with the alignment pin (not shown) fully engaged. Note: Ensure that the exhaust gases flow in the direction of temporary mark. 7. Remove the suitable lifting device from the assembly of the DPF. 8. Position clamps (5) onto DPF (4). Loosely install bolts (8). 9.
UENR0624-03 73 Disassembly and Assembly Section Note: Do not start the engine with the bellows protector in place. 17. Connect the wiring harness assembly to connection (1) on temperature sensor (2). 18. Connect the wiring harness assembly to connection (11) on temperature sensor (3). 19. Connect the pressure sensor tube assembly (9) to the DPF. Tighten the connection to a torque of 30 N·m (265 lb in). End By: a.
UENR0624-03 Disassembly and Assembly Section CEM Assembly Installation Procedure Illustration 123 g03020379 1. Remove bolts (3) from bracket (2). 2. Remove bolts (7) from bracket (2). Illustration 124 g03019496 Illustration 125 g03020379 3. Remove bolts (6) from bracket (2) and remove bracket (2) from the engine. The weight of bracket (2) is approximately 10 kg (22 lb). 4. If necessary, remove bolts (4) from bracket (5). remove bracket (5) from the engine. 5.
UENR0624-03 Disassembly and Assembly Section 4. Using temporary marks align assembly (1) and tighten the bolts. 5. If necessary, tighten bolts (4) to a torque of 25 N·m (221 lb in). End By: a. Install the DPF. Refer to Disassembly and Assembly, “Diesel Particulate Filter - Install ” for the correct procedure. 6. If necessary, tighten bolts (8) to a torque of 25 N·m (221 lb in). 7. Tighten bolts (6) to a torque of 25 N·m (221 lb in). 8. Tighten bolts (7) to a torque of 25 N·m (221 lb in). 9.
UENR0624-03 Disassembly and Assembly Section CEM Assembly installation Procedure End By: a. Install the DPF. Refer to Disassembly and Assembly, “Diesel Particulate Filter - Install ” for the correct procedure. i05270751 Support and Mounting (CEM) Remove and Install (Option 1) CEM Assembly Removal Procedure Start By: a. Remove the DPF. Refer to Disassembly and Assembly, “Diesel Particulate Filter - Remove ” for the correct procedure. Illustration 127 g03017437 1.
UENR0624-03 Disassembly and Assembly Section CEM Assembly Installation Procedure Illustration 129 g03015096 Typical example 1. Remove bolts (2) from bracket (3). Illustration 130 g03013176 Illustration 131 g03015096 2. Remove bolts (4) from bracket (3). 3. Remove bolts (7) from bracket (3) and remove bracket (3) from the engine. The weight of bracket (3) is approximately 10 kg (22 lb). 4. If necessary, remove bolts (9) (not shown) and remove bracket (8) from the engine. 5.
UENR0624-03 Disassembly and Assembly Section 4. Using temporary marks, align support assembly (1) and tighten bolts. 5. Tighten bolts (9) to a torque of 25 N·m (221 lb in) 6. Tighten bolts (6) to a torque of 25 N·m (221 lb in) 7. Tighten bolts (2) to a torque of 45 N·m (33 lb ft) 8. Tighten bolts (4) to a torque of 25 N·m (221 lb in) 9. Tighten bolts (7) to a torque of 25 N·m (221 lb in) End By: a. Install the DPF.
UENR0624-03 79 Disassembly and Assembly Section 7. If necessary, remove diffuser (5) from inlet manifold (6). 8. If necessary, follow Step 8.a through Step 8.d in order to remove adaptor plate (10). a. Remove the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove” for the correct procedure. b. Remove bolts (9) from adaptor plate (10). c. Remove adaptor plate (10) from the cylinder head. d. Remove O-ring seals (11) (not shown).
UENR0624-03 Disassembly and Assembly Section 10. Install sealing washers (14) (not shown) and banjo bolt (15) to tube and bracket assembly (13). Refer to Disassembly and Assembly, “Pressure Sensor (Exhaust Back Pressure) - Remove and Install” for the correct procedure. 11. Position bracket (12) onto inlet manifold (6) and install bolt (7) finger tight. Connect tube and bracket assembly (13 ) onto bracket (12).
UENR0624-03 81 Disassembly and Assembly Section 15. Install exhaust gas temperature connection (3) into bracket (2). NOTICE Keep all parts clean from contaminants. 16. Connect harness assembly (1) to the inlet manifold temperature and pressure sensor and slide the locking tab into the locked position. Contaminants may cause rapid wear and shortened component life.
UENR0624-03 Disassembly and Assembly Section d. Continue to rotate the crankshaft and gradually release the pressure on Tooling (B) until the piston is at the top center position. The valve is now held in a position that allows the valve spring to be safely removed. NOTICE Do not turn the crankshaft while the valve springs are removed. 6. Repeat Steps 2 through 5 in order to remove the remaining valve spring from the appropriate cylinder. 7. Remove Tooling (B).
UENR0624-03 83 Disassembly and Assembly Section 7. Carefully release the pressure on Tooling (B). Note: Ensure that the valve keepers are correctly seated. 8. Repeat Steps 3 to 7 for the remaining valves. The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem.
UENR0624-03 Disassembly and Assembly Section 2. Place a temporary identification mark on the heads of the valves in order to identify the correct position. Inlet valves have a recess in the center of the head. Note: Do not stamp the heads of the valve. Stamping or punching the heads of the valves could cause the valves to fracture. 3. Use a suitable lifting device to position the cylinder head with the valve springs upward. The weight of the cylinder head is approximately 56 kg (125 lb).
UENR0624-03 85 Disassembly and Assembly Section (Table 23, contd) T400158 Valve Spring Compressor 1 Stud M6 by 25mm 1 Valve Stem Seal Installer 1 A B T400154 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.
UENR0624-03 Disassembly and Assembly Section End By: a. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. i05270769 Inlet and Exhaust Valve Guides - Remove and Install Removal Procedure Table 24 Required Tools Tool Part Number A T400159 Part Description Valve Guide Driver Qty 1 Start By: Illustration 145 g03003297 Typical example 7. Install Tooling (A) in the appropriate position on the cylinder head in order to compress valve spring (3).
UENR0624-03 87 Disassembly and Assembly Section Installation Procedure Table 25 Required Tools Tool Part Number Qty T400159 Valve Guide Driver 1 T400153 Stop Collar 1 T400155 Valve Guide Reamer 1 A B Part Description NOTICE Removal and installation of the valve guide and valve seat must be carried out by personnel with the correct training. Also special machinery is required. For more information, refer to your authorized Perkins dealer. NOTICE Keep all parts clean from contaminants.
UENR0624-03 Disassembly and Assembly Section End By: a. Install the inlet valves and the exhaust valves. Refer to Disassembly and Assembly , “Inlet and Exhaust Valves - Remove and Install”. i05270770 Engine Oil Filter Base Remove and Install Removal Procedure Table 26 Required Tools Tool Part Number A T400083 Part Description Filter Cartridge Tool Qty 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
UENR0624-03 89 Disassembly and Assembly Section Installation Procedure 6. Position new gasket (5) (not shown) onto engine oil filter base (4). Install bolts (6) to engine oil filter base (4). Table 27 Required Tools Tool Part Number A T400083 Part Description Qty Filter Cartridge Tool Note: Ensure that the different length bolts are installed in the correct position. 1 7. Install the assembly of the engine oil filter base to the cylinder block.
UENR0624-03 Disassembly and Assembly Section 1. Drain the coolant from the cooling system into a suitable container. Refer to Operation and Maintenance Manual, “Cooling System Coolant Change” for the correct procedure. 2. If the engine oil has become contaminated with coolant, the engine oil and filter must be replaced. Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change” for the correct procedure. 4. Remove bolts (6) from tube assembly (5).
UENR0624-03 91 Disassembly and Assembly Section c. Remove gaskets (11). i05270774 Engine Oil Cooler - Install Installation Procedure 1. Ensure that all components are free from wear and damaged. If necessary, replace any components that are worn or damaged. Illustration 155 g02871598 Tightening sequence for the engine oil cooler. Illustration 154 g02707318 2. If necessary, follow Step 2.a through Step 2.d in order to assembly the engine oil cooler. a.
UENR0624-03 Disassembly and Assembly Section 6. Tighten bolts (3) to a torque of 25 N·m (221 lb in) in sequence that is shown in Illustration 155 . 7. Position bracket (9) onto engine oil cooler (3). Install bolt (8) to bracket (9). Tighten the bolt to a torque of 15 N·m (133 lb in). 17. Check the level of the engine lubricating oil. Refer to Operation and Maintenance Manual, “Engine Oil Level - Check” for the correct procedure. i05270776 8. Install boost pressure chamber cover (4).
UENR0624-03 93 Disassembly and Assembly Section 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. Illustration 158 g02953956 2. Install new O-ring seal (3) to engine oil relief valve (1). 3.
UENR0624-03 Disassembly and Assembly Section End By: NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. a. Install the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove and Install”. i05270783 1. Ensure that bushing is free from wear or damage. Refer to Specifications, “Engine Oil Pump” for more information. If necessary, replace the bushing. Water Pump - Remove Removal Procedure Start By: a.
UENR0624-03 95 Disassembly and Assembly Section 4. Remove seal (3). i05270787 Water Pump - Install Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the water pump is clean and free from wear and damage. If necessary, replace the water pump. Clean the seal surface of the water pump. Illustration 161 g02663376 Illustration 162 g02663417 2. Remove bolts (1) from water pump (2). 3.
UENR0624-03 Disassembly and Assembly Section 6. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change” for the correct procedure. End By: a. Install the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install” for the correct procedure. i05270793 Water Temperature Regulator Remove and Install Removal Procedure Illustration 163 g02663458 NOTICE Keep all parts clean from contaminants.
UENR0624-03 97 Disassembly and Assembly Section 1. Ensure that all components are clean and free of wear and damage. If necessary, replace any components that are worn or damaged. 2. Check the water temperature regulator for correct operation. Refer to System Operation, Testing, and Adjusting, “Water Temperature Regulator Test” for the procedure to test the water temperature regulator. If the water temperature regulator is not operating correctly, the complete assembly must be replaced. 3.
UENR0624-03 Disassembly and Assembly Section 10. Connect the upper radiator hose to water temperature regulator housing (1) and tighten the hose clamps securely. 11. Connect the wiring harness to coolant temperature sensor (4). Slide the locking tab into the locked position. 12. Install the wastegate solenoid. Refer to Disassembly and Assembly, “Wastegate Solenoid - Remove and Install” for the correct procedure. 13. Fill the cooling system to the correct level.
UENR0624-03 99 Disassembly and Assembly Section Option 2 5. Remove bolt (14) from lifting bracket (12). 6. Remove lifting bracket (12) from the flywheel housing. i05270802 Engine Lifting Bracket - Install Installation Procedure Follow the installation procedure for the configuration of engine lifting brackets that are installed.
UENR0624-03 Disassembly and Assembly Section Option 2 Illustration 172 g03001176 View of the engine lifting brackets on the rear of the engine 1. Position lifting bracket (1) onto fan drive (3). Refer to Illustration 171 . Illustration 173 g03001576 View of the engine lifting bracket on the front of the engine 2. Install bolts (2) finger tight to lifting bracket (1). Tighten the bolts to a torque of 45 N·m (33 lb ft). 3. Position lifting bracket (4) onto the cylinder head.
UENR0624-03 101 Disassembly and Assembly Section 4. Install bolt (13) finger tight to lifting bracket (11). Tighten the bolt to a torque of 110 N·m (81 lb ft). 5. Position lifting bracket (12) onto the flywheel housing. Refer to Illustration 174 . 6. Install bolt (14) finger tight to lifting bracket (12). Tighten the bolts to a torque of 110 N·m (81 lb ft). i05270805 Flywheel - Remove Removal Procedure Table 29 Required Tools Tool Part Number A - Part Description Guide Stud M12 x 1.
UENR0624-03 Disassembly and Assembly Section a. Place the flywheel assembly on a suitable support. b. Use a hammer and a punch in order to remove ring gear (3) from flywheel (1). Note: Identify the orientation of the teeth on the flywheel ring gear. 1. If the flywheel ring gear was removed, follow Step 1.a through Step 1.c in order to install a new ring gear (3) to flywheel (1). a. Identify the orientation of teeth (4) on new ring gear (3).
UENR0624-03 103 Disassembly and Assembly Section 7. Remove Tooling (A) and install remaining new bolts (2) hand tight to flywheel (1). NOTICE Keep all parts clean from contaminants. 8. Remove the lifting device from flywheel (1). 9. Use a suitable tool to prevent the flywheel from rotating. Tighten bolts (2) to a torque of 30 N·m (266 lb in). Use Tooling (B) to rotate bolts (2) through an additional 90 degrees in a clockwise direction in order to achieve the required final torque.
UENR0624-03 Disassembly and Assembly Section Installation Procedure Table 32 Required Tools Tool Part Number D T400089 Part Description Crankshaft Rear Seal Installer Qty 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the flange of the crankshaft and the inside of the flywheel housing are clean and free from oil and damage.
UENR0624-03 105 Disassembly and Assembly Section End By: a. Install the flywheel. Refer to Disassembly and Assembly, “Flywheel - Install”. i05270813 Flywheel Housing - Remove and Install (Stressed Cylinder Block) Removal Procedure Table 33 Required Tools Tool Part Number A - Part Description Guide Stud M8 by 100 mm Qty 2 Illustration 182 g02879298 Illustration 183 g02879337 Start By: a. Remove the crankshaft rear seal.
UENR0624-03 Disassembly and Assembly Section 4. Install a suitable lifting device to the flywheel housing in order to support the flywheel housing. The weight of the flywheel housing is approximately 40 kg (88 lb). 5. Remove bolts (2) from flywheel housing (1). 6. Remove bolts (4) from flywheel housing (1). 7. Use the suitable lifting device in order to remove flywheel housing (1) from the cylinder block. Illustration 184 Illustration 185 g02881996 Illustration 186 g02879298 g02879456 8.
UENR0624-03 107 Disassembly and Assembly Section End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Remove and Install” for the correct procedure. b. Install the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove and Install” for the correct procedure. i05270819 Flywheel Housing - Remove and Install (Non-Stressed Cylinder Block) Removal Procedure Illustration 187 g02879337 Table 35 Required Tools 2.
UENR0624-03 Disassembly and Assembly Section 4. Install Tooling (A) into Position (X) on flywheel housing (1). 5. Install a suitable lifting device to the flywheel housing in order to support the flywheel housing. The weight of the flywheel housing is approximately 40 kg (88 lb). 6. Remove bolts (2) from flywheel housing (1). 7. Remove bolts (4) from flywheel housing (1). 8. Use the suitable lifting device in order to remove flywheel housing (1) from the cylinder block.
UENR0624-03 109 Disassembly and Assembly Section Installation Procedure Table 36 Required Tools Part Description Qty Tool Part Number A - Guide Stud M8 by 100 mm 2 B - Loctite 5970 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the flywheel housing is clean and free from damage. If necessary, replace the flywheel housing.
UENR0624-03 Disassembly and Assembly Section Illustration 195 g02661536 13. If necessary, install inspection cover (6) and bolts (7) to flywheel housing (1). Tighten the bolts to a torque of 25 N·m (221 lb in). Illustration 194 g02659276 2. Clean the rear face of the cylinder block. If necessary, install dowels (5) to the cylinder block. 14. Install the electric starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install” for the correct procedure. 3.
UENR0624-03 111 Disassembly and Assembly Section 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. Illustration 196 g02901518 Illustration 197 g02901685 1.
UENR0624-03 Disassembly and Assembly Section 5. Note the position of dowel (4) and dowel (5) in the power take-off drive. Do not remove the dowels unless the dowels are damaged. Installation Procedure Table 37 Required Tools Tool Part Number Part Description Qty A - Delphi Lockheed Compound Rubber Grease 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components are clean and free from wear and damage.
UENR0624-03 113 Disassembly and Assembly Section 6. Equally tighten bolts (2) in order to pull power takeoff drive (1) into the cylinder block 7. Tighten bolts (2) to a torque of 25 N·m (221 lb in) 4. Remove crankshaft multi V-pulley (3). Installation Procedure 8. Ensure that there is tactile backlash between the idler gear and the accessory drive gear. NOTICE Keep all parts clean from contaminants. 9. If necessary, install the OEM driven equipment to power take-off drive (1).
UENR0624-03 Disassembly and Assembly Section End By: a. Install the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install” for the correct procedure. i06096313 Crankshaft Front Seal Remove and Install Removal Procedure Table 38 Required Tools Tool Part Number A - B 27610311 C - Part Description Qty Drill Bit (3 mm) 1 Slide Hammer Puller 1 Telescopic Magnet 1 Start By: a. Remove the crankshaft pulley.
UENR0624-03 115 Disassembly and Assembly Section Procedure 1 End By: NOTICE Keep all parts clean from contaminants. a. Install the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install” for the correct procedure. Contaminants may cause rapid wear and shortened component life. Procedure 2 1. Ensure that the crankshaft pulley adaptor and the front cover are clean and free from oil and damage. 1.
UENR0624-03 Disassembly and Assembly Section End By: a. Install the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install” for the correct procedure. i05270827 4. Remove the crankshaft front seal using a suitable tool. Ensure that the front cover (3) is not damaged during the removal of the crankshaft front seal.
UENR0624-03 117 Disassembly and Assembly Section 6. Install bolts (1) finger tight. 7. Use Tooling (B) and Tooling (C) in order to align the front cover. 8. Remove Tooling (A) and install remaining bolts (1). Illustration 206 g02727693 Illustration 208 g02727967 9. Tighten bolts (1) to a torque of 25 N·m (221 lb in). 10. Remove Tooling (B) and Tooling (C) from the front cover. 11. Install the crankshaft front seal to the front cover.
UENR0624-03 Disassembly and Assembly Section End By: a. Install the crankshaft pulley. Refer to Disassembly and Assembly, “Crankshaft Pulley - Remove and Install” for the correct procedure. b. If the engine was equipped with a fan, install the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install” for the correct procedure. c. Install the camshaft position sensor. Refer to Disassembly and Assembly, “Camshaft Position Sensor - Remove and Install” for the correct procedure.
UENR0624-03 119 Disassembly and Assembly Section d. Rotate the engine until Hole (X) in the camshaft gear is aligned with Position (W) in the front housing. e. Install Tooling (B) through Position (W) and into Hole (X) in the camshaft gear. Illustration 211 g02934298 Illustration 212 g02937163 Illustration 213 g02939977 2. Follow Step 2.a through Step 2.c in order to install the crankshaft positioning tool. a. Remove plug (4) from Position (X) in the cylinder block. b.
UENR0624-03 Disassembly and Assembly Section 5. Remove bolt (12) from idler hub (10). 6. Remove the idler hub (10) and gear (9) from front housing (13). 7. Remove idler hub (10) from gear (9). 8. If necessary, remove lubricating jet (11) from front housing (13).
UENR0624-03 121 Disassembly and Assembly Section 4. Ensure that locating pin (6) is 45 degrees from vertical and parallel to the center of Torx head plug (5), refer to Illustration 214 . 15. If equipped, install the accessory drive. Refer to Disassembly and Assembly, “Accessory Drive Remove and Install” for the correct procedure. 5. Position gear (9) into the front housing. Ensure that the teeth on all gears mesh correctly. 6. Install idler hub (10) to gear (9).
UENR0624-03 Disassembly and Assembly Section Illustration 217 g02729108 Illustration 218 g03025257 Illustration 219 g03025256 2. Remove bolts (5) from front housing (1). Note: Note the positions of the different length bolts for installation purposes. 3. Remove front housing (1) from the cylinder block and dowels (6) (not shown). 4. Dowels (6) (not shown) should only be removed if damaged. 5. If necessary, follow Step 5.a through Step 5.c in order to remove engine oil filler (2). a.
UENR0624-03 123 Disassembly and Assembly Section 7. If necessary, remove plug (7) in Position (Y) from the front housing. i05270839 Housing (Front) - Install Installation Procedure Table 43 Required Tools Part Description Qty Tool Part Number A - Loctite 5970 Silicone Sealant 1 B - Guide Bolt M8 x 1.25 by 35 mm 2 C - Loctite 506 1 D - Delphi Lockheed Compound Rubber Grease 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shorten component life. 1.
UENR0624-03 Disassembly and Assembly Section Illustration 221 g02951196 Illustration 223 g02729108 4. Thoroughly clean the gasket surface of the front housing (1) and the cylinder block. 5. If necessary, install dowels (6) (not shown) to the cylinder block. 6. Install Tooling (B) into the cylinder block in Positions (X). 7. Apply a 3mm bead of Tooling (A) to front housing (1) as shown in Illustration 222 . 8. Install front housing (1) onto Tooling (B) and dowels (6) (not shown). 9.
UENR0624-03 125 Disassembly and Assembly Section Illustration 224 g02951436 12. Install remaining bolts (5). Tighten the bolts in the sequence that is shown in Illustration 224 to a torque of 25 N·m (221 lb in). 13. Install the camshaft gear. Refer to Disassembly and Assembly, “Camshaft Gear - Install” for the correct procedure. 14. Install the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump - Install” for the correct procedure. Illustration 225 g02951696 17.
UENR0624-03 Disassembly and Assembly Section a. Install new O-ring seal (10) to cover plate (8). Apply Tooling (D) to O-ring seal (10). b. Install cover plate (8) to the front housing. c. Install bolts (9) to the cover plate and tighten the bolts to a torque of 25 N·m (221 lb in). 19. If necessary, install the fan drive. Refer to Disassembly and Assembly, “Fan Drive - Remove and Install” for the correct procedure. End By: a. Fill the cooling system with coolant.
UENR0624-03 127 Disassembly and Assembly Section Installation Procedure Table 44 Required Tools Tool Part Number A - Part Description Delphi Lockheed Compound Rubber Grease Qty 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Inspect the bore in the front housing for damage. If necessary, replace the front housing.
UENR0624-03 Disassembly and Assembly Section 8. Ensure that there is tactile backlash between the idler gear and the accessory drive gear. 9. If necessary, install the OEM driven equipment to accessory drive (4). Refer to the OEM for the correct procedure. 10. If the OEM driven equipment was not installed onto accessory drive (4), position new gasket (3) (not shown) and cover plate (2) onto accessory drive (4). 11. Install bolts (1) to cover plate (2).
UENR0624-03 129 Disassembly and Assembly Section Table 46 Required Tools Tool Part Number A - Part Description Qty 1/2 Inch Drive x 19 mm Hex Drive 1 1. Ensure that all components of the crankcase breather are clean and free from wear and damage. Replace any components that are worn or damaged. 7. Install nuts (10) to studs (12). Tighten the nuts to a torque of 10 N·m (7 lb ft). 8. Ensure that hose (8) is clean and free from restriction. 9.
UENR0624-03 Disassembly and Assembly Section 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.
UENR0624-03 131 Disassembly and Assembly Section 1. Thoroughly clean all gasket surfaces of valve mechanism cover (2). Clean the gasket surfaces of the cylinder head. 2. Install a new gasket (9) to valve mechanism cover (2). Note: Ensure that the gasket is fully seated into the groove of the valve mechanism cover. Illustration 235 g03010838 Typical example 8. Remove gasket (9) from valve mechanism cover (2). Installation Procedure NOTICE Keep all parts clean from contaminants.
UENR0624-03 Disassembly and Assembly Section Tighten the bolts 1 through 7 to a torque of 10 N·m (89 lb in). Tighten the bolt 8 to a torque of 27 N·m (239 lb in) . Repeat Step 5 in order to ensure the correct torque. End By: a. Install the electronic unit injectors. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove” for the correct procedure. b. Install the fuel manifold. Refer to Disassembly and Assembly, “Fuel Manifold (Rail) - Remove and Install” for the correct procedure.
UENR0624-03 133 Disassembly and Assembly Section b. Remove O-ring seal (3) from plug (4). c. Install Tooling (A) into the cylinder block in Position (Z). Note: Tooling (A) must be located in Hole (Y) in the crankshaft. Note: Ensure that Tooling (A) is located in the correct drilling in the crankshaft as shown in Illustration 240 . Illustration 241 g02942696 Illustration 242 g02942756 2. Remove bolts (6) from rocker shaft (4) in the reverse numerical sequence shown in Illustration 242 . 3.
UENR0624-03 Disassembly and Assembly Section 6. If necessary, remove dowel (7) (not shown). i05275370 Rocker Shaft - Disassemble Disassembly Procedure Start By: a. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove” for the correct procedure. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
UENR0624-03 135 Disassembly and Assembly Section End By: a. Install the rocker shaft assembly. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Install” for the correct procedure. i05275374 Rocker Shaft and Pushrod Install Installation Procedure Table 49 Required Tools Illustration 244 Tool Part Number A T400086 Part Description Qty Timing Pin (Crankshaft) 1 g02942879 2. Lubricate the bore of rocker arm assemblies (2) for the inlet valve with clean engine oil. 3.
UENR0624-03 Disassembly and Assembly Section Note: Ensure that the push rods are seated in the cups of the lifters 6. Position rocker shaft assembly (4) onto the cylinder head. 7. Install bolts (6) to rocker shaft assembly (4). Tighten the bolts in the numerical sequence that is shown in Illustration 246 to a torque of 10 N·m (89 lb in). Note: Ensure that the rocker arms are seated in the cups of the push rods.
UENR0624-03 137 Disassembly and Assembly Section End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure. i05275396 Cylinder Head - Remove Removal Procedure Note: Put identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies.
UENR0624-03 Disassembly and Assembly Section Illustration 249 g03005658 Sequence for tightening the bolts for the cylinder head 3. Use Tooling (A) and Tooling (B) in order to gradually loosen bolts (1) and bolts (2) in the reverse numerical order to the sequence that is shown in Illustration 249 . Note: Follow the correct sequence in order to help prevent distortion of the cylinder head. 4. Remove bolts (1) and bolts (2) from cylinder head (3). Note: The bolts are two different lengths.
UENR0624-03 139 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages. 2. Inspect the gasket surface of the cylinder head for distortion.
UENR0624-03 Disassembly and Assembly Section Illustration 253 g03005660 Illustration 254 g03005656 Illustration 255 g03005937 6. Use a suitable lifting device to lift the cylinder head. The weight of the cylinder head is approximately 30 kg (66 lb). Note: Use a spreader bar during the lifting operation in order to distribute the weight of the cylinder head. 7. Use Tooling (D) to align cylinder head (3) with the cylinder block. Install the cylinder head to the cylinder block.
UENR0624-03 141 Disassembly and Assembly Section 10. Install Torx bolts (1) and Torx bolts (2) to cylinder head (3). 11. Remove Tooling (D). 12. Install remaining Torx bolts (1) to cylinder head (3). Illustration 257 g03005916 15. Use Tooling (A), Tooling (B), and Tooling (C) in order to turn Torx bolts (1) and Torx bolts (2) through an additional angle in the sequence that is shown in Illustration 256 .
UENR0624-03 Disassembly and Assembly Section Turn Torx bolts (1) through 60 degrees. Start By: 17. Install the injectors. Refer to Disassembly and Assembly, “Injector - Install” for the correct procedure. a. Remove the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install” for the correct procedure. 18. Install the glow plugs. Refer to Disassembly and Assembly, “Glow Plugs - Remove and Install” for the correct procedure. NOTICE Keep all parts clean from contaminants. 19.
UENR0624-03 143 Disassembly and Assembly Section NOTICE Replace all lifters when a new camshaft is installed. 1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. 2. Clean the lifters. Follow Step 2.a through Step 2.c in order to inspect the lifters. Replace any worn lifters or damaged lifters. End By: a. Install the camshaft. Refer to Disassembly and Assembly, “Camshaft - Remove and Install” for the correct procedure.
UENR0624-03 Disassembly and Assembly Section NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed. 4. Carefully remove camshaft (3) from the cylinder block. 3. Inspect the lifters for wear and for damage. Refer to Specifications, “Lifter Group” for more information. If necessary, replace any lifters that are worn or damaged. Refer to Disassembly and Assembly, “Lifter Group - Remove and Install” for the correct procedure. 4.
UENR0624-03 145 Disassembly and Assembly Section End By: a. Install the camshaft gear. Refer to Disassembly and Assembly, “Camshaft Gear - Remove and Install” for the correct procedure. i05279011 Camshaft Gear - Remove and Install Removal Procedure Table 54 Required Tools Part Description Qty Tool Part Number A T400089 Timing Pin (Crankshaft) 1 B T400152 Timing Pin (Camshaft) 1 C - Snap-on PBS650 Small Pry Bar 1 Start By: a. Remove the rocker shaft and pushrods.
UENR0624-03 Disassembly and Assembly Section Illustration 265 g02945576 Illustration 266 g02945776 Illustration 267 g02945716 Illustration 268 g02945837 3. Lubricate the teeth of gear (1) with clean engine oil. 4. Align the timing mark on camshaft (4) in Position (V) with the timing mark on the front housing in Position (W). 5. Position camshaft gear (1) onto camshaft (4). Ensure that dowel (6) is installed into Hole (X) in the camshaft. 6.
UENR0624-03 147 Disassembly and Assembly Section 7. Install Tooling (B). Refer to Disassembly and Assembly, “Idler Gear - Remove” for the correct procedure. 8. Install camshaft timing ring (2) onto dowels (5). 9. Install bolts (3) into camshaft (4). Tighten the bolts to a torque of 25 N·m (221 lb in). End By: a. Install the idler gear. Refer to Disassembly and Assembly, “Idler Gear - Install” for the correct procedure. b. Install the rocker shaft and pushrods.
UENR0624-03 Disassembly and Assembly Section 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. Illustration 270 g02948516 2.
UENR0624-03 149 Disassembly and Assembly Section Illustration 272 g02823476 7. If necessary, follow Step 7.a through Step 7.d in order to remove oil suction pipe (9) from the cylinder block. a. Install new O-ring seal (8) to oil suction pipe (9). b. Install oil suction pipe (9) to the cylinder block. c. Apply Tooling (A) onto the threads of Allen head cap screw (10). Install the Allen head cap screw to the oil suction pipe. b. Remove bolts (11) from oil suction pipe (9). c.
UENR0624-03 Disassembly and Assembly Section Tighten bolts (7) to a torque of 45 N·m (33 lb ft). 9. Install a new sealing washer (5) to oil drain plug (6). 10. Install oil drain plug (6) to the engine oil pan . Tighten the oil drain plug to a torque of 50 N·m (37 lb ft). 11. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change” for the correct procedure.
UENR0624-03 151 Disassembly and Assembly Section Illustration 276 g02835137 Illustration 277 g02835177 Typical example 1. Mount the engine in a suitable stand and place in the inverted position. 2. If necessary, remove dipstick (2) from engine oil pan (3). 8. If necessary, follow Step 8.a through Step 8.d in order to remove oil suction pipe (8) from the cylinder block. 3. Remove sealing washer (5) (not shown) from oil drain plug (6). a. Remove Allen head cap screw (9) from oil suction pipe (8). 4.
UENR0624-03 Disassembly and Assembly Section Illustration 278 g02835177 Illustration 279 g02835137 Typical example 2. If necessary, follow Step 2.a through Step 2.f in order to install oil suction pipe (8). a. Install new O-ring seal (7) to oil suction pipe (8). b. Install the oil suction pipe to the cylinder block. c. Apply Tooling (A) onto the threads of Allen head cap screw (9). Install the Allen head cap screw to the oil suction pipe. d. Apply Tooling (A) onto the threads of bolts (10).
UENR0624-03 153 Disassembly and Assembly Section Illustration 280 g02835539 Initial tightening sequence Illustration 281 g02835357 Secondary tightening sequence 4. Position gasket (1) (not shown) onto engine oil pan (4). 8. Align the rear face of the engine oil pan with the rear of the cylinder block. 5. Attach a suitable lifting device to engine oil pan (3). The engine oil pan can weigh 45 kg (99 lb). 9. Tighten bolts (4) in the initial sequence that is shown in Illustration 280 . 6.
UENR0624-03 Disassembly and Assembly Section 11. Ensure that the face of engine oil pan (3) and the cylinder block are still correctly aligned. 12. Install a new sealing washer (5) to oil drain plug (6). 13. Install oil drain plug (6) to the engine oil pan . Tighten the oil drain plug to a torque of 50 N·m (37 lb ft). 14. Remove the engine from the suitable stand. 15. Fill the engine oil pan to the correct level.
UENR0624-03 155 Disassembly and Assembly Section 10. Do not remove dowels (9) unless the dowels are damaged. i05279048 Balancer - Install Installation Procedure Table 61 Required Tools Illustration 284 g02893017 1. Remove plug (2) from Position (X) in the cylinder block. Remove O-ring seal (1) from the plug. 2. Install Tooling (A) into the cylinder block in Position (X). Note: Tooling (A) must be located in Position (Y) in the crankshaft.
UENR0624-03 Disassembly and Assembly Section Illustration 287 Illustration 285 g02709625 g02887016 3. Install Tooling (A) into Position (X) in the cylinder block. Tooling (A) must be located in Position (Y) in the crankshaft. Note: Ensure that Tooling (A) is located in the correct drilling in the crankshaft as shown in Illustration 285 . Note: Failure to locate the crankshaft in the correct position will cause severe engine damage. 4. Ensure that Tooling (B) is installed to balancer (4).
UENR0624-03 157 Disassembly and Assembly Section When M10 bolts are installed, tighten bolts (6) to a torque of 45 N·m (33 lb ft). 15. Remove Tooling (B) from Position (Z) in the balancer. 16. Remove Tooling (A) from Position (X) in the cylinder block. 17. Install a new O-ring seal (1) to plug (2). Install plug (2) into Position (X) in the cylinder block. Tighten the plug to a torque of 50 N·m (37 lb ft). End By: a. Install the engine oil pan.
UENR0624-03 Disassembly and Assembly Section End By: a. Install the crankshaft. Refer to Disassembly and Assembly, “Crankshaft - Install” for the correct procedure. b. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Install” for the correct procedure. i05279061 Pistons and Connecting Rods - Remove Removal Procedure Table 62 Required Tools Illustration 289 g02895676 1. Clean the piston cooling jets and inspect the piston cooling jets for damage.
UENR0624-03 159 Disassembly and Assembly Section Illustration 290 g03001196 Illustration 291 g02998516 Typical example Typical example Note: Do not stamp the connecting rod assembly. Stamping or punching the connecting rod assembly could cause the connecting rod to fracture. 6. Carefully push piston (4) and the connecting rod out of the cylinder bore. Lift piston (4) out of the top of the cylinder block. 3. The connecting rod and the connecting rod cap should have an etched number in Position (X).
UENR0624-03 Disassembly and Assembly Section Fracture split connecting rods should not be left without the connecting rod caps installed. i05279089 Pistons and Connecting Rods - Disassemble Disassembly Procedure Table 63 Required Tools Part Description Qty Tool Part Number A - Retaining Ring Pliers 1 B - Ring Expander 1 Start By: a. Remove the pistons and the connecting rods. Refer to Disassembly and Assembly, “Piston and Connecting Rods - Remove” for the correct procedure.
UENR0624-03 161 Disassembly and Assembly Section 6. Repeat Step 1 through Step 5 in order to disassemble the remaining pistons and connecting rods. i05282636 Pistons and Connecting Rods - Assemble 3. Position the oil control ring with the word “TOP” in the upward position. Use Tooling (B) to install oil control ring (3) over the piston and the spring. Note: Ensure that the central wire is 180 degrees from the ring gap. 4.
UENR0624-03 Disassembly and Assembly Section 13. Temporarily install connecting rod cap (11) and bolts (12) to connecting rod (7) when the assembly is out of the engine. Ensure that the etched number on connecting rod cap matches the etched number on connecting rod. Ensure the correct orientation of the connecting rod cap. The locating tab for the upper bearing shell and the lower bearing shell should be on the same side. Tighten bolts (12) to a torque of 20 N·m (177 lb in) . 14.
UENR0624-03 163 Disassembly and Assembly Section Illustration 296 g02999358 Illustration 298 g03001177 Typical example 4. Lightly lubricate Tooling A with clean engine oil. Install Tooling (A) onto piston (4) Note: Ensure that the piston assembly is installed into the correct cylinder. Also, ensure the correct orientation of the assembly, refer to Illustration 297 . 7. Ensure that etched number in Position (X) on connecting rod cap (1) matches etched number in Position (X) on connecting rod (3).
UENR0624-03 Disassembly and Assembly Section End By: a. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install” for the correct procedure. b. If necessary, install the balancer. Refer to Disassembly and Assembly, “Balancer Install” for the correct procedure. c. Install the oil suction pipe. Refer to Disassembly and Assembly, “Engine Oil Pan Remove and Install” for the correct procedure.
UENR0624-03 165 Disassembly and Assembly Section 4. Remove lower bearing shell (3) from connecting rod cap (2). Keep the bearing shell and the connecting rod cap together. 5. Carefully push connecting rod (5) into the cylinder bore until connecting rod (5) is clear of the crankshaft. Remove upper bearing shell (4) from the connecting rod. Keep the bearing shells together. Note: Do not push the fracture split surfaces of the connecting rod as damage may result.
UENR0624-03 Disassembly and Assembly Section End By: a. If necessary, install the balancer. Refer to Disassembly and Assembly, “Balancer Install” for the correct procedure. b. Install the engine oil suction pipe. Refer to Disassembly and Assembly, “Engine Oil Pan Remove and Install” for the correct procedure. i05282668 Crankshaft Main Bearings Remove and Install Removal Procedure Table 67 Required Tools Illustration 302 Tool g03005637 8. Install connecting rod cap (2) to connecting rod (5).
UENR0624-03 167 Disassembly and Assembly Section Illustration 303 g03003177 Illustration 305 g03003457 Illustration 306 g03003257 Typical example 2. Remove bolts (1) and remove main bearing cap (2) from the cylinder block. Illustration 304 g03003178 Typical example 3. Remove lower main bearing shell (3) from main bearing cap (2). Keep the main bearing shell and the main bearing cap together. Note: The lower main bearing shell is a plain bearing that has no oil holes. 4.
UENR0624-03 Disassembly and Assembly Section Installation Procedure Table 68 Required Tools Part Description Qty Tool Part Number B 27610289 Angle Gauge 1 21825617 Dial Indicator 1 Magnetic Base and Stand 1 C - NOTICE This procedure must only be used to remove and install the main bearing shells with the crankshaft in position.
UENR0624-03 169 Disassembly and Assembly Section 8. Install bolts (4) to main bearing cap (5). Evenly tighten the bolts in order to pull cap (5) into position. Ensure that the cap is correctly seated. Note: Do not tap the main bearing cap into position as the bearing shell may be dislodged. 9. Tighten bolts (4) to an initial torque of 50 N·m (37 lb ft). 10. Tighten bolts (4) to a torque of 80 N·m (59 lb ft).
UENR0624-03 Disassembly and Assembly Section Start By: a. Remove the engine oil suction pipe. Refer to Disassembly and Assembly, “Engine Oil Pan Remove and Install” for the correct procedure. b. If necessary, remove the balancer. Refer to Disassembly and Assembly, “Balancer Remove” for the correct procedure. c. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel housing - Remove and Install” for the correct procedure. d. Remove the front housing.
UENR0624-03 171 Disassembly and Assembly Section 5. If necessary, remove the crankshaft timing ring (1). Refer to Disassembly and Assembly, “Crankshaft Timing Ring - Remove and Install” for the correct procedure. i05282673 Crankshaft - Install Installation Procedure Table 70 Required Tools Tool Part Number A 21825617 B - Part Description Qty Lifting Sling 2 Dial Indicator 1 Magnetic Base and Stand 1 Illustration 312 NOTICE Keep all parts clean from contaminants.
UENR0624-03 Disassembly and Assembly Section Note: Do not damage any of the finished surfaces on the crankshaft. Do not damage the main bearing shells. 8. Lubricate lower main bearing shells and lubricate the journals of the crankshaft with clean engine oil. Install lower main bearing caps. Refer to Disassembly and Assembly, “Crankshaft Main Bearings - Remove and Install” for the correct procedure. End By: a. If necessary, install the power take-off drive.
UENR0624-03 173 Disassembly and Assembly Section Illustration 313 g03010798 1. Support crankshaft (4) on a suitable stand. 2. Remove Torx screws (1) from crankshaft timing ring (2). Do not reuse the Torx screws. 3. Carefully remove crankshaft timing ring (2) from crankshaft (4). Note: Ensure that the seal surface on adaptor (5) is not damaged when the crankshaft timing ring is removed. Note: Do not remove dowel (3) from the crankshaft unless the dowel is damaged.
UENR0624-03 Disassembly and Assembly Section Note: Do not allow Tooling (A) to extend over the edge of the bearing. (Table 71, contd) - Plastigauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch) 1 - Plastigauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch) 1 - Plastigauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch) 1 - Plastigauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch) 1 A 2. Use the correct torque-turn specifications in order to install the bearing cap.
UENR0624-03 175 Disassembly and Assembly Section Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, “Connecting Rod Bearing Journal” and Specifications Manual, “Main Bearing Journal” for the correct clearances.
UENR0624-03 Disassembly and Assembly Section Illustration 317 g02672140 1. Install a new O-ring seal (5) to camshaft position sensor (3). 2. Install camshaft position sensor (3) to front cover (2). Ensure that the camshaft position sensor is correctly orientated. 3. Apply Tooling (A) onto the threads of bolt (1). Install bolt (1) to the camshaft position sensor. Tighten the bolt to a torque of 10 N·m (89 lb in) 4. Connect harness assembly (4) to camshaft position sensor (3).
UENR0624-03 177 Disassembly and Assembly Section 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 to a level below the coolant temperature sensor.
UENR0624-03 Disassembly and Assembly Section 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. Illustration 321 g02671797 1. Install a new seal washer (3) onto coolant temperature sensor (2).
UENR0624-03 179 Disassembly and Assembly Section NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.
UENR0624-03 Disassembly and Assembly Section Illustration 324 g02876777 3. Disconnect harness assembly (3) from fuel temperature sensor (2). 4. Use a deep socket in order to remove fuel temperature sensor (2) from fuel filter base (1). 5. Use Tooling (A) to plug the open port of the fuel injection pump. 6. Remove sealing washer (4) (not shown) from fuel temperature sensor (2). Installation Procedure NOTICE Keep all parts clean from contaminants. Illustration 325 g02876777 2.
UENR0624-03 181 Disassembly and Assembly Section 7. Turn the battery disconnect switch to the ON position. Installation Procedure Table 74 Required Tools i05282745 Oxygen Sensor - Remove and Install (Catalytic Converter) Tool Part Number A - Part Description Qty Bostik Pure Nickel Anti-Seize Compound 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Removal Procedure Start By: a.
UENR0624-03 Disassembly and Assembly Section End By: Installation Procedure a. Turn the battery disconnect switch to the ON Position. 1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. b.
UENR0624-03 183 Disassembly and Assembly Section 5. If necessary, install the diesel particulate filter mounting bracket. Refer to Disassembly and Assembly, “Support and Mounting (CEM) Remove and Install” for the correct procedure. i05282753 Temperature Sensor (DPF) Remove and Install Removal Procedure NOTICE Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF.
UENR0624-03 Disassembly and Assembly Section 5. If necessary, repeat Step 2 through Step 4 in order to install the remaining temperature sensor to the DPF. Installation Procedure i05282755 Pressure Sensor (DPF) -Remove and Install Removal Procedure Illustration 333 g03005940 1. Position DPF differential pressure sensor (2) onto bracket (1). 2. Install bolt (3) finger tight to DPF differential pressure sensor (2). Tighten the bolt to a torque of 9 N·m (80 lb in) 3.
UENR0624-03 185 Disassembly and Assembly Section End By: a. When a new DPF differential pressure sensor is installed, use the Electronic Service Tool (EST) in order to perform the “ DPF Differential Pressure Sensor Replacement”” procedure. i05284598 Pressure Sensor (Exhaust Back Pressure) - Remove and Install Removal Procedure Illustration 335 g02915178 1. Slide the locking tab into the unlocked position and disconnect harness assembly (3) from exhaust back pressure sensor (5). 2.
UENR0624-03 Disassembly and Assembly Section h. Remove bolt (1) from the bracket for tube assembly (9). i. Remove tube assembly (9) from the exhaust manifold. j. Remove and sealing washers (11) (not shown). Installation Procedure 1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged. Illustration 336 g02915178 Illustration 337 g02917036 2. If necessary, follow Step 2.a through Step 2.i in order to install tube assembly (6). a.
UENR0624-03 187 Disassembly and Assembly Section bracket (7). Tighten banjo bolt assembly (10) finger tight. d. Install bolt (1) to the bracket for tube assembly (6). e. Position adaptor bracket (7) onto the induction manifold and install bolt (2). f. Tighten nut (8) finger tight. g. Tighten bolt (1) and bolt (2) to a torque of 25 N·m (221 lb in). 10. Install bolt (2) to exhaust back pressure sensor (4). Tighten the bolt to a torque of 25 N·m (221 lb in).
UENR0624-03 Disassembly and Assembly Section Installation Procedure 3. Connect the wiring harness assembly (not shown) to inlet manifold temperature sensor (3). i05296471 Inlet Manifold Pressure Sensor - Remove and Install Removal Procedure Illustration 339 g03366344 1. Install new seal (2) (not shown) to the inlet manifold temperature sensor (3). 2. Install inlet manifold temperature sensor (3) to inlet manifold (1).
UENR0624-03 189 Disassembly and Assembly Section Installation Procedure Illustration 341 g03364176 a. Loosen nut (6) on tube assembly (7). b. Remove bolt (5) from inlet manifold temperature sensor housing (7). c. Disconnect tube assembly (7) from inlet manifold temperature sensor housing (4). d. Remove inlet manifold temperature sensor housing (4) from inlet manifold (8). e. Remove banjo bolt (10) and sealing washers (9) (not shown). f. Remove tube assembly (7). Illustration 342 g03364176 1.
UENR0624-03 Disassembly and Assembly Section 2. If necessary, remove the Exhaust Gas Recirculation (EGR) valve. Refer to Disassembly and Assembly, “ Exhaust Gas Recirculation Valve Remove and Install” for the correct procedure. Illustration 343 g03364100 2. Install new seal (3) (not shown) to inlet manifold temperature sensor (1). 3. Install inlet manifold temperature sensor (1) to inlet manifold temperature sensor housing (4). 4. Install Allen head bolt (2).
UENR0624-03 191 Disassembly and Assembly Section End By: a. Install the combined inlet manifold temperature and pressure sensor. Refer to Disassembly and Assembly, “Inlet Manifold Temperature and Pressure Sensor - Remove and Install” for the correct procedure. i05284613 Alternator Belt - Remove and Install Removal Procedure 1. If the engine has guards, remove the guards. Refer to the Original Equipment Manufacture (OEM) for the correct procedure. Illustration 345 g02837996 1.
UENR0624-03 Disassembly and Assembly Section Installation Procedure Note: The ribs on the alternator belt must be located into the grooves of all pulleys. 4. Tighten bolt (1) until adjusting bracket (5) has reached the full extent of the available adjustment in Position (A). 5. Tighten bolt (3) to a torque of 50 N·m (37 lb ft). 6. Tighten nut and bolt (4) to a torque of 50 N·m (37 lb ft) 7. Rotate tensioning bolt (1) two complete revolutions in a counterclockwise direction.
UENR0624-03 193 Disassembly and Assembly Section Illustration 349 g02710322 Illustration 350 g02710444 Typical example Typical example 1. If necessary, remove bolts (1) and remove engine lifting bracket (2). 2. Install bolts (4) to idler pulley (3). Position idler pulley (3) onto the cylinder head. 2. Remove bolt (4) and remove idler pulley (3). 3. Tighten bolt (4) to a torque of 40 N·m (30 lb ft). Installation Procedure 4. If necessary, install bolts (1) to engine lifting bracket (2).
UENR0624-03 Disassembly and Assembly Section End By: a. Install a new alternator belt. Refer to Disassembly and Assembly, “Alternator Belt Install” for the correct procedure. i05284618 Fan - Remove and Install Removal Procedure Start By: a. Remove the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt Remove and Install” for the correct procedure. Illustration 352 g02829456 Typical example 2. If necessary, install studs (5) to fan drive (6).
UENR0624-03 195 Disassembly and Assembly Section Illustration 353 g02827145 2. If necessary, remove nuts (5) from studs (6). 3. Remove the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install” for the correct procedure. 4. Remove fan drive pulley (4). 5. Remove the alternator belt tensioning bracket. Refer to Disassembly and Assembly, “Alternator Remove and Install” for the correct procedure. 6.
UENR0624-03 Disassembly and Assembly Section 8. Install the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install” for the correct procedure. i05284622 Alternator - Remove Removal Procedure Start By: a. Remove the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt Remove and Install” for the correct procedure. 1. Turn the battery disconnect switch to the OFF position. Illustration 355 g02673920 Illustration 356 g02815777 2.
UENR0624-03 197 Disassembly and Assembly Section 7. If necessary, follow Step 7.a through Step 7.e in order to remove pulley (7) from alternator (6). Note: A suitable tool may be required in order to carry out the removal of the alternator pulley. Note: Support the weight of the alternator bracket as the bolts are removed. i05284624 Alternator - Install a. Place the alternator in a suitable support. b. Hold shaft (9) of alternator (6) with a suitable tool. Use a cranked ring spanner to loosen nut (8).
UENR0624-03 Disassembly and Assembly Section Illustration 360 Illustration 358 g02815777 g02815797 a. Position bracket (14) onto the cylinder block. b. Install bolts (13) to bracket (14). c. If necessary, install bolt (13) to the coolant tube assembly. d. Tighten bolts (13) to a torque of 50 N·m (37 lb ft). e. Position tensioner (11) onto the fan drive assembly. f. Install bolt (12) to tensioner (11) finger tight. 3. If necessary, follow Step 3.a through Step 3.
UENR0624-03 199 Disassembly and Assembly Section 6. Install bolt (2) and nut (1) (not shown) finger tight. 7. Install the alternator belt. Refer to Disassembly and Assembly , “Alternator Belt - Remove and Install” for the correct procedure. 8. Tighten the nut and bolt (2) to a torque of 50 N·m (37 lb ft). 9. Tighten nut and bolt (5) to a torque of 50 N·m (37 lb ft). 10. Connect the wiring harness assembly to the alternator. Refer to Specifications, “Alternator” for the correct torque. 11.
UENR0624-03 Disassembly and Assembly Section 5. Turn the battery disconnect switch to the ON position. This document has been printed from SPI2.
UENR0624-03 201 Index Section Index A Accessory Drive - Remove and Install................. 126 Installation Procedure .................................... 127 Removal Procedure ....................................... 126 Alternator - Install .............................................. 197 Installation Procedure .................................... 197 Alternator - Remove .......................................... 196 Removal Procedure .......................................
UENR0624-03 Index Section Removal Procedure ....................................... 178 Engine Oil Pump - Install......................................93 Installation Procedure ......................................93 Engine Oil Pump - Remove ..................................93 Removal Procedure .........................................93 Engine Oil Relief Valve - Remove and Install .........92 Installation Procedure ......................................92 Removal Procedure ........................
UENR0624-03 203 Index Section O Oxygen Sensor - Remove and Install (Catalytic Converter) ...................................................... 181 Installation Procedure .................................... 181 Removal Procedure ....................................... 181 P Piston Cooling Jets - Remove and Install ............ 157 Installation Procedure .................................... 157 Removal Procedure ....................................... 157 Pistons and Connecting Rods - Assemble...........
©2017 Perkins Engines Company Limited All Rights Reserved This document has been printed from SPI2.
