Professional Documents
Culture Documents
September 2007
Disassembly and
Assembly
400C Industrial Engine
HB (Engine)
HD (Engine)
HH (Engine)
HL (Engine)
HM (Engine)
HN (Engine)
HP (Engine)
HR (Engine)
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Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
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. If 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
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
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SENR9973-01 3
Table of Contents
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4 SENR9973-01
Disassembly and Assembly Section
Disassembly and Assembly 2. Install suitable plugs into the fuel lines in order to
prevent contamination.
Section
3. Remove the two setscrews (4) that fasten the fuel
priming pump (1) to the cylinder block.
i02186288
Fuel Priming Pump - Remove 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
flange (2) of the fuel priming pump (1) for assembly.
Removal Procedure 4. Remove the fuel priming pump (1) and the O-ring
(3). Discard the O-ring.
NOTICE
Keep all parts clean from contaminants. Note: In order to remove the fuel priming pump
from the engine, it may be necessary to rotate the
Contaminants may cause rapid wear and shortened crankshaft until the operating plunger of the fuel
component life. priming pump is not under pressure.
i02186279
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Fuel Priming Pump - Install
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids. Installation Procedure
Dispose of all fluids according to local regulations and NOTICE
mandates. Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
g00824616
Illustration 1
Typical example
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SENR9973-01 5
Disassembly and Assembly Section
i02186242
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
g01129954
Illustration 2 nent containing fluids.
Typical example
Dispose of all fluids according to local regulations and
1. Clean the mating surfaces of the fuel priming mandates.
pump on the cylinder block and clean the flange
(2) of the fuel priming pump.
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6 SENR9973-01
Disassembly and Assembly Section
i02186227
Installation Procedure
NOTICE g01118406
Keep all parts clean from contaminants. Illustration 4
Typical example
Contaminants may cause rapid wear and shortened
component life. 1. Align the fuel filter 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).
This document has been printed from SPI. Not for Resale
SENR9973-01 7
Disassembly and Assembly Section
End By:
i02801636
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
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8 SENR9973-01
Disassembly and Assembly Section
g00824793
Illustration 6
404C-22 and 404C-22T engines
The nozzles will be damaged if the top of the injector The 402C-05, 403C-07, 403C-11 and 404C-15
turns in the body. engines have a flexible fuel return hose.
The engine will be damaged if a defective fuel injector For engines with a flexible fuel return hose,
is used because the shape of fuel (spray pattern) that connect the fuel return hose to the banjo piece
comes out of the nozzle will not be correct. and tighten the union nut.
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SENR9973-01 9
Disassembly and Assembly Section
i02207974
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
g00818680 to collect the fluid with suitable containers before
Illustration 8
opening any compartment or disassembling any com-
404C-22 and 404C-22T engines ponent containing fluids.
5. Remove the plastic plugs from the fuel injection Dispose of all fluids according to local regulations and
lines (2) and remove the plastic plugs from the mandates.
outlet connections of the fuel injection pump.
Install the fuel injection lines to the engine as a
unit.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
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10 SENR9973-01
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
i02797470
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
g00825137
Illustration 12
Contaminants may cause rapid wear and shortened Typical example
component life.
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.
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SENR9973-01 11
Disassembly and Assembly Section
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
g00825137
ing, adjusting, and repair of the product. Be prepared Illustration 14
to collect the fluid with suitable containers before Typical example
opening any compartment or disassembling any com-
ponent containing fluids. 3. Position the fuel injection pump (1) close to the
mounting face of the cylinder block, and connect
Dispose of all fluids according to local regulations and the link (6) and the fuel rack control (5) with the
mandates. clip (7).
Note: The installation procedure is similar for the 4. Put the fuel injection pump (1) in position on the
two cylinder, the three cylinder and the four cylinder mounting face of the cylinder block.
engines. The illustrations show the four cylinder
engine. 5. Install the setscrews (4) and the nuts (2) that
fasten the fuel injection pump to the cylinder block.
1. Clean the mounting face of the fuel injection pump
on the cylinder block. Clean the mating surface of For 402C-05, 403C-07, 403C-11 and 404C-15
the fuel injection pump. engines, tighten the setscrews (4) and the nuts (2)
to a torque of 6 Nm (53 lb in).
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12 SENR9973-01
Disassembly and Assembly Section
End By:
i02801638
Removal Procedure
Start By:
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI. Not for Resale
SENR9973-01 13
Disassembly and Assembly Section
i02186260
Removal procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
Illustration 16
g01113718 to collect the fluid with suitable containers before
Typical example
opening any compartment or disassembling any com-
ponent containing fluids.
1. Clean the injector bore in the cylinder head.
Ensure that no debris enters the cylinder head. Dispose of all fluids according to local regulations and
Clean the threads on the body of the injector. mandates.
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14 SENR9973-01
Disassembly and Assembly Section
4. Remove the setscrews (15) and remove the Contaminants may cause rapid wear and shortened
support bracket for the turbocharger (16). Note component life.
the position of the support bracket for installation.
1. Remove all of the plastic plugs from all of the ports
5. Remove the setscrews (22). Remove the exhaust of the turbocharger (1). Clean the mating surfaces
elbow (21) from the turbocharger (1). Remove of the exhaust manifold and the turbocharger.
the gasket for the exhaust elbow (20) from the
turbocharger. Discard the gasket.
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SENR9973-01 15
Disassembly and Assembly Section
3. If the studs (17) were previously removed, install 10. Position the new washers (2) and the oil supply
the studs into the exhaust manifold. Install a new tube assembly (8) onto the turbocharger (1).
gasket (23) over the studs (17). Install the banjo bolt (3). Tighten the banjo bolt to
a torque of 18 Nm (13 lb ft).
Note: Do not use any sealant on the gasket (23).
11. If necessary, install a new O-ring (9) and the oil
Note: Do not use the actuator rod of the wastegate supply tube assembly (8) to the cylinder block.
to lift the turbocharger (1). Install the setscrews (7). Tighten the setscrews to
a torque of 10 Nm (7 lb ft).
4. Position the turbocharger (1) onto the exhaust
manifold. 12. If necessary, install the spacer (not shown) and
install the setscrews (not shown) to the tube clips
5. Install the washers (18) and install the nuts (19). (6). Torque the setscrews to 10 Nm (7 lb ft).
Tighten the nuts to a torque of 25 Nm (18 lb ft).
Note: Ensure that the oil supply tube assembly (8)
6. Lubricate the bearing housing of the turbocharger does not come into contact with any other component
(1) with clean engine oil. Apply the lubricant when the assembly is installed onto the engine.
through the oil supply port (24).
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.
g01114005 i02801640
Illustration 20
7. Clean the oil supply tube assembly (8) and the oil
Exhaust Manifold - Remove
drain tube assembly (11). Inspect the oil supply and Install
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 Removal Procedure
assembly (11) onto the bottom of the turbocharger.
Install the setscrews (13). Tighten the setscrews
NOTICE
to a torque of 10 Nm (7 lb ft).
Keep all parts clean from contaminants.
9. If necessary, position a new joint (10) and the oil
Contaminants may cause rapid wear and shortened
drain tube assembly (11) onto the cylinder block.
component life.
Install the setscrews (12). Tighten the setscrews
to a torque of 10 Nm (7 lb ft).
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16 SENR9973-01
Disassembly and Assembly Section
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 22
Typical example
g00825291
Illustration 21 1. If necessary, install the exhaust manifold studs
Typical example (2) to cylinder head (1).
1. Loosen the nuts (5) and the setscrews (6). 2. Install a new exhaust manifold gasket (3) to the
cylinder head (1).
Note: In order to prevent distortion of the exhaust
manifold, loosen the outer fasteners first. Note: Do not use any sealant on the exhaust
manifold gasket.
2. Remove the nuts (5) and the setscrews (6).
3. Put the exhaust manifold (4) in position on the
Note: Identify setscrews of different lengths so cylinder head (1).
that the setscrews can be reinstalled in the correct
positions. 4. Install the nuts (5) and the setscrews (6).
3. Remove the exhaust manifold (4) from the cylinder Note: Ensure that setscrews with different lengths
head (1). are installed in the correct holes.
4. Remove the gasket (3) from the cylinder head. 5. For 402C-05, 403C-07, 403C-11 and 404C-15
engines, tighten the nuts (5) and the setscrews (6)
5. Remove any remaining gasket material and to a torque of 10 Nm (89 lb in).
carbon from the cylinder head and the exhaust
manifold. Be careful not to damage the mating For 403C-15, 403C-17, 404C-22 and 404C-22T
surface on the cylinder head or the mating surface engines, tighten the nuts (5) and the setscrews (6)
on the exhaust manifold. to a torque of 25 Nm (18 lb ft).
6. If necessary, remove the exhaust manifold studs Note: On three cylinder engines, tighten the two inner
(2) from the cylinder head (1). setscrews first. On four cylinder engines, tighten the
four inner setscrews first. Then tighten the two outer
setscrews and the two nuts.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Note: The two cylinder, the three cylinder and the four
cylinder engines have different exhaust manifolds.
The installation procedure is similar for all models.
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SENR9973-01 17
Disassembly and Assembly Section
i02187986
NOTICE
Inlet and Exhaust Valve Install suitable plugs to the inlet ports of the cylinder
Springs - Remove and Install head in order to prevent the entry of loose parts into
the engine.
Removal Procedure
Table 1
Required Tools
Part Number Part Description Qty
21825666 Valve Spring Compressor 1
27610235 Adapter 1
Start By:
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18 SENR9973-01
Disassembly and Assembly Section
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
Installation Procedure
g01015085
Table 2 Illustration 24
Typical example
Required Tools
Part Number Part Description Qty 1. Place the new valve springs (5) into position on
21825666 Valve Spring Compressor 1
the cylinder head.
Improper assembly of parts that are spring loaded 4. Install two valve keepers (3) in order to lock the
can cause bodily injury. valve springs in position.
To prevent possible injury, follow the established
assembly procedure and wear protective equip- NOTICE
ment. Do not turn the crankshaft while the valve springs are
removed.
NOTICE
5. Carefully release the pressure on the valve
Install suitable plugs to the inlet ports of the cylinder
spring compressor (1). Remove the valve spring
head in order to prevent the entry of loose parts into
compressor. Ensure that all of the valves are
the engine.
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.
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SENR9973-01 19
Disassembly and Assembly Section
End By:
Inlet and Exhaust Valves - Follow the recommended procedure and use all
Remove and Install recommended tooling to release the spring force.
Removal Procedure
Table 3
Required Tools
Part Number Part Description Qty
21825666 Valve Spring Compressor 1
27610235 Adapter 1
Start By:
g01015085
Illustration 25
a. Remove the cylinder head. Refer to Disassembly Typical example
and Assembly, Cylinder Head - Remove.
4. Install the 21825666 Valve Spring Compressor
NOTICE (1) and the 27610235 Adapter (2) in position
Keep all parts clean from contaminants. on the cylinder head in order to compress the
appropriate valve spring (5).
Contaminants may cause rapid wear and shortened
component life. NOTICE
Ensure that the valve spring is compressed squarely
Note: The removal procedure is identical for the or damage to the valve stem may occur.
two cylinder, the three cylinder and the four cylinder
engines. The illustrations show the four cylinder 5. Apply pressure to the valve spring compressor (1).
engine. Remove the valve keepers (3).
1. Clean the bottom face of the cylinder head. 6. Slowly release the pressure on the valve spring
Check the depth of the valves below the face of compressor (1).
the cylinder head before the valve springs are
removed. Refer to Specifications, Cylinder Head
Valves for the correct dimensions.
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20 SENR9973-01
Disassembly and Assembly Section
g01113619
Illustration 26
Typical example
Installation Procedure 4. Lubricate the stems of all valves (7) with clean
engine oil. Install the valves (7) in the appropriate
Table 4 positions.
Required Tools
5. Carefully turn over the cylinder head and ensure
Part Number Part Description Qty that all of the valves remain in place.
21825666 Valve Spring Compressor 1
6. Use a suitable tool to install the new valve stem
27610235 Adapter 1 seals (6) onto each of the valve guides.
This document has been printed from SPI. Not for Resale
SENR9973-01 21
Disassembly and Assembly Section
9. Install the valve spring retainer (4). 14. Remove the valve spring compressor (1) and the
adapter (2) from the cylinder head.
End By:
i02801641
Illustration 28
g01015303 Removal Procedure
Typical example
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
12. Carefully release the pressure on the valve spring 1. Loosen the nut (2) that attaches the oil line (1) to
compressor (1). the fuel injection pump.
13. Repeat steps 8 to 12 for all of the valves.
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22 SENR9973-01
Disassembly and Assembly Section
2. Remove the banjo bolt (3) and remove the Installation Procedure
washers (4) from the cylinder block. Discard the
washers (4).
g01117697
Illustration 30
Typical example
4. Remove the oil line (1) from the engine. 1. Position the oil line (1) on the engine.
g01117697
Illustration 32
Typical example
This document has been printed from SPI. Not for Resale
SENR9973-01 23
Disassembly and Assembly Section
4. Install the nut (2) that attaches the oil line (1) to
the fuel injection pump.
i02186236
NOTICE 3. Remove the hose clamps (2) and the hoses (1)
Keep all parts clean from contaminants. from the coolant inlet and the coolant outlet on
the oil cooler body (3). Note the positions of the
Contaminants may cause rapid wear and shortened coolant inlet and the coolant outlet for installation.
component life.
4. Remove the adapter (4) from the oil cooler body
(3). Remove the oil cooler body (3) from the
NOTICE cylinder block (7).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 5. Remove the O-ring (6) from the oil cooler body
ing, adjusting, and repair of the product. Be prepared (3). Discard the O-ring.
to collect the fluid with suitable containers before
opening any compartment or disassembling any com- Installation Procedure
ponent containing fluids.
This document has been printed from SPI. Not for Resale
24 SENR9973-01
Disassembly and Assembly Section
4. Install the appropriate hoses (1) to the coolant 1. Remove the engine oil relief valve (2) from the
inlet and the coolant outlet on the oil cooler body cylinder block.
(3). Tighten the hose clamps (2).
2. Remove the O-ring (1) from the engine oil relief
5. Lubricate the O-ring of the oil filter element (5) with valve. Discard the O-ring.
clean engine oil. Install the new oil filter element to
the oil cooler body (4). Tighten the oil filter element
by hand. Do not use a strap wrench to tighten the
Installation Procedure
oil filter element.
NOTICE
6. Fill the cooling system with coolant. Fill the Keep all parts clean from contaminants.
lubrication system with engine oil. Refer to the
Operation and Maintenance Manual, Refill Contaminants may cause rapid wear and shortened
Capacities for the cooling system capacity and component life.
for the lubrication system capacity of the engine.
i02182334
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
g00820218
Illustration 35
Contaminants may cause rapid wear and shortened
component life. 1. Install a new O-ring (1) on the engine oil relief
valve (2).
NOTICE
Care must be taken to ensure that fluids are contained 2. Lubricate the engine oil relief valve (2) with clean
during performance of inspection, maintenance, test- engine oil.
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before 3. Install the engine oil relief valve (2) in the cylinder
opening any compartment or disassembling any com- block. Tighten the engine oil relief valve to a
ponent containing fluids. torque of 64 Nm (47 lb ft).
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
Illustration 34
g00820218 Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI. Not for Resale
SENR9973-01 25
Disassembly and Assembly Section
3. Remove the idler gear (3) from the idler hub (1).
NOTICE
If the front housing is not installed, do not turn the 4. Remove the thrust washer (2) from the idler hub
crankshaft. Damage to the engine may occur. (1).
g00825411 g00825406
Illustration 36 Illustration 37
Typical example Typical example
Collar (8)
Spring (7)
Shim (6)
Oil pump cover (5)
Inner rotor (4)
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26 SENR9973-01
Disassembly and Assembly Section
Idler Hub
NOTICE
Keep all parts clean from contaminants.
NOTICE
If the front housing is not installed, do not turn the
crankshaft. Damage to the engine may occur.
Idler Hub
g00831103
Illustration 38
Typical example
i02801642
g01297224
Illustration 39
Engine Oil Pump - Install
1. Install the pin of Tooling (A) to the cylinder block.
This document has been printed from SPI. Not for Resale
SENR9973-01 27
Disassembly and Assembly Section
The drive shaft, the piston, and the drive gear are
under spring force.
g01297225
Illustration 41
g01298012
Illustration 42
Checking end play by using a feeler gauge
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28 SENR9973-01
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
End By:
i02801654 g01124100
Illustration 44
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI. Not for Resale
SENR9973-01 29
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI. Not for Resale
30 SENR9973-01
Disassembly and Assembly Section
g01124046 g01124257
Illustration 47 Illustration 48
Typical example Typical example
4. Loosen the clamps (3) and remove the bypass 2. Install a new gasket (1) in position on the engine.
hose (4) from the water pump (7).
3. Place the water pump (6) in position on the engine
5. Remove the setscrews, the washers (5) and the and install the setscrews, the washers (4) and the
nut (6). nut (5). Tighten setscrews, the washers (4) and
the nut (5) to a torque of 10 Nm (7.4 lb ft).
6. If necessary, gently tap the water pump (7) with a
soft faced hammer in order to loosen the water
pump (7).
i02801657
and 404C-22T Engines) 4. Place the alternator bracket (1) into position on
water pump (6). Install the fasteners (2) on the
NOTICE water pump (6) and hand tighten the fasteners (2).
Keep all parts clean from contaminants.
5. Install the lower hose and install the hose clamp
Contaminants may cause rapid wear and shortened (not shown). Hand tighten the hose clamp. Install
component life. 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).
1. Remove all debris and gasket material from
the mating surfaces of the water pump and the
cylinder block.
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SENR9973-01 31
Disassembly and Assembly Section
End By:
NOTICE
4. Place the alternator bracket (1) into position on
Keep all parts clean from contaminants.
water pump (7). Install the fasteners (2) on the
water pump (7) and hand tighten the fasteners (2).
Contaminants may cause rapid wear and shortened
component life.
5. Install the lower hose and install the hose clamp
(not shown). Hand tighten the hose clamp. Install
1. Remove all debris and gasket material from the hose (4) on the water pump (7) and tighten the
the mating surfaces of the water pump and the hose clamps (3) to a torque of 2.5 Nm (22.1 lb in).
cylinder block.
End By:
i02182980
Illustration 50
g01124046 Removal Procedure
Typical example
NOTICE
2. Install new gaskets (8) and (2) and the spacer (1) Keep all parts clean from contaminants.
in position on the engine.
Contaminants may cause rapid wear and shortened
3. Place the water pump (7) in position on the engine component life.
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).
This document has been printed from SPI. Not for Resale
32 SENR9973-01
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
i02801658
This document has been printed from SPI. Not for Resale
SENR9973-01 33
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
g01125880
Illustration 55
Typical example
This document has been printed from SPI. Not for Resale
34 SENR9973-01
Disassembly and Assembly Section
This document has been printed from SPI. Not for Resale
SENR9973-01 35
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g01125880
Illustration 57
4. Install the outlet connection (2) to the water 2. Remove two setscrews (3) opposite each other
temperature regulator housing (5). from the flywheel.
Note: Ensure the correct orientation of the outlet 3. Install two suitable guide studs in the place of the
connection. setscrews that were removed.
5. Install the setscrews (1) to the outlet connection 4. Remove the remaining setscrews (3) that fasten
(2). the flywheel to the crankshaft.
6. Tighten the setscrews to a torque of 14 Nm 5. Remove the flywheel (2) from the rear of the
(10 lb ft). crankshaft.
7. Fill the cooling system with coolant to the correct Note: On some three cylinder engines, a roll pin is
level. Refer to Operation and Maintenance located between the crankshaft and the flywheel.
Manual, Refill Capacities for more information.
6. Inspect the flywheel ring gear (5) and the flywheel
(2) for wear or damage. If the flywheel ring gear or
i02183594 the flywheel is worn or damaged, use new parts
for replacement.
Flywheel - Remove
Removal Procedure
Start By:
This document has been printed from SPI. Not for Resale
36 SENR9973-01
Disassembly and Assembly Section
g01124041
Illustration 60
Typical example
g01124042
Illustration 61
Typical example
This document has been printed from SPI. Not for Resale
SENR9973-01 37
Disassembly and Assembly Section
End By:
This document has been printed from SPI. Not for Resale
38 SENR9973-01
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g01113706
Illustration 63
Typical example
1. Clean the rear face of the cylinder block (1) and 4. Apply clean engine lubricating oil to the crankshaft
the back plate (6). Inspect the dowels (3) for flange (4) around the running surface of crankshaft
damage. If the dowels are damaged, use new rear seal.
parts for replacement.
5. Place the crankshaft rear seal (5) over the
2. Ensure that the crankshaft flange (4) is clean, dry crankshaft flange (4) and engage the plastic
and free from rough metal edges. sleeve onto the crankshaft flange.
3. Remove the packaging from the new crankshaft 6. Ensure that the plastic sleeve is engaged onto
rear seal (5). Ensure that the plastic sleeve (not the crankshaft flange (4). Push the crankshaft
shown) is squarely installed within the crankshaft rear seal (5) evenly and push the crankshaft rear
rear seal. The plastic sleeve is included in order seal smoothly onto the crankshaft flange until the
to protect the lip of the seal as the lip is pushed crankshaft rear seal is against the cylinder block.
over the crankshaft flange. During this process, the plastic sleeve will be
forced out of the crankshaft rear seal. Discard the
plastic sleeve.
This document has been printed from SPI. Not for Resale
SENR9973-01 39
Disassembly and Assembly Section
For the 403C-15, 403C-17, 404C-22 and 3. Remove the setscrews (3) that fasten the flywheel
404C-22T engines, tighten the setscrews to a housing (8) to the cylinder block.
torque of 25 Nm (19 lb ft).
4. Remove the setscrews (5) on each side of
End By: the cylinder block. These setscrews fasten the
flywheel housing (8) to the cylinder block.
a. Install the flywheel housing. Refer to Disassembly
and Assembly Manual, Flywheel Housing - 5. Remove the setscrews (1) that fasten the back
Remove and Install. plate (2) to the flywheel housing (8).
b. Install the flywheel. Refer to Disassembly and 6. Remove the nuts (7) and the bolts (not shown)
Assembly Manual, Flywheel - Install. that fasten the back plate (2) to the flywheel
housing (8).
i02801660
NOTICE
Keep all parts clean from contaminants.
Typical example
1. Support the engine with a suitable lifting device or
support the engine on blocks that are positioned 7. Use the lifting device (9) to remove the flywheel
on a flat level surface. housing (8) from the back plate.
This document has been printed from SPI. Not for Resale
40 SENR9973-01
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Note: The two cylinder, the three cylinder and the four
cylinder engines have different flywheel housings.
The removal procedure is similar for all models.
g01123577
Illustration 66
Typical example
g00827061
Illustration 68
Typical example
This document has been printed from SPI. Not for Resale
SENR9973-01 41
Disassembly and Assembly Section
1. Clean the rear face of the back plate (2) and the Installation Procedure (Engines
faces of the flywheel housing (8). Inspect the
crankshaft rear seal (not shown) for leaks. Inspect
with Flywheel Housing)
the dowels (6) for damage. If the crankshaft
rear seal or the dowels are damaged, use new NOTICE
parts for replacement. Refer to Disassembly and Keep all parts clean from contaminants.
Assembly, Crankshaft Rear Seal - Remove and
Disassembly and Assembly, Crankshaft Rear Contaminants may cause rapid wear and shortened
Seal - Install. component life.
g01123556
Illustration 70
Typical example
3. Install the nuts (7) and the bolts (not shown) that
fasten the back plate (2) to the flywheel housing
(8).
Typical example
End By:
2. Use the lifting device (3) to align the flywheel
a. Install the flywheel. Refer to Disassembly and
housing (2) to the dowels (5). Install the flywheel
Assembly, Flywheel - Install.
housing to the engine.
This document has been printed from SPI. Not for Resale
42 SENR9973-01
Disassembly and Assembly Section
a. Install the flywheel. Refer to Disassembly and 2. Install the 21825619 Puller (6) to the crankshaft
Assembly, Flywheel - Install. pulley. Use the puller (6) in order to remove the
crankshaft pulley (2) from crankshaft (4).
Removal Procedure
Table 6
Required Tools
Part Number Description Qty
21825619 Puller 1
g00827213
3. Install the washer (3) to the crankshaft (4).
Illustration 72
4. Lubricate the nut (5) with clean engine oil and
1. Remove the nut (5) and the washer (3) from install the nut.
crankshaft pulley (2).
For 402C-05 and 403C-07 engines, tighten the
nut (5) to a torque of 93 Nm (69 lb ft).
This document has been printed from SPI. Not for Resale
SENR9973-01 43
Disassembly and Assembly Section
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE Illustration 75
g01113392
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 1. Clean the bore of the housing (1) for the crankshaft
ing, adjusting and repair of the product. Be prepared to front seal (2) and inspect the bore of the housing
collect the fluid with suitable containers before open- for any damage.
ing any compartment or disassembling any compo-
nent containing fluids. 2. Lubricate the crankshaft front seal (2) with clean
engine oil.
Dispose of all fluids according to local regulations and
mandates. 3. Position the crankshaft front seal (2) in the bore of
the housing (1) for the crankshaft front seal.
Remove the Front Oil Seal that is installed
in the Engine NOTICE
Ensure that the lip of the crankshaft front seal that is
1. If the front cover is still attached to the engine, use spring loaded is facing toward the inside of the front
a suitable lever in order to remove the oil seal housing and that it is square with the bore of the hous-
from the front cover. ing for the crankshaft front seal.
Remove the Front Oil Seal from a 4. Use a suitable tool (3) to install the new crankshaft
Disassembled Front Cover front seal (2).
1. If the front cover has been removed from the Note: Apply clean engine oil on the area of the
engine, use a suitable hydraulic press in order to crankshaft pulley that will be in contact with the
remove the oil seal from the front cover. Ensure crankshaft front seal (2).
that the front cover is supported correctly in order
to prevent damage to the cover while the oil seal End By:
is being removed.
a. Install the crankshaft pulley and the V-belt. Refer
to Disassembly and Assembly, Crankshaft Pulley
- Remove and Install.
This document has been printed from SPI. Not for Resale
44 SENR9973-01
Disassembly and Assembly Section
i02186336
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- g01129574
Illustration 76
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before Typical example
opening any compartment or disassembling any com-
ponent containing fluids. 1. Remove the setscrews and the nuts (5) from the
front housing (4).
Dispose of all fluids according to local regulations and
mandates. 2. Turn the mechanical stop lever (3) to the full
clockwise position so that the spring is held under
tension.
This document has been printed from SPI. Not for Resale
SENR9973-01 45
Disassembly and Assembly Section
Disassembly Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
g01114167
Illustration 77
Dispose of all fluids according to local regulations and
mandates. 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.
This document has been printed from SPI. Not for Resale
46 SENR9973-01
Disassembly and Assembly Section
g01114517
Illustration 79
Typical example
3. Remove the shaft (12) and remove the lever 3. Remove the nut (19) from the arm (24) for the
assembly (11) from the engine front housing (9). stop control. Remove the washer (20) and remove
the spring (21) from the arm (24).
4. Remove the O-ring (13) from the shaft (12).
Discard the O-ring. 4. Remove the arm (24) for the stop control from the
front housing.
5. Remove the angleich unit (15) from the lever
assembly (11). 5. Remove the C-clip (23) and the O-ring (22) from
the arm (24). Discard the O-ring.
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.
This document has been printed from SPI. Not for Resale
SENR9973-01 47
Disassembly and Assembly Section
g01114513
Illustration 80
Typical example
1. Remove the nuts (25) and the bolts (31) from the
PTO cover.
Typical example
Note: The plate (30) is not installed on 402C-05 or
403C-07 engines.
1. Install the O-ring (6) to the shaft of the lever (7).
3. Remove the joint (27) and discard the joint.
2. Lubricate the O-ring (6) and the shaft of the lever
4. Remove the O-ring (29). Discard the O-ring. (7) with clean engine oil. Install the lever (7) into
the front housing (8).
Note: The O-ring (29) is not installed on 402C-05
or 403C-07 engines. 3. Install the C-clip (5) onto the shaft of the lever (7).
5. Check the condition of all parts. Replace any parts 4. Install the arm for the throttle control (3) onto the
that are damaged or worn. lever (7). Tighten the nut (1) and bolt (4) to a
torque of 9 Nm (7 lb ft).
This document has been printed from SPI. Not for Resale
48 SENR9973-01
Disassembly and Assembly Section
g01114377
Illustration 82
g01114562
Illustration 83
Typical example
This document has been printed from SPI. Not for Resale
SENR9973-01 49
Disassembly and Assembly Section
3. Place the spring (24) and the washer (23) onto the
arm (27). Install the nut (22) 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
torque of 10 Nm (7 lb ft).
g01114380
Illustration 84
Typical example
Note: The O-ring (32) and the plate (33) are not
installed on the 402C-05 and 403C-07 engines.
4. Install the nuts (28) and the bolts (34) for the PTO
cover. Tighten the nuts to a torque of 13 Nm
g01114606 (10 lb ft).
Illustration 85
Typical example
End By:
1. Install the C-clip (26) and install the O-ring (25) to a. Install the front housing to the engine. Refer to
the arm (27). Disassembly and Assembly, Housing (Front)
Install for more information.
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.
This document has been printed from SPI. Not for Resale
50 SENR9973-01
Disassembly and Assembly Section
i02801665
Installation Procedure
Table 7
Required Tools
Part Number Part Description Qty
21825620 Seal Guide 1
402C-05, 403C-07, 403C-11
and 404C-15 engines
21825621 Seal Guide 1
403C-15, 403C-17, 404C-22
and 404C-22T engines
NOTICE
Keep all parts clean from contaminants.
g01113288
Contaminants may cause rapid wear and shortened Illustration 87
component life.
3. Align the locating pin (2) with the locating hole on
the oil pump cover (1). Ensure that the oil pump
1. Clean the front housing assembly (4) thoroughly. cover is concentric to the idler gear assembly.
2. For 402C-05, 403C-07, 403C-15 and 404C-11 4. Install a new joint to the front of the cylinder block
engines, install the 21825620 Seal Guide (6) to (7).
the crankshaft.
5. Turn the mechanical stop lever (3) to the full
For 403C-15, 403C-17, 404C-22 and 404C-22T clockwise position so that the spring is held under
engines, install the 21825621 Seal Guide (6) to tension. Observe the position of the linkage for
the crankshaft. the fuel injection pump (not shown) in the front
housing.
This document has been printed from SPI. Not for Resale
SENR9973-01 51
Disassembly and Assembly Section
End By:
i02187994
This document has been printed from SPI. Not for Resale
52 SENR9973-01
Disassembly and Assembly Section
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 89
Typical example
This document has been printed from SPI. Not for Resale
SENR9973-01 53
Disassembly and Assembly Section
Installation Procedure
(Turbocharged Engines)
NOTICE
Keep all parts clean from contaminants.
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
This document has been printed from SPI. Not for Resale
54 SENR9973-01
Disassembly and Assembly Section
g00819350
Illustration 93
Typical example
This document has been printed from SPI. Not for Resale
SENR9973-01 55
Disassembly and Assembly Section
i02187973 g00827968
Illustration 94
Rocker Shaft and Pushrod - Typical example
Removal Procedure 2. Remove the nuts (2) and the setscrews (1) from
the rocker shaft assembly (4).
Start By:
3. Remove the rocker shaft assembly (4) from
a. Remove the engine oil line. Refer to Disassembly cylinder head (7).
and Assembly, Engine Oil Line - Remove and
Install. 4. Remove the pushrods (6) from the cylinder head.
Mark the pushrods for installation. Inspect the
b. Remove the valve mechanism cover. Refer to pushrods for wear or for damage. If the pushrods
Disassembly and Assembly, Valve Mechanism are damaged, use new parts for replacement.
Cover - Remove and Install.
5. Remove the caps (not shown) from the top of the
NOTICE valve stems (5). Mark the caps for installation.
Keep all parts clean from contaminants. Inspect the caps for wear or for damage. If the
caps are worn or damaged, use new parts for
Contaminants may cause rapid wear and shortened replacement.
component life.
6. Remove the joint (9) from the base of the rocker
shaft assembly (8). Inspect the joint. If the joint is
NOTICE worn or damaged, use a new part for replacement.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
This document has been printed from SPI. Not for Resale
56 SENR9973-01
Disassembly and Assembly Section
g01124594 NOTICE
Illustration 95
Keep all parts clean from contaminants.
Typical example
Contaminants may cause rapid wear and shortened
1. Remove the threaded plug (6) from the base of component life.
the rocker shaft (8).
This document has been printed from SPI. Not for Resale
SENR9973-01 57
Disassembly and Assembly Section
i02801668
2. Remove the rocker arms (3), the washers (7), and g01124596
Illustration 97
the springs (8).
Typical example
Note: Place an identification mark on each of the
components for installation. 2. Lubricate the rocker shaft (4) with clean engine
oil. Position the end of the rocker shaft into the
3. Remove the O-ring (6) from the rocker shaft (4). bore in the base of the rocker shaft (8).
4. Remove the adjustment screws (1) and the nuts For 402C-05 engines, align the two recesses (not
(2) from rocker arms (3). shown) in the rocker shaft with the holes in the
base of the rocker shaft (8).
5. Inspect all of the components for wear or for
damage. Refer to the Specifications Manual, For 403C-07, 403C-11 and 404C-15 engines,
Rocker Shaft. If any of the components are worn align the hole (10) in the rocker shaft with the hole
or damaged, use new parts for replacement. (9) in the base of the rocker shaft (8).
This document has been printed from SPI. Not for Resale
58 SENR9973-01
Disassembly and Assembly Section
3. Gradually insert the rocker shaft (4) into the base Assembly Procedure (403C-15,
of the rocker shaft (8). Install the rocker arm (3).
403C-17, 404C-22 and 404C-22T
engines)
Make sure to wear all necessary protective equip- Contaminants may cause rapid wear and shortened
ment. component life.
Follow the recommended procedure and use all Note: The assembly procedure is similar for the three
recommended tooling to release the spring force. cylinder and the four cylinder engines. The illustration
shows a four cylinder engine.
4. Continue to insert the rocker shaft (4) and install
the following components to the rocker shaft: 1. Lubricate the adjustment screw (1) with clean
engine oil. Install the adjustment screw (1) and the
Rocker arm (3) nut (2) to the rocker arm (3). Repeat the process
for the remaining rocker arms.
Washer (9)
Spring (10)
Washer (9)
Rocker arm (3)
5. Repeat Steps 4 and 3 in order to install the
remaining components.
End By: 2. Install a new O-ring (8) onto the rocker shaft (4).
Lubricate the rocker shaft with clean engine oil.
a. Install the rocker shaft and the pushrods. Refer to
Disassembly and Assembly, Rocker Shaft and 3. Position the end of the rocker shaft (4) into the
Pushrod - Install. 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).
This document has been printed from SPI. Not for Resale
SENR9973-01 59
Disassembly and Assembly Section
Washer (9) 1. Install the joint (9) to the base of the rocker shaft
assembly (8).
Rocker arm (3)
2. Lubricate the pushrods (6) with clean engine oil.
6. Repeat Steps 4 and 3 in order to install the Install the pushrods (6) in the cylinder head (7).
remaining components. Ensure that the pushrods are installed correctly in
the socket of the valve lifters.
7. Ensure that the rocker shaft (4) is fully engaged
into the base of the rocker shaft (7). Check that Note: If the pushrods have been used, ensure that
the recesses (5) on the rocker shaft are aligned the pushrods are installed in original positions.
with the holes (6) in the base of the rocker shaft.
3. Lubricate the top of the valve stems (5) with clean
End By: engine oil. Install the caps (not shown) on the top
of the valve stems.
a. Install the rocker shaft and the pushrods. Refer to
Disassembly and Assembly, Rocker Shaft and Note: If the caps have been used, ensure that the
Pushrod - Install. caps are installed in original positions.
i02801669
4. Lubricate the adjustment screws (3) on each
rocker arm with clean engine oil before installation.
Rocker Shaft and Pushrod - Install the rocker shaft assembly (4) to the cylinder
head (7).
Install
Note: Ensure that the ends of the adjustment screws
on each rocker arm are correctly seated in the ends
of the pushrods (6).
Installation Procedure
5. Install the setscrews (1) and the nuts (2).
NOTICE
Keep all parts clean from contaminants. 6. Evenly tighten the nuts (2).
Contaminants may cause rapid wear and shortened Note: The tightening sequence moves from the
component life. center of the rocker shaft outward.
This document has been printed from SPI. Not for Resale
60 SENR9973-01
Disassembly and Assembly Section
For 403C-15, 403C-17, 404C-22 and 404C-22T Contaminants may cause rapid wear and shortened
engines, tighten the setscrews (1) to a torque of component life.
10 Nm (89 lb in). Tighten the nuts (2) to a torque
of 33 Nm (24 lb ft).
NOTICE
8. Adjust the valve lash. Refer to Testing and Care must be taken to ensure that fluids are contained
Adjusting, Engine Valve Lash - Inspect/Adjust for during performance of inspection, maintenance, test-
the correct procedure to adjust the valve lash. ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
End By: opening any compartment or disassembling any com-
ponent containing fluids.
a. Install the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism Dispose of all fluids according to local regulations and
Cover - Remove and Install. mandates.
i02801670
Removal Procedure
Start By:
g00828137
Illustration 100
a. Remove the water pump. Refer to Disassembly
Typical example
and Assembly, Water Pump - Remove.
This document has been printed from SPI. Not for Resale
SENR9973-01 61
Disassembly and Assembly Section
i02801671
Installation Procedure
g01109567
Illustration 103 NOTICE
Typical example for the 4 cylinder head Keep all parts clean from contaminants.
1. Loosen the cylinder head bolts (1) in reverse order Contaminants may cause rapid wear and shortened
as this will help prevent distortion of the cylinder component life.
head (2).
Note: Do not use a pry bar to separate the cylinder Illustration 104
g00828137
head from the cylinder block . Use a rubber mallet to
Typical example
loosen the cylinder head from the cylinder block.
1. Thoroughly clean the top of cylinder block (3) and
2. Attach a suitable lifting device to the cylinder
the bottom of the cylinder head (2). Ensure that
head (2). Carefully lift the cylinder head (2) off the
there is no debris in the cylinder bores.
cylinder block (3).
2. If necessary, install the dowels (6) to the cylinder
Note: Avoid contamination of the cylinder bores with
block (3).
coolant or with debris.
This document has been printed from SPI. Not for Resale
62 SENR9973-01
Disassembly and Assembly Section
g00828396 g01116726
Illustration 105 Illustration 106
Typical example Typical example for the 2 cylinder head
g01109567
Illustration 108
Typical example for the 4 cylinder head
This document has been printed from SPI. Not for Resale
SENR9973-01 63
Disassembly and Assembly Section
This document has been printed from SPI. Not for Resale
64 SENR9973-01
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
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.
a. Install the cylinder head assembly. Refer to 1. Remove the slider (1) from the camshaft gear (4).
Disassembly and Assembly, Cylinder Head -
Install. 2. Before the idler gear is removed, rotate the
crankshaft until the timing marks (2) on the
following components are aligned.
i02801672
Crankshaft gear (3)
Camshaft - Remove
Camshaft gear (4)
Idler gear (5)
Removal Procedure
3. Remove the idler gear (5). Refer to Disassembly
Start By: and Assembly, Engine Oil Pump - Remove.
This document has been printed from SPI. Not for Resale
SENR9973-01 65
Disassembly and Assembly Section
i02196165
Camshaft - Disassemble
g00828468
Illustration 112
Typical example
Disassembly Procedure
4. Rotate the camshaft gear (4) in order to align the
access hole (8) in the camshaft gear with the Start By:
fastener for the camshaft retainer (9).
a. Remove the camshaft assembly. Refer to
Note: The two cylinder and the three cylinder engines Disassembly and Assembly, Camshaft -
have a different type of camshaft retainer (9) to the Remove.
four cylinder engines. The removal procedure is
identical for all models. NOTICE
Keep all parts clean from contaminants.
For 402C-05, 403C-07, 403C-11, 403C-15,
403C-17 and 404C-15 engines, remove the outer Contaminants may cause rapid wear and shortened
setscrew (6) and remove the allen head screw (7). component life.
For 404C-22 and 404C-22T engines, remove the
outer setscrew (6) and remove the setscrew (7)
from the camshaft retainer (9).
g01113616
Illustration 114
Typical example
This document has been printed from SPI. Not for Resale
66 SENR9973-01
Disassembly and Assembly Section
2. Remove the spacer (4) and the woodruff key (2) Note: Ensure that the camshaft bearing (3) is
from the camshaft (1). installed in the correct orientation. The camshaft
bearing should be pressed squarely onto the
3. Use a suitable puller to remove the front camshaft camshaft or damage to the bearing may occur.
bearing (3) from the camshaft (1).
2. Install the spacer (4) and the woodruff key (2) to
Note: Identify the orientation of the camshaft bearing the camshaft (1).
(3) for installation.
3. Align the camshaft gear (5) with the woodruff key
4. Inspect all of the components for wear or damage. (2) on the camshaft (1). Use a suitable press to
Replace any components that are worn or install the camshaft gear to the camshaft.
damaged.
Note: The camshaft gear should be positioned on a
suitable support in order to prevent damage to the
i02196164
governor flyweights during installation.
Camshaft - Assemble End By:
g01113616
Illustration 115
Typical example
g01129587
Illustration 116
This document has been printed from SPI. Not for Resale
SENR9973-01 67
Disassembly and Assembly Section
2. Carefully install the camshaft assembly (10) into Crankshaft gear (3)
the engine cylinder block (11). Be careful not to
damage the lobes of the camshaft or the camshaft Camshaft gear (4)
bearings.
Idler gear (5)
Number one piston will now be in the top dead
center position.
End By:
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Illustration 118
g00828467 Note: The two cylinder, the three cylinder and the
four cylinder engines have different engine oil pans.
5. Install the idler gear (5). Refer to Disassembly and The removal procedure is identical for all models.
Assembly, Engine Oil Pump - Install.
This document has been printed from SPI. Not for Resale
68 SENR9973-01
Disassembly and Assembly Section
g00820013 g00820013
Illustration 119 Illustration 120
Typical example Typical example
1. Remove the drain plugs (5) from the engine oil pan 1. Clean all surfaces thoroughly.
(2). Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and 2. Install a new joint (1) to the engine. Install the
Maintenance Manual, Refill Capacities for the engine oil pan (2) to the engine.
approximate capacity of the lubricating oil system.
3. Install the setscrews (4) for the engine oil pan (2).
2. Remove the sealing washers (3) from the drain Tighten the setscrews for the engine oil pan to a
plugs (5). Discard the sealing washers. torque of 11 Nm (8 lb ft).
3. Remove the setscrews (4) for the engine oil pan 4. Install the drain plugs (5) and new sealing washers
(2). (3) to the oil pan (2). Tighten the drain plugs to a
torque of 34 Nm (25 lb ft).
4. Remove the engine oil pan (2) from the engine.
5. Fill the engine oil pan to the correct level that is
5. Remove the joint (1) from the engine oil pan and indicated on the engine oil level gauge. Refer
the cylinder block. Discard the joint. to Operation and Maintenance Manual, Refill
Capacities for more information.
Installation Procedure
i02189003
NOTICE
Keep all parts clean from contaminants. Pistons and Connecting Rods
- Remove
Contaminants may cause rapid wear and shortened
component life.
Note: The two cylinder, the three cylinder and the Removal Procedure
four cylinder engines have different engine oil pans.
The installation procedure is identical for all models. Start By:
This document has been printed from SPI. Not for Resale
SENR9973-01 69
Disassembly and Assembly Section
Disassembly Procedure
Start By:
4. Remove the nuts (6) from the connecting rod (1). Contaminants may cause rapid wear and shortened
component life.
5. Remove the connecting rod cap (5) with the
bearing shell (3).
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70 SENR9973-01
Disassembly and Assembly Section
g01114004 g01114007
Illustration 122 Illustration 123
Typical example Typical example
1. Use suitable pliers in order to remove the circlips 3. Use a suitable ring expander in order to remove
(2). the piston rings (7) and (6), and the oil control ring
(5) from the piston (4).
2. Remove the piston pin (3) from the piston (4).
Note: Identify the orientation of the piston rings for
Note: If the piston pin cannot be removed by hand, installation.
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.
This document has been printed from SPI. Not for Resale
SENR9973-01 71
Disassembly and Assembly Section
i02189011
Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Installation of the piston pin bushing must be carried
out by personnel with the correct training. Also special
machinery is required.
g01114056
Illustration 125 g01114138
Illustration 126
Typical example
Typical example
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72 SENR9973-01
Disassembly and Assembly Section
g01114155
Illustration 127
Typical example
g01114374
Illustration 129
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SENR9973-01 73
Disassembly and Assembly Section
End By:
i02801688
g01111980
Illustration 130
Installation Procedure Typical example
Contaminants may cause rapid wear and shortened For the 402C-05 and 403C-07 engines, the piston
component life. ring compressor should be suitable for a piston
67 mm (2.64 inch).
1. Thoroughly clean all of the components. For the 403C-11 and 404C-15 engines, the piston
ring compressor should be suitable for a piston
Note: Refer to Disassembly and Assembly, 77 mm (3.03 inch) in diameter.
Connecting Rod Bearings - Install for the inspection
procedure of the connecting rod bearings and the For the 403C-15, 403C-17, 404C-22 and
crankshaft connecting rod journals. 404C-22T engines, the piston ring compressor
should be suitable for a piston 84 mm (3.31 inch)
2. Apply clean engine oil to the following components: in diameter.
Crankshaft journals Note: Move the piston rings on the pistons until
the ring openings are separated by approximately
Inside of the cylinder bores 90 degrees. Refer to Disassembly and Assembly,
Pistons and Connecting Rods - Assemble.
Piston rings
Connecting rod bearings
Note: The piston and the connecting rod are matched
to a specific cylinder. Ensure that the connecting rod
and the pistons are installed in the correct cylinder.
g01112036
Illustration 131
Typical example
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74 SENR9973-01
Disassembly and Assembly Section
5. Put the piston and the connecting rod in the 10. Rotate the crankshaft in order to ensure that no
cylinder bore. Align the identification marks on the binding occurs.
top of the piston to the front of the cylinder block.
Align the identification marks (3) on the side of End By:
the connecting rod to the right side of the cylinder
block. a. Install the oil suction pipe. Refer to Disassembly
and Assembly, Engine Oil Pump- Install.
Note: The right side is determined from the flywheel
end of the engine. b. Install the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Note: Ensure that the piston ring compressor (1) is Install.
installed correctly in order to allow the piston and the
connecting rod to easily slip into the cylinder block. c. Install the cylinder head. Refer to Disassembly
Use tape or rubber tubing on the connecting rod bolts and Assembly, Cylinder Head - Install.
to protect the crankshaft journals.
i02186176
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
Connecting Rod Bearings -
piston ring compressor (1) comes off the piston. Remove
Removal Procedure
Start By:
Illustration 132
g01116685 NOTICE
Typical example Keep all parts clean from contaminants.
7. Push the piston and the connecting rod assembly Contaminants may cause rapid wear and shortened
into the cylinder. Guide the connecting rod component life.
assembly onto the connecting rod journal.
NOTICE
8. Install the connecting rod cap (4) and the
Care must be taken to ensure that fluids are contained
connecting rod nuts (5).
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
For the 402C-05 and 403C-07 engines, tighten
to collect the fluid with suitable containers before
the nuts (5) for the connecting rod cap (4) to a
opening any compartment or disassembling any com-
torque of 23 Nm (16 lb ft).
ponent containing fluids.
For the 403C-11 and 404C-15 engines, tighten the
Dispose of all fluids according to local regulations and
nuts (5) for the connecting rod cap (4) to a torque
mandates.
of 32 Nm (24 lb ft).
For the 403C-15, 403C-17, 404C-22 and Note: The connecting rod and the connecting rod cap
404C-22T engines, tighten the nuts (5) for the should have matching marks (6) on the right hand
connecting rod cap (4)to a torque of 52 Nm side. Mark the connecting rod (1) and the connecting
(38 lb ft). rod cap (5), if necessary. The right side of the engine
is determined from the flywheel end.
9. Repeat Steps 1 through 8 for the remainder of the
pistons and connecting rods.
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SENR9973-01 75
Disassembly and Assembly Section
NOTICE
When the connecting rod caps are installed, ensure
that the identification marks are aligned.
g01111763
Illustration 133
Typical example
2. Remove the lower bearing shell (3) of the 1. Check the clearance between the connecting rod
connecting rod bearing from the connecting rod bearing and the connecting rod bearing journal of
cap (5). the crankshaft. Install the connecting rod bearings
dry when the clearance checks are made. Refer to
3. Carefully push the connecting rod (1) into the Disassembly and Assembly, Bearing Clearance
cylinder bore. Remove the upper bearing shell (3) - Check for information on bearing clearance
of the connecting rod from the connecting rod. checks.
Note: Use tape or rubber tubing on the connecting 2. Clean the bearing surface of the connecting rod
rod bolts to protect the crankshaft journals. The sharp (1) and the connecting rod cap (5). Ensure that the
edges of the connecting rod bolts could damage the number (6) on the connecting rod cap (5) aligns
crankshaft journals. with the number (6) on the connecting rod (1).
4. Repeat Steps 1 through 3 for the remaining 3. Clean the upper connecting rod bearing (3) and
connecting rod bearings. lubricate the bearing face with clean engine oil.
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76 SENR9973-01
Disassembly and Assembly Section
8. Install the connecting rod cap (5) in position on Crankshaft Main Bearings
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).
End By:
g00830378
i02801692 Illustration 135
Crankshaft Main Bearings - Note: Mark the halves of the main bearing carriers
Remove for later installation.
a. Remove the crankshaft. Refer to Disassembly and Note: Dowels (5) are installed in each bearing cap
Assembly, Crankshaft - Remove. in order to align the two halves of the main bearing
carrier.
NOTICE
Keep all parts clean from contaminants. Note: Thrust washers are only installed on the
403C-15, 403C-17, 404C-22 and 404C-22T engines.
Contaminants may cause rapid wear and shortened
component life. 3. For 403C-15 and 403C-17 engines, remove the
lower thrust washers (3).
This document has been printed from SPI. Not for Resale
SENR9973-01 77
Disassembly and Assembly Section
Crankshaft Main Bearings For the 404C-22 and 404C-22T engines, tighten
the setscrews to a torque of 52 Nm (38 lb ft).
g00830378
Illustration 137
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78 SENR9973-01
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g01107393
Illustration 138
End By:
i02192828
Crankshaft - Remove
Removal Procedure
Start By:
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SENR9973-01 79
Disassembly and Assembly Section
g01107623
Illustration 139
Typical example
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80 SENR9973-01
Disassembly and Assembly Section
i02801706
Crankshaft - Install
Installation Procedure
g01109599
Illustration 140
Typical example
This document has been printed from SPI. Not for Resale
SENR9973-01 81
Disassembly and Assembly Section
e. Install the engine oil relief valve. Refer to Note: Perkins does not recommend the checking of
Disassembly and Assembly, Engine Oil Relief the actual bearing clearances particularly on small
Valve - Remove and Install. 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 specific wall thickness.
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
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82 SENR9973-01
Disassembly and Assembly Section
Ensure that the backs of the bearings and the Note: When the Plastic Gauge is used, the readings
bores are clean and dry. can sometimes be unclear. For example, all parts of
the Plastic Gauge are not the same width. Measure
Ensure that the bearing locking tabs are properly the major width in order to ensure that the parts are
seated in the tab grooves. within the specification range. Refer to Specifications
Manual, Connecting Rod Bearing Journal and
The crankshaft must be free of oil at the contact Specifications Manual, Main Bearing Journal for the
points of the Plastic Gauge. correct clearances.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
g00953605
Illustration 141
Typical Example
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SENR9973-01 83
Disassembly and Assembly Section
g00830643 g01121721
Illustration 142 Illustration 143
Typical example Typical example
2. Remove the coolant temperature switch (1) from 2. Remove the coolant temperature switch (1) from
the water temperature regulator housing (2). the water pump housing (2).
3. Clean the coolant temperature switch. Inspect 3. Clean the coolant temperature switch. Inspect
the coolant temperature switch (1) for damage. If the coolant temperature switch (1) for damage. If
the coolant temperature switch is damaged, use the coolant temperature switch is damaged, use
a new part for replacement. For information on a new part for replacement. For information on
testing the coolant temperature switch for correct testing the coolant temperature switch for correct
operation, refer to Testing and Adjusting, Coolant operation, refer to Testing and Adjusting, Coolant
Temperature Switch - Test. Temperature Switch - Test.
2.
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84 SENR9973-01
Disassembly and Assembly Section
g01121721
Illustration 145
Typical example
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SENR9973-01 85
Disassembly and Assembly Section
g01130227 g01130227
Illustration 146 Illustration 147
Typical example Typical example
1. If the oil pressure switch is located in the valve 1. If a used engine oil pressure switch is installed,
mechanism cover, remove the engine oil pressure apply a thin layer of 21820122 POWERPART
switch. Pipe sealant to the threads of the engine oil
pressure switch.
If the oil pressure switch is located in the cylinder
block, remove the engine oil pressure switch 2. If the oil pressure switch is located in the valve
and adapter assembly. Remove the engine oil mechanism cover, install the engine oil pressure
pressure switch from the adapter. switch (1). Tighten the oil pressure switch to a
torque of 11 Nm (8.1 lb ft).
2. Clean the oil pressure switch.
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86 SENR9973-01
Disassembly and Assembly Section
i02801718
Removal Procedure
Start By:
Disconnect batteries before performance of any 1. Install the glow plugs (4) in the cylinder head.
service work.
For the 402C-05,402C-07,403C-11 and 404C-15
engines, tighten the glow plugs to a torque of
NOTICE 11.5 Nm (8.5 lb ft).
Keep all parts clean from contaminants.
For the 403C-15,403C-17,404C-22 and 404C-22T
Contaminants may cause rapid wear and shortened engines, tighten the glow plugs to a torque of
component life. 17.5 Nm (13 lb ft).
End By:
i02196372
Illustration 148
g00820321
V-Belts - Remove and Install
Typical example
1. Remove the nuts (1) and the washers (2) from the
bus bar (3) on the glow plugs (4). Removal Procedure
2. Remove the bus bar (3) from the glow plugs (4).
NOTICE
Keep all parts clean from contaminants.
3. Remove the glow plugs (4) from the cylinder head.
Contaminants may cause rapid wear and shortened
Installation Procedure component life.
NOTICE
Keep all parts clean from contaminants.
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SENR9973-01 87
Disassembly and Assembly Section
i02801722
Illustration 150
g01109566 Removal Procedure (404C-22 and
Typical example 404C-22T Engines)
1. Loosen setscrew (1) and setscrew (2). Loosen the Start By:
fasteners (4) on the alternator (3).
a. Remove the V-Belts. Refer to Disassembly and
2. Push the alternator (3) toward the engine and Assembly, V-Belts - Remove and Install.
remove the V-belt (5).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01109566
Illustration 151
Typical example
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88 SENR9973-01
Disassembly and Assembly Section
g01110541
Illustration 152
Typical example
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SENR9973-01 89
Disassembly and Assembly Section
g01116343
Illustration 153
Typical example
2. Remove the fan (2), the spacer (3) and the pulley
(4) from the water pump (5).
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90 SENR9973-01
Disassembly and Assembly Section
g01110541
Illustration 154
Typical example
4. Install the four setscrews (1) onto the fan (2) and
hand tighten the setscrews.
End By:
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SENR9973-01 91
Disassembly and Assembly Section
g01116343
Illustration 155
Typical example
1. Install the pulley (4), the spacer (3) and the fan (2) i02196771
in position on the water pump (5) and ensure that
the setscrew holes are aligned. Alternator - Remove and Install
2. Install the four setscrews (1) into the fan (2), the
spacer (3) and the pulley (4) and hand tighten the
setscrews. Removal Procedure for the 14 AMP
3. Tighten the four setscrews to a torque of 11 Nm Alternator
(8 lb ft).
Start By:
End By:
a. Remove the V-Belts. Refer to Disassembly and
a. Install the V-Belts. Refer to Disassembly and Assembly, V-Belts - Remove and Install.
Assembly, V-Belts - Remove and Install .
Note: Disconnect all electrical connections to the
alternator before proceeding. Mark the connections
or identify the connections for future installation.
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92 SENR9973-01
Disassembly and Assembly Section
g01122900
Illustration 156
Typical example
1. Remove the bolt (1), the washer (3) and the nut
(4) from the alternator (2).
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SENR9973-01 93
Disassembly and Assembly Section
g01122906
Illustration 157
Typical example
1. Remove the bolt (1), the washer (3) and the nut
(4) from the alternator (2).
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94 SENR9973-01
Disassembly and Assembly Section
g01122919
Illustration 158
Typical example
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SENR9973-01 95
Disassembly and Assembly Section
g01110800
Illustration 159
Typical example
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96 SENR9973-01
Disassembly and Assembly Section
g01123177
Illustration 160
Typical example
2. Remove the bolt (4), the washer (5) and the nut
(6) that fastens the alternator (3) to the engine.
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SENR9973-01 97
Disassembly and Assembly Section
g01122900
Illustration 161
Typical example
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).
End By:
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98 SENR9973-01
Disassembly and Assembly Section
g01122906
Illustration 162
Typical example
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).
End By:
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SENR9973-01 99
Disassembly and Assembly Section
g01122919
Illustration 163
Typical example
End By:
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100 SENR9973-01
Disassembly and Assembly Section
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.
4. Hand tighten the two bolts (6), the two nuts (4)
and the setscrew (1) on the alternator (3) .
End By:
This document has been printed from SPI. Not for Resale
SENR9973-01 101
Disassembly and Assembly Section
g01123177
Illustration 165
Typical example
2. Install the bolt (4), the washer (5) and the nut (6) Electric Starting Motor -
that fastens the alternator (3) to the engine. Remove and Install
3. Install the setscrew (2) and the washer (1) to the
alternator (3).
4. Hand tighten the bolt (4), the nut (6) and the Removal Procedure
setscrew (2) on the alternator (3).
Start By:
Note: When you install the alternator, ensure that the
alternator pulley is in alignment with the crankshaft a. Disconnect all electrical connections to the
pulley within one degree. electric starting motor before proceeding. Mark
all connections or identify all connections for later
Note: Reconnect all electrical connections to the installation.
alternator before operating the engine.
End By:
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102 SENR9973-01
Disassembly and Assembly Section
End By:
g01117494
a. Reconnect all electrical connections to the electric
Illustration 166 starting motor before you operate the engine.
Typical example
Installation Procedure
g01117494
Illustration 167
Typical example
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SENR9973-01 103
Index Section
Index
A Crankshaft - Install................................................. 80
Installation Procedure ........................................ 80
Alternator - Remove and Install ............................. 91 Crankshaft - Remove............................................. 78
Installation Procedure for the 14 AMP Removal Procedure ........................................... 78
Alternator.......................................................... 97 Crankshaft Front Seal - Install ............................... 43
Installation Procedure for the 15 AMP Installation Procedure ........................................ 43
Alternator.......................................................... 98 Crankshaft Front Seal - Remove ........................... 43
Installation Procedure for the 40 AMP Removal Procedure ........................................... 43
Alternator.......................................................... 99 Crankshaft Main Bearings - Install......................... 77
Installation Procedure for the 55 AMP Installation Procedure ........................................ 77
Alternator........................................................ 100 Crankshaft Main Bearings - Remove..................... 76
Installation Procedure for the 65 AMP and the 85 Removal Procedure ........................................... 76
AMP Alternator............................................... 101 Crankshaft Pulley - Remove and Install ................ 42
Removal Procedure for the 14 AMP Alternator.. 91 Installation Procedure ........................................ 42
Removal Procedure for the 15 AMP Alternator.. 92 Removal Procedure ........................................... 42
Removal Procedure for the 40 AMP Alternator.. 93 Crankshaft Rear Seal - Install................................ 37
Removal Procedure for the 55 AMP Alternator.. 94 Installation Procedure ........................................ 37
Removal Procedure for the 65 AMP and the 85 Crankshaft Rear Seal - Remove............................ 37
AMP Alternator................................................. 95 Removal Procedure ........................................... 37
Cylinder Head - Install ........................................... 61
Installation Procedure ........................................ 61
B Cylinder Head - Remove ....................................... 60
Removal Procedure ........................................... 60
Bearing Clearance - Check ................................... 81
Measurement Procedure ................................... 81
D
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104 SENR9973-01
Index Section
H
T
Housing (Front) - Assemble................................... 47
Assembly Procedure.......................................... 47 Table of Contents..................................................... 3
This document has been printed from SPI. Not for Resale
SENR9973-01 105
Index Section
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106 SENR9973-01
Index Section
This document has been printed from SPI. Not for Resale
SENR9973-01 107
Index Section
This document has been printed from SPI. Not for Resale
2007 Perkins Engines Company Limited
All Rights Reserved Printed in U. K.
This document has been printed from SPI. Not for Resale