Perkins 1106C Series Disassembly And Assembly
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Perkins 1106C Series Disassembly And Assembly

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KENR6932-00
May 2007
Disassembly and
Assembly
1106C Genset
PK (Engine)

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Summary of Contents for Perkins 1106C Series

  • Page 1 KENR6932-00 May 2007 Disassembly and Assembly 1106C Genset PK (Engine)
  • Page 2 These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available. When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

  • Page 3: Table Of Contents

    KENR6932 Table of Contents Table of Contents Flywheel Housing - Remove and Install (Standard Housing) .............. 78 Flywheel Housing - Remove and Install (Wet Back End Housing) ............81 Disassembly and Assembly Section Vibration Damper and Pulley - Remove (Pulleys without Split Lock Rings) ........
  • Page 4 KENR6932 Table of Contents Crankshaft Timing Ring - Remove and Install ..161 Crankshaft Gear - Remove and Install ....163 Bearing Clearance - Check ......... 164 Crankshaft Position Sensor - Remove and Install ..............165 Position Sensor (Fuel Injection Pump) - Remove and Install ..............

  • Page 5: Disassembly And Assembly Section

    KENR6932 Disassembly and Assembly Section Disassembly and Assembly Section i02654356 Fuel Priming Pump - Remove and Install (Mechanical Priming Pump) Removal Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct train- ing.

  • Page 6: Fuel Priming Pump - Remove And Install (Electrical Priming Pump)

    KENR6932 Disassembly and Assembly Section Installation Procedure (Manual 3. Position fuel priming pump (4) on the mounting bracket. Install bolts (7) to the fuel priming pump . Priming Pump) Tighten the bolts to a torque of 44 N·m (32 lb ft). NOTICE 4.
  • Page 7 KENR6932 Disassembly and Assembly Section 1. Ensure that electric priming pump (4) is clean and free from wear or damage. If necessary, replace the electric priming pump. g01334857 Illustration 3 Typical example 2. Isolate the electrical supply. g01334857 Illustration 4 Typical example 3.

  • Page 8: Fuel Filter Base - Remove And Install (Secondary Fuel Filter)

    KENR6932 Disassembly and Assembly Section 4. Disconnect plastic tube assemblies (2), (4) and i02654496 (5) from fuel filter base (1). Plug the plastic tube Fuel Filter Base - Remove and assemblies with new plugs. Cap the ports in the Install fuel filter base with new caps.

  • Page 9: Fuel Transfer Pump - Remove

    KENR6932 Disassembly and Assembly Section 2. Position fuel filter base (1) on the mounting 2. Place a suitable container below fuel transfer bracket. Install bolts (3). Tighten the bolts to a pump (2) in order to catch any fuel that might be torque of 44 N·m (32 lb ft).

  • Page 10: Fuel Transfer Pump - Install

    KENR6932 Disassembly and Assembly Section 9. Use an allen wrench with a ball end in order to i02654512 remove allen head screws (3) that secure the fuel Fuel Transfer Pump - Install transfer pump to fuel injection pump (1). Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by...

  • Page 11: Fuel Manifold (Rail) - Remove And Install

    KENR6932 Disassembly and Assembly Section 9. If necessary, install a new O-ring seal to connector (9) and install connector (9) to fuel transfer pump (2). Tighten the connector to torque of 15 N·m (11 lb ft). 10. Connect plastic tube assembly (5) to the outlet of fuel transfer pump (2).
  • Page 12 KENR6932 Disassembly and Assembly Section Installation Procedure 1. If the engine is equipped with a cover over the fuel system this will need to be removed. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct train- ing.

  • Page 13: Fuel Injection Lines - Remove

    KENR6932 Disassembly and Assembly Section 5. Install the bolt to fuel injection line clamp (6). Tighten bolts (6) to a torque of 22 N·m (16 lb ft). NOTICE Ensure that fuel injection line does not contact any Ensure that all adjustments and repairs that are other engine component.
  • Page 14 KENR6932 Disassembly and Assembly Section g01335193 g01335194 Illustration 15 Illustration 16 Typical Example 4. Remove plastic clamps (3) from the fuel injection lines (2). 13. If necessary, disconnect harness assembly (8) from fuel injection pump (7). Slide locking 5. Slide the dust seal from the nut on the fuel tab (9) into the unlocked position.

  • Page 15: Fuel Injection Lines - Install

    KENR6932 Disassembly and Assembly Section NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct train- ing. Before begining ANY work on the fuel system, re- fer to Operation and Maintenance Manual, “Gen- eral Hazard Information and High Pressure Fuel Lines”...
  • Page 16 KENR6932 Disassembly and Assembly Section g01335195 g01335194 Illustration 20 Illustration 21 Typical example 1. Loosely install tube clips (12) and the allen head screws (13) to the fuel injection line (6). 7. Connect harness assembly (8) to position sensor (10). Slide locking tab (9) into the locked position. 2.

  • Page 17: Fuel Injection Pump - Remove

    KENR6932 Disassembly and Assembly Section 10. Loosely connect the nuts at both ends of fuel b. If necessary, remove the fuel priming pump. Refer injection line (2), to electronic unit injector (1) and to Disassembly and Assembly, “Fuel Priming to the appropriate port in fuel manifold (4). Ensure Pump - Remove”.
  • Page 18 KENR6932 Disassembly and Assembly Section 6. Place a suitable container below fuel injection pump (1) in order to catch any fuel that might be spilled. 7. Disconnect plastic tube assembly (2) from fuel injection pump (1). 8. Disconnect harness assembly (7) from solenoid (3) of the fuel injection pump.

  • Page 19: Fuel Injection Pump - Install

    KENR6932 Disassembly and Assembly Section 19. Remove O-ring seal (21) from fuel injection pump (1). 20. If necessary, remove position sensor (4) from fuel injection pump (1). Refer to Disassembly and Assembly, “Position Sensor (Fuel Injection Pump) - Remove and Install”. 21.
  • Page 20 KENR6932 Disassembly and Assembly Section 3. If the fuel injection pump timing has been lost follow Steps 3.a through 3.e in order to reset the fuel injection pump timing. a. If necessary, loosen locking screw (25) on the fuel injection pump. Slide spacer (26) into position (X).
  • Page 21 KENR6932 Disassembly and Assembly Section 5. Use Tooling (F) to lubricate a new O-ring seal (21). 12. Position support bracket (13) onto fuel injection Install the O-ring seal onto fuel injection pump (1). pump (1). Install bolts (14) finger tight. 6.

  • Page 22: Fuel Injection Pump Gear - Remove

    KENR6932 Disassembly and Assembly Section 21. Install plastic tube assembly (10) for the fuel outlet to fuel transfer pump (8). 22. Install plastic tube assembly (11) to fuel transfer pump (8). 23. Connect harness assembly (7) to solenoid (3) on the fuel injection pump. Connect harness assembly (7) to position sensor (4) on the fuel injection pump.
  • Page 23 KENR6932 Disassembly and Assembly Section Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product.

  • Page 24: Fuel Injection Pump Gear - Install

    KENR6932 Disassembly and Assembly Section Note: The fuel injection pump must remain locked until the procedure instructs you to unlock the fuel injection pump. 1. Ensure that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, “Finding Top Center for No.
  • Page 25 KENR6932 Disassembly and Assembly Section 8. Install a new spring washer (10) and install nut (8) to shaft (9) of the fuel injection pump. Apply sufficient pressure to fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash.

  • Page 26: Electronic Unit Injector - Remove

    KENR6932 Disassembly and Assembly Section i02654483 NOTICE Electronic Unit Injector - Care must be taken to ensure that fluids are contained Remove during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids.
  • Page 27 KENR6932 Disassembly and Assembly Section Note: Identification will ensure that the valve bridges 6. Remove the fuel injection line and remove seal can be reinstalled in the original location and the (8) from the appropriate electronic unit injector original orientation. (11).
  • Page 28 KENR6932 Disassembly and Assembly Section NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct train- ing. Before begining ANY work on the fuel system, re- fer to Operation and Maintenance Manual, “Gen- eral Hazard Information and High Pressure Fuel Lines”...
  • Page 29 KENR6932 Disassembly and Assembly Section g01247489 Illustration 47 Typical example 3. Loosen banjo bolt (7) sufficiently in order to allow the fuel to drain from tube assembly (6). g01255700 Illustration 49 8. Use Tooling (C) to pry beneath clamp (13) and free electronic unit injector (11) from the cylinder head.

  • Page 30: Electronic Unit Injector - Install

    KENR6932 Disassembly and Assembly Section i02654481 Electronic Unit Injector - Install Installation Procedure Table 9 Required Tools Tool Part Part Description Number 27610307 T40 Torx Socket GE50028 Vacuum Pump Tube GE50030 7.9 mm (0.31 inch) Outside Diameter 27610294 Injector Pipe Nut Tool 27610296 g01341874 Torque Wrench...
  • Page 31 KENR6932 Disassembly and Assembly Section 4. On installing an original electronic unit injector, Note: Ensure that the ends of the fuel injection line install a new O-ring seal (15) and sealing washer are seated in the electronic unit injector and the fuel (14) to electronic unit injector (11).
  • Page 32 KENR6932 Disassembly and Assembly Section Alternative Installation Procedure Note: Ensure that used valve bridges are reinstalled in the original location and the original orientation. Do not interchange the location or the orientation of Table 10 used valve bridges. Required Tools Tool Part Part Description...
  • Page 33 KENR6932 Disassembly and Assembly Section Ensure that the O-ring seal (15) and sealing washer (14) on a new electronic unit injector are not damaged and in place. Note: Do not lubricate the O-ring seal. 5. Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage.

  • Page 34: Turbocharger - Remove (Turbocharger Top Mounted )

    KENR6932 Disassembly and Assembly Section 10. Use Tooling (B) to tighten torx screw (12) to a torque of 27 N·m (20 lb ft). 11. Use Tooling (E) to tighten the fuel injection line to a torque of 30 N·m (22 lb ft). Refer to Disassembly and Assembly, “Fuel Injecton Lines - Install”.
  • Page 35 KENR6932 Disassembly and Assembly Section 1. Disconnect the air hose for the turbocharger inlet and for the turbocharger outlet. 2. If the turbocharger has a remote wastegate solenoid, disconnect the hose to the solenoid from the turbocharger. 3. Disconnect the exhaust pipe. 4.

  • Page 36: Turbocharger - Remove (Side Mounted Turbocharger)

    KENR6932 Disassembly and Assembly Section i02654359 Turbocharger - Remove (Side Mounted Turbocharger) Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product.

  • Page 37: Turbocharger - Disassemble

    KENR6932 Disassembly and Assembly Section g01335760 Illustration 66 1. Disconnect the pipe for boost sensor (7) at actuator (6). 2. Remove circlip (1) that retains actuator rod (4). 3. Remove actuator rod (4) from pin (2). 4. Remove nuts (5) from bracket (3). 5.

  • Page 38: Turbocharger - Install (Turbocharger Top Mounted)

    KENR6932 Disassembly and Assembly Section i02654360 Turbocharger - Install (Turbocharger Top Mounted) Installation Procedure Table 11 Required Tools Part Tool Part Description Number g01335760 Illustration 67 POWERPART 218200221 Rubber Grease 1. Install actuator (6) to bracket (3). Install nuts (5) to bracket (3).
  • Page 39 KENR6932 Disassembly and Assembly Section 2. Test the wastegate actuator (19) for correct 6. Install nuts (11). Tighten the nuts to a torque of operation. Refer to System Operation, Testing and 44 N·m (32 lb ft). Adjusting, “Turbocharger Inspect”. If the wastegate actuator is damaged or the wastegate actuator 7.

  • Page 40: Turbocharger - Install (Side Mounted Turbocharger)

    KENR6932 Disassembly and Assembly Section 22. Connect the exhaust pipe. 23. If the turbocharger has a remote wastegate solenoid, connect the hose for the solenoid to the turbocharger. 24. Connect the air inlet hose and connect the air outlet hose to the turbocharger. i02654361 Turbocharger - Install (Side Mounted Turbocharger)
  • Page 41 KENR6932 Disassembly and Assembly Section 1. Ensure that the turbocharger is clean and free 7. If a new turbocharger is installed, bearing housing from damage. Inspect the turbocharger for wear. (18) and compressor housing (20) must be Refer to System Operation, Testing and Adjusting, oriented to the correct positions.

  • Page 42: Wastegate Solenoid - Remove And Install

    KENR6932 Disassembly and Assembly Section 8. Ensure that tube assemblies (3) and (10) are clean i02654550 and free from damage. Replace any damaged Wastegate Solenoid - Remove components. and Install 9. Position a new joint (7) and bolts (8) onto tube assembly (10).

  • Page 43: Exhaust Manifold - Remove And Install (Side Mounted Exhaust Manifold)

    KENR6932 Disassembly and Assembly Section i02654364 Exhaust Manifold - Remove and Install (Side Mounted Exhaust Manifold) Removal Procedure Start By: g01335778 a. Remove the turbocharger. Refer to Disassembly Illustration 75 and Assembly, “Turbocharger - Remove”. Typical example 2. Loosely install wastegate solenoid (3) to tube assembly (2).
  • Page 44 KENR6932 Disassembly and Assembly Section g01335790 Illustration 77 1. Loosen bolts (2) and (5) in reverse numerical order. Refer to Illustration 77. Note: This will help prevent distortion of the exhaust manifold. 2. Remove center bolts (2) from exhaust manifold (3).

  • Page 45: Exhaust Manifold - Remove And Install (Top Mounted Exhaust Manifold)

    KENR6932 Disassembly and Assembly Section g01335790 Illustration 78 6. If bolts (2) and (5) have been previously used, the bolts should be thoroughly cleaned. Tooling (B) should be applied to the first two threads of the bolts. Note: Do not apply Tooling (B) to new bolts. 7.
  • Page 46 KENR6932 Disassembly and Assembly Section g01335809 Illustration 80 g01335810 Illustration 81 2. Loosen bolts (4) and (6) in reverse numerical 7. If necessary, remove studs (2) from exhaust order. Refer to Illustration 81. manifold (3). Note: This will help prevent distortion of the exhaust Installation Procedure (Top manifold.

  • Page 47: Exhaust Elbow - Remove And Install

    KENR6932 Disassembly and Assembly Section g01335810 Illustration 82 6. Align exhaust manifold (3) with Tooling (A). Install the exhaust manifold to the cylinder head. 7. If bolts (4) and (6) have been previously used, the bolts should be thoroughly cleaned. Tooling (B) should be applied to the first two threads of the bolts.

  • Page 48: Inlet Manifold - Remove And Install

    KENR6932 Disassembly and Assembly Section 4. Some types of exhaust elbow have a separate support bracket. If necessary, install the bracket and install the bolts that secure the bracket to the exhaust elbow finger tight. 5. Install bolts (2) finger tight. 6.
  • Page 49 KENR6932 Disassembly and Assembly Section Installation Procedure 1. If the engine is equipped with a cover over the fuel system this will need to be removed. Table 15 2. Disconnect the breather hose from the separator Required Tools for the crankcase breather. Refer to Disassembly Part and Assembly, “Crankcase Breather - Remove”.

  • Page 50: Inlet And Exhaust Valve Springs - Remove And Install

    KENR6932 Disassembly and Assembly Section 5. Apply Tooling (A) to bolts (5). Install the bolts to inlet manifold (4). g01335892 Illustration 88 6. Tighten the bolts to a torque of 22 N·m (16 lb ft) in c. If necessary, install the fuel filter base. Refer to the sequence that is shown in Illustration 88.
  • Page 51 KENR6932 Disassembly and Assembly Section 1. Follow Steps 1.a through 1.h in order to remove the harness assemblies for the electronic unit NOTICE injectors. Keep all parts clean from contaminants. a. Place a temporary identification mark on Contaminants may cause rapid wear and shortened connections (1) for harness assembly (4) for component life.
  • Page 52 KENR6932 Disassembly and Assembly Section Installation Procedure b. Use Tooling (B) in order to compress valve spring (11) and open the valve slightly. Table 17 Note: Do not compress the spring so that the valve Required Tools spring retainer (10) touches the valve stem seal. Part Tool Part Description...
  • Page 53 KENR6932 Disassembly and Assembly Section 6. Carefully release the pressure on Tooling (B). 7. Repeat steps 2 to 6 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.

  • Page 54: Inlet And Exhaust Valves - Remove And Install

    KENR6932 Disassembly and Assembly Section a. Ensure that harness assembly (4) for the Start By: electronic unit injectors and the bore in valve mechanism cover base (8) are clean and a. Remove the cylinder head. Refer to Disassembly free from damage. Replace any damaged and Assembly, “Cylinder Head - Remove”.
  • Page 55 KENR6932 Disassembly and Assembly Section 7. Remove valve spring retainer (2). Remove valve spring (3). 8. Repeat steps 4 to 7 for the remaining valves. 9. Remove Tooling (A). 10. Remove valve stem seals (4). 11. Use a suitable lifting device to carefully turn over the cylinder head.
  • Page 56 KENR6932 Disassembly and Assembly Section g01335986 g01335985 Illustration 95 Illustration 96 2. Lubricate the stems of valves (5) with clean engine 6. Install Tooling (A) in the appropriate position on oil. Install valves (5) in the appropriate positions in the cylinder head in order to compress valve the cylinder head.

  • Page 57: Engine Oil Filter Base - Remove And Install

    KENR6932 Disassembly and Assembly Section End By: a. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. i02654484 Engine Oil Filter Base - Remove and Install Removal Procedure g01336008 Illustration 97 Table 20 Typical example Required Tools 2.

  • Page 58: Engine Oil Cooler - Remove (Engine Oil Cooler With A Low Mounted Filter Base)

    KENR6932 Disassembly and Assembly Section i02654366 Engine Oil Cooler - Remove (Engine Oil Cooler with a Low Mounted Filter Base) Removal Procedure Start By: a. Remove the bracket for the Electronic Control Module. Refer to Disassembly and Assembly, g01336008 Illustration 98 “ECM Mounting Bracket - Remove and Install”.
  • Page 59 KENR6932 Disassembly and Assembly Section 2. Place a suitable container below the engine oil d. Cut the cable straps that secure engine wiring cooler in order to catch any fluids that might be harness (4) to the assembly of oil cooler (6). spilled.

  • Page 60: Engine Oil Cooler - Remove (Engine Oil Cooler With A High Mounted Filter Base)

    KENR6932 Disassembly and Assembly Section Disassembly Procedure (Engine Oil Cooler with a Low Mounted Filter NOTICE Ensure that all adjustments and repairs that are Base) carried out to the fuel system are performed by authorised personnel that have the correct train- ing.
  • Page 61 KENR6932 Disassembly and Assembly Section g01336193 Illustration 103 Typical example 8. If necessary, loosen bolts (7). Remove bolts (7) and remove brackets for the tube assemblies. Remove the assembly of oil cooler (4) from the cylinder block. g01336192 Illustration 102 Typical example Note: The bolts are different lengths.

  • Page 62: Engine Oil Cooler - Install (Engine Oil Cooler With A Low Mounted Filter Base)

    KENR6932 Disassembly and Assembly Section 3. Remove joints (10). i02654368 Engine Oil Cooler - Install (Engine Oil Cooler with a Low Mounted Filter Base) Assembly Procedure NOTICE g01336427 Illustration 106 Keep all parts clean from contaminants. Typical example Contaminants may cause rapid wear and shortened 4.
  • Page 63 KENR6932 Disassembly and Assembly Section d. Tighten bolts (11) to a torque of 22 N·m (16 lb ft). 5. Remove the plugs from tube assembly (9). Remove the caps for the fuel return from the cylinder head and from transfer pump (8). Install tube assembly (9) to the cylinder head and to transfer pump (8).

  • Page 64: Engine Oil Cooler - Install (Engine Oil Cooler With A High Mounted Filter Base)

    KENR6932 Disassembly and Assembly Section 5. Install bolts (7) to the assembly of oil cooler (4). i02654367 Engine Oil Cooler - Install Note: The bolts are different lengths. Ensure that the (Engine Oil Cooler with a High different bolts are installed in the correct location. Mounted Filter Base) 6.

  • Page 65: Engine Oil Relief Valve - Remove And Install

    KENR6932 Disassembly and Assembly Section 3. Tighten bolts (7) to a torque of 22 N·m (16 lb ft) in sequence that is shown in Illustration 112. Tighten NOTICE remaining bolts that secure oil filter base to a Keep all parts clean from contaminants. torque of 22 N·m (16 lb ft).

  • Page 66: Engine Oil Pump - Remove

    KENR6932 Disassembly and Assembly Section Installation Procedure Note: The plunger must slide freely in the bore for the relief valve. Table 21 3. Apply Tooling (A) to the threads of cap (1). Use Required Tools an allen wrench to install cap (1) to engine oil Tool Part Number Part Description...

  • Page 67: Engine Oil Pump - Install

    KENR6932 Disassembly and Assembly Section Note: Do not remove dowels (9) or (11)from the housing of the engine oil pump unless the dowels are damaged. i02654486 Engine Oil Pump - Install Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

  • Page 68: Water Pump - Remove

    KENR6932 Disassembly and Assembly Section c. Tighten bolts (1) to a torque of 22 N·m (16 lb ft). End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan - Install”. i02654553 Water Pump - Remove Removal Procedure Start By: a.

  • Page 69: Water Pump - Install

    KENR6932 Disassembly and Assembly Section i02654551 Water Pump - Install Installation Procedure Table 22 Required Tools Part Tool Number Part Description Guide Stud (M8 by 70 mm) NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
  • Page 70 KENR6932 Disassembly and Assembly Section g01336660 Illustration 121 4. Install Tooling (A) in position (X). 5. Use Tooling (A) in order to align new joint (2) to front cover (1). Install the joint to the front cover. g01336659 Illustration 120 6.

  • Page 71: Water Temperature Regulator - Remove And Install

    KENR6932 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids.

  • Page 72: Flywheel - Remove

    KENR6932 Disassembly and Assembly Section A new water temperature regulator housing is supplied with a new O-ring seal. 3. Install water temperature regulator housing (2) to the cylinder head. Note: Ensure the correct orientation of the water temperature regulator housing. g01336667 Illustration 124 Typical example...

  • Page 73: Flywheel - Install

    KENR6932 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. g01336669 Illustration 128 Typical example 7. Inspect flywheel (1) and ring gear (5) for wear or damage. Replace any worn components or damaged components.
  • Page 74 KENR6932 Disassembly and Assembly Section g01336671 Illustration 129 Typical example Always wear protective gloves when handling g01336668 parts that have been heated. Illustration 130 Typical example 1. If the flywheel ring gear was removed, follow 3. Install a suitable lifting device to flywheel (1). The Steps 1.a through 1.c in order to install ring gear flywheel can weigh 70.6 kg (155.6 lb).

  • Page 75: Crankshaft Rear Seal - Remove

    KENR6932 Disassembly and Assembly Section i02654469 Crankshaft Rear Seal - Remove Removal Procedure Table 25 Required Tools Part Tool Part Description Number T40 Torx Socket E12 Torx Socket Start By: a. Remove the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing g01337506 - Remove and Install”.
  • Page 76 KENR6932 Disassembly and Assembly Section Note: The crankshaft rear seal and the housing are manufactured as one assembly. Note: Do not lubricate the crankshaft rear seal or the crankshaft flange. The crankshaft rear seal must be installed dry. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
  • Page 77 KENR6932 Disassembly and Assembly Section End By: a. Install the flywheel housing. Refer to Disassembly and Assembly, “Flywheel Housing - Remove and Install”. Installation Procedure Without Isolating Frame for the Oil Pan Table 27 Required Tools Tool Part Number Part Description T40 Torx Socket Alignment Tool Bolts (M8 by 20 mm)

  • Page 78: Flywheel Housing - Remove And Install (Standard Housing)

    KENR6932 Disassembly and Assembly Section 6. Ensure that plastic sleeve (3) is engaged on crankshaft flange (1). Push crankshaft rear seal (2) squarely onto the crankshaft. Ensure that the crankshaft rear seal is seated against the cylinder block. During this process, plastic sleeve (3) will be forced out of the crankshaft rear seal.
  • Page 79 KENR6932 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. g01337563 Illustration 138 Typical example 4. Remove bolts (2) and remaining bolts (3) from flywheel housing (1). 5. Use the lifting device in order to remove flywheel g01374648 Illustration 137 housing (1) from the cylinder block.
  • Page 80 KENR6932 Disassembly and Assembly Section Installation Procedure (Standard Housing) Table 29 Required Tools Part Tool Part Description Number Guide Stud (M10 by 100 mm) POWERPART 1861117 Universal Jointing Compound NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

  • Page 81: Flywheel Housing - Remove And Install (Wet Back End Housing)

    KENR6932 Disassembly and Assembly Section i02654369 Flywheel Housing - Remove and Install (Wet Back End Housing) Removal Procedure Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, “Flywheel - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
  • Page 82 KENR6932 Disassembly and Assembly Section Installation Procedure (Wet Back End Housing) Table 30 Required Tools Part Tool Part Description Number Guide Stud (M10 by 100 mm) POWERPART 1861117 Universal Jointing Compound NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
  • Page 83 KENR6932 Disassembly and Assembly Section 8. Install a suitable lifting device to the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb). g01337609 Illustration 147 Engine with an aluminum oil pan g01337602 Illustration 149 Typical example 9. Use the lifting device to align flywheel housing (1) with Tooling (A).

  • Page 84: Vibration Damper And Pulley - Remove (Pulleys Without Split Lock Rings)

    KENR6932 Disassembly and Assembly Section 2. Remove remaining bolts (4). i02654373 Vibration Damper and Pulley - 3. Remove vibration damper (3) and crankshaft Remove pulley (2) from crankshaft adapter (1). Remove Tooling (A) from crankshaft adapter (1). (Pulleys without Split Lock Rings) 4.

  • Page 85: Vibration Damper And Pulley - Install (Pulleys Without Split Lock Rings)

    KENR6932 Disassembly and Assembly Section i02654371 Vibration Damper and Pulley - Install (Pulleys without Split Lock Rings) Installation Procedure Table 33 Required Tools Part Tool Number Part Description Guide Stud (M12 by 70 mm) 27610299 E18 Torx socket NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

  • Page 86: Vibration Damper And Pulley - Install (Pulley With Split Lock Rings)

    KENR6932 Disassembly and Assembly Section 4. Repeat Step 3 two more times in order to ensure correct torque. 5. Install Tooling (A) to crankshaft adapter (1). 6. Align crankshaft pulley (2) with Tooling (A). Install the crankshaft pulley to crankshaft adapter (1). 7.

  • Page 87: Crankshaft Front Seal - Remove And Install

    KENR6932 Disassembly and Assembly Section 9. Repeat Step 8 two more times in order to ensure correct torque. 10. Install Tooling (A) to crankshaft adapter (1). 11. Align crankshaft pulley (2) with Tooling (A). Install the crankshaft pulley to crankshaft adapter (1). 12.

  • Page 88: Front Cover - Remove And Install

    KENR6932 Disassembly and Assembly Section Note: In order to remove the front cover, it is not necessary to remove the crankshaft pulley or the alternator. g01337799 Illustration 155 Typical example 2. Assemble Tooling (B). 3. Align new crankshaft front seal (1) to the front housing.

  • Page 89: Gear Group (Front) - Remove And Install

    KENR6932 Disassembly and Assembly Section 8. Tighten the bolts for the water pump to a torque of 22 N·m (16 lb ft). End By: a. If the engine has a fan, install the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”.
  • Page 90 KENR6932 Disassembly and Assembly Section Note: Either Tooling (A) can be used. Use the Tooling 3. Remove plug (4) from the cylinder block. Install that is most suitable. Care must be taken in order to Tooling (C) into hole (Y) in the cylinder block. ensure that the fuel injection pump timing is not lost Use Tooling (C) in order to lock the crankshaft in during the removal of the front gear group.
  • Page 91 KENR6932 Disassembly and Assembly Section Note: Identification will ensure that the gears can be 2. If necessary, install Tooling (C) into hole (Y) in the installed in the original alignment. cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position.

  • Page 92: Idler Gear - Remove

    KENR6932 Disassembly and Assembly Section 10. Remove Tooling (B) and (C). Install plug (4) into hole (Y) in the cylinder block. Refer to Illustration 162. g01337905 Illustration 165 Typical example g01335426 Illustration 167 Checking backlash 11. Ensure that the backlash for gears (1), (2) and (3) is within specified values.
  • Page 93 KENR6932 Disassembly and Assembly Section Start By: a. Remove the fuel injection pump gear. Refer to Disassembly and Assembly, “Fuel Pump Gear - Remove”. b. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the fuel pump gear.
  • Page 94 KENR6932 Disassembly and Assembly Section Removal Procedure (Heavy-Duty Note: Ensure that the gears are marked in order to show alignment. Refer to Illustration 172. Idler Gear) Table 41 Required Tools Part Tool Part Name Number 27610212 Camshaft Timing Pin 27610286 Crankshaft Timing Pin g01337919 Illustration 173...

  • Page 95: Idler Gear - Install

    KENR6932 Disassembly and Assembly Section Note: The idler gear must be tilted during removal. 3. Ensure that Tooling (B) is installed in hole (Y) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position. Refer to i02654519 System Operation, Testing and Adjusting, “Finding Idler Gear - Install...
  • Page 96 KENR6932 Disassembly and Assembly Section Note: The idler gear must be tilted during installation. Ensure that the holes in the hub are aligned with the holes in the cylinder block. 8. Clean plate (3) and inspect the plate for wear or damage.
  • Page 97 KENR6932 Disassembly and Assembly Section 1. Ensure that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, “Finding Top Center for No. 1 Piston”. g01337922 Illustration 184 6. Align the timing mark on idler gear (2) with the timing mark on the camshaft gear.

  • Page 98: Housing (Front) - Remove

    KENR6932 Disassembly and Assembly Section 11. Use Tooling (C) in order to check the end play for d. Remove the engine oil pan. Refer to Disassembly the heavy-duty idler gear. Refer to Specifications, and Assembly, “Engine Oil Pan - Remove”. “Gear Group (Front)”...

  • Page 99: Housing (Front) - Install

    KENR6932 Disassembly and Assembly Section i02654517 Housing (Front) - Install Installation Procedure Table 44 Required Tools Part Tool Part Description Number 21820117 3 Bond 1386D Guide Stud (M8 by 70 mm) 27610216 Alignment Tool studs (M10 by 50 mm) g01337985 Straight Edge Illustration 188 POWERPART...
  • Page 100 KENR6932 Disassembly and Assembly Section 4. Install thrust washer (10) into the recess in the cylinder block. Refer to Disassembly and Assembly, “Camshaft - Install” for more information. g01338002 Illustration 193 (7) M8 by 20 mm (8) M8 by 35 mm (9) M8 by 25 mm g01338000 Illustration 191...

  • Page 101: Accessory Drive - Remove And Install

    KENR6932 Disassembly and Assembly Section End By: a. Install the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump - Install”. b. Install the timing gears. Refer to Disassembly and Assembly, “Gear Group (Front) - Install”. c. If the engine has an accessory drive, install the accessory drive.
  • Page 102 KENR6932 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. g01339557 Illustration 196 1. Remove Allen head screw (1) from accessory drive housing (8). Remove Allen head screws (6) from accessory drive housing (8).

  • Page 103: Crankcase Breather - Remove (Unfiltered Breather)

    KENR6932 Disassembly and Assembly Section d. Apply a small continuous bead of Tooling (A) to outer surface (Y) of bearing (5). Place accessory drive housing (8) on a suitable support. Press the assembly of gear (4) and bearings (3) and (5) into the accessory drive housing .
  • Page 104 KENR6932 Disassembly and Assembly Section g01339688 Illustration 200 2. Loosen clamps (11) and remove hose (12) from cover (1) and from tube (13). 3. Carefully pry cover (1) from breather body (4). Note: Note the orientation of the outlet. 4. Remove gauze (2) from breather body (4). 5.

  • Page 105: Crankcase Breather - Remove (Filtered Breather)

    KENR6932 Disassembly and Assembly Section 1. To remove the breather body, Tooling (A) must be i02654402 used. The tool should be fabricated from 3.1 mm Crankcase Breather - Remove (1/8 inch) steel stock. The dimensions for the tool (Filtered Breather) are given in Illustration 201.

  • Page 106: Crankcase Breather - Install (Unfiltered Breather)

    KENR6932 Disassembly and Assembly Section i02654407 Crankcase Breather - Install (Unfiltered Breather) Installation Procedure Table 48 Required Tools Part Tool Part Description Number Breather Tool NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened g01339655 Illustration 203 component life.
  • Page 107 KENR6932 Disassembly and Assembly Section 1. To install the breather body, Tooling (A) must be 6. Lubricate a new O-ring seal (5) with clean engine used. The tool should be fabricated from 3.1 mm oil. Install the O-ring seal to the bottom of breather (1/8 inch) steel stock.

  • Page 108: Crankcase Breather - Install (Filtered Breather)

    KENR6932 Disassembly and Assembly Section 1. To install the breather body, Tooling (A) must be i02654406 used. The tool should be fabricated from 3.1 mm Crankcase Breather - Install (1/8 inch) steel stock. The dimensions for the tool (Filtered Breather) are given in Illustration 207.

  • Page 109: Valve Mechanism Cover - Remove And Install (Composite Valve Mechanism Cover)

    KENR6932 Disassembly and Assembly Section 6. Lubricate a new O-ring seal (5) with clean engine 16. Install clamp (19) to hose (21). Install hose (21) oil. Install the O-ring seal to the bottom of breather to base (18). Tighten the clamp. body (4).

  • Page 110: Valve Mechanism Cover - Remove And Install

    KENR6932 Disassembly and Assembly Section Installation Procedure 3. Ensure that harness assemblies (6) are not in contact with the rocker arms or in contact with the valve mechanism cover base. Position valve NOTICE mechanism cover (2) onto valve mechanism cover Keep all parts clean from contaminants.
  • Page 111 KENR6932 Disassembly and Assembly Section g01342429 g01342429 Illustration 214 Illustration 215 Typical example Typical example 1. Disconnect the breather hose from the separator 3. Install a new joint (3) to valve mechanism cover for the crankcase breather. Refer to Disassembly (2).

  • Page 112: Valve Mechanism Cover Base - Remove And Install (Composite Valve Mechanism Cover Base)

    KENR6932 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Use a deep socket in order to remove the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
  • Page 113 KENR6932 Disassembly and Assembly Section Installation Procedure e. Repeat Steps 4.a through 4.d in order to remove the remaining harness assembly. Table 51 Required Tools Part Tool Part Description Number Circlip Pliers POWERPART 21820221 Rubber Grease 27610296 Torque wrench NOTICE Keep all parts clean from contaminants.

  • Page 114: Valve Mechanism Cover Base - Remove And Install

    KENR6932 Disassembly and Assembly Section a. Ensure that harness assembly (4) and the bore in valve mechanism cover base (6) are clean and free from damage. Replace any damaged components. b. Use Tooling (B) to lubricate a new O-ring seal (8). Install O-ring seal (8) onto harness assembly (4).
  • Page 115 KENR6932 Disassembly and Assembly Section Start By: f. Repeat steps 3.b through 3.e in order to remove the remaining harness assemblies. a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. b. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove”.
  • Page 116 KENR6932 Disassembly and Assembly Section Installation Procedure Table 53 Required Tools Tool Part Number Part Description Circlip Pliers POWERPART 21820221 Rubber Grease 27610296 Torque wrench NOTICE Keep all parts clean from contaminants. g01342487 Illustration 228 Contaminants may cause rapid wear and shortened 4.

  • Page 117: Rocker Shaft And Pushrod - Remove

    KENR6932 Disassembly and Assembly Section d. Use Tooling (A) to install circlip (5). e. Connect plug (6) to harness assembly (4). f. Use a deep socket to connect harness (4) to electronic unit injectors (2). Use Tooling (C) to tighten connectors (1) to a torque of 2.4 N·m (21 lb in).

  • Page 118: Rocker Shaft - Disassemble

    KENR6932 Disassembly and Assembly Section i02654539 Rocker Shaft - Disassemble Disassembly Procedure Start By: a. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

  • Page 119: Rocker Shaft - Assemble

    KENR6932 Disassembly and Assembly Section g01340048 Illustration 233 6. If necessary, remove retaining clip (7) and remove spring (8) from the front end of rocker shaft (5). 7. If necessary, remove nuts (10) and adjusters (9) from the rocker arms. Make a temporary identification mark on each adjuster in order to show the location.

  • Page 120: Rocker Shaft And Pushrod - Install

    KENR6932 Disassembly and Assembly Section 5. Install rocker arm assembly (3) for number 1 inlet valve to the rocker shaft. Install rocker arm NOTICE assembly (4) for number 1 exhaust valve to rocker Keep all parts clean from contaminants. shaft (5). Contaminants may cause rapid wear and shortened Note: The rocker arm assembly for the inlet valve is component life.

  • Page 121: Cylinder Head - Remove

    KENR6932 Disassembly and Assembly Section 8. Gradually tighten torx screws (1). NOTICE Note: To avoid distortion of rocker shaft assembly Failure to ensure that ALL valve bridges are correct- (2), tighten the torx screws in the center first. Work ly seated onto the valve stems will cause interference toward the outside of the rocker shaft assembly.
  • Page 122 KENR6932 Disassembly and Assembly Section d. Remove the fuel manifold. Refer to Disassembly 2. Disconnect the upper radiator hose from water and Assembly, “Fuel Manifold - Remove and temperature regulator housing (1) on the cylinder Install”. head. e. Remove the electronic control module and the mounting bracket.
  • Page 123 KENR6932 Disassembly and Assembly Section 7. Remove all cable straps that secure harness assembly (4) to the cylinder head or to the inlet manifold. The harness assembly should be positioned in order to avoid causing an obstruction during the removal of the cylinder head. g01340081 Illustration 245 g01340077...

  • Page 124: Cylinder Head - Install

    KENR6932 Disassembly and Assembly Section 15. Remove cylinder head gasket (17). 16. Note the position of dowels (18) in the cylinder block. 17. If necessary, remove water temperature regulator (1) from cylinder head (15). Refer to Disassembly and Assembly, “Water Temperature Regulator - Remove and Install”.
  • Page 125 KENR6932 Disassembly and Assembly Section 9. Remove Tooling (A). g01340176 Illustration 249 g01340188 Illustration 251 4. Inspect dowels (18) for damage. If necessary, replace the dowels in the cylinder block. 10. Clean bolts (14). Follow Steps 10.a for the procedure to inspect the bolts. 5.
  • Page 126 KENR6932 Disassembly and Assembly Section g01340077 Illustration 255 Typical example 17. Remove the plugs and caps from the ports and tube assemblies. 18. Install tube assembly (8) for the fuel return to the g01340192 Illustration 253 cylinder head and to the transfer pump. Secure the tube clips for tube assembly (8).
  • Page 127 KENR6932 Disassembly and Assembly Section b. Slide the locking tab into the locked position. 28. If necessary, fill the engine oil pan to the correct level that is indicated on the engine oil level 21. Follow Steps 21.a and 21.b in order to connect gauge.

  • Page 128: Lifter Group - Remove And Install

    KENR6932 Disassembly and Assembly Section Note: Place a temporary identification mark on each i02654526 lifter in order to identify the correct location. Lifter Group - Remove and Install 3. Repeat Steps 1 and 2 in order to remove the remaining lifters. Installation Procedure Removal Procedure Table 57...

  • Page 129: Camshaft - Remove And Install

    KENR6932 Disassembly and Assembly Section g01340518 g01340531 Illustration 259 Illustration 260 Typical example 4. Use Tooling (B) to install lifters (1) to the cylinder block. Ensure that used lifters are installed in the 2. Remove thrust washer (1) from the cylinder block. correct location.

  • Page 130: Camshaft Gear - Remove And Install

    KENR6932 Disassembly and Assembly Section 1. Clean the camshaft and the thrust washer. Inspect the camshaft and the thrust washer for wear and for damage. Refer to Specifications, “Camshaft” for more information. Replace any worn components or any damaged components. 2.
  • Page 131 KENR6932 Disassembly and Assembly Section Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”. b. Remove the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install”. Note: Either Tooling (A) can be used.
  • Page 132 KENR6932 Disassembly and Assembly Section Installation Procedure Table 59 Required Tools Tool Part Number Part Name 27610212 Camshaft Timing Pin 27610286 Crankshaft Timing Pin 27610287 Adapter NOTICE Keep all parts clean from contaminants. g01340551 Illustration 267 Contaminants may cause rapid wear and shortened component life.

  • Page 133: Camshaft Bearings - Remove And Install

    KENR6932 Disassembly and Assembly Section 8. Tighten bolt (3) to a torque of 95 N·m (70 lb ft). g01340534 Illustration 270 g01335426 Illustration 273 9. Ensure that the backlash for gears (1) and (8) is within specified values. Refer to Specifications, “Gear Group (Front)”...
  • Page 134 KENR6932 Disassembly and Assembly Section Start By: 1. Clean the bearing housing in the cylinder block. Ensure that the oil hole in the bearing housing is a. Remove the engine oil pump. Refer to free from debris. Disassembly and Assembly, “Engine Oil Pump - Remove”.

  • Page 135: Engine Oil Pan - Remove (Aluminum Oil Pan)

    KENR6932 Disassembly and Assembly Section i02654412 Engine Oil Pan - Remove (Aluminum Oil Pan) Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product.

  • Page 136: Engine Oil Pan - Remove (Cast Iron Oil Pan)

    KENR6932 Disassembly and Assembly Section i02654413 Engine Oil Pan - Remove (Cast Iron Oil Pan) Removal Procedure Table 61 Required Tools Tool Part Part Description Number g01340605 Illustration 278 T40 Torx Socket Typical example Note: In order to remove a cast iron oil pan, the 3.

  • Page 137: Engine Oil Pan - Install (Cast Iron Oil Pan)

    KENR6932 Disassembly and Assembly Section 4. Attach a suitable lifting device to engine oil pan (7) and support the weight of the engine oil pan. The NOTICE engine oil pan can weigh 100 kg (220 lb). Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- 5.
  • Page 138 KENR6932 Disassembly and Assembly Section g01340934 Illustration 281 4. Align a new joint (4) with the studs and install the joint to the cylinder block. 5. Attach a suitable lifting device to the engine oil pan (7). The engine oil pan can weigh 100 kg (220 lb). 6.
  • Page 139 KENR6932 Disassembly and Assembly Section g01340935 Illustration 282 9. Tighten bolts (8) and nuts (10) to a torque of 22 N·m (16 lb ft). Tighten the fasteners in the sequence that is shown in Illustration 282. g01340936 Illustration 283 10. Tighten the remaining bolts to a torque of 22 N·m (16 lb ft).

  • Page 140: Engine Oil Pan - Install (Aluminum Oil Pan)

    KENR6932 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids.
  • Page 141 KENR6932 Disassembly and Assembly Section g01340606 Illustration 286 Typical example 2. Ensure that the engine oil pan (7) is clean and free from damage. Clean the isolating screws (8) and (9). Inspect the isolating screws for deterioration or damage. If necessary, replace the isolating screws.
  • Page 142 KENR6932 Disassembly and Assembly Section g01340724 Illustration 287 (X) Position of guide studs. (Z) Position of short isolating screws. 6. Tighten the isolating screws to a torque of 22 N·m (16 lb ft). Tighten the isolating screws in the sequence that is shown in Illustration 287. 7.

  • Page 143: Engine Oil Pan Plate - Remove And Install (Aluminum Oil Pan)

    KENR6932 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids.
  • Page 144 KENR6932 Disassembly and Assembly Section Installation Procedure 1. Install Tooling (B) to positions (X) in the cylinder block. Table 65 2. Install the isolating frame to the cylinder block. Required Tools Follow Steps 2.a through 2.f in order to install the Tool Part Number Part Description...

  • Page 145: Piston Cooling Jets - Remove And Install

    KENR6932 Disassembly and Assembly Section i02654527 Piston Cooling Jets - Remove and Install Removal Procedure Table 66 Required Tools Tool Part Part Description Number 21825576 Crankshaft Turning Tool 27610291 Barring Device Housingl 27610289 Gear Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”.

  • Page 146: Pistons And Connecting Rods - Remove

    KENR6932 Disassembly and Assembly Section Installation Procedure i02654533 Pistons and Connecting Rods Table 67 - Remove Required Tools Tool Part Part Description Number 21825576 Crankshaft Turning Tool Removal Procedure 27610291 Barring Device Housingl Table 68 27610289 Gear Required Tools Tool Part Number Part Description Note: Either Tooling (A) can be used.

  • Page 147: Pistons And Connecting Rods - Disassemble

    KENR6932 Disassembly and Assembly Section 6. Repeat Steps 1 through 5 for the remaining pistons and connecting rods. Note: Fracture split connecting rods should not be left without the connecting rod caps installed. Temporarily install connecting rod cap (2) and bolts (3) to connecting rod (1) when the assembly is out of the engine.
  • Page 148 Removal of the piston pin bushing must be carried out by personnel with the correct training. Also spe- cial machinery is required. For more information refer to your authorized Perkins dealer or your Perkins dis- tributor. 6. Inspect the connecting rod for wear or damage. If necessary, replace connecting rod (6) or replace the bush for piston pin (8).

  • Page 149: Pistons And Connecting Rods - Assemble

    Tool Part Description Number training. Also special machinery is required. For more information refer to your authorized Perkins dealer or Circlip Pliers your Perkins distributor. Piston Ring Expander 3. If connecting rod assembly (6), (8), (11) and (12)

  • Page 150: Pistons And Connecting Rods - Install

    KENR6932 Disassembly and Assembly Section 4. Lubricate the bush for piston pin (8) in the Note: Fracture split connecting rods should not be connecting rod and lubricate the bore for the left without the connecting rod caps installed. After piston pin in piston (4) with clean engine oil. the assembly procedure for the piston and connecting rod is completed, carry out the installation procedure as soon as possible.
  • Page 151 KENR6932 Disassembly and Assembly Section Note: Install the bearing shells for the connecting rods dry when clearance checks are performed. Refer to Disassembly and Assembly, “Bearing Clearance - Check”. Apply clean engine oil to the bearing shells for the connecting rods during final assembly. Note: Ensure that the piston and the connecting rod assembly is installed in the correct cylinder.

  • Page 152: Connecting Rod Bearings - Remove (Connecting Rods In Position)

    KENR6932 Disassembly and Assembly Section b. Install the engine oil pump. Refer to Disassembly If necessary,remove the glow plugs. Ref to and Assembly, “Engine Oil Pump - Install”. Disassembly and Assembly, “Glow Plugs - Remove and Install” c. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”.

  • Page 153: Connecting Rod Bearings - Install (Connecting Rods In Position)

    KENR6932 Disassembly and Assembly Section 4. Remove lower bearing shell (3) from connecting 1. Inspect the pins of the crankshaft for damage. If rod cap (2). Keep the bearing shell and the the crankshaft is damaged, replace the crankshaft. connecting rod cap together. Refer to Disassembly and Assembly, “Crankshaft - Remove”...

  • Page 154: Crankshaft Main Bearings - Remove And Install (Crankshaft In Position)

    KENR6932 Disassembly and Assembly Section 14. If the glow plugs were removed, install the glow plugs. Ref to Disassembly and Assembly, “Glow Plugs - Remove and Install” End By: a. Install the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”. i02654465 Crankshaft Main Bearings - Remove and Install...
  • Page 155 KENR6932 Disassembly and Assembly Section 1. Ensure that the main bearing cap is marked for the correct location and orientation. g01341325 Illustration 311 g01341323 4. For number six main bearing, remove two thrust Illustration 309 washers (4) from the cylinder block. In order to remove thrust washers (4), use Tooling (A) to 2.
  • Page 156 KENR6932 Disassembly and Assembly Section Installation Procedure 3. Lubricate the crankshaft journal and upper main bearing shell (5) with clean engine oil. Slide upper Table 75 main bearing shell (5) into position between the crankshaft journal and the cylinder block. Ensure Required Tools that the locating tab for the upper main bearing Part...

  • Page 157: Crankshaft - Remove

    KENR6932 Disassembly and Assembly Section 5. Install lower main bearing shell (3) into main bearing cap (2). Ensure that the locating tab for the lower main bearing shell is correctly seated into the slot in the bearing cap. Note: The lower main bearing shell is a plain bearing that has no oil holes.
  • Page 158 KENR6932 Disassembly and Assembly Section b. Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) - Remove”. c. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, “Crankshaft Rear Seal - Remove”. d. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod - Remove”.

  • Page 159: Crankshaft - Install

    KENR6932 Disassembly and Assembly Section i02654461 Crankshaft - Install Installation Procedure Table 77 Required Tools Part Tool Part Description Number 21825607 Angle Gauge g01333482 21825617 Illustration 320 Dial Indicator Group Lifting Strap 7. Attach Tooling (A) and a suitable lifting device to crankshaft (4).
  • Page 160 KENR6932 Disassembly and Assembly Section g01341389 Illustration 322 6. Install upper main bearing shells (5) to the cylinder block. Ensure that the locating tabs for the upper main bearing shells are seated in the slots in the cylinder block. g01341402 Illustration 324 Note: The upper main bearing shells have a groove and two oil holes.

  • Page 161: Crankshaft Timing Ring - Remove And Install

    KENR6932 Disassembly and Assembly Section Note: Ensure the correct location and orientation 16. Check the crankshaft end play. Push the of main bearing caps (2). The locating tabs for the crankshaft toward the front of the engine. Install upper and the lower main bearing shells should be Tooling (B) to the cylinder block and the rear face on the same side of the engine.
  • Page 162 KENR6932 Disassembly and Assembly Section b. Remove the crankshaft. Refer to Disassembly and 2. Support crankshaft (1) on a suitable stand. Assembly, “Crankshaft - Remove ”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

  • Page 163: Crankshaft Gear - Remove And Install

    KENR6932 Disassembly and Assembly Section i02654464 Crankshaft Gear - Remove and Install Removal Procedure Table 78 Required Tools Part Tool Part Description Number Bearing Puller Puller Crossblock Puller Leg g01341488 Illustration 331 Start By: Typical example a. Remove the front housing. Refer to Disassembly 1.

  • Page 164: Bearing Clearance - Check

    (1) with key (3) in the crankshaft. Install crankshaft component life. gear (1) to crankshaft (2). Note: Perkins does not recommend the checking of If the crankshaft gear is an interference fit on the the actual clearances of the bearing shells particularly crankshaft, heat crankshaft gear (1) in an oven to on small engines.

  • Page 165: Crankshaft Position Sensor - Remove And Install

    KENR6932 Disassembly and Assembly Section • Ensure that the backs of the bearings and the i02654468 bores are clean and dry. Crankshaft Position Sensor - Remove and Install • Ensure that the bearing locking tabs are properly seated in the tab grooves. •...

  • Page 166: Position Sensor (Fuel Injection Pump) - Remove And Install

    KENR6932 Disassembly and Assembly Section g01341527 Illustration 335 1. Lubricate a new O-ring seal (5) with clean engine oil. Install the new O-ring seal to the first groove on position sensor (3). 2. Align the hole in position sensor (3) with the hole g01341704 Illustration 336 in the cylinder block.

  • Page 167: Coolant Temperature Sensor - Remove And Install

    KENR6932 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com- ponent containing fluids.

  • Page 168: Engine Oil Pressure Sensor - Remove And Install

    KENR6932 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com- ponent containing fluids.

  • Page 169: Fuel Pressure Sensor - Remove And Install

    KENR6932 Disassembly and Assembly Section Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu- el spray may cause a fire hazard. Failure to fol- low these inspection, maintenance and service in- structions may cause personal injury or death. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by...

  • Page 170: Boost Pressure Sensor - Remove And Install

    KENR6932 Disassembly and Assembly Section Note: Clean up any spillage of fuel immediately. 6. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System 5. Use a deep socket to remove fuel pressure sensor - Prime”. (3) from the fuel manifold.

  • Page 171: Inlet Air Temperature Sensor - Remove And Install

    KENR6932 Disassembly and Assembly Section Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. g01341729 Illustration 346 1. Slide locking tab (1) into the unlocked position. 2. Disconnect harness assembly (2) from inlet air pressure sensor (3).

  • Page 172: Glow Plugs - Remove And Install

    KENR6932 Disassembly and Assembly Section g01341729 Illustration 347 1. Lubricate a new O-ring seal (4) with clean engine oil. Install the new O-ring seal onto the inlet air temperature sensor. 2. Install inlet air temperature sensor (3) to the inlet g01341735 Illustration 348 manifold.

  • Page 173: Alternator Belt - Remove And Install

    KENR6932 Disassembly and Assembly Section i02654452 Alternator Belt - Remove and Install Removal Procedure Table 81 Required Tools Tool Part Part Description Number Locking Pin (Ø 8mm by 85 mm) 1. If the engine has fan guards, remove the fan guards.

  • Page 174: Fan - Remove And Install

    KENR6932 Disassembly and Assembly Section 7. If necessary, follow Steps 7.a and 7.b in order to 3. Insert Tooling (A) into hole (Y). Release the remove the tensioner (3) from mounting bracket pressure on the square drive tool. (2). 4. Install alternator belt (1). Ensure that the alternator a.

  • Page 175: Fan Drive - Remove And Install

    KENR6932 Disassembly and Assembly Section 1. Remove locking nuts (1). i02654491 Fan Drive - Remove and Install 2. Remove fan (2). Note: Note the orientation of the fan. Removal Procedure 3. Remove fan adapter (3). 4. Remove fan pulley (4). Start By: 5.

  • Page 176: Electronic Control Module - Remove And Install

    KENR6932 Disassembly and Assembly Section End By: a. Install the fan. Refer to Disassembly and Assembly, “Fan - Remove and Install”. i02654480 Electronic Control Module - Remove and Install Removal Procedure Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.
  • Page 177 KENR6932 Disassembly and Assembly Section g01341878 g01341878 Illustration 357 Illustration 358 Typical example Typical example 8. Loosen bolts (19) and remove the assembly of the 3. If necessary, follow Steps 3.a through 3.d in order electronic control module. Note the orientation of to assemble the electronic control module.

  • Page 178: Ecm Mounting Bracket - Remove And Install

    KENR6932 Disassembly and Assembly Section 13. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime”. i02654477 ECM Mounting Bracket - Remove and Install Removal Procedure Start By: a. Remove the electronic control module. Refer to Disassembly and Assembly, “Electronic Control Module - Remove and Install”.
  • Page 179 KENR6932 Disassembly and Assembly Section g01342046 g01342051 Illustration 361 Illustration 363 3. Remove bolts (9) from fuel manifold (10). 4. Loosen bolts (11) that secure mounting bracket (8) to the inlet manifold. g01342046 Illustration 364 2. Position mounting bracket (8) against the cylinder block.

  • Page 180: Alternator - Remove (Alternators With Mounting Lugs)

    KENR6932 Disassembly and Assembly Section i02654421 Alternator - Remove (Alternators with Mounting Lugs) Removal Procedure Start By: a. Remove the alternator belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened g01342045 Illustration 365...

  • Page 181: Alternator - Remove (Alternators With Mounting Pads)

    KENR6932 Disassembly and Assembly Section 6. If necessary, follow Steps 6.a and 6 in order to a. Hold the shaft of alternator (1) with an allen remove pulley (7) from alternator (3). wrench. Use a cranked ring spanner to loosen nut (5).

  • Page 182: Alternator - Install (Alternators With Mounting Pads)

    KENR6932 Disassembly and Assembly Section 2. Position alternator (3) on alternator mounting 2. Position alternator (1) on alternator mounting bracket (4). bracket (2). Install bolts (3) into the alternator bracket. Tighten the bolts to a torque of 44 N·m 3. Install bolt (5) to alternator (3). Install washer (2) (32 lb ft).

  • Page 183: Air Compressor - Remove And Install

    KENR6932 Disassembly and Assembly Section 1. If necessary, install studs (5) into flywheel housing (1). 2. If necessary, install a new joint (4) onto the studs in flywheel housing (1). 3. Position electric starting motor (3) onto the studs in flywheel housing (1). 4.
  • Page 184 KENR6932 Disassembly and Assembly Section 5. Remove the plug (1) from the cylinder block. Install Tooling (B) into the hole (X) in the cylinder block. NOTICE Use Tooling (B) in order to lock the crankshaft in Keep all parts clean from contaminants. the correct position.
  • Page 185 KENR6932 Disassembly and Assembly Section g01353470 g01353471 Illustration 374 Illustration 375 Typical example Typical example 10. Support air compressor (5). Remove nuts (14) 11. Remove O-ring seal (19) from air compressor (5). and remove the air compressor from front housing (7).
  • Page 186 KENR6932 Disassembly and Assembly Section c. Apply Tooling (D) to the threads of the shaft. Install nut (18) to the shaft of air compressor NOTICE (5). Tighten the nut to a torque of 120 N·m Keep all parts clean from contaminants. (89 lb ft).
  • Page 187 KENR6932 Disassembly and Assembly Section Note: Ensure that timing mark (X) is aligned with the timing mark A6. Refer to Illustration 378 for air compressors with a SAE drive. Refer to Illustration 379 for air compressors with a DIN drive. 7.
  • Page 188 KENR6932 Disassembly and Assembly Section 12. Install tube assembly (8) to air compressor (5) and to the cylinder block. Tighten the nuts to a torque of 9 N·m (80 lb in). 13. Remove Tooling (B) from hole (X) in the cylinder block.

  • Page 189: Index

    KENR6932 Index Section Index Crankcase Breather - Remove (Filtered Breather)............105 Accessory Drive - Remove and Install....101 Removal Procedure ......... 105 Installation Procedure ........102 Crankcase Breather - Remove (Unfiltered Breather)............103 Removal Procedure ......... 101 Removal Procedure ......... 103 Air Compressor - Remove and Install....
  • Page 190 KENR6932 Index Section Electronic Unit Injector - Remove ......26 Alternative Removal Procedure ......28 Fan - Remove and Install ........174 Removal Procedure ........... 26 Engine Oil Cooler - Install (Engine Oil Cooler with a Installation Procedure ........175 High Mounted Filter Base) ........
  • Page 191 KENR6932 Index Section Position Sensor (Fuel Injection Pump) - Remove and Install ..............166 Gear Group (Front) - Remove and Install....89 Installation Procedure ........166 Installation Procedure ........91 Removal Procedure ......... 166 Removal Procedure ........... 89 Glow Plugs - Remove and Install ......172 Installation Procedure ........
  • Page 192 Water Pump - Remove .......... 68 Removal Procedure ........... 68 Water Temperature Regulator - Remove and Install ..............71 Installation Procedure ........72 Removal Procedure ........... 71 Copyright © 2007 Perkins Engines Company Limited Printed in U.K . All Rights Reserved...

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