Perkins 1106D Disassembly And Assembly
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Perkins 1106D Disassembly And Assembly

Industrial engine
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SENR9983
October 2005
Disassembly and
Assembly
1106D Industrial Engine
PJ (Engine )

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Summary of Contents for Perkins 1106D

  • Page 1 SENR9983 October 2005 Disassembly and Assembly 1106D Industrial Engine PJ (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

    SENR9983 Table of Contents Table of Contents Valve Mechanism Cover Base - Remove and Install ..............109 Rocker Shaft and Pushrod - Remove ....111 Rocker Shaft - Disassemble ....... 112 Disassembly and Assembly Section Rocker Shaft - Assemble ........113 Rocker Shaft and Pushrod - Install ......

  • Page 4: Disassembly And Assembly Section

    SENR9983 Disassembly and Assembly Section Disassembly and Assembly Section i02295884 Fuel Priming Pump - Remove and Install Removal Procedure (Manual Priming Pump) 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 5 SENR9983 Disassembly and Assembly Section Removal Procedure (Electric Fuel 7. Remove the electric priming pump (4) from the mounting bracket. Priming Pump) Installation Procedure (Manual NOTICE Priming Pump) Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct train- NOTICE ing.
  • Page 6 SENR9983 Disassembly and Assembly Section d. Tighten the plugs and the connectors to a torque of 20 N·m (14 lb ft). 3. Position the fuel priming pump (4) on the mounting bracket. Install the two setscrews (6) to the fuel priming pump .

  • Page 7: Fuel Filter Base - Remove And Install (Secondary Fuel Filter)

    SENR9983 Disassembly and Assembly Section 4. Disconnect the plastic tube assemblies (3), (4) i02295889 and (5) from the fuel filter base (1). Plug the plastic Fuel Filter Base - Remove and tube assemblies with new plugs. Cap the ports in Install the fuel filter base with new caps.

  • Page 8: Fuel Transfer Pump - Remove

    SENR9983 Disassembly and Assembly Section 2. Position the fuel filter base (1) on the mounting i02296828 bracket. Install the setscrews (2). Tighten the Fuel Transfer Pump - Remove setscrews to a torque of 44 N·m (32 lb ft). 3. Remove the plugs from the plastic tube assemblies.
  • Page 9 SENR9983 Disassembly and Assembly Section g01162543 Illustration 8 10. Remove fuel transfer pump (1) from the fuel injection pump (8). Note: Do not remove the dowels (10) from the fuel injection pump. g01162545 Illustration 7 Typical example 3. Remove the plastic tube assembly (2) from the fuel transfer pump (1).

  • Page 10: Fuel Transfer Pump - Install

    SENR9983 Disassembly and Assembly Section i02296829 Fuel Transfer Pump - Install Installation 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. Before begining ANY work on the fuel system, re- g01162543 Illustration 11 fer to Operation and Maintenance Manual, “Gen-...

  • Page 11: Fuel Injection Lines - Remove

    SENR9983 Disassembly and Assembly Section 6. Install the tube assembly (5) for the engine oil supply to the fuel injection pump (8) and to the NOTICE cylinder block. Ensure that all adjustments and repairs that are carried out to the fuel system are performed by 7.

  • Page 12: Fuel Injection Lines - Install

    SENR9983 Disassembly and Assembly Section 8. Plug the open port in the fuel manifold (5) immediately. Use Tooling (A) in order to plug the open port in the fuel manifold. 9. Remove the seal (6) from the electronic unit injector (4) and the base of the valve mechanism cover (not shown).
  • Page 13 SENR9983 Disassembly and Assembly Section 1. Loosely install the assemblies of the three tube clips (13) and the allen head screws (14) to the NOTICE fuel injection line (7). Ensure that all adjustments and repairs that are carried out to the fuel system are performed by 2.

  • Page 14: Fuel Manifold (Rail) - Remove And Install

    SENR9983 Disassembly and Assembly Section 15. Install two new clamps (2) to the fuel injection lines. Ensure that the clamps are fully closed in order to retain the fuel injection lines. Note: Ensure that fuel injection lines do not contact any other engine component.
  • Page 15 SENR9983 Disassembly and Assembly Section 1. Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage. Note: Do not install a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines or the fuel pressure sensor are installed.

  • Page 16: Fuel Injection Pump - Remove

    SENR9983 Disassembly and Assembly Section If the fuel pressure sensor (4) was removed from the fuel manifold (1), install the fuel pressure NOTICE sensor (4) and a new sealing washer. Refer Ensure that all adjustments and repairs that are to Disassembly and Assembly Manual, “Fuel carried out to the fuel system are performed by Pressure Sensor - Revove and Install”...
  • Page 17 SENR9983 Disassembly and Assembly Section 6. Place a suitable container below the fuel injection pump (1) in order to catch any fuel that might be spilled. Note: Clean up any spillage of fuel immediately. 7. Disconnect the plastic tube assembly (2) from the fuel injection pump (1).

  • Page 18: Fuel Injection Pump - Install

    SENR9983 Disassembly and Assembly Section 19. Remove the O-ring seal (21) from the fuel injection pump (1). Discard the O-ring seal. 20. If necessary, remove the position sensor (4) from the fuel injection pump (1). Refer to Disassembly and Assembly Manual, “Position Sensor (Fuel Injection Pump) - Remove and Install”.
  • Page 19 SENR9983 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 the locking screw (25) on the fuel injection pump. Slide the spacer (26) into position (X).
  • Page 20 SENR9983 Disassembly and Assembly Section 5. Use Tooling (F) to lubricate a new O-ring seal (21). Install the O-ring seal onto the fuel injection pump (1). 6. Align the holes in the fuel injection pump (1) with the holes in the front housing (19). Carefully install the fuel injection pump to the front housing.
  • Page 21 SENR9983 Disassembly and Assembly Section 15. Remove the appropriate plugs and caps in order to install tube assembly (9) for the engine oil supply to the fuel injection pump. Install the tube assembly (9). Tighten the nuts at both ends of the tube assembly.

  • Page 22: Fuel Injection Pump Gear - Remove

    SENR9983 Disassembly and Assembly Section 1. Use Tooling (A) in order to rotate the crankshaft i02296762 so that number one piston is at top dead center Fuel Injection Pump Gear - on the compression stroke. Refer to Testing and Remove Adjusting Manual, “Finding Top Centre Position for No.1 Piston”.

  • Page 23: Fuel Injection Pump Gear - Install

    SENR9983 Disassembly and Assembly Section g01196132 Illustration 36 6. Loosen the nut (8) for the fuel pump gear (3). 7. Install Tooling (D) through two opposite holes in the fuel pump gear (3). Tighten Tooling (D) until the fuel pump gear (3) is released. g01196435 Illustration 34 8.
  • Page 24 SENR9983 Disassembly and Assembly Section 7. Install the fuel pump gear (3) to the shaft (9) of the fuel injection pump. Ensure that the timing marks on the gears (2) and (3) are in alignment and that the mesh of the gears is correct. g01195325 Illustration 37 2.

  • Page 25: Electronic Unit Injector - Remove

    SENR9983 Disassembly and Assembly Section 9. Remove Tooling (B) and (C). Install the plug (4) into hole (Y) in the cylinder block. Refer to Illustration 37. Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu- 10.
  • Page 26 SENR9983 Disassembly and Assembly Section c. Make a temporary mark on the valve bridges 6. Remove the fuel injection line (not shown) and (5) in order to show the location and orientation. the seal (7) from the appropriate electronic unit Remove valve bridges from the cylinder head.
  • Page 27 SENR9983 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 28: Electronic Unit Injector - Install

    SENR9983 Disassembly and Assembly Section 8. Use Tooling (C) to pry beneath the clamp (12) and free the electronic unit injector (8) from the cylinder head. 9. Remove the electronic unit injector (10) and the clamp (12) from the cylinder head. g01193297 Illustration 51 g01193293...
  • Page 29 SENR9983 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 30 SENR9983 Disassembly and Assembly Section Note: The seal can be damaged by contact with fuel. 9. Remove the cap from the electronic unit injector (10). Install the seal (7) to the electronic unit injector (10). Ensure that the flange on the seal is flush with the valve mechanism cover base.
  • Page 31 SENR9983 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 32: Turbocharger - Remove

    SENR9983 Disassembly and Assembly Section Note: The seal can be damaged by contact with fuel. i02295944 Turbocharger - Remove 9. Remove the cap from the electronic unit injector (10). Install the seal (7) to the electronic unit injector (10). Ensure that the flange on the seal is flush with the valve mechanism cover base.
  • Page 33 SENR9983 Disassembly and Assembly Section g01171991 Illustration 62 7. Remove the four nuts (15) from the turbocharger (6) and remove the turbocharger (6) from the exhaust manifold (12). Note: Ensure that the weight of the turbocharger is g01165546 Illustration 61 supported as the nuts are loosened.
  • Page 34 SENR9983 Disassembly and Assembly Section 6. Remove the setscrew (8) in order to disconnect the tube assembly (7) from the cylinder block. NOTICE Care must be taken to ensure that fluids are contained 7. Remove the fasteners for the tube clips (2). during performance of inspection, maintenance, test- ing, adjusting and repair of the product.

  • Page 35: Turbocharger - Disassemble

    SENR9983 Disassembly and Assembly Section 12. Remove the two setscrews (14) and remove the tube assembly (4) for the oil drain from the NOTICE turbocharger (12). Do not attempt to disassemble the turbocharger cartridge assembly or wastegate. Do not remove 13.

  • Page 36: Turbocharger - Install

    SENR9983 Disassembly and Assembly Section End By: 2. Test the wastegate actuator (19) for correct operation. Refer to Testing and Adjusting Manual, a. To check the wastegate actuator for correct “Turbocharger Inspect”. If the wastegate actuator operation, refer to Testing and Adjusting, is damaged or the wastegate actuator does not “Wastegate - Inspect”.
  • Page 37 SENR9983 Disassembly and Assembly Section 7. If a new turbocharger is installed, the bearing 8. Ensure that the tube assemblies (3) and (10) housing (18) and the compressor housing (20) are clean and free from damage. Replace any must be oriented to the correct positions. Follow damaged components.
  • Page 38 SENR9983 Disassembly and Assembly Section Installation Procedure (Top Mounted Turbochargers) Table 12 Required Tools Part Tool Part Description Number POWERPART 218200221 Rubber Grease NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. g01185011 Illustration 71 3.
  • Page 39 SENR9983 Disassembly and Assembly Section 7. If a new turbocharger is installed, the bearing housing (18) and the compressor housing (20) must be oriented to the correct positions. Refer to Illustration 70. Follow Steps 7.a through 7.d in order to orient the bearing housing and the compressor housing.

  • Page 40: Wastegate Solenoid - Remove And Install

    SENR9983 Disassembly and Assembly Section 22. Connect the exhaust pipe (not shown). Refer to Note: The tube clips must be loose in order to release OEM information for the correct procedure. the tube assembly from the wastegate solenoid. 23. If the turbocharger has a remote wastegate 4.

  • Page 41: Exhaust Manifold - Remove And Install

    SENR9983 Disassembly and Assembly Section c. If the wire lead (1) is secured with a cable tie, install a new cable tie. i02295960 Exhaust Manifold - Remove and Install Removal Procedure (Side Mounted Exhaust Manifold) Start By: a. Remove the turbocharger. Refer to Disassembly and Assembly Manual, “Turbocharger - Remove”.
  • Page 42 SENR9983 Disassembly and Assembly Section Note: Support the manifold as the setscrews are removed. 3. Remove the exhaust manifold (3). 4. Remove the two exhaust manifold gaskets (1). Discard the gaskets. 5. If necessary, remove the four studs (6) from the exhaust manifold (3).
  • Page 43 SENR9983 Disassembly and Assembly Section 3. Remove the center four setscrews (2) from the exhaust manifold (3). Remove the outer eight setscrews (5) and the spacers (4) from the exhaust manifold (3). Note: Support the manifold as the setscrews are removed.
  • Page 44 SENR9983 Disassembly and Assembly Section End By: a. Install the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Install”. Installation Procedure (Top Mounted Exhaust Manifold) Table 14 Required Tools Part Tool Part Description Number Guide Stud (M10 by 100 mm) Loctite 575 g01174489 Illustration 80...

  • Page 45: Exhaust Elbow - Remove And Install

    SENR9983 Disassembly and Assembly Section g01176487 Illustration 81 7. If the setscrews (2) and (5) have been previously used, the setscrews should be thoroughly cleaned. Tooling (B) should be applied to the first two threads of the setscrews. Note: Do not apply Tooling (B) to new setscrews. 8.

  • Page 46: Inlet Manifold - Remove And Install

    SENR9983 Disassembly and Assembly Section 4. Some types of exhaust elbow have a separate support bracket. If necessary, install the bracket and install the setscrews that secure the bracket to the exhaust elbow finger tight. 5. Install setscrews (1) finger tight. 6.
  • Page 47 SENR9983 Disassembly and Assembly Section 8. Do not remove the two dowel pins (7). NOTICE Installation Procedure Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened Table 15 component life. Required Tools Part Tool Part Name 1.

  • Page 48: Inlet And Exhaust Valve Springs - Remove And Install

    SENR9983 Disassembly and Assembly Section 4. Align the dowel pins (7) to the holes in the cylinder head. Install the inlet manifold (4) to the cylinder head. 5. Apply Tooling (A) to the setscrews (5). Install the setscrews to the inlet manifold (4). g01175792 Illustration 87 6.
  • Page 49 SENR9983 Disassembly and Assembly Section Start By: a. Remove the rocker shaft assembly. Refer to Disassembly and Assembly Manual, “Rocker Shaft and Pushrod - Remove”. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. NOTICE Keep all parts clean from contaminants.
  • Page 50 SENR9983 Disassembly and Assembly Section Note: Valve springs must be replaced in pairs for the inlet valve or the exhaust valve of each cylinder. If all valve springs require replacement the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders.
  • Page 51 SENR9983 Disassembly and Assembly Section Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. Improper assembly of parts that are spring loaded NOTICE can cause bodily injury. Keep all parts clean from contaminants. To prevent possible injury, follow the established Contaminants may cause rapid wear and shortened assembly procedure and wear protective equip- component life.

  • Page 52: Inlet And Exhaust Valves - Remove And Install

    SENR9983 Disassembly and Assembly Section End By: a. Install the rocker shaft assembly. Refer to Disassembly and Assembly Manual, “Rocker Shaft and Pushrod - Install”. i02296088 Inlet and Exhaust Valves - Remove and Install Removal Procedure Table 18 Required Tools Tool Part Number Part Description...
  • Page 53 SENR9983 Disassembly and Assembly Section Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equip- ment. Follow the recommended procedure and use all recommended tooling to release the spring force. g01162650 Illustration 93 7.
  • Page 54 SENR9983 Disassembly and Assembly Section a. Inspect the cylinder head for wear and for Note: The outer face of the valve guides must be damage. Refer to Testing and Adjusting clean and dry before installing the valve stem seals Manual, “Cylinder Head Inspect”. (4).

  • Page 55: Engine Oil Filter Base - Remove And Install

    SENR9983 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained The valve keepers can be thrown from the valve during performance of inspection, maintenance, test- when the valve spring compressor is released. En- ing, adjusting, and repair of the product. Be prepared sure that the valve keepers are properly installed to collect the fluid with suitable containers before on the valve stem.

  • Page 56: Engine Oil Cooler - Remove

    SENR9983 Disassembly and Assembly Section 7. If necessary, remove the plug (8) from the engine i02296106 oil filter base (2). Remove the O-ring seal (7) from Engine Oil Cooler - Remove the plug (8). Discard the O-ring seal. Installation Procedure Removal Procedure NOTICE Keep all parts clean from contaminants.
  • Page 57 SENR9983 Disassembly and Assembly Section Note: Clean up any spillage immediately. c. Remove the joint (not shown). Discard the joint. 4. Make temporary identification marks on the plastic tube assemblies (3) in order to show the correct position of the tube assemblies. 5.

  • Page 58: Engine Oil Cooler - Install

    SENR9983 Disassembly and Assembly Section Disassembly Procedure (Engine Oil 9. Remove the joint (16). Refer to Illustration 101 and Illustration 102. Discard the joint. Cooler with a High Mounted Filter Base) Disassembly Procedure (Engine Oil Cooler with a Low Mounted Filter Base) g01180538 Illustration 102...
  • Page 59 SENR9983 Disassembly and Assembly Section Note: The holes in the joint have serrations that hold the setscrews captive. Assembly Procedure (Engine Oil Cooler with a High Mounted Filter Base) g01174007 Illustration 103 1. Ensure that the cooler matrix (19) is clean and free from damage.
  • Page 60 SENR9983 Disassembly and Assembly Section Note: The setscrews are different lengths. Ensure that the different setscrews are installed in the correct location. 6. Install the joint (16) to the assembly of the oil cooler (6). Push the setscrews (7) through the holes in the joint.

  • Page 61: Engine Oil Relief Valve - Remove And Install

    SENR9983 Disassembly and Assembly Section If the engine has a right hand side oil filter, follow Steps 7.a through 7.d in order to install the blanking plate (12). a. Install the four setscrews (11) to the blanking plate (12). b. Position a new joint (not shown) onto the blanking plate (12).
  • Page 62 SENR9983 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Personal injury can result from being struck by parts propelled by a released spring force. Contaminants may cause rapid wear and shortened component life. Make sure to wear all necessary protective equip- ment.

  • Page 63: Engine Oil Pump - Remove

    SENR9983 Disassembly and Assembly Section Note: Ensure that the spring is properly located inside the plunger and the cap. Ensure that Tooling (A) does not contaminate the bore for the relief valve in the housing of the engine oil pump. End By: a.

  • Page 64: Engine Oil Pump - Install

    SENR9983 Disassembly and Assembly Section 6. If necessary, remove the allen head screws (6) 2. If necessary, install the pressure relief valve (5). and the front cover assembly (7). Remove the Refer to Disassembly and Assembly Manual, outer rotor (8) from the housing of the engine oil “Engine Oil Relief Valve - Remove and Install”...

  • Page 65: Water Pump - Remove

    SENR9983 Disassembly and Assembly Section a. Install the components of the support bracket. Ensure the correct location and orientation of the bracket and the retaining clip. b. Tighten the setscrews finger tight in order to align the components of the support bracket. c.

  • Page 66: Water Pump - Install

    SENR9983 Disassembly and Assembly Section i02296136 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 67: Water Temperature Regulator - Remove And Install

    SENR9983 Disassembly and Assembly Section g01204116 g01183807 Illustration 119 Illustration 120 4. Install Tooling (A) in position (X). 9. Tighten the setscrews (4) and (7) in the sequence that is shown in Illustration 120 to a torque of 5. Use Tooling (A) in order to align the new joint (2) 22 N·m (16 lb ft).
  • Page 68 SENR9983 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 69: Flywheel - Remove

    SENR9983 Disassembly and Assembly Section 2. If the original water temperature regulator housing Start By: is installed, position a new O-ring seal (3) into the groove in the water temperature regulator housing a. Remove the electric starting motor. Refer to (2).

  • Page 70: Flywheel - Install

    SENR9983 Disassembly and Assembly Section g01162553 g01163617 Illustration 126 Illustration 127 7. Inspect the flywheel (1) and the ring gear (5) for wear or damage. Replace any worn components or damaged components. Always wear protective gloves when handling parts that have been heated. 8.

  • Page 71: Crankshaft Rear Seal - Remove

    SENR9983 Disassembly and Assembly Section i02296656 Crankshaft Rear Seal - Remove Removal Procedure Table 25 Required Tools Part Tool Part Description Number T40 Torx Socket Start By: a. Remove the flywheel housing. Refer to Disassembly and Assembly Manual, “Flywheel Housing - Remove and Install”. g01159176 Illustration 128 NOTICE...

  • Page 72: Crankshaft Rear Seal - Install

    SENR9983 Disassembly and Assembly Section Note: The assembly of the crankshaft rear seal is nonserviceable. If the assembly of the crankshaft rear seal is removed, the assembly must be replaced. 1. Remove the torx screws (1) from the assembly of the crankshaft rear seal (2).
  • Page 73 SENR9983 Disassembly and Assembly Section 4. Place the assembly of the crankshaft rear seal over the crankshaft palm (1). Align the dowel (5) NOTICE with the slot in the crankshaft rear seal (2). Keep all parts clean from contaminants. 5. Ensure that the plastic sleeve (3) is engaged on Contaminants may cause rapid wear and shortened the crankshaft palm (1).
  • Page 74 SENR9983 Disassembly and Assembly Section g01183431 Illustration 132 Alignment tool 1. To install the crankshaft rear seal without the 2. Ensure that the crankshaft palm (1) is clean, dry isolating frame for the oil pan in position, Tooling and free from damage. If the crankshaft palm (B) must be used.

  • Page 75: Crankshaft Wear Sleeve (Rear) - Remove And Install

    SENR9983 Disassembly and Assembly Section i02403282 Crankshaft Wear Sleeve (Rear) - Remove and Install Removal Procedure Start By: a. Remove the crankshaft rear seal. Refer to Disassembly and Assembly Manual, “Crankshaft Rear Seal - Remove”. g01201892 Illustration 134 NOTICE 5. Place the assembly of the crankshaft rear seal Keep all parts clean from contaminants.

  • Page 76: Flywheel Housing - Remove And Install

    SENR9983 Disassembly and Assembly Section Installation Procedure 3. Align the crankshaft wear sleeve (1) with the crankshaft (2). Position the installation tool (3) Table 28 that is provided with the crankshaft wear sleeve over the crankshaft. Use a hammer to drive the Required Tools crankshaft wear sleeve onto the crankshaft.
  • Page 77 SENR9983 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Install a suitable lifting device to the flywheel housing in order to support the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb). g01165544 Illustration 138 2.
  • Page 78 SENR9983 Disassembly and Assembly Section g01202954 Illustration 143 Engine with an aluminum oil pan g01215183 Illustration 142 5. Remove the joint (7). Discard the joint. 6. If necessary, remove the two dowels (5) from the cylinder block. 7. Remove the oil seal (8) from the flywheel housing (1).
  • Page 79 SENR9983 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 80 SENR9983 Disassembly and Assembly Section g01215184 Illustration 147 Engine with an aluminum oil pan g01202953 Illustration 149 9. Use the lifting device to align the flywheel housing (1) with Tooling (A). Install the flywheel housing to the cylinder block. 10. Install the two M16 setscrews (2), two M12 setscrews (4) and two M10 setscrews (3).

  • Page 81: Vibration Damper And Pulley - Remove

    SENR9983 Disassembly and Assembly Section i02296662 Vibration Damper and Pulley - Remove Removal Procedure (Pulleys with Split Lock Rings) Table 31 Required Tools Part Tool Number Part Description Guide Stud (M12 by 70 mm) 27610299 E18 Torx socket Start By: a.

  • Page 82: Vibration Damper And Pulley - Install

    SENR9983 Disassembly and Assembly Section Removal Procedure (Pulleys 4. Use a suitable tool in order to prevent the crankshaft from rotating. Use Tooling (B) to without Split Lock Rings) remove the three torx screws (5). Table 32 5. Remove the crankshaft adapter (1) from the Required Tools crankshaft.
  • Page 83 SENR9983 Disassembly and Assembly Section 9. Repeat Step 8 two more times in order to ensure correct torque. 10. Install Tooling (A) to the crankshaft adapter (1). 11. Align the crankshaft pulley (2) with Tooling (A). Install the crankshaft pulley to the crankshaft adapter (1).

  • Page 84: Crankshaft Front Seal - Remove And Install

    SENR9983 Disassembly and Assembly Section End By: a. Install the alternator belt. Refer to Disassembly and Assembly Manual, “Alternator Belt - Remove and Install”. i02403280 Crankshaft Front Seal - Remove and Install Removal Procedure Table 35 Required Tools Part Tool Part Description Number g01167596...

  • Page 85: Crankshaft Wear Sleeve (Front) - Remove And Install

    SENR9983 Disassembly and Assembly Section 2. Screw the setscrew (2) into Tooling (A) in order to 5. Remove Tooling (B) from the crankshaft. remove the crankshaft front seal (1). Discard the crankshaft front seal (1). End By: a. Install the crankshaft pulley. Refer to Disassembly Installation Procedure and Assembly, “Crankshaft Pulley - Remove and Install”.

  • Page 86: Front Cover - Remove And Install

    SENR9983 Disassembly and Assembly Section 2. Insert a thin blade between the wear sleeve (1) and the crankshaft adapter (2) below the scored line. The wear sleeve will separate along the line. 3. Remove the wear sleeve (1) from the crankshaft adapter (2).
  • Page 87 SENR9983 Disassembly and Assembly Section b. Remove the water pump. Refer to Disassembly and Assembly Manual, “Water Pump - Remove”. Note: In order to remove the front cover, it is not necessary to remove the crankshaft pulley or the alternator. g01156385 Illustration 159 Typical example...

  • Page 88: Gear Group (Front) - Remove And Install

    SENR9983 Disassembly and Assembly Section 7. Tighten the setscrews (3), (4) and (5) to a torque of 22 N·m (16 lb ft). NOTICE Care must be taken to ensure that fluids are contained 8. Tighten the setscrews for the water pump to a during performance of inspection, maintenance, test- torque of 22 N·m (16 lb ft).
  • Page 89 SENR9983 Disassembly and Assembly Section g01195325 Illustration 162 3. Remove the plug (4) from the cylinder block. Install Tooling (C) into the hole (Y) in the cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position. Refer to Testing and Adjusting Manual, “Finding Top Centre Position for No.1 g01194949 Illustration 164...
  • Page 90 SENR9983 Disassembly and Assembly Section g01195325 Illustration 165 2. If necessary, install Tooling (C) into the hole (Y) in the cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position. Refer to Testing and Adjusting Manual, “Finding Top Centre Position for No.1 Piston”.

  • Page 91: Idler Gear - Remove

    SENR9983 Disassembly and Assembly Section 6. Install the idler gear (2). Ensure that the timing b. Install the front cover. Refer to Disassembly and marks on the gears (1) and (2) are in alignment Assembly Manual, “Front Cover - Remove and and that the mesh of the gears is correct.
  • Page 92 SENR9983 Disassembly and Assembly Section 1. Ensure that Tooling (A) is installed into hole (X) in the camshaft gear. Use Tooling (A) in order to lock the camshaft in the correct position. Note: Ensure that the gears are marked in order to show alignment.

  • Page 93: Idler Gear - Install

    SENR9983 Disassembly and Assembly Section Note: The assembly of heavy-duty idler gear is not Note: Failure to ensure that ALL adjusters are fully serviceable. Do not disassemble the heavy-duty idler unscrewed can result in contact between the valves gear. and pistons. 4.
  • Page 94 SENR9983 Disassembly and Assembly Section 6. Lubricate the hub (7) with clean engine oil. Slide the hub (7) into the idler gear (2). Ensure that the timing marks are toward the front of the idler gear. g01197578 Illustration 179 Alignment of timing marks g01198122 2.
  • Page 95 SENR9983 Disassembly and Assembly Section Installation Procedure (Heavy-Duty Idler Gear) Table 44 Required Tools Part Tool Part Name Number 27610212 Camshaft Timing Pin 27610286 Crankshaft Timing Pin 21825496 Dial gauge Magnetic Base g00944081 Illustration 183 NOTICE Checking end play by using a set of feeler gauge’s Keep all parts clean from contaminants.

  • Page 96: Housing (Front) - Remove

    SENR9983 Disassembly and Assembly Section 4. Clean the assembly of the idler gear (2) and 10. Use Tooling (C) in order to check the end inspect the assembly of the idler gear for wear or play for the heavy-duty idler gear. Refer to damage.
  • Page 97 SENR9983 Disassembly and Assembly Section d. Remove the engine oil pan. Refer to Disassembly and Assembly Manual, “Engine Oil Pan - Remove”. e. If the engine has an accessory drive, remove the accessory drive. Refer to Disassembly and Assembly Manual, “Accessory Drive - Remove and Install”.

  • Page 98: Housing (Front) - Install

    SENR9983 Disassembly and Assembly Section 4. Install the thrust washer (10) into the recess in i02296671 the cylinder block. Refer to Disassembly and Housing (Front) - Install Assembly Manual, “Camshaft - Install” for more information. Installation Procedure Table 45 Required Tools Part Tool Part Description...
  • Page 99 SENR9983 Disassembly and Assembly Section g01203928 g01203927 Illustration 196 Illustration 197 (7) M8 by 20 mm 13. Tighten the setscrews (6), (7) and (8) in the (8) M8 by 35 mm (9) M8 by 25 mm sequence that is shown in illustration 197 to a torque of 28 N·m (20 lb ft).

  • Page 100: Accessory Drive - Remove And Install

    SENR9983 Disassembly and Assembly Section End By: a. Install the fuel injection pump. Refer to Disassembly and Assembly Manual, “Fuel Injection Pump - Install”. b. Install the timing gears. Refer to Disassembly and Assembly Manual, “Gear Group (Front) - Install”. c.

  • Page 101: Crankcase Breather - Remove

    SENR9983 Disassembly and Assembly Section d. Apply a small continuous bead of Tooling (A) to the outer surface (Y) of the bearing (5). Place NOTICE the accessory drive housing (8) on a suitable Keep all parts clean from contaminants. support. Press the assembly of the gear (4) and the bearings (3) and (5) into the accessory Contaminants may cause rapid wear and shortened drive housing .
  • Page 102 SENR9983 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. g01200785 Illustration 202 g01206039 Illustration 201 Breather tool 1. To remove the breather body, Tooling (A) must be used. The tool should be fabricated from 3.1 mm (1/8 inch) steel stock.
  • Page 103 SENR9983 Disassembly and Assembly Section 3. Carefully pry the cover (1) from the breather body (4). Note: Note the orientation of the outlet. 4. Remove the gauze (2) from the breather body (4). 5. Remove the O-ring seal (3) from the breather body (4).

  • Page 104: Crankcase Breather - Install

    SENR9983 Disassembly and Assembly Section 2. Remove the canister (20) for the breather. Refer to Operation and maintenance Manual, “Crankcase Breather (Canister) - Replace”. 3. Loosen the clamp (19) and remove the hose (21). 4. Release the two spring clamps (14) in order to remove the hose (15).
  • Page 105 SENR9983 Disassembly and Assembly Section NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. g01200785 Illustration 208 2. Ensure that all components of the crankcase breather are clean and free from damage. Replace any components that are damaged.
  • Page 106 SENR9983 Disassembly and Assembly Section 10. Install the cover (1) to the breather body (4). Note: Ensure that the outlet of the cover is in the correct position in order to align with the hose (12) for the breather. g01200791 Illustration 209 11.
  • Page 107 SENR9983 Disassembly and Assembly Section 10. Install the cover (1) to the breather body (4). Note: Ensure that the outlet of the cover is in the correct position in order to align with the hose (15) for the breather. g01200786 Illustration 212 11.

  • Page 108: Valve Mechanism Cover - Remove And Install

    SENR9983 Disassembly and Assembly Section Installation Procedure i02296674 Valve Mechanism Cover - NOTICE Remove and Install Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Removal Procedure 1. Thoroughly clean all surfaces of the valve mechanism cover.

  • Page 109: Valve Mechanism Cover Base - Remove And Install

    SENR9983 Disassembly and Assembly Section i02296675 Valve Mechanism Cover Base - Remove and Install Removal Procedure Table 51 Required Tools Part Tool Part Description Number g01202951 Illustration 215 Circlip Pliers 4. Ensure that the harness assemblies (5) are Start By: not in contact with the rocker arms of the valve mechanism cover base.
  • Page 110 SENR9983 Disassembly and Assembly Section 3. If necessary, follow steps 3.a through 3.f in order 4. Loosen the isolated screws (9) in reverse to remove the harness assemblies (4) from the numerical order. Refer to illustration 219. This will valve mechanism cover base (6). help prevent distortion of the valve mechanism cover base (6).

  • Page 111: Rocker Shaft And Pushrod - Remove

    SENR9983 Disassembly and Assembly Section 2. Install the seal (10) to the valve mechanism cover b. Use Tooling (B) to lubricate a new O-ring seal base (6). Ensure that the seal (10) is seated (8). Install the new O-ring seal (8) onto the correctly in the groove in the machined face of the harness assembly (4).

  • Page 112: Rocker Shaft - Disassemble

    SENR9983 Disassembly and Assembly Section Note: Identification will ensure that the valve bridges can be reinstalled in the original location and the original orientation. Do not interchange the location or the orientation of used valve bridges. i02296678 Rocker Shaft - Disassemble g01182556 Illustration 223 Disassembly Procedure...

  • Page 113: Rocker Shaft - Assemble

    SENR9983 Disassembly and Assembly Section g01181801 Illustration 226 6. If necessary, remove retaining clip (7) and remove spring (8) from the front end of the rocker shaft (5). 7. If necessary, remove the nuts (10) and the adjusters (9) from the rocker arms. Make a temporary identification mark on each adjuster in order to show the location.

  • Page 114: Rocker Shaft And Pushrod - Install

    SENR9983 Disassembly and Assembly Section 5. Install the rocker arm assembly (3) for number 1 inlet valve to the rocker shaft. Install the rocker arm assembly (4) for number 1 exhaust valve to the rocker shaft (5). Note: The rocker arm assembly for the inlet valve is longer than the rocker arm assembly for the exhaust valve.
  • Page 115 SENR9983 Disassembly and Assembly Section 5. Ensure that the rocker shaft assembly is clean and free from wear or damage. Install the 12 torx NOTICE screws (1) in the rocker shaft. Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

  • Page 116: Cylinder Head - Remove

    SENR9983 Disassembly and Assembly Section End By: NOTICE a. Install the valve mechanism cover. Refer to Care must be taken to ensure that fluids are contained Disassembly and Assembly Manual, “Valve during performance of inspection, maintenance, test- Mechanism Cover - Remove and Install”. ing, adjusting and repair of the product.
  • Page 117 SENR9983 Disassembly and Assembly Section 4. Follow Steps 4.a and 4.b in order to disconnect 9. If the engine has a wastegate solenoid, loosen the the harness assembly (4) from the coolant tube clips for the tube assembly (9). Remove the temperature sensor (5).

  • Page 118: Cylinder Head - Install

    SENR9983 Disassembly and Assembly Section 11. Gradually loosen the setscrews (14) in the reverse numerical order to the tightening sequence. Refer to the illustration 238. Note: Follow the correct sequence in order to help prevent distortion of the cylinder head. 12.
  • Page 119 SENR9983 Disassembly and Assembly Section 1. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Do not damage the mating surfaces of the cylinder head of the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
  • Page 120 SENR9983 Disassembly and Assembly Section b. Use a straight edge to check the threads of the 15. Turn the setscrews through an additional 225 setscrews. Refer to Illustration 243. Replace degrees in the numerical sequence. Refer to any setscrews that show visual reduction in the Illustration 245.
  • Page 121 SENR9983 Disassembly and Assembly Section g01175424 g01176154 Illustration 248 Illustration 249 Typical example Typical example 20. Follow Steps 20.a and 20.b in order to connect the 25. If necessary, install the water temperature harness assembly (4) to the inlet air temperature regulator housing (1) to the cylinder head.

  • Page 122: Lifter Group - Remove And Install

    SENR9983 Disassembly and Assembly Section f. Install the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold - Remove and Install”. g. If necessary, install the fuel filter base and the secondary fuel filter. Refer to Disassembly and Assembly Manual, “Fuel Filter Base - Remove and Install”.

  • Page 123: Camshaft - Remove And Install

    SENR9983 Disassembly and Assembly Section b. Inspect the shank of the lifter for wear or b. Remove the front housing. Refer to Disassembly damage. Refer to Specifications Manual, “Lifter and Assembly Manual, “Housing (Front) - Group” for more information. Remove”. c.
  • Page 124 SENR9983 Disassembly and Assembly Section 4. If necessary, remove the key (4) from the camshaft (3). NOTICE Do not damage the lobes or the bearings when the Installation Procedure camshaft is removed or installed. 6. Carefully install the camshaft (3) into the cylinder NOTICE block.

  • Page 125: Camshaft Gear - Remove And Install

    SENR9983 Disassembly and Assembly Section i02296687 Camshaft Gear - Remove and Install Removal Procedure Table 57 Required Tools Part Tool Part Name Number g01196831 21825576 Illustration 256 Crankshaft Turning Tool 27610289 Crankshaft Turning Tool 2. Install Tooling (B) through the hole (X) in the camshaft gear (1) into the front housing.
  • Page 126 SENR9983 Disassembly and Assembly Section Installation Procedure Table 58 Required Tools Part Tool Part Name Number 27610212 Camshaft Timing Pin 27610286 Crankshaft Timing Pin NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened g01196847 Illustration 259 component life.

  • Page 127: Camshaft Bearings - Remove And Install

    SENR9983 Disassembly and Assembly Section g01196847 g00944084 Illustration 263 Illustration 265 Alignment of timing marks Checking backlash 5. Align the keyway in the camshaft gear (1) with the 9. Ensure that the backlash for the gears (1) key in the camshaft. Install camshaft gear onto the and (8) is within specified values.
  • Page 128 SENR9983 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 Manual, “Engine Oil Pump - Remove”.

  • Page 129: Engine Oil Pan - Remove

    SENR9983 Disassembly and Assembly Section i02296799 Engine Oil Pan - Remove Removal Procedure (Aluminum Oil Pan) Table 60 Required Tools Tool Part Part Description Number T40 Torx Socket Start By: a. Remove the flywheel housing. Refer to Disassembly and Assembly Manual, “Flywheel Housing - Remove and Install”.
  • Page 130 SENR9983 Disassembly and Assembly Section 6. Remove the assembly of the engine oil pan from Note: In order to remove a cast iron oil pan, the the engine. engine must be removed from the application. Refer to OEM information for the correct procedure. Ensure 7.

  • Page 131: Engine Oil Pan - Install

    SENR9983 Disassembly and Assembly Section i02296794 Engine Oil Pan - Install Installation Procedure (Aluminum Oil Pan) Table 62 Required Tools Part Tool Number Part Description T40 Torx Socket Guide Stud (M8 by 100 mm) POWERPART 21826038 Silicon Rubber Sealant POWERPART 21820117 Threadlock and Nutlock NOTICE...
  • Page 132 SENR9983 Disassembly and Assembly Section g01215700 g01215533 Illustration 273 Illustration 274 Tooling (B) is not shown for clarity. 1. Install Tooling (B) to positions (X) in the cylinder block. c. Apply a bead of Tooling (C) to positions (Y). 2. If necessary, follow Steps 2.a through 2.f in order to install the isolating frame.
  • Page 133 SENR9983 Disassembly and Assembly Section d. Position a new joint (10) onto the isolating 6. Align the assembly of the engine oil pan with frame (12). Tooling (B). Install the assembly of the engine oil pan to the isolating frame (12). Install the clip e.
  • Page 134 SENR9983 Disassembly and Assembly Section g01215571 Illustration 277 (X) Position of guide studs. (Z) Position of short isolating screws. 7. 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 277. 8.
  • Page 135 SENR9983 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 136 SENR9983 Disassembly and Assembly Section g01178884 Illustration 281 4. Align a new joint (4) with the studs (not shown) 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 137 SENR9983 Disassembly and Assembly Section g01212463 Illustration 282 9. Tighten the setscrews (8) and the nuts (10) to a torque of 22 N·m (16 lb ft). Tighten the fasteners in the sequence that is shown in Illustration 282. g01212464 Illustration 283 10.

  • Page 138: Piston Cooling Jets - Remove And Install

    SENR9983 Disassembly and Assembly Section Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly Manual , “Engine Oil Pump - Remove”. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. NOTICE Keep all parts clean from contaminants.

  • Page 139: Pistons And Connecting Rods - Remove

    SENR9983 Disassembly and Assembly Section i02296693 NOTICE Pistons and Connecting Rods Keep all parts clean from contaminants. - Remove Contaminants may cause rapid wear and shortened component life. Removal Procedure Table 66 Required Tools Tool Part Number Part Description 21825576 Crankshaft Turning Tool 27610289 Crankshaft Turning Tool...

  • Page 140: Pistons And Connecting Rods - Disassemble

    SENR9983 Disassembly and Assembly Section Note: Do not push on the fracture split surfaces of the connecting rod as damage may result. 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.
  • Page 141 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.

  • Page 142: Pistons And Connecting Rods - Assemble

    Circlip Pliers rod must be carried out by personnel with the correct Piston Ring Expander training. Also special machinery is required. For more information refer to your authorized Perkins dealer or your Perkins distributor. NOTICE Keep all parts clean from contaminants.
  • Page 143 SENR9983 Disassembly and Assembly Section Note: If the piston pin cannot be installed by hand, heat the piston to a temperature of 45° ± 5°C (113° ± 9°F). 6. Use Tooling (A) in order to install the circlips (5) to the piston pin bore in the piston (4).

  • Page 144: Pistons And Connecting Rods - Install

    SENR9983 Disassembly and Assembly Section i02296696 Pistons and Connecting Rods - Install Installation Procedure Table 69 Required Tools Tool Part Part Description Number g01154542 21825576 Illustration 294 Crankshaft Turning Tool 27610289 Crankshaft Turning Tool 4. Install Tooling (B) onto the piston (4). 27610290 Gear Note: Ensure that Tooling (B) is installed correctly...

  • Page 145: Connecting Rod Bearings - Remove (Connecting Rods In Position)

    SENR9983 Disassembly and Assembly Section Note: Ensure that the etched number (X) on i02296697 connecting rod cap (2) matches the etched number Connecting Rod Bearings - (X) on connecting rod (1). Ensure the correct Remove orientation of the connecting rod cap (2). The locating tab for the upper bearing shell and the lower bearing (Connecting rods in position) shell should be on the same side.

  • Page 146: Connecting Rod Bearings - Install (Connecting Rods In Position)

    SENR9983 Disassembly and Assembly Section 5. Carefully push the connecting rod (5) into the cylinder bore until the connecting rod (5) is clear of the crankshaft. Remove the upper bearing shell (4) from the connecting rod. Keep the bearing shells together. Note: Do not push on the fracture split surfaces of the connecting rod as damage may result.
  • Page 147 SENR9983 Disassembly and Assembly Section 1. Inspect the pins of the crankshaft for damage. If the crankshaft is damaged, replace the crankshaft. Refer to Disassembly and Assembly Manual, “Crankshaft - Remove” and Disassembly and Assembly Manual, “Crankshaft - Install”. Ensure that the bearing shells are clean and free from wear or damage.

  • Page 148: Crankshaft Main Bearings - Remove And Install (Crankshaft In Position)

    SENR9983 Disassembly and Assembly Section i02296801 Crankshaft Main Bearings - Remove and Install (Crankshaft in position) Removal Procedure Table 72 Required Tools Tool Part Number Part Description g00947823 Illustration 300 21825576 Crankshaft Turning Tool 2. Remove the two setscrews (1) and the main 27610289 Crankshaft Turning Tool bearing cap (2) from the cylinder block.
  • Page 149 SENR9983 Disassembly and Assembly Section Installation Procedure Table 73 Required Tools Part Tool Part Description Number 21825607 Angle Gauge 21825496 Dial Gauge Magnetic Base NOTICE This procedure must only be used to remove and in- stall the main bearing shells with the crankshaft in po- sition.
  • Page 150 SENR9983 Disassembly and Assembly Section Note: The upper main bearing shell has a groove and two oil holes. g01158224 Illustration 307 6. Lubricate the crankshaft journal and the lower main bearing shell with clean engine oil. Install the main bearing cap (2) to the cylinder block. Note: Ensure the correct orientation of the main bearing cap.

  • Page 151: Crankshaft - Remove

    SENR9983 Disassembly and Assembly Section c. Remove the crankshaft rear seal. Refer to Disassembly and Assembly Manual, “Crankshaft Rear Seal - Remove”. d. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly Manual, “Rocker Shaft and Pushrod - Remove”. e.

  • Page 152: Crankshaft - Install

    SENR9983 Disassembly and Assembly Section g01153150 Illustration 312 g01152971 Illustration 310 7. Remove the upper main bearing shells (5) from 5. Remove the lower main bearing shells (3) from the cylinder block. Keep the upper main bearing the main bearing caps (2). Keep the lower main shells with the respective main bearing caps.
  • Page 153 SENR9983 Disassembly and Assembly Section 7. Lubricate the upper main bearing shells (5) with clean engine oil. NOTICE If the crankshaft has been reground or if the crankshaft has been replaced, the height of the piston above the cylinder block must be inspected. It is necessary to remove the cylinder head in order to inspect the height of the piston above the cylinder block.
  • Page 154 SENR9983 Disassembly and Assembly Section Note: Do not tap the main bearing caps into position as the bearing shells may be dislodged. 14. Tighten the setscrews (1) to a torque of 80 N·m (59 lb ft). Turn the setscrews (1) through an additional 90 degrees.

  • Page 155: Crankshaft Timing Ring - Remove And Install

    SENR9983 Disassembly and Assembly Section End By: a. If necessary, install the pistons and connecting rods. Refer to Disassembly and Assembly Manual, “Pistons and Connecting Rods - Install”. b. If necessary, install the cylinder head. Refer to Disassembly and Assembly Manual, “Cylinderhead - Install”.

  • Page 156: Crankshaft Gear - Remove And Install

    SENR9983 Disassembly and Assembly Section i02296703 Crankshaft Gear - Remove and Install Removal Procedure Table 75 Required Tools Part Tool Part Description Number Bearing Puller Puller Crossblock Puller Leg g01159924 Illustration 320 Start By: 3. If the dowel (5) was removed, install a new dowel a.
  • Page 157 SENR9983 Disassembly and Assembly Section g01169343 Illustration 323 Typical example 2. If necessary, install a new key (3) to the crankshaft (2). Note: The crankshaft gear may be a sliding fit on the g01158655 Illustration 322 crankshaft or an interference fit on the crankshaft. Typical example 1.

  • Page 158: Bearing Clearance - Check

    Illustration 324 component life. Typical example Note: Perkins does not recommend the checking of 1. Place a piece of the Plastigauge (1) onto the the actual clearances of the bearing shells particularly crown of the bearing shell that is in the cap.

  • Page 159: Crankshaft Position Sensor - Remove And Install

    SENR9983 Disassembly and Assembly Section Installation Procedure Note: When Plastigauge is used, the readings can sometimes be unclear. For example, all parts of the Plastigauge are not the same width. Measure the NOTICE major width in order to ensure that the parts are within Keep all parts clean from contaminants.
  • Page 160 SENR9983 Disassembly and Assembly Section Installation Procedure NOTICE Care must be taken to ensure that fluids are contained NOTICE during performance of inspection, maintenance, test- Keep all parts clean from contaminants. ing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before Contaminants may cause rapid wear and shortened opening any compartment or disassembling any com-...

  • Page 161: Engine Oil Pressure Sensor - Remove And Install

    SENR9983 Disassembly and Assembly Section Installation Procedure i02296726 Engine Oil Pressure Sensor - NOTICE Remove and Install Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

  • Page 162: Position Sensor (Fuel Injection Pump) - Remove And Install

    SENR9983 Disassembly and Assembly Section Installation Procedure i02343353 Position Sensor (Fuel Injection NOTICE Pump) - Remove and Install Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

  • Page 163: Fuel Pressure Sensor - Remove And Install

    SENR9983 Disassembly and Assembly Section i02296806 Fuel Pressure Sensor - Remove and Install Removal Procedure Table 77 Required Tools Part Tool Part Name Number Seal Pick Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu- g01175003 Illustration 333 el spray may cause a fire hazard.

  • Page 164: Boost Pressure Sensor - Remove And Install

    SENR9983 Disassembly and Assembly Section g01175003 g01160297 Illustration 334 Illustration 335 1. Position a new sealing washer (4) on the fuel 1. Slide the locking tab (1) into the unlocked position. pressure sensor (3). 2. Disconnect the harness assembly (2) from the 2.

  • Page 165: Inlet Air Temperature Sensor - Remove And Install

    SENR9983 Disassembly and Assembly Section g01160297 g01160296 Illustration 336 Illustration 337 1. Lubricate a new O-ring seal (4) with clean engine 1. Slide the locking tab (1) into the unlocked position. oil. Install the new O-ring seal onto the boost pressure sensor (3).

  • Page 166: Glow Plugs - Remove And Install

    SENR9983 Disassembly and Assembly Section g01160296 Illustration 338 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 the inlet air temperature sensor (3) to the g01172800 Illustration 339 inlet manifold.

  • Page 167: Alternator Belt - Remove And Install

    SENR9983 Disassembly and Assembly Section i02296810 Alternator Belt - Remove and Install Removal Procedure Table 78 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 168: Fan - Remove And Install

    SENR9983 Disassembly and Assembly Section 7. If necessary, follow Steps 7.a and 7.b in order 2. Install a suitable square drive tool into hole (X) in to remove the tensioner (3) from the mounting the tensioner (1). From the front of the engine, bracket (2).

  • Page 169: Fan Drive - Remove And Install

    SENR9983 Disassembly and Assembly Section g01159068 g01159068 Illustration 343 Illustration 344 Typical example Typical example 1. Remove the locking nuts (1). 2. If necessary, install the four studs (5) to the fan drive (6). 2. Remove the fan (2). 3. Install the fan pulley (4). Note: Note the orientation of the fan.

  • Page 170: Electronic Control Module - Remove And Install

    SENR9983 Disassembly and Assembly Section i02296737 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. g00944500 Before begining ANY work on the fuel system, Illustration 345 refer to Operation and Maintenance Manual,...
  • Page 171 SENR9983 Disassembly and Assembly Section 3. Cut the cable tie (3). Unscrew the fastener (6) that a. Remove the isolation mounts (20) and the secures the OEM harness (2) to the electronic spacers (21). control module (5). Disconnect the OEM harness from the electronic control module.

  • Page 172: Ecm Mounting Bracket - Remove And Install

    SENR9983 Disassembly and Assembly Section b. Position the bracket (14) on the electronic 6. Remove the plugs from the plastic tube assemblies control module. Ensure that the bracket is (4) and (11). If necessary, remove the caps from correctly oriented. Install the torx screw (15). the connectors in the electronic control module.
  • Page 173 SENR9983 Disassembly and Assembly Section g01177811 Illustration 353 5. Remove the four setscrews (12) that secure the mounting bracket (8) to the cylinder block. 6. Slide the mounting bracket (8) horizontally away from the cylinder block in order to remove the g01202607 Illustration 351 mounting bracket.
  • Page 174 SENR9983 Disassembly and Assembly Section g01202608 Illustration 355 2. Position the mounting bracket (8) against the cylinder block. Ensure that the two slots in the top face of the mounting bracket are aligned with the setscrews (11). Slide the mounting bracket into position against the cylinder block.

  • Page 175: Alternator - Remove

    SENR9983 Disassembly and Assembly Section a. Hold the shaft of the alternator (1) with an allen i02296739 wrench. Use a cranked ring spanner to loosen Alternator - Remove the nut (7). b. Remove the nut (7) and the pulley (8) from the alternator (1).

  • Page 176: Alternator - Install

    SENR9983 Disassembly and Assembly Section 5. Tighten the nut (3) and the setscrew (2) to a i02296740 torque of 22 N·m (16 lb ft). Alternator - Install 6. Connect the wiring harness assembly (not shown) to the alternator (1). Installation Procedure (Alternators 7.

  • Page 177: Electric Starting Motor - Remove And Install

    SENR9983 Disassembly and Assembly Section 6. If a joint is installed, remove the joint (4). Discard i02296742 the joint. Electric Starting Motor - Remove and Install 7. If necessary, remove the studs (5) from the flywheel housing (1). Installation Procedure Removal Procedure Accidental engine starting can cause injury or death to personnel working on the equipment.

  • Page 178: Index

    SENR9983 Index Section Index Crankshaft - Remove........... 151 Removal Procedure ......... 151 Accessory Drive - Remove and Install....100 Crankshaft Front Seal - Remove and Install..84 Installation Procedure ........100 Installation Procedure ........85 Removal Procedure ......... 100 Removal Procedure ........... 84 Alternator - Install ..........
  • Page 179 SENR9983 Index Section Electronic Unit Injector - Remove ......25 Flywheel Housing - Remove and Install ....76 Removal Procedure (All Injectors) ..... 27 Installation Procedure (Standard Housing) ..78 Removal Procedure (One Injector) ....25 Installation Procedure (Wet Back End Engine Oil Cooler - Install........
  • Page 180 Rocker Shaft and Pushrod - Install....... 114 Installation Procedure ........114 Rocker Shaft and Pushrod - Remove....111 Removal Procedure .......... 111 Copyright © 2005 Perkins Engines Company Limited A ll R i ght s R es er ve d Printed in U.K.

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