400 C

SENR9973-01
September 2007
Disassembly and
Assembly
400C Industrial Engine
HB (Engine)
HD (Engine)
HH (Engine)
HL (Engine)
HM (Engine)
HN (Engine)
HP (Engine)
HR (Engine)
This document has been printed from SPI. Not for Resale
Important Safety Information
M ost accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. I f these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANG ER, WARNI NG or CAUTI O N. The Safety Alert WARNI NG label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
O perations that may cause product damage are identified by NO TI CE labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. O btain 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.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
SENR9973-01 3
Table of Contents
Table of Contents
Disassembly and Assembly Section
Fuel Priming Pump - Remove ................................. 4
Fuel Priming Pump - Install ..................................... 4
Fuel Filter Base - Remove ..................................... 5
Fuel Filter Base - Install ......................................... 6
Fuel Injection Lines - Remove and Install .............. 7
Fuel Shutoff Solenoid - Remove and Install .......... 9
Fuel Injection Pump - Remove ............................ 10
Fuel Injection Pump - Install ................................. 11
Fuel Injector - Remove ........................................ 12
Fuel Injector - Install ............................................ 12
Turbocharger - Remove and Install ..................... 13
Exhaust Manifold - Remove and Install ............... 15
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 17
Inlet and Exhaust Valves - Remove and Install .... 19
Engine Oil Line - Remove and Install ................... 21
Engine Oil Cooler - Remove and Install ............... 23
Engine Oil Relief Valve - Remove and Install ....... 24
Engine Oil Pump - Remove .................................. 24
Engine Oil Pump - Install ...................................... 26
Water Pump - Remove ......................................... 28
Water Pump - Install ............................................. 30
Water Temperature Regulator Housing - Remove and
Install .................................................................. 31
Water Temperature Regulator - Remove and Install
............................................................................. 32
Flywheel - Remove ............................................... 35
Flywheel - Install ................................................... 36
Crankshaft Rear Seal - Remove ........................... 37
Crankshaft Rear Seal - Install ............................... 37
Flywheel Housing - Remove and Install .............. 39
Crankshaft Pulley - Remove and Install ............... 42
Crankshaft Front Seal - Remove .......................... 43
Crankshaft Front Seal - Install .............................. 43
Housing (Front) - Remove .................................... 44
Housing (Front) - Disassemble ............................. 45
Housing (Front) - Assemble .................................. 47
Housing (Front) - Install ........................................ 50
Crankcase Breather - Remove and Install ........... 51
Valve Mechanism Cover - Remove and Install ..... 54
Rocker Shaft and Pushrod - Remove ................... 55
Rocker Shaft - Disassemble ................................ 56
Rocker Shaft - Assemble ..................................... 57
Rocker Shaft and Pushrod - Install ....................... 59
Cylinder Head - Remove ...................................... 60
Cylinder Head - Install .......................................... 61
Lifter Group - Remove and Install ......................... 63
Camshaft - Remove .............................................. 64
Camshaft - Disassemble ....................................... 65
Camshaft - Assemble ........................................... 66
Camshaft - Install .................................................. 66
Engine Oil Pan - Remove and Install ................... 67
Pistons and Connecting Rods - Remove .............. 68
Pistons and Connecting Rods - Disassemble ....... 69
Pistons and Connecting Rods - Assemble ........... 71
Pistons and Connecting Rods - Install .................. 73
Connecting Rod Bearings - Remove .................... 74
Connecting Rod Bearings - Install ........................ 75
Crankshaft Main Bearings - Remove .................... 76
Crankshaft Main Bearings - Install ........................ 77
Crankshaft - Remove ............................................ 78
Crankshaft - Install ................................................ 80
Bearing Clearance - Check ................................... 81
Coolant Temperature Switch - Remove and
Install ................................................................... 82
Engine Oil Pressure Switch - Remove and Install
............................................................................. 84
Glow Plugs - Remove and Install ......................... 86
V-Belts - Remove and Install ................................ 86
Fan - Remove and Install ..................................... 87
Alternator - Remove and Install ........................... 91
Electric Starting Motor - Remove and Install ..... 101
Index Section
Index ................................................................... 103
4 SENR9973-01
Disassembly and Assembly
Section
i02186288
Fuel Priming Pump - Remove

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 uids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the uid with suitable containers before
opening any compartment or disassembling any com-
ponent containing uids.
Dispose of all uids according to local regulations and
mandates.
g00824616
Illustration 1
Typical example
1. Loosen the hose clamps and remove the two fuel
lines from the fuel priming pump (1). Note the
positions of the fuel inlet and the fuel outlet for
installation.
2. Install suitable plugs into the fuel lines in order to
prevent contamination.
3. Remove the two setscrews (4) that fasten the fuel
priming pump (1) to the cylinder block.
Note: The fuel priming pump can be oriented in two
positions. Before removing the fuel priming pump (1)
from the cylinder block, note the orientation of the
ange (2) of the fuel priming pump (1) for assembly.
4. Remove the fuel priming pump (1) and the O-ring
(3). Discard the O-ring.
Note: In order to remove the fuel priming pump
from the engine, it may be necessary to rotate the
crankshaft until the operating plunger of the fuel
priming pump is not under pressure.
i02186279
Fuel Priming Pump - Install

Installation Procedure
NOTICE
component life.
NOTICE
mandates.
SENR9973-01 5
g01129954
Illustration 2
Typical example
1. Clean the mating surfaces of the fuel priming
pump on the cylinder block and clean the ange
(2) of the fuel priming pump.
Note: Ensure that the camshaft lobe for the fuel
priming pump is at minimum lobe lift before the fuel
priming pump is installed. The fuel priming pump
can be oriented in two positions. Ensure that the fuel
priming pump is oriented in the correct position.
2. Install a new O-ring (3) to the fuel priming pump(1).
3. Lubricate the operating plunger of the fuel priming
pump (1) with clean engine oil.
4. Install the fuel priming pump (1) to the engine.
Ensure that the operating plunger is positioned
correctly on the camshaft lobe.
5. Install the two setscrews (4) that fasten the fuel
priming pump (1) to the cylinder block. Tighten the
setscrews to a torque of 6 Nm (4.5 lb ft).
6. Loosely install the hose clamps to the fuel lines.
Connect the appropriate fuel lines to the fuel inlet
and the fuel outlet of the fuel priming pump (1).
Tighten the hose clamps.
Note: The fuel inlet for the fuel priming can be
rotated 360 degrees by loosening setscrew (5). The
fuel inlet is adjustable in 15 degree increments. If
adjustment is made to the position of the fuel inlet,
tighten setscrew (5) to a torque of 2.5 Nm (22 lb in).
7. Prime the fuel system. Refer to Testing and
Adjusting, Fuel System - Prime for additional
information.
i02186242
Fuel Filter Base - Remove

Removal Procedure
NOTICE
component life.
NOTICE
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
mandates.
g01118406
Illustration 3
Typical example
1. Disconnect the fuel lines (1) and (2). Inspect the
condition of the rubber olives (not shown) that seal
the fuel lines. If the olives are damaged or worn,
use new parts for replacement.
6 SENR9973-01
Note: Put identication marks on all the fuel lines for
installation purposes. Plug all the fuel lines and all
the ports in the fuel lter base. This helps prevent
uid loss, and this helps to keep contaminants from
entering the system.
2. Remove the fuel lter element (4). Refer to
Operations and Maintenance Manual, Fuel
System Filter - Replace.
3. If necessary, remove the plugs (5), the washers
(6) and the inner seals (7).
4. Remove the setscrews (8) and the nuts (not
shown).
5. Remove the fuel lter base (3) from the engine.
i02186227
Fuel Filter Base - Install

NOTICE
component life.
g01118406
Illustration 4
Typical example
1. Align the fuel lter base (3) with the mounting
bracket. Install the bolts (8) and nuts (not shown).
Tighten the nuts to a torque of 22 Nm (16.2 lb ft).
Note: Some fuel lters are installed by the OEM and
torques for the mounting fasteners may vary. Check
with the OEM Installation Manual for the correct
torque setting.
2. If necessary, install the fuel lter element (4)
to the fuel lter base (3). Refer to Operations
and Maintenance Manual, Fuel System Filter -
Replace.
3. If necessary, install new olives onto the fuel lines.
Connect the fuel lines (1) and (2) to the fuel lter
base (3). Tighten the nuts on the fuel lines (1) and
(2) to a torque of 9 Nm (6.6 lb ft).
4. If necessary, install new inner seals (7) to the fuel
lter base (3).
Install new washers (6) onto the plugs (5) and
install the plugs (5) to the fuel lter base (3).
Tighten the plugs (5) to a torque of 22.5 Nm
(16.6 lb ft).
SENR9973-01 7
End By:
a. Remove the air from the fuel system. Refer
to Operations and Maintenance Manual, Fuel
System - Prime.
i02801636
Fuel Injection Lines - Remove
and Install

Removal Procedure
NOTICE
component life.
NOTICE
mandates.
NOTICE
Do not let the tops of fuel injectors turn when the fuel
line nuts are loosened or tightened.
The nozzles will be damaged if the top of the injector
turns in the body.
The engine will be damaged if a defective fuel injector
is used because the shape of fuel (spray pattern) that
comes out of the nozzle will not be correct.
Note: The removal procedure is similar for the two
cylinder, the three cylinder and the four cylinder
engines. The illustrations show the 404C-22 and
404C-22T engines.
g00818680
Illustration 5
404C-22 and 404C-22T engines
1. Disconnect the union nuts (1) for the fuel injection
lines (2) from the fuel injectors.
2. Disconnect the union nuts (1) for the fuel injection
lines (2) from the fuel injection pump.
3. Remove the fuel injection lines (2) from the engine
as a unit.
Note: Place identication marks on all tube
assemblies for installation. Plug all tube assemblies
in order to prevent contamination.
4. Install suitable plastic plugs to the outlet
connections of the fuel injection pump.
5. The 403C-15, 403C-17, 404C-22 and 404C-22T
engines have a rigid fuel return line.
For engines with a rigid fuel return line, remove
the banjo bolt (4) from the fuel return line (3).
Remove the washers (8) from the fuel return line
(3). Discard the washers.
The 402C-05, 403C-07, 403C-11 and 404C-15
engines have a exible fuel return hose.
For engines with a exible fuel return hose,
disconnect the union nut from the banjo piece.
8 SENR9973-01
g00824793
Illustration 6
6. Remove the nut (5) from the fuel injectors (7).
7. Remove the fuel return line (3) from the engine
and remove washers (6) from the fuel injectors
(7). Discard the washers.
8. Install suitable plastic plugs to the fuel injectors.
NOTICE
component life.
NOTICE
Do not let the tops of fuel injectors turn when the fuel
line nuts are loosened or tightened.
The nozzles will be damaged if the top of the injector
turns in the body.
The engine will be damaged if a defective fuel injector
is used because the shape of fuel (spray pattern) that
comes out of the nozzle will not be correct.
Note: The installation procedure is similar for the
two cylinder, the three cylinder and the four cylinder
engines. The illustrations show the 404C-22 and
404C-22T engines.
g00824793
Illustration 7
1. Remove the plastic plugs from the fuel injectors
(7). Install new washers (6) to the fuel injectors
(7) and install the fuel return line (3) to the fuel
injectors.
Note: The washers (6) have two small holes.
2. Install the nuts (5) to the fuel injectors (7).
3. The 403C-15, 403C-17, 404C-22 and 404C-22T
engines have a rigid fuel return line.
For engines with a rigid fuel return line, install new
washers (8) to the fuel return line (3) and install the
banjo bolt (4) to the fuel injection pump. Tighten
the banjo bolt (4) to a torque of 7 Nm (5.2 lb ft).
The 402C-05, 403C-07, 403C-11 and 404C-15
engines have a exible fuel return hose.
For engines with a exible fuel return hose,
connect the fuel return hose to the banjo piece
and tighten the union nut.
4. Tighten the nuts (5) to a torque of 27 Nm (20 lb ft).
SENR9973-01 9
g00818680
Illustration 8
5. Remove the plastic plugs from the fuel injection
lines (2) and remove the plastic plugs from the
outlet connections of the fuel injection pump.
Install the fuel injection lines to the engine as a
unit.
6. Connect the fuel injection lines (2) to the fuel
injection pump.
7. Connect the fuel injection lines (2) to the fuel
injectors (7).
8. For the 402C-05 and 403C-07 engines, tighten
the union nuts (1) to a torque of 20 Nm (15 lb ft).
For the 403C-11, 403C-15,403C-17, 404C-15,
404C-22 and 404C-22T engines, tighten the union
nuts (1) to a torque of 23 Nm (17 lb ft).
9. Prime the fuel system. Refer to Testing and
Adjusting, Fuel System - Prime for more
information.
Note: If new fuel injection lines have been installed,
do not make any adjustments to the engine controls.
Check the maximum engine speed at no load. Refer
to Testing and Adjusting, Engine Speed - Check
for more information.
i02207974
Fuel Shutoff Solenoid -
Remove and Install

Removal Procedure
NOTICE
component life.
NOTICE
mandates.
g00824952
Illustration 9
1. Disconnect electrical connections (3) to the fuel
shutoff solenoid (1). Mark all connections for later
installation.
2. Remove fuel shutoff solenoid (1) from the fuel
injection pump housing by rotating the fuel shutoff
solenoid in a counterclockwise direction.
3. Remove the O-ring (2) from fuel shutoff solenoid
(1).
NOTICE
component life.
10 SENR9973-01
g00824952
Illustration 10
1. Check the condition of O-ring (2). If the O-ring is
worn or damaged use a new part for replacement.
2. Install fuel shutoff solenoid (1) into the fuel
injection pump housing by rotating the fuel shutoff
solenoid in a clockwise direction. Tighten the fuel
shutoff solenoid to a torque of 17.5 Nm (12.9 lb ft).
3. Reconnect electrical connection (3) to fuel shutoff
solenoid (1) before you operate the engine.
i02797470
Fuel Injection Pump - Remove

Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, Fuel Injection Lines
- Remove and Install.
b. Remove the fuel shutoff solenoid. Refer to
Disassembly and Assembly, Fuel Shutoff
Solenoid - Remove and Install.
NOTICE
component life.
NOTICE
mandates.
engines. The illustrations show the four cylinder
engine.
g00825132
Illustration 11
Typical example
g00825137
Illustration 12
Typical example
1. Remove the setscrews (4) and the nuts (2) that
fasten the fuel injection pump to the cylinder block.
Note: If the fuel rack control (5) has not been moved
away from the recess of the stop solenoid, damage
may occur.
SENR9973-01 11
2. Carefully raise the fuel injection pump (1) from
the cylinder block and remove the clip (7) that
connects the link (6) to the fuel rack control (5).
3. Remove the fuel injection pump (1) from the
cylinder block.
4. Remove the shims (3) from the mounting face of
the cylinder block.
Note: Record the thickness of each shim and the
number of shims for reassembly. The fuel injection
timing is determined by the thickness of the shim
pack that is between the fuel injection pump and
the mounting face on the cylinder block. For more
information on the fuel injection pump, refer to
Specications, Fuel Injection Pump.
i02801637
Fuel Injection Pump - Install

NOTICE
component life.
NOTICE
mandates.
engine.
1. Clean the mounting face of the fuel injection pump
on the cylinder block. Clean the mating surface of
the fuel injection pump.
g00825132
Illustration 13
Typical example
2. Install the correct thickness and the correct
number of shims (3) on the mounting face of
the cylinder block. Refer to Specications, Fuel
Injection Pump.
g00825137
Illustration 14
Typical example
3. Position the fuel injection pump (1) close to the
mounting face of the cylinder block, and connect
the link (6) and the fuel rack control (5) with the
clip (7).
4. Put the fuel injection pump (1) in position on the
mounting face of the cylinder block.
5. Install the setscrews (4) and the nuts (2) that
fasten the fuel injection pump to the cylinder block.
For 402C-05, 403C-07, 403C-11 and 404C-15
engines, tighten the setscrews (4) and the nuts (2)
to a torque of 6 Nm (53 lb in).
For 403C-15, 403C-17, 404C-22 engines and
404C-22T engines, tighten the setscrews (4) and
the nuts (2) to a torque of 15 Nm (11 lb ft).
12 SENR9973-01
End By:
a. Install the fuel shutoff solenoid. Refer to
Disassembly and Assembly, Fuel Shutoff
Solenoid - Remove and Install.
b. Install the fuel injection lines. Refer to Disassembly
and Assembly, Fuel Injection Lines - Remove
and Install.
i02801638
Fuel Injector - Remove

Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to
NOTICE
component life.
NOTICE
mandates.
g01124706
Illustration 15
Typical example
1. Use a deep socket to remove the fuel injector (1)
from the cylinder head.
2. Remove the seat washers (2) from the cylinder
head. Discard the old seat washers.
Note: 402C-05 and 403C-07 engines have two seat
washers. The seat washers are different diameters.
403C-11, 403C-15, 403C-17, 404C-15, 404C-22 and
404C-22T engines have one seat washer.
3. Cap all openings or plug all openings immediately
after disassembly.
i02801639
Fuel Injector - Install

NOTICE
component life.
SENR9973-01 13
g01113718
Illustration 16
Typical example
1. Clean the injector bore in the cylinder head.
Ensure that no debris enters the cylinder head.
Clean the threads on the body of the injector.
2. Install new seat washers (3) into the injector bore
in the cylinder head.
Note: 402C-05 and 403C-07 engines have two seat
washers. The seat washers are different diameters.
403C-11, 403C-15, 403C-17, 404C-15, 404C-22 and
404C-22T engines have one seat washer.
3. Apply a bead of 1861117 POWERPART Universal
Jointing Compound (2) to the rst two threads of
the injector that engage into the cylinder head.
The bead of Universal Jointing Compound should
have a diameter of 2 mm (0.08 inch) and a length
of 6 mm (0.25 inch).
Note: Ensure that the universal jointing compound
does not cover the surface of the fuel injector body
below the threads.
4. Install the fuel injector (1) into the cylinder head.
Use a deep socket to tighten the fuel injector to a
torque of 64 Nm (47 lb ft).
Note: If a new fuel injector has been installed, do not
make any adjustments to the engine controls. Refer
to Testing and Adjusting, Engine Speed - Check
for more information.
End By:
a. Install the fuel injection lines. Refer to Disassembly
and Assembly, Fuel Injection Lines - Remove
and Install.
i02186260
Turbocharger - Remove and
Install

Removal procedure
NOTICE
component life.
NOTICE
mandates.
g01114005
Illustration 17
1. Clean the outer surfaces of the turbocharger (1).
2. Loosen the hose clamps (4). Remove the air inlet
hose (5).
14 SENR9973-01
g01114003
Illustration 18
3. Remove the exhaust pipe (not shown) from the
exhaust elbow (21). Refer to the OEM provided
information for the correct procedure in order to
remove the exhaust pipe.
4. Remove the setscrews (15) and remove the
support bracket for the turbocharger (16). Note
the position of the support bracket for installation.
5. Remove the setscrews (22). Remove the exhaust
elbow (21) from the turbocharger (1). Remove
the gasket for the exhaust elbow (20) from the
turbocharger. Discard the gasket.
6. Place a suitable container below the turbocharger
(1) in order to collect any spillage of oil.
7. Remove the banjo bolt (3). Remove the oil supply
tube assembly (8). Remove the washers (2)
from the turbocharger. Discard the washers. If
necessary, remove the setscrews (not shown)
for the tube clips (6). Remove the setscrews (7).
Remove the oil supply tube assembly (8) from the
cylinder block. Remove the O-ring (9). Discard
the O-ring.
8. Remove the setscrews (13). Remove the oil
drain tube assembly (11) from the turbocharger.
Remove the joint (14) and discard the joint. If
necessary, remove the setscrews (12) and remove
the oil drain tube assembly (11) from the cylinder
block. Remove the joint (10). Discard the joint.
9. Remove the nuts (19) and the washers (18).
Remove the turbocharger (1) from the exhaust
manifold. Remove the turbocharger gasket (23)
from the exhaust manifold. Discard the gasket.
If necessary, remove the studs (17) from the
exhaust manifold.
Note: Do not use the actuator rod of the wastegate
to lift the turbocharger.
10. Inspect the turbocharger for damage. If the
turbocharger is damaged use a new part for
replacement. Refer to Testing and Adjusting,
Wastegate - Test.
11. Install suitable plastic plugs into the oil supply
and into the oil drain ports of the turbocharger (1).
Install suitable plastic covers to the inlet and to the
outlet of the turbocharger. Install suitable plastic
plugs to the oil supply tube assembly (8) and to
the oil drain tube assembly (11).
Installation procedure
NOTICE
component life.
1. Remove all of the plastic plugs from all of the ports
of the turbocharger (1). Clean the mating surfaces
of the exhaust manifold and the turbocharger.
g01114003
Illustration 19
2. Ensure that all of the turbocharger inlet and outlet
ports are clean and free from restrictions. The
turbocharger shaft must rotate freely.
SENR9973-01 15
3. If the studs (17) were previously removed, install
the studs into the exhaust manifold. Install a new
gasket (23) over the studs (17).
Note: Do not use any sealant on the gasket (23).
Note: Do not use the actuator rod of the wastegate
to lift the turbocharger (1).
4. Position the turbocharger (1) onto the exhaust
manifold.
5. Install the washers (18) and install the nuts (19).
Tighten the nuts to a torque of 25 Nm (18 lb ft).
6. Lubricate the bearing housing of the turbocharger
(1) with clean engine oil. Apply the lubricant
through the oil supply port (24).
g01114005
Illustration 20
7. Clean the oil supply tube assembly (8) and the oil
drain tube assembly (11). Inspect the oil supply
tube assembly and the oil drain tube assembly. If
necessary, replace the tube assemblies.
8. Position a new joint (14) and the oil drain tube
assembly (11) onto the bottom of the turbocharger.
Install the setscrews (13). Tighten the setscrews
to a torque of 10 Nm (7 lb ft).
9. If necessary, position a new joint (10) and the oil
drain tube assembly (11) onto the cylinder block.
Install the setscrews (12). Tighten the setscrews
10. Position the new washers (2) and the oil supply
tube assembly (8) onto the turbocharger (1).
Install the banjo bolt (3). Tighten the banjo bolt to
a torque of 18 Nm (13 lb ft).
11. If necessary, install a new O-ring (9) and the oil
supply tube assembly (8) to the cylinder block.
Install the setscrews (7). Tighten the setscrews to
a torque of 10 Nm (7 lb ft).
12. If necessary, install the spacer (not shown) and
install the setscrews (not shown) to the tube clips
(6). Torque the setscrews to 10 Nm (7 lb ft).
Note: Ensure that the oil supply tube assembly (8)
does not come into contact with any other component
when the assembly is installed onto the engine.
13. Clean the mating surfaces of the exhaust elbow
(21). Position a new gasket (20) and the exhaust
elbow (21) on the turbocharger (1). Install the
setscrews (22). Tighten the setscrews to a torque
of 32 Nm (24 lb ft).
14. Install the set screws (15) and install the support
bracket for the turbocharger (16). Tighten the
setscrews to a torque of 25 Nm (18 lb ft).
15. Ensure that the inlet hose (5) is clean and free
from defects or restrictions. Loosely install the
hose clamps (4) to the air inlet hose (5). Install
the air inlet hose to the connection of the inlet
manifold and to the inlet of the turbocharger.
Tighten the hose clamps.
Note: Do not use oil or grease in order to install the
air inlet hose. In order to install a new air inlet hose,
lubricate the connection of the inlet manifold and
lubricate the inlet of the turbocharger with a solution
of water and 5% soap.
16. Position the exhaust pipe onto the exhaust elbow
(21). Refer to the OEM information for the correct
procedure in order to install the exhaust pipe.
i02801640
Exhaust Manifold - Remove
and Install

Removal Procedure
NOTICE
component life.
16 SENR9973-01
Note: The two cylinder, the three cylinder and the four
cylinder engines have different exhaust manifolds.
The removal procedure is similar for all models.
g00825291
Illustration 21
Typical example
1. Loosen the nuts (5) and the setscrews (6).
Note: In order to prevent distortion of the exhaust
manifold, loosen the outer fasteners rst.
2. Remove the nuts (5) and the setscrews (6).
Note: Identify setscrews of different lengths so
that the setscrews can be reinstalled in the correct
positions.
3. Remove the exhaust manifold (4) from the cylinder
head (1).
4. Remove the gasket (3) from the cylinder head.
5. Remove any remaining gasket material and
carbon from the cylinder head and the exhaust
manifold. Be careful not to damage the mating
surface on the cylinder head or the mating surface
on the exhaust manifold.
6. If necessary, remove the exhaust manifold studs
(2) from the cylinder head (1).
NOTICE
component life.
cylinder engines have different exhaust manifolds.
The installation procedure is similar for all models.
g00825291
Illustration 22
Typical example
1. If necessary, install the exhaust manifold studs
(2) to cylinder head (1).
2. Install a new exhaust manifold gasket (3) to the
cylinder head (1).
Note: Do not use any sealant on the exhaust
manifold gasket.
3. Put the exhaust manifold (4) in position on the
cylinder head (1).
4. Install the nuts (5) and the setscrews (6).
Note: Ensure that setscrews with different lengths
are installed in the correct holes.
5. For 402C-05, 403C-07, 403C-11 and 404C-15
engines, tighten the nuts (5) and the setscrews (6)
to a torque of 10 Nm (89 lb in).
For 403C-15, 403C-17, 404C-22 and 404C-22T
engines, tighten the nuts (5) and the setscrews (6)
Note: On three cylinder engines, tighten the two inner
setscrews rst. On four cylinder engines, tighten the
four inner setscrews rst. Then tighten the two outer
setscrews and the two nuts.
SENR9973-01 17
i02187986
Inlet and Exhaust Valve
Springs - Remove and Install

Removal Procedure
Table 1
Required Tools
Part Number Part Description Qty
21825666 Valve Spring Compressor 1
27610235 Adapter 1
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.
NOTICE
component life.
Note: Before you begin the removal of the valve
springs, refer to Specications, Cylinder Head -
Valves and Testing and Adjusting, Cylinder Head
- Inspect for appropriate information on the valve
springs.
Note: The following procedure should be adopted
in order to remove the valve springs when the
cylinder head is still installed onto the cylinder block.
Refer to Disassembly and Assembly, Inlet and
Exhaust Valves - Remove and Install for the correct
procedure that should be used to remove the valve
springs from a cylinder head that has been removed
from the cylinder block.
Note: Ensure that the appropriate piston is at top
dead center before the valve spring is removed.
Failure to ensure that the piston is at top dead center
may allow the valve to drop into the cylinder bore.
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.
NOTICE
Install suitable plugs to the inlet ports of the cylinder
head in order to prevent the entry of loose parts into
the engine.
g01015085
Illustration 23
Typical example
1. Use the following procedure in order to nd the
top dead center position of the appropriate piston.
a. Install 21825666 Valve Spring Compressor
(1) and the appropriate 27610235 Adapter
(2) in position on the cylinder head in order to
compress the appropriate valve spring (5).
b. Compress the valve spring (5) sufciently in
order to open the valve only. Do not compress
the valve spring so that the valve keepers (3)
could be removed from the recess in the valve
stem or so that the valve stem seal (not shown)
could be damaged.
c. Slowly turn the crankshaft until the piston
touches the valve.
d. Continue to turn the crankshaft and release the
pressure on the valve spring compressor (1)
until the piston is at the top center position.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
Note: If you are replacing all of the valve springs,
on four cylinder engines only, the procedure can
be done on two cylinders at the same time. The
procedure can be done on cylinder 1 and cylinder 4,
or on cylinder 2 and cylinder 3. Remember that the
crankshaft must not be turned while the valve springs
are removed. Ensure that all of the valve springs are
installed before changing from one pair of cylinders
to the other pair of cylinders.
18 SENR9973-01
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
2. Use the valve spring compressor (1) and the
adapter (2) in order to compress the valve spring
(5). Remove the valve keepers (3).
3. Remove the valve spring retainer (4) and remove
the valve spring (5).
Table 2
Required Tools
27610235 Adapter 1
NOTICE
component life.
Improper assembly of parts that are spring loaded
can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equip-
ment.
NOTICE
Install suitable plugs to the inlet ports of the cylinder
head in order to prevent the entry of loose parts into
the engine.
g01015085
Illustration 24
Typical example
1. Place the new valve springs (5) into position on
the cylinder head.
2. Install the valve spring retainer (4).
3. Install the valve spring compressor (1) and the
adapter (2) in position on the cylinder head in
order to compress the appropriate valve spring
(5). Compress the valve spring (5).
NOTICE
4. Install two valve keepers (3) in order to lock the
valve springs in position.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
5. Carefully release the pressure on the valve
spring compressor (1). Remove the valve spring
compressor. Ensure that all of the valves are
secured in place by a valve spring and valve
keepers. Rotate the crankshaft through about
45 degrees in order to clear the piston from the
valve. Lightly strike the top of the valve with a soft
hammer in order to ensure that the valve keepers
(3) are properly installed.
Note: If you are replacing all of the valve springs,
on four cylinder engines only, the procedure can
be done on two cylinders at the same time. The
procedure can be done on cylinder 1 and cylinder 4,
or on cylinder 2 and cylinder 3.
SENR9973-01 19
End By:
a. Install the rocker shaft assembly. Refer to
Pushrod - Install.
i02187989
Inlet and Exhaust Valves -
Remove and Install

Removal Procedure
Table 3
Required Tools
27610235 Adapter 1
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
NOTICE
component life.
Note: The removal procedure is identical for the
engine.
1. Clean the bottom face of the cylinder head.
Check the depth of the valves below the face of
the cylinder head before the valve springs are
removed. Refer to Specications, Cylinder Head
Valves for the correct dimensions.
2. Place an identication mark on the heads of the
valves for installation purposes.
Note: The head of the inlet valve has a larger
diameter than the head of the exhaust valve.
3. Position the cylinder head on a suitable surface
with the valve springs facing upward.
Note: Ensure that the machined face of the cylinder
head is kept on a clean, soft surface in order to
prevent damage to the machined surface.
ment.
g01015085
Illustration 25
Typical example
4. Install the 21825666 Valve Spring Compressor
(1) and the 27610235 Adapter (2) in position
on the cylinder head in order to compress the
appropriate valve spring (5).
NOTICE
5. Apply pressure to the valve spring compressor (1).
Remove the valve keepers (3).
6. Slowly release the pressure on the valve spring
compressor (1).
20 SENR9973-01
g01113619
Illustration 26
Typical example
7. Remove the valve spring retainer (4).
8. Remove the valve spring (5).
9. Repeat steps 4 to 8 for the remaining valves.
10. Remove the valve spring compressor (1) and the
adapter (2).
11. Remove the valve stem seals (6).
12. Carefully turn over the cylinder head.
13. Remove the valves (7).
Table 4
Required Tools
27610235 Adapter 1
NOTICE
component life.
Note: The installation procedure is identical for the
engine.
1. Clean all parts. Ensure that all ports, all coolant
passages and all lubrication passages are free
from debris. To inspect the cylinder head, refer
to Testing and Adjusting, Cylinder Head Inspect
for further information.
2. Inspect all of the valve seats for wear and for
damage. Refer to Specications, Cylinder Head
Valves and refer to Testing and Adjusting, Valve
Depth - Inspect for further information.
3. Inspect all of the valve guides for wear and for
damage. Refer to Specications, Cylinder Head
Valves and refer to Testing and Adjusting , Valve
Guide - Inspect for further information.
g01113619
Illustration 27
Typical example
4. Lubricate the stems of all valves (7) with clean
engine oil. Install the valves (7) in the appropriate
positions.
5. Carefully turn over the cylinder head and ensure
that all of the valves remain in place.
6. Use a suitable tool to install the new valve stem
seals (6) onto each of the valve guides.
Note: The outer face of the valve guides must be
clean and dry before installing the valve stem seals
(6). The inlet valve stem and the exhaust valve stem
use seals that are different parts.
7. Inspect the valve springs (5) for wear and for the
correct installed length. Refer to Specications,
Cylinder Head Valves for further information.
8. Install the valve spring (5) onto the cylinder head.
SENR9973-01 21
9. Install the valve spring retainer (4).
ment.
g01015303
Illustration 28
Typical example
NOTICE
10. Install the 21825666 Valve Spring Compressor
(1) and the 27610235 adapter (2) in position
on the cylinder head in order to compress the
appropriate valve spring (5).
NOTICE
11. Apply pressure to the valve spring compressor
(1). Install the valve keepers (3).
The valve keepers can be thrown from the valve
when the valve spring compressor is released. En-
sure that the valve keepers are properly installed
on the valve stem. To help prevent personal injury,
keep away from the front of the valve keepers and
valve springs during the installation of the valves.
12. Carefully release the pressure on the valve spring
compressor (1).
13. Repeat steps 8 to 12 for all of the valves.
14. Remove the valve spring compressor (1) and the
adapter (2) from the cylinder head.
15. Place the cylinder head on a suitable support.
Ensure that the heads of the valves are not
obstructed. Gently strike the top of the valves with
a soft hammer in order to ensure that the valve
keepers (3) are properly installed.
16. Turn over the cylinder head and check the depth
of the valves below the face of the cylinder head.
Refer to Specications, Cylinder Head Valves for
more information.
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02801641
Engine Oil Line - Remove and
Install

Removal Procedure
g01117696
Illustration 29
Typical example
1. Loosen the nut (2) that attaches the oil line (1) to
22 SENR9973-01
2. Remove the banjo bolt (3) and remove the
washers (4) from the cylinder block. Discard the
washers (4).
g01117697
Illustration 30
Typical example
3. Remove the banjo bolt (3) and remove the
washers (4) from the cylinder head. Discard the
washers (4).
4. Remove the oil line (1) from the engine.
g01117696
Illustration 31
Typical example
1. Position the oil line (1) on the engine.
2. Position the banjo bolt (3) and the new washers
(4) on the oil line (1). Install the oil line to the
cylinder block.
g01117697
Illustration 32
Typical example
SENR9973-01 23
3. Position the banjo bolt (3) and the new washers
(4) to the oil line (1). Install the oil line to the
cylinder head.
4. Install the nut (2) that attaches the oil line (1) to
For the 402C-05, 403C-07, 403C-11 and 404C-15
engines, tighten the nut (2) to a torque of 6 Nm
(4.4 lb ft).
For the 403C-15, 403C-17, 404C-22 and
404C-22T engines, tighten the nut (2) to a torque
5. Tighten the banjo bolts (3) to 11.5 Nm (8.5 lb ft).
i02186236
Engine Oil Cooler - Remove
and Install

Removal Procedure
NOTICE
component life.
NOTICE
mandates.
1. Drain the coolant from the cooling system into
a suitable container. Drain the engine oil into a
suitable container. Refer to the Operation and
Maintenance Manual for the procedure on draining
the coolant and the engine oil.
g01113679
Illustration 33
2. By using a suitable strap wrench, remove the
oil lter element (5) from the oil cooler body (3).
Discard the oil lter element in a suitable manner.
3. Remove the hose clamps (2) and the hoses (1)
from the coolant inlet and the coolant outlet on
the oil cooler body (3). Note the positions of the
coolant inlet and the coolant outlet for installation.
4. Remove the adapter (4) from the oil cooler body
(3). Remove the oil cooler body (3) from the
cylinder block (7).
5. Remove the O-ring (6) from the oil cooler body
(3). Discard the O-ring.
NOTICE
component life.
1. Clean the mating surfaces of the oil cooler base
on the cylinder block (7) and clean the oil cooler
body (3).
2. Install a new O-ring (6) to the oil cooler body (3).
Install the oil cooler body (3) to the cylinder block
(7).
3. Install the adapter (4) through the oil cooler body
(3) to the cylinder block (7). Tighten the adapter
(4) to a torque of 34 Nm (25 lb ft).
24 SENR9973-01
4. Install the appropriate hoses (1) to the coolant
inlet and the coolant outlet on the oil cooler body
(3). Tighten the hose clamps (2).
5. Lubricate the O-ring of the oil lter element (5) with
clean engine oil. Install the new oil lter element to
the oil cooler body (4). Tighten the oil lter element
by hand. Do not use a strap wrench to tighten the
oil lter element.
6. Fill the cooling system with coolant. Fill the
lubrication system with engine oil. Refer to the
Operation and Maintenance Manual, Rell
Capacities for the cooling system capacity and
for the lubrication system capacity of the engine.
i02182334
Engine Oil Relief Valve -
Remove and Install

Removal Procedure
NOTICE
component life.
NOTICE
mandates.
g00820218
Illustration 34
1. Remove the engine oil relief valve (2) from the
cylinder block.
2. Remove the O-ring (1) from the engine oil relief
valve. Discard the O-ring.
NOTICE
component life.
g00820218
Illustration 35
1. Install a new O-ring (1) on the engine oil relief
valve (2).
2. Lubricate the engine oil relief valve (2) with clean
engine oil.
3. Install the engine oil relief valve (2) in the cylinder
block. Tighten the engine oil relief valve to a
i02182152
Engine Oil Pump - Remove

Removal Procedure
Start By:
a. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove.
NOTICE
component life.
SENR9973-01 25
NOTICE
If the front housing is not installed, do not turn the
crankshaft. Damage to the engine may occur.
NOTICE
mandates.
Engine Oil Pump
g00825411
Illustration 36
Typical example
ment.
1. Remove the C-clip (9) that retains the idler gear
(3) on the idler hub (1).
2. Remove the following items from the idler hub (1):
Collar (8)
Spring (7)
Shim (6)
Oil pump cover (5)
Inner rotor (4)

3. Remove the idler gear (3) from the idler hub (1).
4. Remove the thrust washer (2) from the idler hub
(1).
5. Inspect all the components for wear or damage.
Any components that are worn or damaged should
be replaced with new parts.
Note: Refer to Specications, Engine Oil Pump for
more information.
6. If the engine oil pump has excessive buildup of
sludge, inspect the oil strainer. The oil strainer can
be removed by using the following procedure:
a. Remove the engine oil pan. Refer to
Disassembly and Assembly, Engine Oil Pan -
Remove and Install.
g00825406
Illustration 37
Typical example
b. Remove the setscrews (12) and the oil strainer
(13) from the cylinder block. Inspect the
oil strainer for damage. If the oil strainer is
damaged, use a new part for replacement.
c. Remove the oil tube (11) from the cylinder
block.
d. Remove the O-ring (10) from the oil tube.
Discard the used O-ring.
26 SENR9973-01
Idler Hub
g00831103
Illustration 38
Typical example
1. Remove the crankshaft. Refer to Disassembly and
Assembly, Crankshaft - Remove.
2. Use a hammer and use a suitable drift to remove
idler hub (1) from the cylinder block (2). Align the
drift to the rear face of the hub and drive the hub
from the inside of the cylinder block outward.
i02801642
Engine Oil Pump - Install

Table 5
Required Tools
Tool
Part
Number Part Description Qty
A
(1)
21825624 Alignment Tool 1
A
(2)
A
(3)
B - Multipurpose Grease 1
(1)
402C-05 and 403C-07 engines
(2)
403C-11 and 404C-15 engines
(3)
403C-15, 403C-17, 404C-22 and 404C-22T engines
NOTICE
component life.
NOTICE
If the front housing is not installed, do not turn the
crankshaft. Damage to the engine may occur.
Idler Hub
g01297224
Illustration 39
1. Install the pin of Tooling (A) to the cylinder block.
2. Position the guide plate of Tooling (A) onto idler
hub (1). Align the guide plate of Tooling (A) with
pin of Tooling (A).
3. Use a hammer in order to strike the guide plate of
Tooling (A). This will install idler hub (1).
4. Remove Tooling (A).
SENR9973-01 27
Engine Oil Pump
g00825411
Illustration 40
g01297225
Illustration 41
Improper assembly of parts that are spring loaded
can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equip-
ment.
1. Apply Tooling (B) to the faces of inner rotor (4)
and to the vanes of idler gear (3).
2. Align timing marks (X) on idler gear (3) with the
respective timing marks on gears (14) and (15).
Install idler gear (3) onto idler hub (1).
3. Install inner rotor (4) to idler gear (3).
Personal injury can result from the release of the
spring force.
The drive shaft, the piston, and the drive gear are
under spring force.
Use a press to slowly release the spring force be-
fore the components are removed.
4. Install the following items to idler hub (1):
Oil pump cover (5)
Shim (6)
Spring (7)
Collar (8)
Refer to Illustration 40.
5. Install retaining ring (9) on idler hub (1).
g01298012
Illustration 42
Checking end play by using a feeler gauge
6. Use a feeler gauge in order to measure the end
play of engine oil pump. Refer to Specications,
Engine Oil Pump.
7. If the oil strainer was removed, use the following
procedure for installation:
28 SENR9973-01
g01037619
Illustration 43
a. Install a new O-ring seal (10) on oil tube
assembly (11).
b. Install oil tube assembly (11) in the cylinder
block.
c. Install oil strainer (13) to the cylinder block and
tighten bolts (12) to a torque of 11 Nm (8 lb ft).
End By:
a. Install the front housing. Refer to Disassembly and
Assembly, Housing (Front) - Install.
b. Install the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.
i02801654
Water Pump - Remove

Removal Procedure (403C-11,
403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T Engines)
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, Fan - Remove and Install.
b. Remove the alternator. Refer to Disassembly and
Assembly, Alternator - Remove and Install.
NOTICE
component life.
NOTICE
mandates.
1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, Rell
Capacities for the approximate capacity of the
cooling system.
2. Loosen the clamps and remove the hose from the
water pump inlet (not shown).
g01124100
Illustration 44
Typical example
3. Remove the fasteners (2) and the alternator
bracket (1) from the water pump (3).
SENR9973-01 29
g01124257
Illustration 45
Typical example
4. Loosen the clamps (2) and remove the bypass
hose (3) from the water pump (6).
5. Remove the setscrews, the washers (4) and the
nut (5).
6. If necessary, gently tap the water pump (6) with a
soft faced hammer in order to loosen the water
pump (6).
7. Remove the water pump (6). Remove the joint (1)
from the cylinder block. Discard the joint (1).
Removal Procedure (402C-05 and
403C-07 Engines)
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, Fan - Remove and Install.
b. Remove the alternator. Refer to Disassembly and
Assembly, Alternator - Remove and Install.
NOTICE
component life.
NOTICE
mandates.
cooling system.
2. Loosen the clamps and remove the hose from the
water pump inlet (not shown).
g01124100
Illustration 46
typical example
3. Remove the fasteners (2) and the alternator
bracket (1) from the water pump (3).
30 SENR9973-01
g01124046
Illustration 47
Typical example
4. Loosen the clamps (3) and remove the bypass
hose (4) from the water pump (7).
5. Remove the setscrews, the washers (5) and the
nut (6).
6. If necessary, gently tap the water pump (7) with a
soft faced hammer in order to loosen the water
pump (7).
7. Remove the water pump (7). Remove the joint (8),
the spacer (1), and the joint (2) from the cylinder
head. Discard the joint (8) and the joint (2).
i02801657
Water Pump - Install

Installation Procedure (403C-11,
403C-15, 403C-17, 404C-15, 404C-22
and 404C-22T Engines)
NOTICE
component life.
1. Remove all debris and gasket material from
the mating surfaces of the water pump and the
cylinder block.
g01124257
Illustration 48
Typical example
2. Install a new gasket (1) in position on the engine.
3. Place the water pump (6) in position on the engine
and install the setscrews, the washers (4) and the
nut (5). Tighten setscrews, the washers (4) and
the nut (5) to a torque of 10 Nm (7.4 lb ft).
g01124637
Illustration 49
Typical example
4. Place the alternator bracket (1) into position on
water pump (6). Install the fasteners (2) on the
water pump (6) and hand tighten the fasteners (2).
5. Install the lower hose and install the hose clamp
(not shown). Hand tighten the hose clamp. Install
the hose (3) on the water pump (6) and tighten the
hose clamps (2) to a torque of 2.5 Nm (22.1 lb in).
SENR9973-01 31
End By:
a. Fill the cooling system with coolant to the correct
level. Refer to Operation and Maintenance
Manual, Rell Capacities.
b. Install the pulley, the adapter and the fan. Refer to
Disassembly and Assembly, Fan - Remove and
Install.
c. Install the V-Belts. Refer to Disassembly and
Assembly, V-Belts - Remove and Install.
Installation Procedure (402C-05
and 403C-07 Engines)
NOTICE
component life.
1. Remove all debris and gasket material from
the mating surfaces of the water pump and the
cylinder block.
g01124046
Illustration 50
Typical example
2. Install new gaskets (8) and (2) and the spacer (1)
in position on the engine.
3. Place the water pump (7) in position on the engine
and install the setscrews, the washers (5) and the
nut (6). Tighten setscrews, the washers (5) and
the nut (6) to a torque of 10 Nm (7.4 lb ft).
g01124662
Illustration 51
Typical example
4. Place the alternator bracket (1) into position on
water pump (7). Install the fasteners (2) on the
water pump (7) and hand tighten the fasteners (2).
5. Install the lower hose and install the hose clamp
(not shown). Hand tighten the hose clamp. Install
the hose (4) on the water pump (7) and tighten the
hose clamps (3) to a torque of 2.5 Nm (22.1 lb in).
End By:
a. Fill the cooling system with coolant to the correct
Manual, Rell Capacities.
b. Install the pulley, the adapter and the fan. Refer to
Disassembly and Assembly, Fan - Remove and
Install.
c. Install the V-Belts. Refer to Disassembly and
i02182980
Water Temperature Regulator
Housing - Remove and Install

Removal Procedure
NOTICE
component life.
32 SENR9973-01
NOTICE
mandates.
to the OEM for the approximate capacity of
the cooling system. Refer to the Operation and
Maintenance Manual, Cooling System Coolant
(DEAC) - Change or Operation and Maintenance
Manual, Cooling System Extended Life Coolant
- Change.
g01124076
Illustration 52
Typical example
2. Remove the setscrews (4) and the nuts (3).
3. Remove the water temperature regulator housing
(2) from the cylinder head.
4. Remove the gasket (1) from the cylinder head.
Discard the gasket.
NOTICE
component life.
1. Clean the mating surfaces of the cylinder
head. Clean the mating surfaces of the water
temperature regulator housing.
g01124076
Illustration 53
Typical example
2. Install a new gasket (1) on the cylinder head.
3. Install the water temperature regulator housing
(2) to the cylinder head.
4. Install the setscrews (4) and the nuts (3) that
fasten the water temperature regulator housing
to the cylinder head. Tighten the fasteners to a
torque of 10 Nm (7.4 lb ft).
5. Fill the cooling system with coolant to the correct
level. Refer to the Operation and Maintenance
Manual, Rell Capacities for more information.
i02801658
Water Temperature Regulator -
Remove and Install

403C-07 engines)
NOTICE
component life.
SENR9973-01 33
NOTICE
mandates.
cooling system.
g01112497
Illustration 54
Typical example
Personal injury can result from parts and/or cov-
ers under spring pressure.
Spring force will be released when covers are re-
moved.
Be prepared to hold spring loaded covers as the
bolts are loosened.
2. Remove the setscrews (6) and the nuts (5).
3. Remove the outlet connection (4) for the water
temperature regulator.
4. Remove the joint (3).
5. Remove the water temperature regulator (2) and
the spring (1) from the cylinder head.
6. Inspect the water temperature regulator (2)
for wear or damage. If the water temperature
regulator is worn or damaged, use a new part
for replacement. Refer to Testing and Adjusting,
Water Temperature Regulator - Test for more
information on testing the water temperature
regulator.
403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T engines)
NOTICE
component life.
NOTICE
mandates.
cooling system.
g01125880
Illustration 55
Typical example
2. Remove the setscrews (1).
34 SENR9973-01
3. Remove the outlet connection (2) for the water
temperature regulator.
Note: Identify the orientation of the outlet connection
for installation.
4. Remove the joint (3).
5. Remove the water temperature regulator (4) from
the water temperature regulator housing (5).
6. Inspect the water temperature regulator (4)
for wear or damage. If the water temperature
regulator is worn or damaged, use a new part
for replacement. Refer to Testing and Adjusting,
Water Temperature Regulator - Test for more
information on testing the water temperature
regulator.
and 403C-07 engines)
NOTICE
component life.
1. Remove all debris and gasket material from the
mating surfaces of both the outlet connection
(4) for the water temperature regulator and the
cylinder head.
ment.
g01112497
Illustration 56
2. Install the spring (1) and the water temperature
regulator (2) to the cylinder head.
Note: Install the water temperature regulator with the
jiggle pin in the vertically upward position.
3. Install a new joint (3) to the cylinder head.
4. Install the outlet connection (4) to the cylinder
head.
5. Install the nut (5) and the setscrews (6) to the
outlet connection (4).
6. Tighten the fasteners to a torque of 6 Nm
(53 lb in).
403C-15, 403C-17, 404C-15, 404C-22
and 404C-22T engines)
NOTICE
component life.
1. Remove all debris and all gasket material from the
mating surfaces of both the outlet connection (2)
and the water temperature regulator housing (5).
SENR9973-01 35
g01125880
Illustration 57
2. Install the water temperature regulator (4) to the
water temperature regulator housing (5). Refer
to specications, Water Regulator Housing
for 403C-11, 403C-15, 403C-17, 404C-15,
404C-22and 404C-22T Engines for the correct
orientation of the water temperature regulator.
3. Install a new joint (3) to the cylinder head.
4. Install the outlet connection (2) to the water
temperature regulator housing (5).
Note: Ensure the correct orientation of the outlet
connection.
5. Install the setscrews (1) to the outlet connection
(2).
6. Tighten the setscrews to a torque of 14 Nm
(10 lb ft).
i02183594
Flywheel - Remove

Removal Procedure
Start By:
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
NOTICE
component life.
Note: The two cylinder, the three cylinder and the
four cylinder engines have different ywheels. The
removal procedure is similar for all models.
g01123637
Illustration 58
Typical example
1. Install a suitable lifting device (1) to the ywheel
(2).
2. Remove two setscrews (3) opposite each other
from the ywheel.
3. Install two suitable guide studs in the place of the
setscrews that were removed.
4. Remove the remaining setscrews (3) that fasten
the ywheel to the crankshaft.
5. Remove the ywheel (2) from the rear of the
crankshaft.
Note: On some three cylinder engines, a roll pin is
located between the crankshaft and the ywheel.
6. Inspect the ywheel ring gear (5) and the ywheel
(2) for wear or damage. If the ywheel ring gear or
the ywheel is worn or damaged, use new parts
for replacement.
36 SENR9973-01
g01123614
Illustration 59
Typical example
7. To remove the ywheel ring gear (5) from the
ywheel (2), place the ywheel on a suitable
support. Use a suitable hammer (not shown) and
a punch (4) in order to remove the ring gear from
the ywheel.
i02183590
Flywheel - Install

NOTICE
component life.
Always wear protective gloves when handling
parts that have been heated.
g01124041
Illustration 60
Typical example
1. Thoroughly clean the ywheel housing. Inspect
the crankshaft rear seal for leaks. If there are
any oil leaks refer to Disassembly and Assembly,
Crankshaft Rear Seal - Remove.
2. If necessary, perform the following procedure to
install the ring gear (2) to the ywheel (1).
a. Identify the orientation of the new ring gear in
order to install the ring gear correctly onto the
ywheel.
Note: The chamfered side of the gear teeth (3) must
face toward the starting motor when the ywheel is
installed. This will ensure the correct engagement of
the starting motor.
b. Heat the ywheel ring gear (2) in an oven to a
maximum temperature of 150C (302F) prior
to installation.
Note: Do not use a torch to heat the ring gear.
c. Ensure that the orientation of the ring gear (2)
is correct and quickly install the ring gear onto
the ywheel (1).
g01124042
Illustration 61
Typical example
SENR9973-01 37
(1).
4. Install two suitable guide studs opposite each
other in the end of the crankshaft.
5. Position the ywheel (1) onto the two guide studs.
On three cylinder engines that have a roll pin,
ensure that the roll pin is installed to the crankshaft
and that the roll pin is free from damage. Align
the hole in the ywheel with the roll pin in the
crankshaft.
6. Install the setscrews (5) that fasten the ywheel
to the crankshaft.
7. Remove the two guide studs and install the two
remaining setscrews (5) in the ywheel.
8. Use a suitable tool to prevent the ywheel (1) from
rotating. Tighten the setscrews (5) to a torque of
73.5 Nm (54.2 lb ft).
9. Remove the lifting device (4) from the ywheel.
Note: Refer to Specications, Flywheel for
information on ywheel runout.
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
i02183600
Crankshaft Rear Seal - Remove

Removal Procedure
Start By:
a. Remove the ywheel housing. Refer to
Disassembly and Assembly, Flywheel Housing
NOTICE
component life.
NOTICE
mandates.
four cylinder engines have different congurations for
the ywheel housing and the backplate. The removal
process is similar for all models.
g00847841
Illustration 62
Typical example
1. Remove the setscrews (3) and the backplate (2)
from the rear of the cylinder block.
2. Remove the crankshaft rear seal (1) from the
cylinder block. Discard the used crankshaft oil
seal.
i02801659
Crankshaft Rear Seal - Install

Note: Inspect the crankshaft rear seal and replace
the assembly if there is the slightest sign of damage
to the seal.
Note: The following procedure assumes that the
crankshaft rear seal is a replacement assembly.
38 SENR9973-01
NOTICE
component life.
g01113706
Illustration 63
Typical example
1. Clean the rear face of the cylinder block (1) and
the back plate (6). Inspect the dowels (3) for
damage. If the dowels are damaged, use new
parts for replacement.
2. Ensure that the crankshaft ange (4) is clean, dry
and free from rough metal edges.
3. Remove the packaging from the new crankshaft
rear seal (5). Ensure that the plastic sleeve (not
shown) is squarely installed within the crankshaft
rear seal. The plastic sleeve is included in order
to protect the lip of the seal as the lip is pushed
over the crankshaft ange.
4. Apply clean engine lubricating oil to the crankshaft
ange (4) around the running surface of crankshaft
rear seal.
5. Place the crankshaft rear seal (5) over the
crankshaft ange (4) and engage the plastic
sleeve onto the crankshaft ange.
6. Ensure that the plastic sleeve is engaged onto
the crankshaft ange (4). Push the crankshaft
rear seal (5) evenly and push the crankshaft rear
seal smoothly onto the crankshaft ange until the
crankshaft rear seal is against the cylinder block.
During this process, the plastic sleeve will be
forced out of the crankshaft rear seal. Discard the
plastic sleeve.
SENR9973-01 39
7. Apply a continuous bead of 21826038
POWERPART Silicone Adhesive to the rear face
of the cylinder block around the mating surface of
the crankshaft rear seal and around the rear core
plug for the camshaft (2).
8. Align the back plate (6) to the dowels (3) and
install the back plate to the cylinder block (1).
9. Install the setscrews (7) that fasten back plate (6)
to the cylinder block (1).
For the 402C-05 and 403C-07 engines, tighten
the setscrews to a torque of 15 Nm (11 lb ft).
For the 403C-11 and 404C-15 engines, tighten the
For the 403C-15, 403C-17, 404C-22 and
404C-22T engines, tighten the setscrews to a
End By:
a. Install the ywheel housing. Refer to Disassembly
and Assembly Manual, Flywheel Housing -
Remove and Install.
b. Install the ywheel. Refer to Disassembly and
Assembly Manual, Flywheel - Install.
i02801660
Flywheel Housing - Remove
and Install

Removal Procedure (Engines with
Flywheel Housing and Back plate)
Start By:
a. Remove the ywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
component life.
1. Support the engine with a suitable lifting device or
support the engine on blocks that are positioned
on a at level surface.
housing and support the weight of the housing (8).
g00827061
Illustration 64
Typical example
3. Remove the setscrews (3) that fasten the ywheel
housing (8) to the cylinder block.
4. Remove the setscrews (5) on each side of
the cylinder block. These setscrews fasten the
ywheel housing (8) to the cylinder block.
5. Remove the setscrews (1) that fasten the back
plate (2) to the ywheel housing (8).
6. Remove the nuts (7) and the bolts (not shown)
that fasten the back plate (2) to the ywheel
housing (8).
g01113237
Illustration 65
Typical example
7. Use the lifting device (9) to remove the ywheel
housing (8) from the back plate.
40 SENR9973-01
Removal Procedure (Engines with
Flywheel Housing)
Start By:
a. Remove the ywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
component life.
cylinder engines have different ywheel housings.
The removal procedure is similar for all models.
1. Support the engine with a suitable lifting device or
support the engine on blocks that are positioned
on a at level surface.
housing and support the weight of the housing (2).
g01123577
Illustration 66
Typical example
3. Remove the setscrews (1) that fasten the ywheel
g01123555
Illustration 67
Typical example
4. Use the lifting device (3) to remove the ywheel
housing (2) from the engine.
Installation Procedure (Engines
with Flywheel Housing and Back
plate)
NOTICE
component life.
g00827061
Illustration 68
Typical example
SENR9973-01 41
1. Clean the rear face of the back plate (2) and the
faces of the ywheel housing (8). Inspect the
crankshaft rear seal (not shown) for leaks. Inspect
the dowels (6) for damage. If the crankshaft
rear seal or the dowels are damaged, use new
parts for replacement. Refer to Disassembly and
Assembly, Crankshaft Rear Seal - Remove and
Disassembly and Assembly, Crankshaft Rear
Seal - Install.
g01113237
Illustration 69
Typical example
2. Use the lifting device (9) to align the ywheel
housing (8) to the dowels (6). Install the ywheel
housing to the back plate.
3. Install the nuts (7) and the bolts (not shown) that
fasten the back plate (2) to the ywheel housing
(8).
4. Install the setscrews (1) that fasten the back plate
(2) to the ywheel housing (8).
5. Install the setscrews (5) on each side of the
cylinder block. These setscrews fasten the
ywheel housing (8) to the cylinder block.
6. Remove the lifting device (9) from the ywheel
housing.
8. For 403C-15, 404C-22 and 404C-22T engines,
tighten the fasteners to a torque of 25 Nm
(19 lb ft).
End By:
a. Install the ywheel. Refer to Disassembly and
Assembly, Flywheel - Install.
Installation Procedure (Engines
with Flywheel Housing)
NOTICE
component life.
g01123556
Illustration 70
Typical example
1. Clean the mating face of the ywheel housing
(2). Inspect the crankshaft rear seal (4) for
leaks. Inspect the dowels (5) for damage. If
the crankshaft rear seal or the dowels are
damaged, use new parts for replacement. Refer
to Disassembly and Assembly, Crankshaft Rear
Seal - Remove and Disassembly and Assembly,
Crankshaft Rear Seal - Install.
g01123555
Illustration 71
Typical example
2. Use the lifting device (3) to align the ywheel
housing (2) to the dowels (5). Install the ywheel
housing to the engine.
42 SENR9973-01
housing to the cylinder block.
For 402C-05 and 403C-07 engines, tighten the
4. Remove the lifting device (3) from the ywheel
housing.
End By:
a. Install the ywheel. Refer to Disassembly and
i02801663
Crankshaft Pulley - Remove
and Install

Removal Procedure
Table 6
Required Tools
Part Number Description Qty
21825619 Puller 1
1. Remove the fan drive belt. Refer to Disassembly
and Assembly, V Belts Remove and Install for
more information.
g00827213
Illustration 72
1. Remove the nut (5) and the washer (3) from
crankshaft pulley (2).
g01122953
Illustration 73
2. Install the 21825619 Puller (6) to the crankshaft
pulley. Use the puller (6) in order to remove the
crankshaft pulley (2) from crankshaft (4).
3. Remove the woodruff key (1) from the crankshaft
(4).
g00827213
Illustration 74
Note: Inspect the following components for damage:
the taper of the crankshaft, the woodruff key, and
the bore of the crankshaft pulley. Replace any
components that are damaged. Ensure that the taper
of the crankshaft and the bore of the crankshaft
pulley are clean and dry before assembly.
1. Install the woodruff key (1) to the crankshaft (4).
2. Install the crankshaft pulley (2) to the crankshaft
(4).
3. Install the washer (3) to the crankshaft (4).
4. Lubricate the nut (5) with clean engine oil and
install the nut.
nut (5) to a torque of 93 Nm (69 lb ft).
SENR9973-01 43
For 403C-11 and 404C-15 engines, tighten the nut
(5) to a torque of 123 Nm (91 lb ft).
For 403C-15, 403C-17, 404C-22 and 404C-22T
engines, tighten the nut (5) to a torque of 304 Nm
(224 lb ft).
5. Install the V-belt to the engine. Refer to
Disassembly and Assembly, V Belts Remove and
Install for more information.
i02200446
Crankshaft Front Seal -
Remove

Removal Procedure
NOTICE
component life.
NOTICE
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
mandates.
Remove the Front Oil Seal that is installed
in the Engine
1. If the front cover is still attached to the engine, use
a suitable lever in order to remove the oil seal
from the front cover.
Remove the Front Oil Seal from a
Disassembled Front Cover
1. If the front cover has been removed from the
engine, use a suitable hydraulic press in order to
remove the oil seal from the front cover. Ensure
that the front cover is supported correctly in order
to prevent damage to the cover while the oil seal
is being removed.
i02187983
Crankshaft Front Seal - Install

NOTICE
component life.
g01113392
Illustration 75
1. Clean the bore of the housing (1) for the crankshaft
front seal (2) and inspect the bore of the housing
for any damage.
2. Lubricate the crankshaft front seal (2) with clean
engine oil.
3. Position the crankshaft front seal (2) in the bore of
the housing (1) for the crankshaft front seal.
NOTICE
Ensure that the lip of the crankshaft front seal that is
spring loaded is facing toward the inside of the front
housing and that it is square with the bore of the hous-
ing for the crankshaft front seal.
4. Use a suitable tool (3) to install the new crankshaft
front seal (2).
Note: Apply clean engine oil on the area of the
crankshaft pulley that will be in contact with the
crankshaft front seal (2).
End By:
a. Install the crankshaft pulley and the V-belt. Refer
to Disassembly and Assembly, Crankshaft Pulley
44 SENR9973-01
i02186336
Housing (Front) - Remove

Removal Procedure
Start By:
a. Remove the fuel injection pump. Refer to
Disassembly and Assembly, Fuel Injection Pump
- Remove.
b. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, Crankshaft Pulley
NOTICE
component life.
NOTICE
mandates.
g01129574
Illustration 76
Typical example
1. Remove the setscrews and the nuts (5) from the
front housing (4).
2. Turn the mechanical stop lever (3) to the full
clockwise position so that the spring is held under
tension.
3. Remove the front housing (4) from the front of
cylinder block (6).
Note: Identify the position of the locating pin (2) and
the locating hole (1) for installation.
4. Remove the joint (not shown) from the cylinder
block (6) or from the front housing (4). Discard the
joint.
5. Inspect the front housing assembly (4) for wear
or damage. If the front housing assembly is
damaged, use new parts for replacement.
SENR9973-01 45
i02186302
Housing (Front) - Disassemble

Disassembly Procedure
Start By:
a. Remove the engine front housing. Refer to
Disassembly and Assembly, Housing (Front) -
Remove.
NOTICE
component life.
NOTICE
mandates.
Removal of the Throttle Control
g01114167
Illustration 77
Typical example
1. Remove the spring (5) from the lever (8) for the
throttle control.
2. Loosen the nut (1) and the bolt (4) that secures
the arm (3) to the lever (8) for the throttle control.
Note: Identify the position of the arm in relation to the
lever for installation. Do not remove the nut (1) and
the washers (2) from the bolt (4).
3. Remove the arm (3) from the lever (8).
4. Remove the C-clip (6) from the lever (8).
5. Remove the lever (8) from the front housing (9).
6. Remove the O-ring (7) from lever (8). Discard the
O-ring.
7. Check the components for wear or damage.
Replace any components that are worn or
damaged.
Removal of the linkage for the Fuel
Injection Pump
Note: When the linkage for the fuel injection pump is
removed or the engine front cover is replaced, the
setting for the maximum fuel may be affected.
46 SENR9973-01
g01114159
Illustration 78
Typical example
1. Remove the spring (10) from the lever assembly
(11).
2. Remove the C-clip (14) from the shaft (12).
3. Remove the shaft (12) and remove the lever
assembly (11) from the engine front housing (9).
4. Remove the O-ring (13) from the shaft (12).
Discard the O-ring.
5. Remove the angleich unit (15) from the lever
assembly (11).
Note: The angleich unit is not installed to the
402C-05, 403C-07, 403C-11 and 404C-15 engines,
or engines that run at a constant speed.
6. Check the components for wear or damage.
damaged.
Removal of the Stop Control
g01114517
Illustration 79
Typical example
1. Remove the nut (16) and remove the washer (17)
that secures the lever (18) to the arm (24) for the
stop control.
2. Remove the lever (18) from the arm (24) for the
stop control.
Note: Identify the position of the lever (18) on the
shaft (24) for installation.
3. Remove the nut (19) from the arm (24) for the
stop control. Remove the washer (20) and remove
the spring (21) from the arm (24).
4. Remove the arm (24) for the stop control from the
front housing.
5. Remove the C-clip (23) and the O-ring (22) from
the arm (24). Discard the O-ring.
SENR9973-01 47
Removal of the PTO Cover
g01114513
Illustration 80
Typical example
1. Remove the nuts (25) and the bolts (31) from the
PTO cover.
2. Remove the plates (26) and (30).
Note: The plate (30) is not installed on 402C-05 or
403C-07 engines.
3. Remove the joint (27) and discard the joint.
4. Remove the O-ring (29). Discard the O-ring.
Note: The O-ring (29) is not installed on 402C-05
or 403C-07 engines.
5. Check the condition of all parts. Replace any parts
that are damaged or worn.
i02801664
Housing (Front) - Assemble

Assembly Procedure
Note: If the engine front housing is replaced, ensure
that a new emissions label is installed.
Installation of the Throttle Control
g01114382
Illustration 81
Typical example
1. Install the O-ring (6) to the shaft of the lever (7).
2. Lubricate the O-ring (6) and the shaft of the lever
(7) with clean engine oil. Install the lever (7) into
the front housing (8).
3. Install the C-clip (5) onto the shaft of the lever (7).
4. Install the arm for the throttle control (3) onto the
lever (7). Tighten the nut (1) and bolt (4) to a
Installation of the linkage for the Fuel
Injection Pump
1. If necessary, perform the following procedure to
install the angleich unit (15) to the lever assembly
(11).
48 SENR9973-01
g01114377
Illustration 82
a. Apply 21820117 POWERPART Threadlock to
the rst two threads of the angleich unit (18).
b. Install the angleich unit (18) to the lever
assembly (11). Tighten the angleich unit to a
torque of 5 Nm (44 lb in).
Note: Ensure that no 21820117 POWERPART
Threadlock is allowed to contaminate the plunger
assembly of the angleich unit. Contamination of
the plunger assembly will render the angleich unit
inoperative.
g01114562
Illustration 83
Typical example
2. Install the spring (10) to the lever assembly (11).
3. Install the O-ring (13) to the shaft (12). Lubricate
the shaft with clean oil.
4. Position the lever assembly (11) in the front
housing (8). Install the shaft (12) to outside of the
front housing (8).
Note: Ensure that the groove for the C-clip (16) in
the shaft (12) is positioned between the boss (15) on
the front housing and the cast retainer (17) on the
front housing (8).
5. Install the C-clip (14) to the shaft (12).
SENR9973-01 49
g01114380
Illustration 84
Typical example
6. Attach the spring (10) to the notch on the inside
of the front housing (8).
7. Install the spring (9) to the lever assembly (11).
8. Attach the spring (9) to the lever (7).
Installation of the Stop Control
g01114606
Illustration 85
Typical example
1. Install the C-clip (26) and install the O-ring (25) to
the arm (27).
2. Lubricate the O-ring (25) and the shaft of the arm
(27) with clean oil. Install the arm assembly (27) to
the front housing.
3. Place the spring (24) and the washer (23) onto the
arm (27). Install the nut (22) onto the arm (27).
4. Install the lever (21) onto the arm (27).
5. Install the washer (20) and the nut (19) onto the
arm (27). Tighten the nuts (19) and (22) to a
Installation of the PTO Cover
g01114607
Illustration 86
Typical example
Note: The O-ring (32) and the plate (33) are not
installed on the 402C-05 and 403C-07 engines.
1. For 403C-11, 403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T engines, install the O-ring
(32) to the groove in the front housing (31).
2. Install a new joint (30) to the rear of the front
housing.
3. For 403C-11, 403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T engines, install the plates
(29) and (33).
For 402C-05 and 403C-07 engines, install the
plate (29).
4. Install the nuts (28) and the bolts (34) for the PTO
cover. Tighten the nuts to a torque of 13 Nm
(10 lb ft).
End By:
a. Install the front housing to the engine. Refer to
Disassembly and Assembly, Housing (Front)
Install for more information.
50 SENR9973-01
b. Check the maximum engine speed at no load.
Refer to Testing and Adjusting, Engine Speed -
Check for more information.
i02801665
Housing (Front) - Install

Table 7
Required Tools
21825620 Seal Guide
402C-05, 403C-07, 403C-11
and 404C-15 engines
1
21825621 Seal Guide
403C-15, 403C-17, 404C-22
and 404C-22T engines
1
NOTICE
component life.
1. Clean the front housing assembly (4) thoroughly.
2. For 402C-05, 403C-07, 403C-15 and 404C-11
engines, install the 21825620 Seal Guide (6) to
the crankshaft.
For 403C-15, 403C-17, 404C-22 and 404C-22T
engines, install the 21825621 Seal Guide (6) to
the crankshaft.
g01113288
Illustration 87
3. Align the locating pin (2) with the locating hole on
the oil pump cover (1). Ensure that the oil pump
cover is concentric to the idler gear assembly.
4. Install a new joint to the front of the cylinder block
(7).
5. Turn the mechanical stop lever (3) to the full
clockwise position so that the spring is held under
tension. Observe the position of the linkage for
the fuel injection pump (not shown) in the front
housing.
6. Position the front housing (4) on the front of
cylinder block (7). Guide the linkage for the fuel
injection pump into position so that the link is free
to move inside the aperture on the cylinder block
for the fuel injection pump.
7. Align the front housing (4) with the dowels in the
front of the cylinder block (7). Press the front
housing into position. Release the stop lever (3).
8. Install the fasteners (5) nger tight.
9. Tighten the fasteners (5) to a torque of 10 Nm
(7 lb ft).
10. Remove seal guide (6) from the crankshaft.
SENR9973-01 51
End By:
a. Install the crankshaft pulley. Refer to Disassembly
and Assembly, Crankshaft Pulley - Remove and
Install.
b. Install the fuel injection pump. Refer to
Disassembly and Assembly, Fuel Injection Pump
- Install.
i02187994
Crankcase Breather - Remove
and Install

Removal Procedure (Naturally
Aspirated Engines)
NOTICE
component life.
NOTICE
mandates.
The two cylinder, the three cylinder and the four
cylinder engines have different crankcase breathers.
The removal procedure is identical for all models.
g01114038
Illustration 88
Typical example
breather cover (2) from the valve mechanism
cover (10).
2. Remove the spring (3). Remove the diaphragm
assembly (4).
3. Clean the vent hole (6). Clean the cavity (5) for
the breather assembly in the valve mechanism
cover (10).
4. If necessary, remove the setscrews (7). Remove
the plate (8) and remove the gauze (9).
5. Clean all parts and inspect all parts. Replace any
parts that are worn or damaged.
Removal Procedure (Turbocharged
Engines)
NOTICE
component life.
52 SENR9973-01
NOTICE
mandates.
g01114041
Illustration 89
Typical example
breather cover (2) from the valve mechanism
cover (12).
2. Remove the spring (3). Remove the diaphragm
assembly (4).
3. Remove the adapter (6). Remove the joint (7).
Clean the vent hole (5).
4. Clean the cavity (8) for the breather assembly in
the valve mechanism cover (12).
5. If necessary, remove the setscrews (9). Remove
the plate (10) and remove the gauze (11).
6. Clean all parts and inspect all parts. Replace any
parts that are worn or damaged.
Installation Procedure (Naturally
Aspirated Engines)
NOTICE
component life.
NOTICE
Make sure that the components of the breather as-
sembly are installed correctly. Engine damage may
occur if the breather assembly is not working properly.
The two cylinder, the three cylinder and the four
cylinder engines have different crankcase breathers.
The installation procedure is identical for all models.
g01114038
Illustration 90
Typical example
SENR9973-01 53
1. If necessary, install a new gauze (9). Apply a
bead of 1861108 POWERPART silicon jointing
compound to the mating face of the plate in the
valve mechanism cover (10). Install the plate (8).
a torque of 1.5 Nm (13 lb in).
2. Install a new diaphragm assembly (4) into cavity
(5) of the valve mechanism cover. Install a new
spring (3).
3. Install the breather cover (2) and the four
of 3 Nm (27 lb in).
(Turbocharged Engines)
NOTICE
component life.
NOTICE
Make sure that the components of the breather as-
sembly are installed correctly. Engine damage may
occur if the breather assembly is not working properly.
g01114041
Illustration 91
Typical example
1. If necessary, install a new gauze (11). Apply a
bead of 1861108 POWERPART silicon jointing
compound to the mating face of the plate in the
valve mechanism cover (12). Install the plate (10).
a torque of 1.5 Nm (13 lb in).
2. Install a new joint (7). Install the adapter (6).
Note: the connection on the adapter should face to
the rear of the engine. The vent hole (5) should face
upward.
3. Install a new diaphragm assembly (4) into the
adapter (6). Install a new spring (3).
4. Install the breather cover (2) and the four
of 3 Nm (27 lb in).
54 SENR9973-01
i02801666
Valve Mechanism Cover -
Remove and Install

Removal Procedure
NOTICE
component life.
NOTICE
mandates.
engine.
Note: The inlet manifold is part of the valve
mechanism cover.
g00819350
Illustration 92
Typical example
1. Remove the setscrews (2) from the connector
(3) and remove the connector from the valve
mechanism cover (6). Remove the gasket (4).
Discard the gasket.
2. Remove the setscrews (1) and remove the cap
nuts (5) that attach the valve mechanism cover (6)
to the housing (7) for the rocker shaft assembly.
3. Remove the valve mechanism cover (6) from the
housing (7) for the rocker shaft assembly. Remove
the joint (8) from the valve mechanism cover (6).
Inspect the joint. If the joint is worn or damaged,
use a new part for replacement.
NOTICE
component life.
engine.
1. Clean all surfaces thoroughly.
g00819350
Illustration 93
Typical example
2. Install the joint (8) to the valve mechanism cover
(6).
3. Install the valve mechanism cover (6) to the
housing (7) for the rocker shaft assembly.
SENR9973-01 55
4. Install the setscrews (1) and install the cap nuts
(5).
5. For 402C-05 and 403C-07 engines, tighten the
setscrews and cap nuts to a torque of 10 Nm
(7.5 lb ft).
setscrews and the cap nuts to a torque of 11 Nm
(8.1 lb ft).
For 403C-15, 403C-17, 404C-22 and 404C-22T
engines, tighten the setscrews and the cap nuts
6. Install a new gasket (4) to the valve mechanism
cover (6). Install the connector (3) to the valve
mechanism cover (6) with setscrews (2). Tighten
i02187973
Rocker Shaft and Pushrod -
Remove

Removal Procedure
Start By:
a. Remove the engine oil line. Refer to Disassembly
and Assembly, Engine Oil Line - Remove and
Install.
b. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
NOTICE
component life.
NOTICE
mandates.
engines. The illustration shows the four cylinder
engine.
g00827968
Illustration 94
Typical example
1. Loosen the nuts and the adjustment screws (3)
on the rocker arms in order to release the tension
from the rocker shaft assembly (4).
2. Remove the nuts (2) and the setscrews (1) from
the rocker shaft assembly (4).
3. Remove the rocker shaft assembly (4) from
cylinder head (7).
4. Remove the pushrods (6) from the cylinder head.
Mark the pushrods for installation. Inspect the
pushrods for wear or for damage. If the pushrods
are damaged, use new parts for replacement.
5. Remove the caps (not shown) from the top of the
valve stems (5). Mark the caps for installation.
Inspect the caps for wear or for damage. If the
caps are worn or damaged, use new parts for
replacement.
6. Remove the joint (9) from the base of the rocker
shaft assembly (8). Inspect the joint. If the joint is
worn or damaged, use a new part for replacement.
56 SENR9973-01
i02801667
Rocker Shaft - Disassemble

Disassembly Procedure (402C-05,
403C-07, 403C-11 and 404C-15
engines)
Start By:
a. Remove the rocker shaft and the pushrods. Refer
to Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.
NOTICE
component life.
g01124594
Illustration 95
Typical example
1. Remove the threaded plug (6) from the base of
the rocker shaft (8).
2. Remove the O-ring (5) from the threaded plug (6).
Discard the O-ring.
3. On 403C-07, 403C-11 and 404C-15 engines,
remove the setscrew (7) that locates the rocker
shaft (4) to the base of the rocker shaft (8).
4. In order to remove the rocker shaft (4), install a
suitable setscrew with a M8 x 1.25 thread into the
end of the rocker shaft. Use the setscrew to pull
the rocker shaft (4) from the base of the rocker
shaft (8).
ment.
5. Remove the rocker arms (3), the washers (9), and
the springs (10).
Note: Place an identication mark on each of the
components for installation.
6. Remove the adjustment screws (1) and the nuts
(2) from rocker arms (3).
7. Inspect all of the components for wear or for
damage. Refer to the Specications Manual,
Rocker Shaft. If any of the components are worn
or damaged, use new parts for replacement.
Disassembly Procedure (403C-15,
403C-17, 404C-22 and 404C-22T
engines)
Start By:
a. Remove the rocker shaft and the pushrods. Refer
Pushrod - Remove.
NOTICE
component life.
SENR9973-01 57
g01124595
Illustration 96
Typical example
1. In order to remove the rocker shaft (4), install a
suitable M8 setscrew into the end of the rocker
shaft. Use the setscrew to pull the rocker shaft (4)
from the base of the rocker shaft (5).
ment.
2. Remove the rocker arms (3), the washers (7), and
the springs (8).
Note: Place an identication mark on each of the
components for installation.
3. Remove the O-ring (6) from the rocker shaft (4).
4. Remove the adjustment screws (1) and the nuts
(2) from rocker arms (3).
5. Inspect all of the components for wear or for
damage. Refer to the Specications Manual,
Rocker Shaft. If any of the components are worn
or damaged, use new parts for replacement.
i02801668
Rocker Shaft - Assemble

Assembly Procedure (402C-05,
403C-07, 403C-11 and 404C-15
engines)
NOTICE
component life.
Note: The assembly procedure is similar for the
engines. The illustration shows a three cylinder
engine.
1. Lubricate the adjustment screw (1) with clean
engine oil. Install the adjustment screw (1) and the
nut (2) to the rocker arm (3). Repeat the process
for the remaining rocker arms.
g01124596
Illustration 97
Typical example
2. Lubricate the rocker shaft (4) with clean engine
oil. Position the end of the rocker shaft into the
bore in the base of the rocker shaft (8).
For 402C-05 engines, align the two recesses (not
shown) in the rocker shaft with the holes in the
base of the rocker shaft (8).
For 403C-07, 403C-11 and 404C-15 engines,
align the hole (10) in the rocker shaft with the hole
(9) in the base of the rocker shaft (8).
58 SENR9973-01
3. Gradually insert the rocker shaft (4) into the base
of the rocker shaft (8). Install the rocker arm (3).
ment.
4. Continue to insert the rocker shaft (4) and install
the following components to the rocker shaft:
Rocker arm (3)
Washer (9)
Spring (10)
Washer (9)
Rocker arm (3)

5. Repeat Steps 4 and 3 in order to install the
remaining components.
6. Ensure that the rocker shaft (4) is fully engaged
into the base of the rocker shaft (8). Check that
the alignment of the rocker shaft is correct.
7. For 403C-07, 403C-11 and 404C-15 engines,
apply 21820117 POWERPART Threadlock to
the rst two threads of the setscrew (7). Install
the setscrew (7) in the hole (9) in the base of the
rocker shaft. Tighten the setscrew.
Note: Ensure that no 21820117 POWERPART
Threadlock is allowed to contaminate the oil gallery
in the rocker shaft.
8. Install a new O-ring (5) to the threaded plug (6).
9. Install the threaded plug (6) to the base of the
rocker shaft (9). Tighten the plug to a torque of
15 Nm (11 lb ft).
End By:
a. Install the rocker shaft and the pushrods. Refer to
Pushrod - Install.
Assembly Procedure (403C-15,
403C-17, 404C-22 and 404C-22T
engines)
NOTICE
component life.
Note: The assembly procedure is similar for the three
cylinder and the four cylinder engines. The illustration
shows a four cylinder engine.
1. Lubricate the adjustment screw (1) with clean
engine oil. Install the adjustment screw (1) and the
nut (2) to the rocker arm (3). Repeat the process
for the remaining rocker arms.
g01113618
Illustration 98
Typical example
2. Install a new O-ring (8) onto the rocker shaft (4).
Lubricate the rocker shaft with clean engine oil.
3. Position the end of the rocker shaft (4) into the
bore in the base of the rocker shaft (7). Align the
recesses (5) on the rocker shaft with the holes (6)
in the base of the rocker shaft (7).
SENR9973-01 59
4. Gradually insert the rocker shaft (4) into the base
of the rocker shaft (7). Install the rocker arm (3).
ment.
5. Continue to insert the rocker shaft (4) and install
the following components to the rocker shaft:
Rocker arm (3)
Washer (9)
Spring (10)
Washer (9)
Rocker arm (3)

6. Repeat Steps 4 and 3 in order to install the
remaining components.
7. Ensure that the rocker shaft (4) is fully engaged
into the base of the rocker shaft (7). Check that
the recesses (5) on the rocker shaft are aligned
with the holes (6) in the base of the rocker shaft.
End By:
a. Install the rocker shaft and the pushrods. Refer to
Pushrod - Install.
i02801669
Rocker Shaft and Pushrod -
Install

NOTICE
component life.
engine.
g00827968
Illustration 99
Typical example
1. Install the joint (9) to the base of the rocker shaft
assembly (8).
2. Lubricate the pushrods (6) with clean engine oil.
Install the pushrods (6) in the cylinder head (7).
Ensure that the pushrods are installed correctly in
the socket of the valve lifters.
Note: If the pushrods have been used, ensure that
the pushrods are installed in original positions.
3. Lubricate the top of the valve stems (5) with clean
engine oil. Install the caps (not shown) on the top
of the valve stems.
Note: If the caps have been used, ensure that the
caps are installed in original positions.
4. Lubricate the adjustment screws (3) on each
rocker arm with clean engine oil before installation.
Install the rocker shaft assembly (4) to the cylinder
head (7).
Note: Ensure that the ends of the adjustment screws
on each rocker arm are correctly seated in the ends
of the pushrods (6).
5. Install the setscrews (1) and the nuts (2).
6. Evenly tighten the nuts (2).
Note: The tightening sequence moves from the
center of the rocker shaft outward.
7. For 402C-05 and 403C-07 engines, tighten the
setscrews (1) and the nuts (2) to a torque of
10 Nm (89 lb in).
60 SENR9973-01
setscrews (1) to a torque of 10 Nm (89 lb in).
Tighten the nuts (2) to a torque of 23 Nm (17 lb ft).
For 403C-15, 403C-17, 404C-22 and 404C-22T
engines, tighten the setscrews (1) to a torque of
10 Nm (89 lb in). Tighten the nuts (2) to a torque
8. Adjust the valve lash. Refer to Testing and
Adjusting, Engine Valve Lash - Inspect/Adjust for
the correct procedure to adjust the valve lash.
End By:
a. Install the valve mechanism cover. Refer to
b. Install the engine oil line. Refer to Disassembly
and Assembly, Engine Oil Line- Remove and
Install.
i02801670
Cylinder Head - Remove

Removal Procedure
Start By:
a. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.
b. Remove the exhaust manifold. Refer to
Disassembly and Assembly, Exhaust Manifold-
Remove and Install.
c. Remove the valve mechanism cover. Refer to
d. Remove the rocker shaft and the pushrods. Refer
Pushrod - Remove.
e. Remove the fuel injection lines. Refer to
f. Remove the fuel injectors. Refer to Disassembly
and Assembly, Fuel Injectors - Remove.
g. Remove the oil line. Refer to Disassembly and
Assembly, Engine Oil Line - Remove and Install.
NOTICE
component life.
NOTICE
mandates.
g00828137
Illustration 100
Typical example
g01116726
Illustration 101
Typical example for the 2 cylinder head
SENR9973-01 61
g00854316
Illustration 102
g01109567
Illustration 103
1. Loosen the cylinder head bolts (1) in reverse order
as this will help prevent distortion of the cylinder
head (2).
For the 402C-05 engine, gradually loosen the
cylinder head bolts (1) in the reverse order that is
shown in illustration 101.
For the 403C-07, 403C-11, 403C-15 and 403C-17
engines, gradually loosen the cylinder head bolts
(1) in the reverse order that is shown in illustration
102.
For the 404C-15, 404C-22 and 404C-22T engines,
gradually loosen the cylinder head bolts (1) in the
reverse order that is shown in illustration 103.
Note: Do not use a pry bar to separate the cylinder
head from the cylinder block . Use a rubber mallet to
loosen the cylinder head from the cylinder block.
2. Attach a suitable lifting device to the cylinder
head (2). Carefully lift the cylinder head (2) off the
cylinder block (3).
Note: Avoid contamination of the cylinder bores with
coolant or with debris.
3. Remove the cylinder head gasket from the cylinder
block (3) or the cylinder head (2). Do not reuse the
old cylinder head gasket for the cylinder head (2).
Note: Place the cylinder head on a surface that will
not scratch the face of the cylinder head.
Note: The old gasket for the cylinder head should
be used for identication. Head gaskets of different
thickness are available. Refer to Specications,
Cylinder Head. The piston height relative to the
cylinder head is controlled by the thickness of
the head gasket. Refer to Testing and Adjusting,
Cylinder Head - Inspect.
4. If necessary, remove the cylinder head dowels
from the cylinder block (3). Use a suitable puller to
remove the cylinder head dowels.
5. Inspect the cylinder head (2). Refer to Testing and
Adjusting, Cylinder Head - Inspect and Testing
and Adjusting, Valve Depth - Inspect.
i02801671
Cylinder Head - Install

NOTICE
component life.
g00828137
Illustration 104
Typical example
1. Thoroughly clean the top of cylinder block (3) and
the bottom of the cylinder head (2). Ensure that
there is no debris in the cylinder bores.
2. If necessary, install the dowels (6) to the cylinder
block (3).
62 SENR9973-01
g00828396
Illustration 105
Typical example
3. Install suitable guide studs (not shown) to the
cylinder block (3). Place the cylinder head gasket
(4) over the guide studs and align the gasket (4)
with the dowels (6) in the cylinder block (3).
Note: The old gasket for the cylinder head should
be used for identication. Head gaskets of different
thickness are available. Refer to Specications,
Cylinder Head. The piston height relative to the
cylinder head is controlled by the thickness of
the head gasket. Refer to Testing and Adjusting,
Cylinder Head - Inspect.
Note: A four digit number is stamped on cylinder
head gasket (4) at location (5). This number should
face the cylinder head in order to ensure the correct
positioning of the cylinder head gasket. Do not use
any gasket sealant or compound on the cylinder
head gasket.
4. Attach a suitable lifting device to the cylinder head
(2).
5. Install the cylinder head (2) to the cylinder block
(3). Check that the cylinder head is positioned
correctly.
6. Lubricate the cylinder head bolts (1) with clean
engine oil.
g01116726
Illustration 106
g00854316
Illustration 107
g01109567
Illustration 108
7. Install the cylinder head bolts (1) nger tight.
For 402C-05 engines, tighten the cylinder head
bolts to a torque of 36.5 Nm (26.9 lb ft). Use the
numerical sequence that is shown in illustration
106.
SENR9973-01 63
107.
107.
cylinder head bolts to a torque of 100.5 Nm
(74.1 lb ft). Use the numerical sequence that is
108.
For 404C-22 and 404C-22T engines, tighten the
cylinder head bolts to a torque of 100.5 Nm
(74.1 lb ft). Use the numerical sequence that is
End By:
a. Install the rockershaft and pushrods. Refer to
Disassembly and Assembly, Rockershaft and
Pushrods - Remove and Install.
b. Install the valve mechanism cover. Refer to
c. Install the water pump. Refer to Disassembly and
Assembly, Water Pump - Install.
d. Install the oil line. Refer to Disassembly and
Assembly, Engine Oil Line - Remove and Install.
e. Install the exhaust manifold. Refer to Disassembly
and Assembly, Exhaust Manifold - Remove and
Install.
f. Install the fuel injectors. Refer to Disassembly and
Assembly, Fuel Injectors - Remove and Install.
g. Install the fuel injection lines. Refer to Disassembly
and Assembly, Fuel Injection lines - Remove and
Install.
i02187977
Lifter Group - Remove and
Install

Removal Procedure
Start By:
a. Remove the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head -
Remove.
NOTICE
component life.
Note: Mark the original location of the lifters for later
installation.
g01110885
Illustration 109
Typical example
1. Use a suitable telescopic magnet (1) to remove
the lifter (2) from the cylinder block.
2. Inspect the lifter (2) for wear or damage. If the
lifter (2) is worn or damaged, use a new part for
replacement.
3. Repeat Steps 1 and 2 for the remaining lifters.
64 SENR9973-01
NOTICE
component life.
g01116687
Illustration 110
Typical example
1. Ensure that the lifter (2) is clean and that the oil
hole (3) in the lifter (2) is not restricted. Lubricate
the lifter (2) with clean engine oil and install the
lifter (2) in the cylinder block.
Note: Ensure that the lifters (2) are installed in the
original location. If the camshaft has been replaced,
install new lifters (2). Do not install worn lifters to a
new camshaft.
2. Repeat Step 1 for the remaining lifters.
End By:
a. Install the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head -
Install.
i02801672
Camshaft - Remove

Removal Procedure
Start By:
a. Remove the lifters. Refer to Disassembly and
Assembly, Lifter Group - Remove and Install.
b. Remove the engine front housing. Refer to
Remove.
c. Remove the fuel priming pump. Refer to
Disassembly and Assembly, Fuel Priming Pump
- Remove.
NOTICE
component life.
NOTICE
mandates.
g00828467
Illustration 111
Typical example
1. Remove the slider (1) from the camshaft gear (4).
2. Before the idler gear is removed, rotate the
crankshaft until the timing marks (2) on the
following components are aligned.
Crankshaft gear (3)
Camshaft gear (4)
Idler gear (5)

3. Remove the idler gear (5). Refer to Disassembly
and Assembly, Engine Oil Pump - Remove.
SENR9973-01 65
g00828468
Illustration 112
Typical example
4. Rotate the camshaft gear (4) in order to align the
access hole (8) in the camshaft gear with the
fastener for the camshaft retainer (9).
Note: The two cylinder and the three cylinder engines
have a different type of camshaft retainer (9) to the
four cylinder engines. The removal procedure is
identical for all models.
For 402C-05, 403C-07, 403C-11, 403C-15,
403C-17 and 404C-15 engines, remove the outer
setscrew (6) and remove the allen head screw (7).
For 404C-22 and 404C-22T engines, remove the
outer setscrew (6) and remove the setscrew (7)
from the camshaft retainer (9).
5. Remove the camshaft retainer (9).
g01129576
Illustration 113
Typical example
6. Carefully remove the camshaft assembly (10)
from the cylinder block (11). Be careful not to
damage the lobes of the camshaft or the camshaft
bearings.
7. Inspect the components for wear or damage.
Refer to specications, Camshaft for details of
the camshaft lobes. Replace any components that
are worn or damaged.
i02196165
Camshaft - Disassemble

Start By:
a. Remove the camshaft assembly. Refer to
Disassembly and Assembly, Camshaft -
Remove.
NOTICE
component life.
g01113616
Illustration 114
Typical example
1. Use a suitable puller to remove the camshaft gear
(5) from the camshaft (1).
Note: The camshaft gear should be positioned on a
suitable support in order to prevent damage to the
governor yweights during disassembly.
66 SENR9973-01
2. Remove the spacer (4) and the woodruff key (2)
from the camshaft (1).
3. Use a suitable puller to remove the front camshaft
bearing (3) from the camshaft (1).
Note: Identify the orientation of the camshaft bearing
(3) for installation.
4. Inspect all of the components for wear or damage.
damaged.
i02196164
Camshaft - Assemble

Assembly Procedure
NOTICE
component life.
g01113616
Illustration 115
Typical example
1. Ensure that the camshaft (1) is clean. Lubricate
the front end of the camshaft with clean engine oil.
Use a suitable press to install the front camshaft
bearing (3) to the camshaft.
Note: Ensure that the camshaft bearing (3) is
installed in the correct orientation. The camshaft
bearing should be pressed squarely onto the
camshaft or damage to the bearing may occur.
2. Install the spacer (4) and the woodruff key (2) to
the camshaft (1).
3. Align the camshaft gear (5) with the woodruff key
(2) on the camshaft (1). Use a suitable press to
install the camshaft gear to the camshaft.
Note: The camshaft gear should be positioned on a
suitable support in order to prevent damage to the
governor yweights during installation.
End By:
a. Install the camshaft assembly. Refer to
Disassembly and Assembly, Camshaft - Install.
i02801686
Camshaft - Install

NOTICE
component life.
1. Ensure that the camshaft is clean. Lubricate the
camshaft with clean engine oil.
g01129587
Illustration 116
SENR9973-01 67
2. Carefully install the camshaft assembly (10) into
the engine cylinder block (11). Be careful not to
damage the lobes of the camshaft or the camshaft
bearings.
g00828468
Illustration 117
Typical example
3. Install the camshaft retainer (9).
Note: The two cylinder and the three cylinder engines
have a different camshaft retainer (9) and fasteners
(6) and (7), to the four cylinder engines. The removal
procedure is similar for all models.
4. Align the holes in the camshaft retainer (9) with
the holes in the cylinder block (11).
For 402C-05, 403C-07, 403C-11, 403C-15,
403C-17 and 404C-15 engines, install the outer
setscrew (6) and install the allen head screw (7).
For 404C-22 and 404C-22T engines, install the
setscrews (6) and (7).
Torque both fasteners to 11 Nm (8 lb ft).
g00828467
Illustration 118
5. Install the idler gear (5). Refer to Disassembly and
Assembly, Engine Oil Pump - Install.
Note: When you install the idler gear, ensure
that timing marks (2) are aligned on the following
components.
Crankshaft gear (3)
Camshaft gear (4)
Idler gear (5)

Number one piston will now be in the top dead
center position.
6. Install the slider (1) to the camshaft (4).
Note: Ensure that the notch on the base of the slider
(1) is engaged on the pin of the camshaft gear (4).
End By:
a. Install the engine front housing. Refer to
Install.
b. Install the fuel priming pump. Refer to Disassembly
and Assembly, Fuel Priming Pump - Install.
c. Install the lifters. Refer to Disassembly and
Assembly, Lifter Group- Remove and Install.
i02186340
Engine Oil Pan - Remove and
Install

Removal Procedure
NOTICE
component life.
NOTICE
mandates.
four cylinder engines have different engine oil pans.
The removal procedure is identical for all models.
68 SENR9973-01
g00820013
Illustration 119
Typical example
1. Remove the drain plugs (5) from the engine oil pan
(2). Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and
Maintenance Manual, Rell Capacities for the
approximate capacity of the lubricating oil system.
2. Remove the sealing washers (3) from the drain
plugs (5). Discard the sealing washers.
3. Remove the setscrews (4) for the engine oil pan
(2).
4. Remove the engine oil pan (2) from the engine.
5. Remove the joint (1) from the engine oil pan and
the cylinder block. Discard the joint.
NOTICE
component life.
four cylinder engines have different engine oil pans.
The installation procedure is identical for all models.
g00820013
Illustration 120
Typical example
1. Clean all surfaces thoroughly.
2. Install a new joint (1) to the engine. Install the
engine oil pan (2) to the engine.
3. Install the setscrews (4) for the engine oil pan (2).
Tighten the setscrews for the engine oil pan to a
4. Install the drain plugs (5) and new sealing washers
(3) to the oil pan (2). Tighten the drain plugs to a
5. Fill the engine oil pan to the correct level that is
indicated on the engine oil level gauge. Refer
Capacities for more information.
i02189003
Pistons and Connecting Rods
- Remove

Removal Procedure
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
b. Remove the engine oil pan. Refer to Disassembly
Install.
c. Remove the oil suction pipe. Refer to Disassembly
and Assembly, Engine Oil Pump - Remove.
SENR9973-01 69
NOTICE
component life.
1. Position the piston that is being removed in the
bottom center position.
g00829370
Illustration 121
Typical example
2. Remove the carbon buildup from the inner surface
of the top of the cylinder bore.
3. Ensure that the connecting rod and the cap are
correctly marked to the cylinder.
Note: Do not punch the connecting rod or stamp the
connecting rod assembly as this may cause damage.
4. Remove the nuts (6) from the connecting rod (1).
5. Remove the connecting rod cap (5) with the
bearing shell (3).
Note: Use tape or rubber tubing on connecting rod
bolts (2) to protect the crankshaft journals. The sharp
edges of the connecting rod bolts could damage the
crankshaft journals.
6. Push the piston and connecting rod (1) away from
the crankshaft until the piston rings are out of the
cylinder bore. Remove the piston from the cylinder
block.
Note: Make a mark under the piston on the pin boss
in order to identify the cylinder. Always mark the front
pin boss to aid installation.
7. Remove connecting rod bearings (3) from
connecting rod (1) and connecting rod cap (5).
8. Keep connecting rods (1) and connecting rod caps
(5) together. Ensure that the identication marks
are on the connecting rod and on the connecting
rod cap. This will ensure that the piston is installed
into the correct cylinder in the cylinder block.
9. Repeat Steps 1 through 8 for removing the
remaining pistons and connecting rods.
i02189019
- Disassemble

Start By:
a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, Pistons and
Connecting Rods - Remove.
NOTICE
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.
NOTICE
component life.
70 SENR9973-01
g01114004
Illustration 122
Typical example
1. Use suitable pliers in order to remove the circlips
(2).
2. Remove the piston pin (3) from the piston (4).
Note: If the piston pin cannot be removed by hand,
heat the piston to a temperature of 45 5 C
(113 9 F). Do not use a oxyacetylene torch to heat
the piston. Mark the piston pin for installation.
g01114007
Illustration 123
Typical example
3. Use a suitable ring expander in order to remove
the piston rings (7) and (6), and the oil control ring
(5) from the piston (4).
Note: Identify the orientation of the piston rings for
installation.
SENR9973-01 71
g01114027
Illustration 124
Typical example
4. Remove the nuts (8) for the connecting rod cap
(9). Remove the connecting rod cap (9) from
the connecting rod (1). Remove the bearing
shells (10) from the connecting rod (1) and the
connecting rod cap (9).
g01114056
Illustration 125
Typical example
5. Use a suitable press and a suitable adapter in
order to remove the piston pin bushing (11) from
the connecting rod (1).
i02189011
- Assemble

Assembly Procedure
NOTICE
component life.
NOTICE
Installation of the piston pin bushing must be carried
out by personnel with the correct training. Also special
machinery is required.
1. If the piston pin bushing was removed, refer to
your authorized Perkins dealer or your Perkins
distributor for assistance.
g01114138
Illustration 126
Typical example
2. Align the identication marks (2) on the connecting
rod (1) and the piston (5).
72 SENR9973-01
Note: The Shibaura name inside the piston must
align with the stamped number on the connecting rod.
3. Lubricate the piston pin (4) with clean engine oil.
Install the piston pin (4) into the piston (5) and the
connected rod (1).
Note: If the piston pin cannot be installed by hand,
heat the piston to a temperature of 45 5C
(113 9F).
4. Use suitable pliers to install the two circlips (3).
Ensure that the circlips are seated into the grooves
in the piston (5).
g01114155
Illustration 127
Typical example
Note: Refer to Specications, Pistons and Rings for
more information on piston identication.
g01114373
Illustration 128
typical example
5. Use a suitable ring expander to install the piston
rings onto the piston (5). Use the following
procedure to install the piston rings onto the
piston.
a. Install the oil control ring (6) in the groove that
is lowest on the piston (5). The latch pin (10)
that is on the oil control ring (6) must be inside
the ends of spring (11).
Note: Ensure that the latch pin that is on the oil
control ring is 180 degrees from the oil control ring
gap.
g01114374
Illustration 129
b. Install the intermediate piston ring (7) with the
tapered face into the second groove on the
piston. The step (12) must be toward the top
of the piston.
SENR9973-01 73
c. Install the top piston ring (8) with the barrel
face and the molybdenum insert into the top
groove on the piston.
d. Lubricate the piston rings with clean engine oil.
Position the piston ring gaps (9) at 90 degrees
away from each other.
End By:
a. Install the pistons and the connecting rods.
Refer to Disassembly and Assembly, Piston and
Connecting Rods - Install.
i02801688
- Install

NOTICE
component life.
1. Thoroughly clean all of the components.
Note: Refer to Disassembly and Assembly,
Connecting Rod Bearings - Install for the inspection
procedure of the connecting rod bearings and the
crankshaft connecting rod journals.
2. Apply clean engine oil to the following components:
Crankshaft journals
Inside of the cylinder bores
Piston rings
Connecting rod bearings

Note: The piston and the connecting rod are matched
to a specic cylinder. Ensure that the connecting rod
and the pistons are installed in the correct cylinder.
Note: Do not punch the connecting rod or stamp the
connecting rod assembly as this may cause damage.
3. Rotate the crankshaft until the bearing journal is
at the bottom center.
g01111980
Illustration 130
Typical example
4. Use a suitable piston ring compressor (1) in order
to compress the piston rings.
For the 402C-05 and 403C-07 engines, the piston
ring compressor should be suitable for a piston
67 mm (2.64 inch).
For the 403C-11 and 404C-15 engines, the piston
ring compressor should be suitable for a piston
77 mm (3.03 inch) in diameter.
For the 403C-15, 403C-17, 404C-22 and
404C-22T engines, the piston ring compressor
should be suitable for a piston 84 mm (3.31 inch)
in diameter.
Note: Move the piston rings on the pistons until
the ring openings are separated by approximately
90 degrees. Refer to Disassembly and Assembly,
Pistons and Connecting Rods - Assemble.
g01112036
Illustration 131
Typical example
74 SENR9973-01
5. Put the piston and the connecting rod in the
cylinder bore. Align the identication marks on the
top of the piston to the front of the cylinder block.
Align the identication marks (3) on the side of
the connecting rod to the right side of the cylinder
block.
Note: The right side is determined from the ywheel
end of the engine.
Note: Ensure that the piston ring compressor (1) is
installed correctly in order to allow the piston and the
connecting rod to easily slip into the cylinder block.
Use tape or rubber tubing on the connecting rod bolts
to protect the crankshaft journals.
6. Align the piston and the connecting rod assembly
with the crankshaft. Use a soft faced hammer (2)
to tap the piston into the cylinder bore until the
piston ring compressor (1) comes off the piston.
g01116685
Illustration 132
Typical example
7. Push the piston and the connecting rod assembly
into the cylinder. Guide the connecting rod
assembly onto the connecting rod journal.
8. Install the connecting rod cap (4) and the
connecting rod nuts (5).
For the 402C-05 and 403C-07 engines, tighten
the nuts (5) for the connecting rod cap (4) to a
For the 403C-11 and 404C-15 engines, tighten the
nuts (5) for the connecting rod cap (4) to a torque
For the 403C-15, 403C-17, 404C-22 and
404C-22T engines, tighten the nuts (5) for the
connecting rod cap (4)to a torque of 52 Nm
(38 lb ft).
9. Repeat Steps 1 through 8 for the remainder of the
pistons and connecting rods.
10. Rotate the crankshaft in order to ensure that no
binding occurs.
End By:
a. Install the oil suction pipe. Refer to Disassembly
and Assembly, Engine Oil Pump- Install.
Install.
c. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02186176
Connecting Rod Bearings -
Remove

Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly
Install.
b. Remove the oil supply tube. Refer to Disassembly
and Assembly, Crankshaft - Remove.
NOTICE
component life.
NOTICE
mandates.
Note: The connecting rod and the connecting rod cap
should have matching marks (6) on the right hand
side. Mark the connecting rod (1) and the connecting
rod cap (5), if necessary. The right side of the engine
is determined from the ywheel end.
SENR9973-01 75
g01111763
Illustration 133
Typical example
1. Rotate the crankshaft until the piston is at the
bottom center. Remove the connecting rod nuts
(4) from the connecting rod bolts (2). Remove the
connecting rod cap (5) from the connecting rod (1).
2. Remove the lower bearing shell (3) of the
connecting rod bearing from the connecting rod
cap (5).
3. Carefully push the connecting rod (1) into the
cylinder bore. Remove the upper bearing shell (3)
of the connecting rod from the connecting rod.
Note: Use tape or rubber tubing on the connecting
rod bolts to protect the crankshaft journals. The sharp
edges of the connecting rod bolts could damage the
crankshaft journals.
4. Repeat Steps 1 through 3 for the remaining
connecting rod bearings.
i02186171
Connecting Rod Bearings -
Install

NOTICE
component life.
NOTICE
When the connecting rod caps are installed, ensure
that the identication marks are aligned.
g01111763
Illustration 134
Typical example
1. Check the clearance between the connecting rod
bearing and the connecting rod bearing journal of
the crankshaft. Install the connecting rod bearings
dry when the clearance checks are made. Refer to
Disassembly and Assembly, Bearing Clearance
- Check for information on bearing clearance
checks.
2. Clean the bearing surface of the connecting rod
(1) and the connecting rod cap (5). Ensure that the
number (6) on the connecting rod cap (5) aligns
with the number (6) on the connecting rod (1).
3. Clean the upper connecting rod bearing (3) and
lubricate the bearing face with clean engine oil.
4. Clean the lower connecting rod bearing (3) and
lubricate the bearing face with clean engine oil.
Note: Align the tabs on the back of the connecting rod
bearings (3) with the tab grooves in the connecting
rod (1) and the tab grooves on the connecting rod
cap (5).
5. Install the upper connecting rod bearing (3) to the
connecting rod (1).
6. Position the connecting rod (1) against the
crankshaft.
7. Install the lower connecting rod bearing (3) in the
connecting rod cap (5).
76 SENR9973-01
8. Install the connecting rod cap (5) in position on
the connecting rod (1) and install the nuts (4) to
the connecting rod bolts (2). Refer to Disassembly
and Assembly, Pistons and Connecting Rods -
Install for the correct torque of the connecting rod
nuts (4).
Note: The identication marks must face the right
hand side of the engine for the correct installation.
9. Repeat Steps 2 through 8 for the installation of the
remaining connecting rod bearings.
End By:
a. Install the oil supply tube. Refer to Disassembly
and Assembly, Crankshaft - Install.
Install.
i02801692
Crankshaft Main Bearings -
Remove

Removal Procedure
Start By:
a. Remove the crankshaft. Refer to Disassembly and
Assembly, Crankshaft - Remove.
NOTICE
component life.
Crankshaft Main Bearings
g00830378
Illustration 135
Note: Mark the halves of the main bearing carriers
for later installation.
1. Remove the setscrews (1) that secure the upper
half of main bearing cap (2) to the lower half of
main bearing cap (7).
2. Separate the upper half of main bearing cap (2)
from the lower half of main bearing cap (7).
Note: Dowels (5) are installed in each bearing cap
in order to align the two halves of the main bearing
carrier.
Note: Thrust washers are only installed on the
403C-15, 403C-17, 404C-22 and 404C-22T engines.
3. For 403C-15 and 403C-17 engines, remove the
lower thrust washers (3).
For 404C-22 and 404C-22T engines, remove the
lower thrust washers (3) and the upper thrust
washer (6).
4. Remove the main bearings (4) from the main
bearing caps.
Crankshaft Bearing (Front)
Table 8
27610275 Driver Gp 1
SENR9973-01 77
g01107352
Illustration 136
1. Remove the bush for the crankshaft (1). Use
Tooling (2) and a hammer to drive out the bush for
the crankshaft (1) from the inside of the cylinder
block (3).
i02801697
Crankshaft Main Bearings -
Install

Crankshaft Main Bearings
g00830378
Illustration 137
1. Install the main bearings (4) into the halves of the
main bearing caps.
2. Position the upper half of the main bearing cap (2)
in position on the crankshaft. Position the lower
half ofthe main bearing cap (7) in position on the
crankshaft.
Note: Refer to the identication marks that have
been made on the main bearing carriers for correct
alignment.
Note: Ensure that the dowels (5) are in the correct
position. This will ensure that the two halves of the
main bearing caps are aligned.
Note: Ensure that the lubricating oil holes align with
the oil feed holes in the cylinder block.
Note: Thrust washers are only installed to 403C-15,
403C-17, 404C-22 and 404C-22T engines.
3. For 403C-15 and 403C-17 engines, install the two
lower thrust washers (3).
For 404C-22 and 404C-22T engines, install the
two lower thrust washers (3) and the upper thrust
washer (6).
Note: Ensure that the thrust washers are aligned
correctly and that the oil grooves are facing the
crankshaft.
4. Install the setscrews (1).
For the 402C-05, 403C-07, 403C-11, 403C-15,
403C-17 and 404C-15 engines, tighten the
For the 404C-22 and 404C-22T engines, tighten
Bush for the Crankshaft (Front)
Table 9
Required Tools
27610275 Driver Gp 1
78 SENR9973-01
g01107393
Illustration 138
1. Install the bush for the crankshaft (1). Use Tooling
(6) and a hammer to drive in the bush for the
crankshaft (1) from the outside of the cylinder
block (5).
Note: Ensure that the oil supply hole (4) is aligned
with the oil gallery in the cylinder block (5).
Note: Ensure that the chamfered side (3) of the bush
for the crankshaft (1) is facing toward the cylinder
block (5) and that the joint (2) of the bush for the
crankshaft (1) is facing toward the top of the cylinder
block (5).
End By:
a. Install the crankshaft. Refer to Disassembly and
Assembly, Crankshaft - Install.
i02192828
Crankshaft - Remove

Removal Procedure
Start By:
a. Remove the engine oil relief valve. Refer to
Disassembly and Assembly, Engine Oil Relief
Valve - Remove and Install.
b. Remove the ywheel. Refer to Disassembly and
Assembly, Flywheel - Remove and Install.
c. Remove the housing for the crankshaft rear seal.
Refer to Disassembly and Assembly, Crankshaft
Rear Seal - Remove.
d. Remove the engine oil pump. Refer to
Disassembly and Assembly, Engine Oil Pump
- Remove.
e. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, Pistons and
Connecting Rods - Remove.
NOTICE
component life.
SENR9973-01 79
g01107623
Illustration 139
Typical example
1. Remove the bolts (3) from the crankcase cross
member.
2. Remove the two allen head screws (2) that are
recessed. The allen head screws are located at
the rear of the engine.
3. Place the rear of the engine in an upward position.
Attach a suitable lifting device (1) to the crankshaft
and the main bearing assembly (6).
4. Lift the crankshaft (6) and the main bearing
assembly from cylinder block (5). Do not scratch
any of the nished surfaces on the crankshaft.
80 SENR9973-01
i02801706
Crankshaft - Install

g01109599
Illustration 140
Typical example
NOTICE
Ensure that the oil passages in the main bearings align
with the oil passages in the cylinder block.
1. Lower the crankshaft and the main bearing
assembly (9) into the cylinder block (8). Do
not scratch any of the nished surfaces on the
crankshaft.
2. Align the two setscrew holes (2) in the main
bearing assembly (9) to the two holes in the
cylinder block (6).
3. Install the two allen head screws (3) that are
recessed. The allen head screws are located at
the rear of the engine.
Tighten the allen head screws (3) to a torque of
27 Nm (20 lb ft).
4. Ensure that the three setscrew holes (7) in the
main bearing assembly (9) are aligned to the three
holes (5) in the cylinder block (8).
Note: The third hole in the main bearing assembly
(7) is not shown.
5. Install the three setscrews (4) in the holes in the
cylinder block (5).
SENR9973-01 81
For the 402C-05, 403C-07, 403C-11 and 404C-15
engines, tighten the setscrews (4) to a torque of
27 Nm (20 lb ft).
For the 403C-15, 403C-17, 404C-22 and
404C-22T engines, tighten the setscrews (4) to a
6. Check the crankshaft for end play. Force the
crankshaft toward the front of the engine and
insert a feeler gauge between the rear thrust
washer and the crankshaft. Alternatively, install a
dial indicator to one end of the crankshaft. Force
the crankshaft to the front of the engine and then
force the crankshaft to the rear of the engine.
Record the variation on the dial indicator. Refer
to Specications, Crankshaft for the maximum
permissible crankshaft end play.
End By:
a. Install the pistons and the connecting rods. Refer
to Disassembly and Assembly, Pistons and
Connecting Rods - Install.
b. Install the engine oil pump. Refer to Disassembly
and Assembly, Engine Oil Pump - Install.
c. Install the housing for the crankshaft rear seal.
Refer to Disassembly and Assembly, Crankshaft
Rear Seal - Install.
d. Install the ywheel. Refer to Disassembly and
e. Install the engine oil relief valve. Refer to
Disassembly and Assembly, Engine Oil Relief
Valve - Remove and Install.
i01996219
Bearing Clearance - Check

Measurement Procedure
Table 10
Required Tools
Part Description Qty
Plastic Gauge (Green)
0.025 to 0.076 mm
(0.001 to 0.003 inch)
1
Plastic Gauge (Red)
0.051 to 0.152 mm
(0.002 to 0.006 inch)
1
Plastic Gauge (Blue)
0.102 to 0.229 mm
(0.004 to 0.009 inch)
1
Plastic Gauge (Yellow)
0.230 to 0.510 mm
(0.009 to 0.020 inch)
1
NOTICE
component life.
Note: Perkins does not recommend the checking of
the actual bearing clearances particularly on small
engines. This is because of the possibility of obtaining
inaccurate results and the possibility of damaging the
bearing or the journal surfaces. Each Perkins engine
bearing is quality checked for specic wall thickness.
Note: The measurements should be within
specications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, the use of Plastic Gauge is an
acceptable method. Plastic Gauge is less accurate
on journals with small diameters if clearances are
less than 0.10 mm (0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
The technician must be very careful to use Plastic
Gauge correctly. The following points must be
remembered:
82 SENR9973-01
Ensure that the backs of the bearings and the

bores are clean and dry.
Ensure that the bearing locking tabs are properly

seated in the tab grooves.
The crankshaft must be free of oil at the contact

points of the Plastic Gauge.
1. Put a piece of the Plastic Gauge on the crown of
the bearing that is in the cap.
Note: Do not allow the Plastic Gauge to extend over
the edge of the bearing.
2. Use the correct torque-turn specications in order
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
when the cap is installed.
Note: Do not turn the crankshaft when the Plastic
Gauge is installed.
3. Carefully remove the cap, but do not remove
the Plastic Gauge. Measure the width of the
Plastic Gauge while the Plastic Gauge is in the
bearing cap or on the crankshaft journal. Refer
to Illustration 141.
g00953605
Illustration 141
Typical Example
4. Remove all of the Plastic Gauge before you install
the bearing cap.
Note: When the Plastic Gauge is used, the readings
can sometimes be unclear. For example, all parts of
the Plastic Gauge are not the same width. Measure
the major width in order to ensure that the parts are
within the specication range. Refer to Specications
Manual, Connecting Rod Bearing Journal and
Specications Manual, Main Bearing Journal for the
correct clearances.
i02801717
Coolant Temperature Switch -
Remove and Install

403C-15, 403C-17, 404C-15,
404C-22, and 404C-22T Engines)
NOTICE
component life.
NOTICE
mandates.
a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
Maintenance Section.
SENR9973-01 83
g00830643
Illustration 142
Typical example
2. Remove the coolant temperature switch (1) from
the water temperature regulator housing (2).
3. Clean the coolant temperature switch. Inspect
the coolant temperature switch (1) for damage. If
the coolant temperature switch is damaged, use
a new part for replacement. For information on
testing the coolant temperature switch for correct
operation, refer to Testing and Adjusting, Coolant
Temperature Switch - Test.
Removal Procedure (402C-05, and
403C-07 Engines)
NOTICE
component life.
NOTICE
mandates.
a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
Maintenance Section.
g01121721
Illustration 143
Typical example
2. Remove the coolant temperature switch (1) from
the water pump housing (2).
3. Clean the coolant temperature switch. Inspect
the coolant temperature switch (1) for damage. If
the coolant temperature switch is damaged, use
a new part for replacement. For information on
testing the coolant temperature switch for correct
operation, refer to Testing and Adjusting, Coolant
Temperature Switch - Test.
403C-15, 403C-17, 404C-15,
404C-22, and 404C-22T Engines)
NOTICE
component life.
g00830643
Illustration 144
Typical example
1. If a used coolant temperature switch is installed,
apply 21820122 POWERPART Pipe sealant to
the threads of the coolant temperature switch (1).
2.
84 SENR9973-01
3. Install the coolant temperature switch (1) into
the water temperature regulator housing. Tighten
the coolant temperature switch (1) to a torque of
27 Nm (20 lb ft).
Manual, Rell Capacities for additional
information.
NOTICE
component life.
g01121721
Illustration 145
Typical example
1. If a used coolant temperature switch is installed,
apply 21820122 POWERPART Pipe sealant to
the threads of the coolant temperature switch (1).
2. Install the coolant temperature switch (1) into
the water pump housing (2). Tighten the coolant
temperature switch (1) to a torque of 27 Nm
(20 lb ft).
Manual, Rell Capacities for additional
information.
i02195380
Engine Oil Pressure Switch -
Remove and Install

Removal Procedure
NOTICE
component life.
NOTICE
mandates.
Note: The engine oil pressure switch can be located
in one of two positions. The oil pressure switch can
be located in the valve mechanism cover (1), or in
the cylinder block (2). Refer to Specications Manual,
Engine Oil Pressure Switch for the correct location.
SENR9973-01 85
g01130227
Illustration 146
Typical example
1. If the oil pressure switch is located in the valve
mechanism cover, remove the engine oil pressure
switch.
If the oil pressure switch is located in the cylinder
block, remove the engine oil pressure switch
and adapter assembly. Remove the engine oil
pressure switch from the adapter.
2. Clean the oil pressure switch.
Note: The engine oil pressure switch can be located
in one of two positions. The oil pressure switch can
be located in the valve mechanism cover (1), or in
the cylinder block (2). Refer to Specications Manual,
Engine Oil Pressure Switch for the correct location.
g01130227
Illustration 147
Typical example
1. If a used engine oil pressure switch is installed,
apply a thin layer of 21820122 POWERPART
Pipe sealant to the threads of the engine oil
pressure switch.
2. If the oil pressure switch is located in the valve
mechanism cover, install the engine oil pressure
switch (1). Tighten the oil pressure switch to a
torque of 11 Nm (8.1 lb ft).
If the oil pressure switch is located in the cylinder
block (2), install the engine oil pressure switch
to the adapter. Tighten the engine oil pressure
switch to a torque of 23 Nm (16.9 lb ft). Install the
adapter and oil pressure switch assembly to the
cylinder block. Tighten the adapter to a torque of
11 Nm (8.1 lb ft).
86 SENR9973-01
i02801718
Glow Plugs - Remove and
Install

Removal Procedure
Start By:
a. Remove the fuel injection lines, if necessary. Refer
to Disassembly and Assembly, Fuel Injection
Lines - Remove and Install.
Disconnect batteries before performance of any
service work.
NOTICE
component life.
g00820321
Illustration 148
Typical example
1. Remove the nuts (1) and the washers (2) from the
bus bar (3) on the glow plugs (4).
2. Remove the bus bar (3) from the glow plugs (4).
3. Remove the glow plugs (4) from the cylinder head.
NOTICE
component life.
g00820321
Illustration 149
Typical example
1. Install the glow plugs (4) in the cylinder head.
For the 402C-05,402C-07,403C-11 and 404C-15
engines, tighten the glow plugs to a torque of
11.5 Nm (8.5 lb ft).
For the 403C-15,403C-17,404C-22 and 404C-22T
engines, tighten the glow plugs to a torque of
17.5 Nm (13 lb ft).
2. Install the bus bar (3) on the glow plugs (4).
3. Install the washers (2) and the nuts (1) on the
glow plugs (4). Tighten the nuts (1) to a torque
of 1.2 Nm (10.6 lb in).
End By:
a. Install the fuel injection lines, if necessary. Refer to
i02196372
V-Belts - Remove and Install

Removal Procedure
NOTICE
component life.
SENR9973-01 87
g01109566
Illustration 150
Typical example
1. Loosen setscrew (1) and setscrew (2). Loosen the
fasteners (4) on the alternator (3).
2. Push the alternator (3) toward the engine and
remove the V-belt (5).
NOTICE
component life.
g01109566
Illustration 151
Typical example
1. Check the condition of the V-belt (5). If the
V-belt is worn or damaged, use a new V-belt for
replacement.
2. Install the V-belt (5) in position on the engine.
3. Slide the alternator (3) away from the engine.
Tighten the setscrew (1) and setscrew (2) to
a torque of 25.5 Nm (18.8 lb ft). Tighten the
fasteners (4) to a torque of 25.5 Nm (18.8 lb ft) for
the alternator (3). Refer to Testing and Adjusting,
Belt Tension Chart for more information on the
correct belt tension.
i02801722
Fan - Remove and Install

404C-22T Engines)
Start By:
a. Remove the V-Belts. Refer to Disassembly and
88 SENR9973-01
g01110541
Illustration 152
Typical example
1. Remove the four setscrews (1) from the fan (2)
and remove the fan (2) from the adapter (4).
2. Remove the four allen head screws (3) that secure
the adapter (4) and the pulley (5) to the water
pump (6).
3. Remove the adapter (4) and the pulley (5) from
the water pump (6).
403C-07, 403C-11, 403C-15,
403C-17 and 404C-15 Engines)
Start By:
SENR9973-01 89
g01116343
Illustration 153
Typical example
1. Remove the four setscrews (1) that secure the fan
(2), the spacer (3) and the pulley (4) to the water
pump (5).
2. Remove the fan (2), the spacer (3) and the pulley
(4) from the water pump (5).
90 SENR9973-01
and 404C-22T Engines)
g01110541
Illustration 154
Typical example
1. Install the pulley (5) and the adapter (4) in position
on the water pump (6) and ensure that the
setscrew holes are aligned.
2. Install the four allen head screws (3) in position
on the adapter (4) and align the setscrews with
the setscrew holes in pulley (5) and the setscrew
holes in the water pump (6). Tighten the four allen
head screws (3) to a torque of 10 Nm (7 lb ft).
3. Position the fan (2) so that the setscrew holes
align with the setscrew holes in adapter (4).
4. Install the four setscrews (1) onto the fan (2) and
hand tighten the setscrews.
5. Tighten the four setscrews (1) to a torque of
11 Nm (8 lb ft).
End By:
a. Install the V-Belts. Refer to Disassembly and
Assembly, V-Belts - Remove and Install .
SENR9973-01 91
403C-07, 403C-11, 403C-15, 403C-17
g01116343
Illustration 155
Typical example
1. Install the pulley (4), the spacer (3) and the fan (2)
in position on the water pump (5) and ensure that
the setscrew holes are aligned.
2. Install the four setscrews (1) into the fan (2), the
spacer (3) and the pulley (4) and hand tighten the
setscrews.
3. Tighten the four setscrews to a torque of 11 Nm
(8 lb ft).
End By:
Assembly, V-Belts - Remove and Install .
i02196771
Alternator - Remove and Install

Removal Procedure for the 14 AMP
Alternator
Start By:
Note: Disconnect all electrical connections to the
alternator before proceeding. Mark the connections
or identify the connections for future installation.
92 SENR9973-01
g01122900
Illustration 156
Typical example
1. Remove the bolt (1), the washer (3) and the nut
(4) from the alternator (2).
2. Remove the setscrew (5) that fastens the
alternator (2) to the engine.
3. Remove the alternator (2) from the engine.
Alternator
Start By:
SENR9973-01 93
g01122906
Illustration 157
Typical example
(4) from the alternator (2).
2. Remove the setscrew (5) that fastens the
alternator (2) to the engine.
Alternator
Start By:
94 SENR9973-01
g01122919
Illustration 158
Typical example
1. Remove the setscrew (6), the washer (5) and the
spacer (1) from the alternator (2).
2. Remove the setscrew (4) and the washer (3) that
fastens the alternator (2) to the engine.
Alternator
Start By:
SENR9973-01 95
g01110800
Illustration 159
Typical example
1. Remove the setscrew (1) and the washer (2) from
the alternator (3).
2. Remove the two bolts (6), the two washers (5)
and the two nuts (4) that fasten the alternator (3)
to the engine.
and the 85 AMP Alternator
Start By:
96 SENR9973-01
g01123177
Illustration 160
Typical example
1. Remove the setscrew (2) and the washer (1) from
the alternator (3).
(6) that fastens the alternator (3) to the engine.
SENR9973-01 97
Installation Procedure for the 14
AMP Alternator
g01122900
Illustration 161
Typical example
1. Position the alternator (2) on the engine.
2. Install the setscrew (5) that fastens the alternator
(2) to the engine.
3. Install the bolt (1), the washer (3) and the nut (4)
to the alternator (2).
4. Hand tighten the setscrew (5), the bolt (1) and the
nut (4) on the alternator (2).
Note: When you install the alternator, ensure that the
alternator pulley is in alignment with the crankshaft
pulley within one degree.
Note: Reconnect all electrical connections to the
alternator before operating the engine.
End By:
98 SENR9973-01
AMP Alternator
g01122906
Illustration 162
Typical example
2. Install the setscrew (5) that fastens the alternator
(2) to the engine.
to the alternator (2).
4. Hand tighten the setscrew (5), the bolt (1) and the
nut (4) on the alternator (2).
End By:
SENR9973-01 99
AMP Alternator
g01122919
Illustration 163
Typical example
2. Install the setscrew (4) and the washer (3) that
fastens the alternator (2) to the engine.
3. Install the setscrew (6), the washer (5) and the
spacer (1) to the alternator (2).
4. Hand tighten the setscrew (4) and the setscrew
(6) on the alternator (2).
End By:
100 SENR9973-01
AMP Alternator
g01110800
Illustration 164
Typical example
2. Install the two bolts (6), the two washers (5) and
the two nuts (4) that fasten the alternator (3) on
the engine.
3. Install the setscrew (1) and the washer (2) to the
alternator (3).
4. Hand tighten the two bolts (6), the two nuts (4)
and the setscrew (1) on the alternator (3) .
End By:
SENR9973-01 101
AMP and the 85 AMP Alternator
g01123177
Illustration 165
Typical example
that fastens the alternator (3) to the engine.
3. Install the setscrew (2) and the washer (1) to the
alternator (3).
4. Hand tighten the bolt (4), the nut (6) and the
setscrew (2) on the alternator (3).
End By:
i02801726
Electric Starting Motor -
Remove and Install

Removal Procedure
Start By:
a. Disconnect all electrical connections to the
electric starting motor before proceeding. Mark
all connections or identify all connections for later
installation.
102 SENR9973-01
g01117494
Illustration 166
Typical example
1. Remove the fasteners (1) that secure the electric
starting motor (2) to the engine.
For the 403C-11, 403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T engines, the electric
starting motor is secured to the engine with bolts,
washers and nuts (not shown).
For the 402C-05 and 403C-07 engines, the
electric starting motor is secured to the engine
with setscrews and washers.
2. Remove the electric starting motor (2) from the
engine.
g01117494
Illustration 167
Typical example
1. Install the electric starting motor (2) in position on
the engine.
2. Install the fasteners (1) that secure the electric
starting motor (2) to the engine.
For the 403C-11, 403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T engines, the electric
starting motor is secured to the engine with bolts,
washers and nuts (not shown).
For the 402C-05 and 403C-07 engines, the
electric starting motor is secured to the engine
with setscrews and washers.
Tighten the fasteners to a torque of 50 Nm
(36.9 lb ft).
End By:
a. Reconnect all electrical connections to the electric
starting motor before you operate the engine.
SENR9973-01 103
Index Section
Index
A
Alternator - Remove and Install ............................. 91
Installation Procedure for the 14 AMP
Alternator.......................................................... 97
Alternator.......................................................... 98
Alternator.......................................................... 99
Alternator........................................................ 100
Installation Procedure for the 65 AMP and the 85
AMP Alternator............................................... 101
Removal Procedure for the 14 AMP Alternator.. 91
Removal Procedure for the 65 AMP and the 85
AMP Alternator................................................. 95
B
Bearing Clearance - Check ................................... 81
Measurement Procedure ................................... 81
C
Camshaft - Assemble ............................................ 66
Assembly Procedure.......................................... 66
Camshaft - Disassemble ....................................... 65
Disassembly Procedure..................................... 65
Camshaft - Install................................................... 66
Installation Procedure ........................................ 66
Camshaft - Remove............................................... 64
Removal Procedure........................................... 64
Connecting Rod Bearings - Install ......................... 75
Connecting Rod Bearings - Remove..................... 74
Coolant Temperature Switch - Remove and
Install ................................................................... 82
Installation Procedure (402C-05, and 403C-07
Engines) ........................................................... 84
Installation Procedure (403C-11, 403C-15,
403C-17, 404C-15, 404C-22, and 404C-22T
Engines) ........................................................... 83
Removal Procedure (402C-05, and 403C-07
Engines) ........................................................... 83
Removal Procedure (403C-11, 403C-15, 403C-17,
404C-15, 404C-22, and 404C-22T Engines) ... 82
Crankcase Breather - Remove and Install............. 51
Installation Procedure (Naturally Aspirated
Engines) ........................................................... 52
Installation Procedure (Turbocharged
Engines) ........................................................... 53
Removal Procedure (Naturally Aspirated
Engines) ........................................................... 51
Removal Procedure (Turbocharged Engines) ... 51
Crankshaft - Install................................................. 80
Installation Procedure........................................ 80
Crankshaft - Remove............................................. 78
Removal Procedure ........................................... 78
Crankshaft Front Seal - Install ............................... 43
Crankshaft Front Seal - Remove........................... 43
Crankshaft Main Bearings - Install......................... 77
Crankshaft Main Bearings - Remove..................... 76
Crankshaft Pulley - Remove and Install ................ 42
Crankshaft Rear Seal - Install................................ 37
Crankshaft Rear Seal - Remove............................ 37
Cylinder Head - Install ........................................... 61
Cylinder Head - Remove....................................... 60
D
Disassembly and Assembly Section........................ 4
E
Electric Starting Motor - Remove and Install ....... 101
Installation Procedure...................................... 102
Removal Procedure ......................................... 101
Engine Oil Cooler - Remove and Install ................ 23
Engine Oil Line - Remove and Install .................... 21
Engine Oil Pan - Remove and Install..................... 67
Engine Oil Pressure Switch - Remove and Install .. 84
Engine Oil Pump - Install ....................................... 26
Engine Oil Pump - Remove................................... 24
Engine Oil Relief Valve - Remove and Install ........ 24
Exhaust Manifold - Remove and Install ................. 15
104 SENR9973-01
Index Section
F
Fan - Remove and Install ...................................... 87
403C-11, 403C-15, 403C-17 and 404C-15
Engines) ........................................................... 91
Installation Procedure (404C-22 and 404C-22T
Engines) ........................................................... 90
403C-15, 403C-17 and 404C-15 Engines)....... 88
Removal Procedure (404C-22 and 404C-22T
Engines) ........................................................... 87
Flywheel - Install .................................................... 36
Flywheel - Remove................................................ 35
Flywheel Housing - Remove and Install ................ 39
Installation Procedure (Engines with Flywheel
Housing and Back plate) .................................. 40
Installation Procedure (Engines with Flywheel
Housing)........................................................... 41
Removal Procedure (Engines with Flywheel
Housing and Back plate) .................................. 39
Removal Procedure (Engines with Flywheel
Housing)........................................................... 40
Fuel Filter Base - Install ........................................... 6
Installation Procedure .......................................... 6
Fuel Filter Base - Remove....................................... 5
Removal Procedure............................................. 5
Fuel Injection Lines - Remove and Install................ 7
Removal Procedure............................................. 7
Fuel Injection Pump - Install ................................... 11
Installation Procedure ......................................... 11
Fuel Injection Pump - Remove .............................. 10
Fuel Injector - Install .............................................. 12
Fuel Injector - Remove .......................................... 12
Fuel Priming Pump - Install ..................................... 4
Fuel Priming Pump - Remove ................................. 4
Removal Procedure ............................................. 4
Fuel Shutoff Solenoid - Remove and Install ............ 9
Removal Procedure ............................................. 9
G
Glow Plugs - Remove and Install .......................... 86
H
Housing (Front) - Assemble................................... 47
Housing (Front) - Disassemble.............................. 45
Housing (Front) - Install ......................................... 50
Housing (Front) - Remove..................................... 44
I
Important Safety Information................................... 2
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 17
Inlet and Exhaust Valves - Remove and Install ..... 19
L
Lifter Group - Remove and Install.......................... 63
P
Pistons and Connecting Rods - Assemble ............ 71
Pistons and Connecting Rods - Disassemble ....... 69
Pistons and Connecting Rods - Install................... 73
Pistons and Connecting Rods - Remove............... 68
R
Rocker Shaft - Assemble....................................... 57
Assembly Procedure (402C-05, 403C-07, 403C-11
and 404C-15 engines)...................................... 57
Assembly Procedure (403C-15, 403C-17, 404C-22
and 404C-22T engines) ................................... 58
Rocker Shaft - Disassemble.................................. 56
Disassembly Procedure (402C-05, 403C-07,
403C-11 and 404C-15 engines) ....................... 56
Disassembly Procedure (403C-15, 403C-17,
404C-22 and 404C-22T engines)..................... 56
Rocker Shaft and Pushrod - Install ........................ 59
Rocker Shaft and Pushrod - Remove.................... 55
T
Table of Contents..................................................... 3
SENR9973-01 105
Index Section
Turbocharger - Remove and Install ....................... 13
Installation procedure......................................... 14
Removal procedure............................................ 13
V
V-Belts - Remove and Install ................................. 86
Valve Mechanism Cover - Remove and Install ...... 54
W
Water Pump - Install .............................................. 30
Installation Procedure (402C-05 and 403C-07
Engines) ........................................................... 31
403C-17, 404C-15, 404C-22 and 404C-22T
Engines) ........................................................... 30
Water Pump - Remove.......................................... 28
Removal Procedure (402C-05 and 403C-07
Engines) ........................................................... 29
404C-15, 404C-22 and 404C-22T Engines) .... 28
Water Temperature Regulator - Remove and
Install ................................................................... 32
Installation Procedure (402C-05 and 403C-07
engines) ........................................................... 34
403C-17, 404C-15, 404C-22 and 404C-22T
engines) ........................................................... 34
Removal Procedure (402C-05 and 403C-07
engines) ........................................................... 32
404C-15, 404C-22 and 404C-22T engines)..... 33
Water Temperature Regulator Housing - Remove and
Install ................................................................... 31
106 SENR9973-01
Index Section
SENR9973-01 107
Index Section
2007 Perkins Engines Company Limited
All Rights Reserved Printed in U. K.

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SENR9973-01

Oil pump cover (5)

Inner rotor (4)

Oil pump cover (5)

Rocker arm (3)

Rocker arm (3)

Rocker arm (3)

Rocker arm (3)

Crankshaft gear (3)

Camshaft gear (4)

Idler gear (5)

Crankshaft gear (3)

Camshaft gear (4)

Idler gear (5)

Inside of the cylinder bores

Connecting rod bearings

Ensure that the backs of the bearings and the

Ensure that the bearing locking tabs are properly

The crankshaft must be free of oil at the contact

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