Disassembly and Assembly: 4012-46A Industrial Engine

KENR6924
August 2008
Disassembly and
Assembly
4012-46A Industrial Engine
S12 (Engine)
This document has been printed from SPI². Not for RESALE
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 correctly.
Incorrect 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.
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.
Operations that may cause product damage are identified by “NOTICE” 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. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
KENR6924 3
Table of Contents
Table of Contents Aftercooler - Install (Air Charge Cooler, TWG

Engines) .............................................................. 76
Engine Support (Front) - Remove and Install
(Backplate) .......................................................... 78
Disassembly and Assembly Section Flywheel - Remove ............................................... 79
Flywheel - Install ................................................... 80
Fuel Priming Pump - Remove and Install (Early
Crankshaft Rear Seal - Remove and Install ......... 82
Type) ..................................................................... 5
Flywheel Housing - Remove and Install .............. 83
Fuel Priming Pump - Remove and Install (Late
Vibration Damper and Pulley - Remove and Install
Type) ..................................................................... 6
(Single Vibration Damper) ................................... 86
Fuel Filter Base - Remove and Install .................... 7
Vibration Damper and Pulley - Remove and Install
Fuel Transfer Pump - Remove and Install (Lift
(Twin Vibration Dampers) ................................... 89
Pump) ................................................................... 8
Crankshaft Front Seal - Remove and Install ......... 93
Fuel Manifold (Rail) - Remove and Install ............... 9
Gear Group (Front) - Remove .............................. 94
Governor - Remove (Electronic Control Unit) ....... 12
Gear Group (Front) - Install .................................. 96
Governor - Install (Electronic Control Unit) ........... 12
Housing (Front) - Remove (Timing Case) ............. 98
Governor Actuator - Remove and Install ............. 13
Housing (Front) - Install (Timing Case) ................. 99
Fuel Injection Control Linkage - Remove ............. 16
Crankcase Breather - Remove and Install ......... 100
Fuel Injection Control Linkage - Install ................. 18
Valve Mechanism Cover - Remove and Install
Fuel Injector - Remove ........................................ 20
(Rocker Box Cover) .......................................... 101
Fuel Injector - Disassemble .................................. 22
Valve Mechanism Cover Base - Remove and Install
Fuel Injector - Assemble ....................................... 24
(Rocker Box) ..................................................... 102
Fuel Injector - Install ............................................ 26
Rocker Arm and Shaft - Remove ........................ 105
Fuel Injector Sleeve - Remove ............................. 27
Rocker Arm - Disassemble ................................. 105
Fuel Injector Sleeve - Install ................................. 28
Rocker Arm - Assemble ...................................... 106
Air Cleaner - Remove and Install .......................... 30
Rocker Arm and Shaft - Install ............................ 108
Turbocharger - Remove ........................................ 32
Cylinder Head - Remove .................................... 109
Turbocharger - Install ............................................ 33
Cylinder Head - Install ......................................... 111
Air Shutoff - Remove ............................................ 35
Lifter Group - Remove (Cam Followers) .............. 113
Air Shutoff - Install ................................................ 36
Lifter Group - Disassemble (Cam Followers) ....... 115
Air Lines - Remove and Install (Air Pipes, TAG
Lifter Group - Assemble (Cam Followers) ........... 116
engines) .............................................................. 37
Lifter Group - Install (Cam Followers) .................. 117
Exhaust Manifold - Remove and Install ............... 39
Camshaft - Remove ............................................. 118
Exhaust Elbow - Remove and Install ................... 42
Camshaft - Install ................................................. 119
Inlet Manifold - Remove ....................................... 43
Camshaft Bearings - Remove .............................. 119
Inlet Manifold - Install ........................................... 45
Camshaft Bearings - Install ................................. 120
Inlet and Exhaust Valves - Remove and Install .... 46
Engine Oil Pan - Remove .................................. 121
Inlet and Exhaust Valve Guides - Remove and
Engine Oil Pan - Install ...................................... 123
Install ................................................................... 48
Cylinder Liner - Remove ..................................... 125
Engine Oil Filter Base - Remove .......................... 50
Cylinder Liner - Install ......................................... 126
Engine Oil Filter Base - Disassemble ................... 51
Piston Cooling Jets - Remove and Install ........... 128
Engine Oil Filter Base - Assemble ........................ 52
Pistons and Connecting Rods - Remove ............ 130
Engine Oil Filter Base - Install .............................. 52
Pistons and Connecting Rods - Disassemble ..... 131
Engine Oil Cooler - Remove ................................. 54
Pistons and Connecting Rods - Assemble ......... 132
Engine Oil Cooler - Disassemble ......................... 56
Pistons and Connecting Rods - Install ................ 134
Engine Oil Cooler - Assemble .............................. 57
Crankshaft Main Bearings - Remove and Install
Engine Oil Cooler - Install ..................................... 58
........................................................................... 136
Engine Oil Relief Valve - Remove and Install (Engine
Crankshaft - Remove .......................................... 137
Oil Pressure Regulator) ...................................... 59
Crankshaft - Install .............................................. 138
Engine Oil Relief Valve - Remove and Install ....... 61
Crankshaft Gear - Remove and Install .............. 141
Engine Oil Pump - Remove .................................. 62
Bearing Clearance - Check ................................. 142
Engine Oil Pump - Disassemble ........................... 64
Engine Sensors - Remove and Install (Exhaust
Engine Oil Pump - Assemble ................................ 65
Temperature) ..................................................... 143
Engine Oil Pump - Install ...................................... 66
Coolant Temperature Switch - Remove and
Water Pump - Remove ......................................... 68
Install ................................................................. 144
Water Pump - Disassemble ................................. 69
Engine Oil Pressure Switch - Remove and Install
Water Pump - Assemble ...................................... 69
(Alternator Warning Lamp) ................................ 145
Water Pump - Install ............................................. 71
Engine Oil Pressure Switch - Remove and Install
Water Temperature Regulator Housing - Remove and
........................................................................... 145
Install (Thermostat Housing) ............................... 72
Engine Speed Sensor - Remove and Install
Aftercooler - Remove (Air Charge Cooler, TWG
(Overspeed Sensor) .......................................... 146
Engines) .............................................................. 74
Engine Speed Sensor - Remove and Install ....... 147
Boost Pressure Sensor - Remove and Install ..... 147
4 KENR6924
Table of Contents
V-Belts - Remove and Install (Fan Drive Belts) .. 148

Alternator - Remove and Install (Battery Charging
Alternator) ......................................................... 150
Alternator - Remove and Install (Alternator
Drive) ................................................................ 152
Electric Starting Motor - Remove and Install ..... 154
Index Section
Index ................................................................... 156
KENR6924 5
Disassembly and Assembly Section
Disassembly and Assembly Note: Use two spanners to disconnect the connection
and the hose assembly from the fuel priming pump in
Section order to prevent the fuel priming pump from turning
on the mounting bracket. Cap all open connections
on the fuel priming pump.
i02887616
Fuel Priming Pump - Remove 2. Remove pipe (10) and connection (9).
and Install 3. Disconnect hose assembly (1) from fuel priming

pump (4).
(Early Type)
4. Remove nuts (2). Remove fuel priming pump (4)
and bracket (3) from the engine as an assembly.
Removal Procedure 5. If necessary, follow Step 5.a through Step 5.c in

order to disassemble the fuel priming pump.
NOTICE
Keep all parts clean from contaminants. a. Remove banjo bolt (7) and separate fuel
priming pump (4) from bracket (3). Remove the
Contaminants may cause rapid wear and shortened sealing washers.
component life.
Note: Make a temporary mark in order to show the
orientation of the fuel priming pump on the bracket.
NOTICE
Care must be taken to ensure that fluids are contained b. Remove non-return valve (8) from bracket (3).
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to c. Remove adapter (6) and connection (5) from
collect the fluid with suitable containers before open- fuel priming pump (3).
ing any compartment or disassembling any compo-
nent containing fluids. Installation Procedure
Dispose of all fluids according to local regulations and Table 1
mandates.
Required Tools
1. Turn the fuel supply to the “OFF” position. Tool Part Number Part Description Qty
A - LOCTITE 542 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened

component life.
g01437339
Illustration 1
6 KENR6924
i02855338
Fuel Priming Pump - Remove

and Install
(Late Type)
Removal Procedure
NOTICE

component life.
NOTICE
Care must be taken to ensure that fluids are contained
g01437339
Illustration 2 ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
1. If necessary, follow Step 1.a through Step 1.c in ing any compartment or disassembling any compo-
order to assemble the fuel priming pump. nent containing fluids.
a. Apply Tooling (A) to the threads of adapter Dispose of all fluids according to local regulations and
(6) and connection (5). Install adapter (6) and mandates.
connection (5) to fuel priming pump (3).
1. Turn the fuel supply to the “OFF” position.
b. Install non-return valve (8) to bracket (3).
Tighten the non-return valve to a torque of
27 N·m (20 lb ft).
c. Position fuel priming pump assembly (4) and

two new sealing washers on bracket (3). Install
banjo bolt (7). Tighten the banjo bolt securely.
Note: Ensure the correct orientation of the fuel

priming pump on the bracket.
2. Place the assembly of fuel priming pump (4) and

bracket (3) in position and install nuts (2). Tighten
the nuts to a torque of 50 N·m (35 lb ft).
Note: Use two spanners to connect the hose

assembly and the connection to the fuel priming
pump in order to prevent the fuel priming pump from
turning on the mounting bracket.
3. Connect hose assembly (1) to fuel priming pump

(3).
g01429922
Illustration 3
4. Install pipe (10) and connection (9).
2. Remove bolts (3). Remove fuel priming pump (4)
5. Turn the fuel supply to the “ON” position. from fuel lift pump (1).
6. Remove the air from the fuel system. Refer to 3. Remove joint (2) (not shown).
Operation and Maintenance Manual, “Fuel System
- Prime”.
KENR6924 7
Installation Procedure i03112890
NOTICE
Fuel Filter Base - Remove and
Keep all parts clean from contaminants. Install
component life.
Removal Procedure
1. Ensure that the joint surfaces of the fuel priming
pump and the fuel lift pump are clean and free NOTICE
from damage. Keep all parts clean from contaminants.

component life.
NOTICE
ing, adjusting and repair of the product. Be prepared to
nent containing fluids.
Dispose of all fluids according to local regulations and

mandates.
g01429922
Illustration 4
2. Position a new joint (2) (not shown) on fuel lift

pump (1).
Note: Ensure correct orientation of the joint.
3. Position fuel priming pump (4) on fuel lift pump

(1) and install bolts (3). Tighten the M6 bolt to a
torque of 10 N·m (90 lb in). Tighten the M8 bolt to
a torque of 25 N·m (220 lb in).
4. Turn the fuel supply to the “ON” position.
5. Remove the air from the fuel system. Refer to

- Prime”.
g01430577
Illustration 5
2. Drain and remove fuel filter (5). Refer to Operation

and Maintenance Manual, “Fuel System Filter -
Replace” for the correct procedure.
3. Disconnect pipe (2) from filter head (4).
4. Loosen pipe (3) at the lift pump. Disconnect the

pipe from filter head (4).
8 KENR6924
5. Remove nuts and bolts (1) and remove filter head i03112920
(4) from the mounting bracket.
Fuel Transfer Pump - Remove
Note: Cap all open pipes and connections. and Install
Installation Procedure (Lift Pump)
NOTICE
Removal Procedure
component life. NOTICE
1. Ensure that the filter head is clean and free from Contaminants may cause rapid wear and shortened
damage. component life.
NOTICE

mandates.
g01430577
Illustration 6
2. Position filter head (4) on the mounting bracket.

Loosely connect the filter head to pipe (3).
3. Install nuts and bolts (1). Tighten the nuts and

bolts to a torque of 40 N·m (30 lb ft).
4. Connect pipe (2) to filter head (4) and tighten the

nuts at both ends of pipe (3) securely.
5. Install a new fuel filter (5) to filter head (4). Refer

to Operation and Maintenance Manual, “Fuel
System Filter - Replace” for the correct procedure.
g01429930
Illustration 7
A fuel lift pump that is equipped with the later type of fuel priming
pump
2. If the fuel lift pump is equipped with the later type
- Prime”.
of fuel priming pump, disconnect pipe (3) from
fuel lift pump (5).
If the fuel lift pump is equipped with the early type

of fuel priming pump, remove the banjo bolt and
sealing washers and remove pipe (3).
KENR6924 9
Remove pipe (4). 3. Position a new joint (2) (not shown) on the engine
oil pump. Lubricate the drive for the fuel lift pump
Note: Cap all open pipes and connections. and the seal in the engine oil pump with clean
engine oil.
3. Remove nuts (1) and remove fuel lift pump (5)
from the engine oil pump. Note: Ensure that the shaft of the fuel lift pump is
aligned with the drive in the rear of engine oil pump.
4. Remove joint (2) (not shown).
4. Position fuel lift pump (5) on the engine oil pump.
5. If the fuel lift pump is equipped with the later type Install nuts (1). Tighten the nuts to a torque of
of fuel priming pump, remove fuel priming pump 25 N·m (18 lb ft).
(6) from fuel lift pump (5). Refer to Disassembly
and Assembly, “Fuel Priming Pump - Remove and 5. Install pipe (4).
Install” for the correct procedure.
If the fuel lift pump is equipped with the later type
of fuel priming pump, connect pipe (3) to fuel lift
Installation Procedure pump (5).
NOTICE If the fuel lift pump is equipped with the early type
Keep all parts clean from contaminants. of fuel priming pump, install pipe (3). Install the
banjo bolt and new sealing washers. Tighten the
Contaminants may cause rapid wear and shortened banjo bolt to a torque of 68 N·m (50 lb ft).
component life.
1. Ensure that the joint surfaces of the fuel lift pump
and the engine oil pump are clean and free from 7. Remove the air from the fuel system. Refer to
damage. Inspect the seal and inspect the drive for Operation and Maintenance Manual, “Fuel System
the fuel lift pump for wear or damage. - Prime”.
i02887615
Fuel Manifold (Rail) - Remove

and Install
Removal Procedure
Start By:
a. Remove the electronic governor control unit.

Refer to Disassembly and Assembly, “Governor
- Remove and Install”. Removal of the electronic
governor control unit is only necessary if A Bank
fuel rail requires removal.
NOTICE
g01429930
Illustration 8
A fuel lift pump that is equipped with the late type of fuel priming Contaminants may cause rapid wear and shortened
pump component life.
2. If the fuel lift pump is equipped with the late type

of fuel priming pump, install fuel priming pump (6)
to fuel lift pump (5). Refer to Disassembly and
Assembly, “Fuel Priming Pump - Remove and
Install” for the correct procedure.
10 KENR6924
NOTICE

mandates.
2. Cut the cable straps that secure the thermocouples

for the exhaust temperature sensors to the fuel rail.
Loosen the clips that secure the thermocouples
for the exhaust temperature sensors to the fuel rail
and detach the thermocouples from the fuel rail.
Note: Do not allow the unions to turn when the pipes g01437839
are disconnected from the fuel rail. This will damage Illustration 10
the threads in the fuel rail. Use two spanners in order Typical example
to loosen the pipes from the unions.
4. Disconnect hose assembly (5) from fuel rail (1).
5. Remove pipe (6) and remove pipe (8).
6. Remove bolt (4) and remove pipe (7).
7. Repeat Step 5 and Step 6 in order to remove the

remaining pipes.
Note: Cap the pipes and cap the connections on the

fuel rail.
g01437826
Illustration 9
Typical example
3. Disconnect pipe (2) from fuel rail (1). Allow the fuel
g01437840
to drain from the fuel rail. Disconnect pipe (3) from Illustration 11
fuel rail (1). Allow the oil to drain from the fuel rail. Typical example
8. Remove bolts (9). Remove fuel rail (1) from the

engine.
KENR6924 11
Installation Procedure 4. Install pipe (8) and install pipe (6).
NOTICE 5. Repeat Step 3 and Step 4 in order to install the

Keep all parts clean from contaminants. remaining pipes.
Contaminants may cause rapid wear and shortened 6. Connect hose assembly (5) to fuel rail (1).
component life.
1. Ensure that the fuel rail and the pipes are clean
and free from restrictions.
g01437840
Illustration 12
Typical example
g01437826
Illustration 14
2. Place fuel rail (1) in position and install bolts (9). Typical example
Tighten the bolts to a torque of 50 N·m (35 lb ft).
7. Connect pipe (2) and connect pipe (3) to fuel rail
Note: Do not allow the unions to turn when the pipes (1).
are connected to the fuel rail. This will damage the
threads in the fuel rail. Use two spanners in order to 8. Position the thermocouples for the exhaust
tighten the pipes to the unions. temperature sensors on the fuel rail. Secure the
thermocouples to the fuel rail with clips and new
cable straps.

- Prime”.
End By:
a. Install the electronic governor control unit. Refer to

Disassembly and Assembly, “Governor - Remove
and Install”. Installation of the electronic governor
control unit is only necessary if A Bank fuel rail
was removed.
g01437839
Illustration 13
Typical example
3. Install pipe (7). Install bolt (4) to the tube clip.

Tighten the bolt to a torque of 40 N·m (30 lb ft).
12 KENR6924
i02855349 3. Cut the cable straps that secure harness assembly

(9) to plate (3). Remove nut (1) (not shown), nut
Governor - Remove (8) and nut (4). Loosen the clip that secures the
(Electronic Control Unit) harness assembly to plate (2). Detach the harness
assembly from the plate.
4. Loosen nuts (6) and (10). Remove electronic

governor control unit (2) and plate (3) as an
Removal Procedure assembly.
NOTICE

component life.
Accidental engine starting can cause injury or

death to personnel working on the equipment.
To avoid accidental engine starting, disconnect

the battery cable from the negative (−) battery ter-
g01438725
minal. Completely tape all metal surfaces of the Illustration 16
disconnected battery cable end in order to prevent
contact with other metal surfaces which could ac- 5. If necessary, remove nuts and bolts (12) and
tivate the engine electrical system. remove plate (11).
Place a Do Not Operate tag at the Start/Stop switch

i02855350
location to inform personnel that the equipment is
being worked on. Governor - Install
(Electronic Control Unit)
Installation Procedure
NOTICE

component life.
1. If necessary, follow Step 1.a and Step 1.b in

order to install the mounting plate for the electric
governor control unit.
g01430611
Illustration 15
Typical example
1. Disconnect electrical connectors (7) from

electronic governor control unit (2).
2. Disconnect harness assembly (9) from solenoids

(5).
KENR6924 13
5. Position harness assembly (9) on plate (3). Secure

the harness assembly to the plate with the clip and
new cable straps. Install nut (4). Tighten the nut
to a torque of 25 N·m (18 lb ft).
i02855353
Governor Actuator - Remove

and Install
Removal Procedure
g01438725
Illustration 17
NOTICE
a. Ensure that the anti-vibrationmounts on plate Keep all parts clean from contaminants.
(11) are free from damage.
b. Position plate (11) and install nuts and bolts component life.
(12). Tighten the nuts and bolts to a torque of
50 N·m (35 lb ft).


minal. Completely tape all metal surfaces of the
contact with other metal surfaces which could ac-
tivate the engine electrical system.

being worked on.
g01452119
Illustration 18
Typical example
2. Install electronic governor control unit (2) and

plate (3) to plate (11) (not shown) as an assembly.
Install nut (1) (not shown) and nut (8). Tighten nuts
(1), (6), (8) and (10) to a torque of 25 N·m (18 lb ft).
If a replacement electronic governor control

unit has been installed, the feedback for the
governor must be calibrated. Refer to Special
Instruction, “Pandoras Digital Govenor” for the
correct procedure.
3. Connect harness assembly (9) to solenoids (5).
4. Connect electrical connectors (7) to electronic

governor control unit (2).
14 KENR6924
Governor Actuator Stop Solenoids and Governor Actuator

Mounting Bracket
g01430622
Illustration 20
1. Cut cable straps (12) and slide rubber covers (13)

down harness assemblies (14).
2. Make temporary identification marks on the

connections of harness assemblies (14).
Disconnect the harness assemblies from stop
solenoids (7).
3. Remove nuts and bolts (11) and remove stop

solenoids (7) from the mounting brackets.
g01452129
Illustration 19
1. Disconnect electrical connector (6) from governor

actuator (8).
2. Compress the plungers on stop solenoids (7).

Use suitable cable straps in order to secure the
plungers in the compressed position.
g01452125
3. Remove the heat shield from the thermostat Illustration 21
housings.
4. If necessary, remove nuts (15) and remove
4. Remove nuts (3), bolts (2) and spacers (1) in order mounting bracket (11) from the timing case.
to disconnect control rods (4) from lever (5).
5. Remove allen head bolts (9) and carefully lift
governor actuator (8) from mounting bracket (10). NOTICE
6. If necessary, remove lever (5) from governor
actuator (8). Contaminants may cause rapid wear and shortened
component life.
Note: Mark the position of the lever for installation
purposes.
KENR6924 15
Stop solenoids and Governor Actuator Governor Actuator

Mounting Bracket
NOTICE

component life.
For safe operation and the ability to stop the en-

gine, ensure that the governor actuator will return
the fuel injectors to the “NO FUEL” position.
Failure to stop the engine may result in personal

injury or death.
g01452125
Illustration 22
1. If necessary, position mounting bracket (11) on

the studs in the timing case. Install nuts (15) hand
tight.
2. Install the governor actuator. Refer to “Governor

Actuator, Installation Procedure”.
g01430622
Illustration 23
3. Position stop solenoids (7) on the mounting

brackets. Install nuts and bolts (11). Tighten the
nuts and bolts to a torque of 25 N·m (18 lb ft).
Ensure that the lever of the actuator has full
movement. Carefully remove the cable straps that
secured the plungers for the stop solenoids in the
compressed position.
Note: If the lever on the actuator has restricted

movement, adjust the position of the mounting
brackets for the stop solenoids until full movement Illustration 24
g01452129
of the lever is achieved.
1. If necessary, install lever (5) to governor actuator
4. Connect harness assemblies (14) to stop (7). Tighten the clamp bolt securely.
solenoids (7).
Note: Ensure that the lever is aligned in the correct
5. Slide rubber covers (13) into position. Secure the position.
rubber covers with new cable straps (12).
16 KENR6924
2. Position governor actuator (8) onto mounting Removal of the Fuel Injection Control
bracket (10) and install allen head bolts (9). Linkage from the Cylinder Head
Tighten the allen head bolts to a torque of 25 N·m
(18 lb ft). If the mounting bracket was removed
from the timing case, tighten the nuts to a torque
of 50 N·m (35 lb ft).
3. Connect electrical connector (6) to governor

actuator (8).
4. Calibrate the operation of the governor actuator

and the governor electronic control unit. Refer to
Operation and Maintenance Manual, “Governor
Actuator - Check” for more information.
5. Connect control rods (4) to lever (5). Install bolts

(2), spacers (1) and nuts (3). Tighten the nuts and
bolts to a torque of 10 N·m (89 lb in). Illustration 25
g01621558
The “FULL FUEL” position on the governor actuator

6. Install the heat shield to the thermostat housings.
1. Set the governor actuator to the “FULL FUEL”
i02855355 position.
Fuel Injection Control Linkage

- Remove
Removal Procedure
Start By:
a. Remove the rocker assemblies. Refer to

Disassembly and Assembly, “Rocker Arm and
Shaft - Remove”.
b. Remove the cam followers. Refer to Disassembly

and Assembly, “Lifter Group - Remove”.
NOTICE
Contaminants may cause rapid wear and shortened g01438795

Illustration 26
component life.
2. Remove allen head bolt (1) in order to disconnect
link (2) from fuel injector (4). Remove spacer (3).
3. Remove the nut and bolt (5). Remove link (2).
KENR6924 17
g01438735
Illustration 27
4. Remove the nut and bolt (6) in order to disconnect

rod (8) from break-back lever (7).
g01452204
Illustration 29
2. Remove nut (10) and bolt (14) from lever (13).
3. Remove lever (13) from shaft (18).
4. Remove pin (17) from shaft (18).
5. Remove bolts (15) and remove housing (16) from

the timing case. Remove joint (12).
6. Remove seal (11) from housing (16).

g01438762
Illustration 28
Removal of the Fuel Injection Control
5. If necessary, remove locking nut (9) and remove Linkage from the Crankcase
break-back lever (7) from the cylinder head.
Removal of the Fuel Injection Control

Linkage from the Timing Case
1. Remove the governor actuator. Refer to
Disassembly and Assembly, “Governor Actuator
- Remove and Install”.
g01439276
Illustration 30
1. Remove nuts and bolts (21) and remove rods (8).
2. Remove bolts (20). Carefully remove control

shafts (19) through the front of the crankcase.
18 KENR6924
i02855358 3. Install bolts (20). Tighten the bolts hand tight.

Ensure that the control shafts are free to rotate as
Fuel Injection Control Linkage each bolt is tightened.
- Install
4. Tighten bolts (20) to a torque of 50 N·m (35 lb ft).
Note: Ensure that the control shafts are still free to

rotate.
5. Connect rods (8) to control shafts (19) and install
NOTICE nuts and bolts (21). Tighten the nuts and bolts to a
Keep all parts clean from contaminants. torque of 8 N·m (70 lb in).
Contaminants may cause rapid wear and shortened Installation of the Fuel Injection Control
component life.
Linkage to the Timing Case
Installation of the Fuel Injection Control

Linkage to the Crankcase
1. Lubricate the bearing surfaces of the control
shafts with clean engine oil.
g01439276 g01452204
Illustration 31 Illustration 33
g01439294 g01452554
(A) A Bank control shaft A Bank Fuel injection control linkage
(B) B Bank control shaft
1. Ensure that housing (16) is clean and free from
2. Carefully install control shafts (19) through the damage. Lubricate the outer diameter of a new
front of the timing case. Ensure the correct seal (11) with clean engine oil. Install the seal to
location and orientation of the control shafts. Refer the housing.
to Illustration 32.
Note: Ensure that the inner face of the seal is seated
squarely against the shoulder in the housing.
KENR6924 19
2. Install a new joint (12) to the timing case.
3. Ensure that the end of control shaft (18) is free

from burrs or sharp edges. Lubricate the end of
the control shaft with clean engine oil.
4. Carefully slide seal (11) over the end of control

shaft (18) and position housing (16) against the
gear case.
Note: Ensure that the lip of the seal is not damaged

as the seal is pushed over the groove in the shaft.
5. Install bolts (15). Tighten the bolts to a torque of

50 N·m (35 lb ft). g01438762
Illustration 36
6. Install pin (17) to shaft (18). Tap the pin into the
shaft until the leading edge of the pin is flush with 2. Install break-back lever (7) to the cylinder head.
the edge of the shaft. Install locking nut (9) hand tight.
7. Align slot (X) with pin (17) and install lever (13) to 3. Insert a 0.25 mm (0.010 inch) feeler gauge
shaft (18). between the arm and the block of break-back lever
(7). Rotate the break-back in an counterclockwise
Note: Ensure that the front face of the lever is flush direction. Tighten the nut to a torque of 50 N·m
with the front of the shaft. (35 lb ft). Remove the feeler gauge.
8. Install bolt (14) to lever (13) and tighten securely.

Install nut (10) to bolt (14) and tighten securely.
9. Install the governor actuator. Refer to Disassembly

and Assembly, “Governor Actuator - Remove and
Install”.
g01438735
Illustration 37
4. Connect rod (8) to break-back lever (7) and install

the nut and bolt (6). Tighten the nut and bolt to a
torque of 8 N·m (70 lb in).
g01621558
Illustration 35
The “FULL FUEL” position on the governor actuator
10. Set the governor actuator to the “FULL FUEL”

position.
Installation of the Fuel Injection Control

Linkage to the Cylinder Head
1. If the break-back lever is removed from the
cylinder head, check the tension of the spring.
Refer to Systems Operation, Testing and
Adjusting, “Fuel Injector Adjustment” for the
correct procedure.
20 KENR6924
b. Install the rocker assemblies. Refer to

Shaft - Install”.
i02855359
Fuel Injector - Remove
Removal Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A T6253/350 Puller 1
Start By:
g01439296
Illustration 38 a. Remove the rocker assembly. Refer to
Shaft - Remove”.
NOTICE

component life.
NOTICE
Illustration 39
g01439634 collect the fluid with suitable containers before open-
5. If a new link is installed, ensure that Dimension nent containing fluids.
(Y) is 85 mm (3.347 inch).
Connect link (2) to break-back lever (7) (not mandates.
shown). Install the nut and bolt (5). Tighten the nut
and bolt to a torque of 8 N·m (70 lb in). 1. Turn the fuel supply to the “OFF” position.
6. Position spacer (3) and connect link (2) to fuel Note: Do not allow the unions to turn when the pipes
injector (4). Install allen head bolt (1). Tighten the are disconnected from the fuel rail. This will damage
allen head bolt to a torque of 8 N·m (70 lb in). the threads in the fuel rail. Use two spanners in order
to loosen the pipes from the unions.
7. Calibrate the fuel injector, Refer to Operation
and Maintenance Manual, “Fuel Injector -
Inspect/Adjust” for the correct procedure.
Note: If three or more links have been installed, all of

the fuel injectors should be calibrated.
End By:
a. Install the cam followers. Refer to Disassembly

and Assembly, “Lifter Group - Install”.
KENR6924 21
g01439660
Illustration 40
Typical example
2. Disconnect pipe (2) and pipe (3) from fuel rail (1).
Allow the fuel to drain from the fuel rail.
g01439663
Illustration 42
3. Remove allen head bolt (5) in order to disconnect

link (6) from fuel injector (4). Remove spacer (7).
4. Remove allen head bolt (8) from clamp (9).
5. Install Tooling (A) to the cylinder head. Tighten the

bolt on Tooling (A) in order to pull clamp (9) and
fuel injector (4) from the cylinder head. Remove
Tooling (A). Remove the fuel injector and the
clamp from the cylinder head.
Note: Do not pull on the spring of the fuel injector in

order to remove the fuel injector from the cylinder
head.
6. Remove clamp (9) from fuel injector (4).
g01439666
Illustration 41
22 KENR6924
NOTICE
The fuel injectors should only be disassembled, ser-
viced and assembled by trained personnel using the
correct tools. The fuel injectors should only be disas-
sembled, serviced and assembled in an environment
that is free from dust and contamination.
NOTICE

component life.
g01439664
Illustration 43
7. Remove sealing washer (12) from fuel injector

(4). Remove O-ring seal (10) and O-ring seal (11)
from fuel injector (4).
i03126122
g01600495
Fuel Injector - Disassemble Illustration 44
Tooling (C) contains the following items:
(CA) Brass wire brush
(CB) Wire holder
(CC) Seat scraper
Disassembly Procedure (CD) Fuel chamber scraper
Table 3 1. Follow Step 1.a through Step 1.c in order to clean

Required Tools the exterior of the fuel injector.
Tool Part Number Part Description Qty a. Plug the ports in the fuel injector in order to
Fuel Injector Clamp prevent the entry of debris.
B(1) T6253/146 and Fuel Feed Adapter 1
(12mm) b. Wash the fuel injector with clean fuel.
Fuel Injector Clamp c. Use brass wire brush (CA) in order to remove
B(2) T6253/356 and Fuel Feed Adapter 1
the carbon deposits from the fuel injector.
(14mm)
Injector Nozzle
C T6253/202 1
Cleaning Tools
D T6253/203 Needle Gauge 1
E T6253/204 Multiclean 1
(1) 1800 rpm engines
Start By:
a. Remove the fuel injectors. Refer to Disassembly

and Assembly, “Fuel Injectors - Remove”.
KENR6924 23
g01600617
Illustration 47
6. Place Tooling (B) in a suitable vise and tighten the

vise securely. Install housing (15) to Tooling (B)
with the housing upward.
g01600595
Illustration 45
g01602959
Illustration 46
2. Use a screwdriver to release the plate that retains

spring assembly (13) from dowel (14).
3. Remove spring assembly (13) from housing (15).
Note: The spring assembly is matched to the

housing of the fuel injector. These components
must not be interchanged. If these components are
worn or damaged, they should be replaced with g01600515
service exchange items that are available from your Illustration 48
authorized Perkins distributor. To ensure that the
spring assembly is assembled to the correct housing, 7. Use a 27 mm socket in order to remove holder
it is advisable to work on one fuel injector at any time. (17).
4. Remove timing pin (16) from housing (15). 8. Remove the assembly of nozzle and needle (18),
transfer block (19) and thrust cap (20). Place the
5. Place spring assembly (13) and housing (15) into components into a container of clean fuel.
a container of clean fuel. The components should
be allowed to soak in the fuel until any carbon 9. Remove housing (15) from Tooling (B). Remove
deposits have softened. spring (21) and shims (22) from the housing. Place
the components into the container of clean fuel.
Note: Ensure that all shims have been removed from

the housing.
24 KENR6924
Cleaning and Inspection of the Fuel i03126123
Injector Components Fuel Injector - Assemble

1. Wash the housing in clean fuel. Remove any
carbon deposits from the nozzle clamping
shoulder on the housing.
Assembly Procedure
2. Check the mating surface of the housing, the
nozzle and the transfer block. The mating surfaces Table 4
of these components must be smooth and flat. Required Tools
Note: It is possible to remove minor wear or staining Tool Part Number Part Description Qty
from the mating surfaces by lightly lapping the Fuel Injector Clamp
surfaces on a lapping plate. B(1) T6253/146 and Fuel Feed Adapter 1
(12mm)
3. Wash the assembly of the nozzle and the needle
Fuel Injector Clamp
in clean fuel. Remove the needle from the nozzle B(2) T6253/356 and Fuel Feed Adapter 1
and check the surface of the needle. The surface (12mm)
must be free from discoloration or damage. The
needle must slide smoothly in the bore of the (2) 1500 rpm engines
nozzle.
4. Use Tooling (D) in order to check the lift of the NOTICE

needle in the nozzle. If the lift of the needle is The fuel injectors should only be disassembled, ser-
greater than the service wear limit, the assembly viced and assembled by trained personnel using the
of nozzle and needle must be replaced. correct tools. The fuel injectors should only be disas-
sembled, serviced and assembled in an environment
Needle lift (new) ............................. 0.4 to 0.6 mm that is free from dust and contamination.
(0.016 to 0.024 inch)
Needle lift (service wear limit) ................ 0.75 mm NOTICE

(0.030 inch) Keep all parts clean from contaminants.
5. Follow Step 5.a through Step 5.d in order to clean Contaminants may cause rapid wear and shortened
the nozzle of the fuel injector. component life.
a. Insert Tooling (CD) into the bore of the nozzle, 1. Ensure that all components of the fuel injector
so that the tip of the tool is located in the fuel are clean and free from wear or damage. Refer
gallery. Press the tool against the side of the to Disassembly and Assembly, “Fuel Injectors -
fuel gallery and rotate the tool in order to Disassemble” for the correct procedure.
remove any carbon deposits. Use brass wire
of a suitable diameter in order to clean out the 2. Lubricate the bore in the nozzle with clean fuel
fuel passages in the nozzle. and install the needle to the nozzle.
b. Insert Tooling (CC) into the valve seat of the Note: The needle must slide smoothly in the bore of
nozzle. Press the tool against the valve seat the nozzle.
and rotate the tool in order to remove any
carbon deposits.
c. Install a piece of brass wire 0.3 mm diameter

into Tooling (CB). The wire should protrude from
the tool by 1.5 to 2.0 mm (0.060 to 0.080 inch).
Use Tooling (CB) to insert the brass wire into
the spray holes in the nozzle. Carefully rotate
the tool in order to clean out the spray holes
in the nozzle.
d. Use Tooling (E) in order to remove the

remaining carbon from the inside of the nozzle.
Ensure that the nozzle is completely free from
carbon or other contamination.
KENR6924 25
6. Lubricate the nozzle clamping shoulder on

housing (15) with grease. Install holder (17) to
the shoulder hand tight. Use a 27 mm socket in
order to tighten the holder to a torque of 205 N·m
(150 lb ft).
7. Remove housing (15) and Tooling (B) from the

vise as an assembly. Test the fuel injector. Refer
to Systems Operation Testing and Adjusting,
“Test and Set the Fuel Injectors” for the correct
procedure. If necessary, the nozzle opening
pressure can be adjusted by varying the thickness
of the shims. An increase in shim thickness of
0.51 mm (0.020 inch) will give a pressure increase
of approximately 517 kPa (75 psi). Remove
housing (15) from Tooling (B).
g01600515
Illustration 49
3. Install shims (22), spring (21) and thrust cap (20)

to the housing of the fuel injector. g01602959
Illustration 51
4. Align the dowels on transfer block (19) with the

housing of the fuel injector and install the transfer
block to the housing. Align the assembly of nozzle
and needle (18) with the dowels on the transfer
block and install the assembly of nozzle and
needle to the transfer block.
g01602960
Illustration 50
g01602880 Illustration 52
5. Place Tooling (B) in a suitable vise and tighten the 8. Install timing pin (16) to housing (15).
vise securely. Install housing (15) to Tooling (B)
with the housing upward. 9. Install spring assembly (13) to housing (15).
Ensure that dowel (14) and timing pin (16) engage
into the holes in the plate that retains spring
assembly (13).
26 KENR6924
Note: The spring assembly is matched to the housing

of the fuel injector. These components must not be
interchanged.
End By:
a. Install the fuel injectors. Refer to Disassembly and

Assembly, “Fuel Injectors - Install”.
i02855361
Fuel Injector - Install
Table 5
Required Tools
Tool Part Number Part Description Qty g01439664
Illustration 53
GE50028 Vacuum Pump 1
Tube 2. Install a new O-ring seal (10) and a new O-ring
F
GE50030 7.9 mm (0.31 inch) 1 seal (11) to fuel injector (4). Lubricate the O-ring
Outside Diameter seals with Tooling (G). Install a new sealing
washer (12) to fuel injector (4).
POWERPART
G 21820221 1
Rubber Grease
3. Ensure that the sleeve for the fuel injector in the
cylinder head is clean and free from damage. If
NOTICE necessary, replace the sleeve for the fuel injector.
Keep all parts clean from contaminants. Refer to Disassembly and Assembly, “Fuel
Injector Sleeve - Remove” and Disassembly and
Contaminants may cause rapid wear and shortened Assembly, “Fuel Injector Sleeve - Install”.
component life.
1. Use Tooling (F) in order to remove any fuel from

the cylinder.
Note: Evacuate as much fuel as possible from the

cylinder before installing the fuel injector.
g01621582
Illustration 54
4. Install clamp (9) to fuel injector (4). Install the fuel

injector and the clamp to the cylinder head as an
assembly.
5. Install allen head bolt (8) to clamp (9) finger tight.

Rotate injector (4) in a clockwise direction against
the clamp. Ensure that the fuel injector is pushed
firmly downward against the seat in the cylinder
head. Tighten the allen head bolt to a torque of
95 N·m (70 lb ft).
KENR6924 27
g01440088
Illustration 55
(X) “NO FUEL” position
6. Rotate the arm on fuel injector (4) counterclockwise

to Position (X). The fuel injector is now in the “NO
FUEL” position.
g01439660
Illustration 57
Typical example
9. Connect pipe (2) and pipe (3) to fuel rail (1).

Tighten the nuts on the pipes securely.
Note: Do not allow the unions to turn when the pipes

are connected to the fuel rail. This will damage the
threads in the fuel rail. Use two spanners in order to
tighten the pipes to the unions.

Illustration 56
g01440095 Operation and Maintenance Manual, “Fuel System
- Prime”.
7. Position spacer (7) and link (6) on fuel injector (4).
Install allen head bolt (5). Tighten the allen head End By:
bolt to a torque of 8 N·m (70 lb in).
a. Install the rocker assembly. Refer to Disassembly
8. Calibrate the fuel injectors, Refer to Operation and Assembly, “Rocker Arm and Shaft - Install”.
and Maintenance Manual, “Fuel Injector -
Inspect/Adjust” for the correct procedure. i02855364
Note: If three or more fuel injectors have been Fuel Injector Sleeve - Remove
installed, all of the fuel injectors should be calibrated.
Removal Procedure
Table 6
Required Tools
Drill
A - (22 mm with 60 degree 1
point)
Tap
B - (M36 or 1 3/8 inch - 1
UNF)
28 KENR6924
Start By: 3. Place the cylinder head in the inverted position.

Insert a suitable brass rod into the injector bore of
a. Remove the cylinder head. Refer to Disassembly the cylinder head. Use a hammer and the brass
and Assembly, “Cylinder Head - Remove”. rod in order to remove Tooling (B) and sleeve (1)
from the cylinder head.
NOTICE

component life.
g01449477
Illustration 60
4. Remove O-ring seal (2) from the cylinder head.
i02855367
g01449476
Illustration 58
Fuel Injector Sleeve - Install
1. Place the cylinder head in the inverted position on
a suitable support. Use Tooling (A) in order to drill
out the swaging from sleeve (1).
Note: Take care to avoid drilling into the cylinder
head. Table 7
Required Tools
2. Place the cylinder head in the upright position.
Screw Tooling (B) into sleeve (1). Tool Part Number Part Description Qty
POWERPART
C 21820221 1
Rubber Grease
Injector Bush Insertion
D T85002/2 1
Tool
Injector Bush Expanding
E T85002/6 1
Tool (Lower)
Injector Bush Expanding
F T85002/58 1
Tool (Upper)
Injector Bush Swaging
G T85002/156 1
Tool
Injector Bush Facing
H T85002/7 1
Cutter
Injector Bush Depth
J T85002/14B 1
Guage
NOTICE
Illustration 59
g01449478 Contaminants may cause rapid wear and shortened
Removing the sleeve from the cylinder head
component life.
KENR6924 29
1. Ensure that the bore in the cylinder head for the 4. Place the cylinder head in the upright position on
sleeve is clean and free from corrosion. a suitable support. Position sleeve (1) and Tooling
(D) in the bore in the cylinder head. Carefully
tap the sleeve into position until Distance (Y) is
1.5 mm (0.060 inch). Remove Tooling (D).
Note: Ensure that the O-ring seal is not damaged or

displaced during this procedure.
g01449503
Illustration 61
2. Lubricate a new O-ring seal (2) with Tooling (C). 5. Use Tooling (G) in order to swage the end of
Install the new O-ring seal to the bore in the sleeve (1) sufficiently so that the sleeve is held
cylinder head. in position.
Note: The final forming of the swage is completed

after the sleeve has been expanded.
g01449498
Illustration 62
3. Place a new sleeve (1) over Tooling (D) and install g01449504
Illustration 66
the locating pin.
6. Place the cylinder head in the inverted position.
Use Tooling (E) in order to expand the bottom of
sleeve (1).
g01449501
Illustration 63
g01453408
Illustration 67
7. Place the cylinder head in the upright position. Use

Tooling (F) in order to expand top of sleeve (1).
g01449502
Illustration 64
30 KENR6924
i02855383
Air Cleaner - Remove and

Install
Illustration 68
g01449503 Removal Procedure
8. Use Tooling (G) in order to swage the end of NOTICE
sleeve (1). Tighten the nut on Tooling (G) to a Keep all parts clean from contaminants.
torque of 55 N·m (40 lb ft) in order to swage the
end of the sleeve to the correct form. Contaminants may cause rapid wear and shortened
component life.
g01449505
Illustration 69
g01422630
Illustration 71
g01449517
Illustration 70
g01422637
Illustration 72
9. Use Tooling (J) in order to check Distance
(Z). Use Tooling (H) in order to face sleeve 1. Loosen hose clamp (2) and release hose (1) from
(1) so that Distance (Z) is 122.6 ± 0.166 mm air cleaner (3).
(4.8207 ± 0.004 inch).
2. Use a suitable lifting device to support the weight
End By: of air cleaner (3). The weight of the air cleaner is
approximately 23 kg (51 lb).
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install”.
KENR6924 31
3. Remove nuts and bolts (4). Use the lifting device

in order to remove air cleaner (3) from mounting
bracket (5).
4. Repeat Step 1 through Step 3 in order to remove

the remaining air cleaner.
g01422633
Illustration 74
1. If necessary, use a suitable lifting device in order

to position mounting bracket (5) on the exhaust
manifolds. Install bolts (6). Tighten the bolts to a
torque of 50 N·m (35 ft).
g01422633
Illustration 73
5. If necessary, remove bolts (6) and use a suitable

lifting device in order to remove mounting bracket
(5) from the exhaust manifolds.
NOTICE

component life.
g01422630
Illustration 75
32 KENR6924
1. Remove the exhaust elbows. Refer to Disassembly

and Assembly, “Exhaust Elbow - Remove and
Install”.
g01422637
Illustration 76
2. Use a suitable lifting device to lift air cleaner (3)

into position. The weight of the air cleaner is
3. Carefully push air cleaner (3) onto hose (1) and

align the air cleaner with mounting bracket (5).
4. Install nuts and bolts (4). Tighten the nuts and g01435802
Illustration 77
Typical example of a TAG engine
Note: Ensure that there is adequate clearance
between the air cleaner and the air pipe in order to 2. Disconnect pipe (3) from the tee connector.
allow removal of the air cleaner element.
3. Disconnect pipe (6) from the tee connector.
5. Tighten hose clamp (2) to a torque of 7 N·m
(62 lb in). Note: Plug and cap all open connectors and pipes in
order to prevent the entry of dirt.
6. Repeat Step 2 through Step 5 in order to install
the remaining air cleaner. 4. Loosen the hose clamps and slide hose (1)
forward in order to disconnect the hose from
turbocharger (2).
i02855385
Turbocharger - Remove of turbocharger (2). The weight of the turbocharger
is approximately 21 kg (46 lb).
6. Remove nuts and bolts (7). Use the lifting device

Removal Procedure to carefully remove turbocharger (2).
NOTICE 7. Remove gasket (8) (not shown).

8. Remove gland (5). Remove O-ring seals (4) from
Contaminants may cause rapid wear and shortened the gland.
component life.
NOTICE

mandates.
KENR6924 33
1. Ensure that the turbochargers are clean and

free from damage. Inspect the turbochargers for
wear. Refer to Systems Operation, Testing and
Adjusting, “Turbocharger” for more information.
Ensure that all pipes are clean and free from
restrictions.
g01605633
Illustration 78
2. Loosen v-band clamp (13) and v-band clamp (14).

9. Remove allen head bolts (9) and (12). Remove
Ensure that the housings are free to rotate on the
pipes (3) and (6). Remove joints (10) and (11).
body of the turbocharger. If necessary, remove
the v-band clamps and clean the mating surfaces
Note: Plug all open ports in order to prevent the
of the turbocharger. Lubricate the mating surfaces
entry of dirt.
with Tooling (B) and install the v-band clamps.
the remaining turbochargers.
i02855386
Turbocharger - Install
Table 8
Required Tools
Part
Tool Number Part Description Qty
POWERPART
A 21820221 1
Rubber Grease
POWERPART
B CV60889 1
Anti-Sieze Compound g01605934
Illustration 80
Typical example of a TWG engine
NOTICE
Keep all parts clean from contaminants. 3. Install new O-ring seals (4) to gland (5). Lubricate
the O-ring seals with Tooling (A).
component life. 4. Install gland (5) to turbocharger (2).
Note: Install the gland so that the machined end of

the bore is located in the turbocharger.
5. Position a new gasket (8) (not shown) onto the

exhaust manifold.
34 KENR6924
6. Use a suitable lifting device to lift turbocharger (2) 11. Follow Step 11.a through Step 11.g in order to
into position on the exhaust manifold. The weight align the turbocharger to the oil pipes.
of the turbocharger is approximately 21 kg (46 lb).
Align the compressor housing of the turbocharger Note: The alignment procedure should be carried
with air pipe (17) and push the turbocharger into out on the pair of turbochargers from the same
position. Ensure that gland (5) is seated in the air bank. The oil pipes must be correctly aligned with
pipe. Align the body of the turbocharger so that the turbochargers before the oil pipes are secured.
the joint faces of the oil pipes are horizontal. Failure to align the oil pipes correctly can result in
damage to the oil pipes.
7. Install nuts and bolts (7) hand tight.
a. Temporarily install oil feed pipes (3) and allen
Note: TWG and early TAG engines use temporary head bolts (9). Tighten the allen head bolts (9)
spacers and allen head bolts in order to seat the air hand tight.
pipes.
Note: Install the oil feed pipes without joints.
8. If necessary, temporarily install spacers (16)
between air pipe (17) and turbocharger (2). Install b. Tighten the nuts that secure oil feed pipes (3)
allen head bolts (15) hand tight in order to pull the to tee connector (18) hand tight.
air pipe into position.
c. Tighten allen head bolts (9) to a torque of
9. Tighten nuts and bolts (7) to a torque of 70 N·m 50 N·m (35 lb ft). Tighten the nuts that secure
(50 lb ft). the oil feed pipes to tee connector (18) to a
torque of 70 N·m (50 lb ft).
the remaining turbocharger to the same bank. d. Temporarily install oil drain pipes (6) and allen
head bolts (12). Tighten the allen head bolts
hand tight.
Note: Install the oil drain pipes without joints.
e. Check the alignment of oil drain pipes (6). If the

oil drain pipes do not align with tee connector
(19), loosen nuts and bolts (7) and adjust the
position of the turbochargers. If necessary,
repeat Step 11.a through Step 11.c in order to
align the turbochargers with the oil feed pipes
and the oil drain pipes.
Note: If the position of the turbocharger is adjusted,

ensure that bolts (7) are tightened to correct torque.
g01605935
Illustration 81
g01426578
Illustration 83
Seating the v-band clamps on the turbocharger
g01608736
Illustration 82
KENR6924 35
f. Tighten v-band clamps (13) and v-band clamps 15. If allen head bolts and spacers were used to pull
(14) to a torque of 9 N·m (80 lb in). Lightly tap the air pipes into position, remove allen head bolts
the v-band clamps with a soft faced hammer (9) and spacers (10) from all turbochargers.
in order to seat the v-band clamps. Again,
tighten the v-band clamps to a torque of 9 N·m 16. Install the exhaust elbows. Refer to Disassembly
(80 lb in). Repeat this Step until the v-band and Assembly, “Exhaust Elbow - Remove and
clamps are secure. Install”.
g. Remove oil feed pipes (3) and oil drain pipes 17. Prime the engine oil system. Refer to Operation
(6). and Maintenance Manual, “Before Starting the
Engine” for the correct procedure.
12. Slide hoses (1) into position on turbochargers (2).
Tighten the hose clamps securely.
i02855388
Air Shutoff - Remove
Removal Procedure
Start By:
a. Remove the air cleaners. Refer to Disassembly

and Assembly, “Air Cleaners - Remove and
Install”.
NOTICE

component life.
g01425734
Illustration 84
13. Follow Step 13.a and Step 13.b in order to install

the oil feed pipes and the oil drain pipes to the
turbochargers.
a. Position new joints (11) and install pipes (6)

to turbochargers (2). Install allen head bolts
(12). Tighten the allen head bolts to a torque of
50 N·m (35 lb ft). Tighten the nuts that secure
the pipes to the tee connector to a torque of
70 N·m (50 lb ft).
b. Position strainer joints (10) and install pipes (3)

to turbochargers (2). Install allen head bolts
(9). Tighten the allen head bolts to a torque of
50 N·m (35 lb ft). Tighten the nuts that secure
the pipes to the tee connector to a torque of
70 N·m (50 lb ft).
g01423804
Illustration 85
Note: After a major engine rebuild, a strainer joint
must be installed to the turbocharger. When the
1. Disconnect electrical connections (3) (not shown)
initial running period has been completed, the
from air shut off valve (2).
strainer joint must be replaced with a standard
joint.
2. Loosen the hose clamps and release hoses (4)
from turbochargers (1).
the turbochargers to the alternate bank.
36 KENR6924
3. Remove bolts (5) and remove air shut off valve (2) i02855392
from the mounting bracket.
Air Shutoff - Install
NOTICE

component life.
g01425078
Illustration 86
4. Loosen the hose clamps and remove hoses (4)

and (6) from air shut off valve (2).

the remaining air shut off valve.
g01425412
Illustration 88
1. If necessary, use a suitable lifting device in order

to position mounting bracket (7) onto the exhaust
manifolds. Install bolts (8). Tighten the bolts to a
g01425412
Illustration 87
6. If necessary, follow Step 6.a and Step 6.b in order

to remove the mounting bracket for the air shut
off valves.
a. Remove bolts (8) which secure the mounting

bracket to the exhaust manifolds.
b. Use a suitable lifting device in order to remove

mounting bracket (7).
g01425414
Illustration 89
2. Clean air shut off valve (2). Inspect the

components of the air shut off valve. Ensure that
butterfly valve (9) is not worn or damaged. Ensure
that the butterfly valve is free to move in the body
of the air shut off valve.
KENR6924 37
Note: When the butterfly valve is in the CLOSED End By:

position, an airtight seal must be formed against the
body of the air shut off valve. a. Install the air cleaners. Refer to Disassembly and
Assembly, “Air Cleaners - Remove and Install”.
i02857754
Air Lines - Remove and Install

(Air Pipes, TAG engines)
Removal Procedure
NOTICE
g01425078
Illustration 90
3. Loosely install hoses (4) and (6) and the hose component life.
clamps to air shut off valve (2).
g01428449
Illustration 92
g01423804
Illustration 91
4. Position air shut off valve (2) on the mounting

bracket and align hoses (4) with turbochargers (1).
Push air shut off valve (2) into position.

50 N·m (35 lb ft).
6. Ensure that hoses (4) and (6) are correctly

positioned. Tighten the hose clips to a torque of
7 N·m (62 lb in).
7. Connect electrical connections (3) (not shown) to

air shut off valve (2).

the remaining air shut off valve.
38 KENR6924
7. Remove gasket (5) (not shown) .
8. Remove glands (8). Remove O-ring seals (7) from

the glands.
9. Remove nuts and bolts (11) and separate air pipe

(1) from air pipe (2). Remove gasket (12) (not
shown).
Table 9
Required Tools
Part
POWERPART
A 21820221 1
Rubber Grease
NOTICE
g01435410 Keep all parts clean from contaminants.
Illustration 93

component life.
1. Ensure that the air pipes and glands are clean and
free from damage.
g01462706
Illustration 94
Turbocharger
1. Use a suitable lifting device to support the

assembly of air pipe (1) and air pipe (2). The
weight of the air pipes is approximately 21 kg
(46 lb).
2. Remove bolts (9).
3. Remove nuts and bolts (6) and disconnect air pipe

(2) from air pipe (3).
4. Remove nuts and bolts (10) and remove bracket g01428449

Illustration 95
(4).
5. Loosen v-band clamp (13) and hose clamp (14)

on the outer turbocharger. Carefully disconnect air
pipe (1) from the turbocharger.
Note: Rotate the compressor housing of the

turbocharger in order to disconnect the air pipe.
6. Use the lifting device in order to remove the

assembly of air pipe (1) and air pipe (2).
KENR6924 39
7. Ensure that the compressor housing of the outer

turbocharger is free to rotate. Align air pipe (2)
with glands (8) in the turbochargers. Push air pipe
(2) into position so that the gap between the air
pipe and each turbocharger is an equal distance.
8. Place bracket (4) in position. Install nuts and bolts

(10) hand tight. Install bolts (9) hand tight.
Note: Ensure that the gap between the air pipe and
each turbocharger is still an equal distance.
9. Tighten nuts and bolts (10) to a torque of 50 N·m

(37 lb ft).
11. Tighten v-band clamp (13) to a torque of 9 N·m

(80 lb in). Lightly tap the v-band clamp with a soft
faced hammer in order to seat the v-band clamp.
Again, tighten the v-band clamp to a torque of
Illustration 96
g01435410 9 N·m (80 lb in). Repeat this Step until the v-band
clamp is secure. Tighten the hose clamp (14)
securely.
i02855394
Exhaust Manifold - Remove

and Install
Removal Procedure
NOTICE
Illustration 97
Turbocharger
component life.
2. Position a new gasket (12) (not shown) between
air pipe (1) and air pipe (2). Install nuts and bolts
(11). Tighten the nuts and bolts to a torque of NOTICE
50 N·m (35 lb ft). The exhaust manifolds should be removed as individ-
ual sections. If the exhaust manfold is removed as a
3. Lubricate new O-ring seals (7) with Tooling (A). complete assembly, damage to the bellows may oc-
Install the O-ring seals to glands (8). cur.
4. Install glands (8) to the turbochargers.
Note: It is possible to remove individual sections of
Note: Install the glands so that the machined end of an exhaust manifold without removing the complete
the bores are to the turbochargers. manifold. If removal of a complete manifold is
necessary, begin the removal procedure at the front
5. Use a suitable lifting device in order to lift of the engine and work toward the rear. Remove the
the assembly of air pipe (1) and air pipe (2) outer center sections of the manifold before removing
into position. The weight of the air pipes is the inner center sections of the manifold.
Manifold Front and Center Sections
6. Position a new gasket (5) (not shown) between
air pipe (2) and air pipe (3). Loosely install nuts 1. Remove the air cleaners. Refer to Disassembly
and bolts (6). and Assembly, “Air Cleaner - Remove and Install”.
40 KENR6924
2. Remove the air shut off valves. Refer to

Disassembly and Assembly, “Air Shut Off -
Remove”.
3. Remove the air pipes from TAG engines. Refer to

Disassembly and Assembly, “Air Lines - Remove
and Install”.
g01429522
Illustration 99
A typical rear section of an exhaust manifold
3. Remove nuts and bolts (11), (12), (15) and (17).
4. Remove nuts and bolts (16). Remove exhaust

manifolds (9), (10), (13) and (14) from the support
g01429116
Illustration 98 brackets.
A typical front section of an exhaust manifold
4. Remove nuts and bolts (1). Remove any mounting

brackets that are retained by the nuts and bolts. Table 10
Note: Mark the location and orientation of the Required Tools

brackets for installation. Part
5. Loosen bolts (6).
POWERPART
A CV60889 1
Anti-Sieze Compound
6. Remove bellows (8), gasket (4) (not shown) and
gasket (7) (not shown). Torque Adaptor
B - 15mm - 12 point, 3/8" 1
7. Support exhaust manifold (2) with a suitable lifting drive
device. Remove bolts (6) and spacers (5). Use
the lifting device to carefully remove the exhaust NOTICE
manifold from the cylinder head. Keep all parts clean from contaminants.
8. Remove gasket (3) (not shown). Contaminants may cause rapid wear and shortened
component life.
the remaining front sections of the exhaust
manifold or the remaining center sections of the Note: If installation of a complete manifold is
exhaust manifold. necessary, begin the installation procedure at the
rear of the engine and work toward the front. Install
Manifold Rear Sections the inner center sections of the manifold before
installing the outer center sections of the manifold.
1. Remove the turbochargers. Refer to Disassembly
and Assembly, “Turbochargers - Remove”. Manifold Rear Sections
2. Remove the exhaust temperature sensors. Refer 1. Ensure that the gasket surfaces of the exhaust
to Disassembly and Assembly, “Engine Sensors manifolds are clean and free from damage.
KENR6924 41
g01429522 g01429172
A typical rear section of an exhaust manifold A typical front section of an exhaust manifold
2. Position exhaust manifolds (10) and (13) on the 2. Position a new gasket (3) (not shown) on the
mounting bracket. Install nuts and bolts (16) hand cylinder head. Use a suitable lifting device to lift
tight. exhaust manifold (2) into position.
3. Install nuts and bolts (11) and (12). Tighten the 3. Apply Tooling (A) to the threads of bolts (6).
nuts and bolts to a torque of 163 N·m (120 lb ft).
4. Loosely install bolts (6) and spacers (5).
(50 lb ft). 5. Slide gasket (4) (not shown), bellows (8) and
gasket (7) (not shown) into position.
5. Position exhaust manifolds (9) and (14) on the
mounting brackets. Install the remaining nuts and Note: Ensure that Arrow (X) is toward the
bolts (16) hand tight. turbocharger.
6. Install nuts and bolts (15) and (17). Tighten the 6. Place any mounting brackets in position and install
nuts and bolts to a torque of 163 N·m (120 lb ft). nuts and bolts (1) hand tight.
7. Tighten the remaining nuts and bolts (16) to a Note: Ensure the correct location and orientation of
torque of 70 N·m (50 lb ft). the brackets. If necessary, use a straight edge to
align the brackets.
8. Install the exhaust temperature sensors. Refer to
Disassembly and Assembly, “Engine Sensors - 7. Use Tooling (B) to tighten bolts (6) to a torque of
Remove and Install”. 70 N·m (50 lb ft).
9. Install the turbochargers. Refer to Disassembly 8. Tighten nuts and bolts (1) to a torque of 70 N·m
and Assembly, “Turbocharger - Install”. (50 lb ft).
Manifold Front and Center Sections 9. Repeat Step 2 through Step 8 in order to install
the remaining center sections of the exhaust
1. Ensure that the gasket surfaces of the exhaust manifold or the remaining front sections of the
manifolds and the cylinder heads are clean and exhaust manifold.
free from damage. Ensure that the bellows are
clean and free from damage. 10. Install the air pipes to TAG engines. Refer to
Disassembly and Assembly, “Air Lines - Remove
and Install”.
11. Install the air shut off valves. Refer to Disassembly

and Assembly, “Air Shut Off - Install”.
42 KENR6924
12. Install the air cleaners. Refer to Disassembly and

Assembly, “Air Cleaner - Remove and Install”.
i02862391
Exhaust Elbow - Remove and

Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants. g01428093
Illustration 103
Contaminants may cause rapid wear and shortened 6. Remove v-band clamps (6) and bellows (5) from
component life. the turbochargers.
1. Disconnect the exhaust system from the exhaust Installation Procedure

elbow.
NOTICE
Note: Ensure that the exhaust system is adequately Keep all parts clean from contaminants.
supported.
component life.
1. Ensure that the exhaust elbow and bellows are

clean and free from damage.
g01428093
Illustration 104
g01428045
Illustration 102
2. Remove nuts and bolts (2) and disconnect bellows

(5) from exhaust elbow (1).

of exhaust elbow (1). The weight of the exhaust
elbow is approximately 43 kg (95 lb).
4. Remove nuts (4). Use the lifting device in order

to remove exhaust elbow (1) from the mounting
bracket.
5. Remove gaskets (3) (not shown).
KENR6924 43
8. Tighten v-band clamps (6) to a torque of 9 N·m

(80 lb in). Lightly tap the v-band clamps with a soft
faced hammer in order to seat the v-band clamps.
Again, tighten the v-band clamp to a torque of
9 N·m (80 lb in).
9. Connect the exhaust systems to the exhaust

elbows.
i02855395
Inlet Manifold - Remove
Removal Procedure
Start By:
a. Remove the module for the exhaust temperature

Illustration 105
g01428045 sensors. Refer to Disassembly and Assembly,
“Engine Sensors - Remove and Install”.
2. Position bellows (5) on the turbochargers and
install v-band clamps (6) hand tight. b. Remove the fuel rail. Refer to Disassembly and
Assembly, “Fuel Manifold (Rail) - Remove and
3. Use a suitable lifting device to lift exhaust elbow Install”.
(1) onto the mounting bracket. The weight of the
exhaust elbow is approximately 43 kg (95 lb). NOTICE
4. Position new gaskets (3) between bellows (5) and
exhaust elbow (1). Ensure that the gaskets and Contaminants may cause rapid wear and shortened
the bellows are aligned with the exhaust elbow. component life.
Install nuts and bolts (2) hand tight.
Note: It is possible to remove individual sections
5. Install nuts (4) hand tight. of an inlet manifold without removing the complete
manifold. If removal of a complete manifold is
6. Tighten nuts and bolts (2) to a torque of 163 N·m necessary, use a suitable lifting device.
(120 lb ft).
7. Tighten nuts (4) to a torque of 163 N·m (120 lb ft).
g01428427
Illustration 106
Seating the v-band clamp on the turbocharger
44 KENR6924
Manifold Front and Center Sections 9. Remove O-ring seal (12) (not shown).
Manifold Rear Section (TAG Engines)

Note: To remove the rear section of an inlet manifold
from a TWG, refer to Disassembly and Assembly,
“Aftercooler - Remove”.
1. If the inlet manifold is equipped with a

condensation drain, disconnect the pipe for the
condensation drain.
g01429073
Illustration 107
A typical front section of an inlet manifold
1. Remove nuts and bolts (5) and disconnect air pipe

(4) from inlet manifold (3).
2. Remove nuts and bolts (7).
3. Support inlet manifold (3). Remove bolts (1) and

remove the inlet manifold.
g01436487
Illustration 109
4. Remove gaskets (2) (not shown). A typical rear section of an inlet manifold
5. Remove O-ring seal (6) (not shown) and O-ring 2. If the inlet manifold is equipped with a boost
seal (8) (not shown). pressure sensor (19), slide the locking tab on the
plug into the unlocked position and disconnect the
harness assembly from the boost pressure sensor.
4. Support inlet manifold (16). Remove bolts (14)

and remove the inlet manifold. Note the position
of any pipe clips that are retained by the bolts.
6. Remove O-ring seal (17) (not shown).
7. If necessary, follow Step 7.a and Step 7.b in order

g01436488 to disassemble the rear inlet manifold.
Illustration 108
A typical center section of an inlet manifold a. Remove nuts and bolts (21) and remove plate
(20).
b. Remove O-ring seal (22) (not shown).
7. Support inlet manifold (13). Remove bolts (10)
and remove the inlet manifold. Note the position
of any tube clips that are retained by the bolts.
KENR6924 45
i02855397 2. If necessary, install a new O-ring seal (22) (not

shown). Position plate (20) on the inlet manifold
Inlet Manifold - Install and install nuts and bolts (21). Tighten the nuts
and bolts to a torque of 50 N·m (35 lb ft).
3. Install a new O-ring seal (17) (not shown).

4. Position new gaskets (15) (not shown) on the
Table 11 cylinder heads.
Required Tools
5. Place inlet manifold (16) in position and install
Part bolts (14) hand tight.
Torque Adaptor 6. Install nuts and bolts (18) hand tight.
A - 13 mm - 12 point, 3/8" 1
drive 7. Use Tooling (A) in order to tighten bolts (14) to a
NOTICE 8. Tighten nuts and bolts (18) to a torque of 50 N·m

Keep all parts clean from contaminants. (35 lb ft).
Contaminants may cause rapid wear and shortened 9. If the inlet manifold is equipped with a boost
component life. pressure sensor (19), connect the harness
assembly to the boost pressure sensor and slide
Note: If the inlet manifold is installed as a complete the locking tab on the plug into the locked position.
assembly, use a suitable lifting device to lift the inlet
manifold. The inlet manifold should only be installed 10. If the inlet manifold is equipped with a
as a complete assembly if the inlet manifold has not condensation drain, connect the pipe for the
been disassembled. condensation drain.
Manifold Rear Section (TAG Engines) Manifold Front and Center Sections
Note: To install the rear section of an inlet manifold to 1. Ensure that the gasket surfaces of the inlet
a TWG engine, refer to Disassembly and Assembly, manifolds and the cylinder heads are clean and
“Aftercooler - Install ”. free from damage.
1. Ensure that the gasket surfaces of the inlet

manifold and the cylinder heads are clean and
free from damage.
g01436488
Illustration 111
A typical center section of an inlet manifold
2. Install a new O-ring seal (12) (not shown).
3. Position new gaskets (9) (not shown) on the

cylinder heads.
4. Place inlet manifold (13) in position and install

bolts (10) hand tight. Ensure that any pipe clips
g01436487
that are retained by the bolts are positioned
Illustration 110 correctly.
A typical rear section of an inlet manifold
46 KENR6924
5. Install nuts and bolts (11). Tighten the nuts and i02855398
bolts hand tight.
Inlet and Exhaust Valves -
6. Use Tooling (A) in order to tighten the bolts (10) Remove and Install

(35 lb ft).
Removal Procedure
Table 12
Required Tools
Part
A T6253/243 Valve Spring Compressor 1
Start By:
a. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove”.
NOTICE

component life.
Illustration 112
g01429073 1. Clean the bottom face of the cylinder head.
A typical front section of an inlet manifold Check the depth of the valves below the face of
the cylinder head before the valve springs are
8. Install a new O-ring seal (6) (not shown) and a removed. Refer to Specifications, “Cylinder Head
new O-ring seal (8) (not shown). Valves” for the correct dimensions.
9. Position new gaskets (2) (not shown) on the 2. Place a temporary identification mark on the
cylinder heads. heads of the valves in order to identify the correct
position.
10. Place inlet manifold (3) in position and install bolts
(1) hand tight. Note: Do not stamp the heads of the valves.
Stamping or punching the heads of the valves could
11. Install nuts and bolts (7) hand tight. cause the valves to fracture.
12. Use Tooling (A) in order to tighten bolts (1) to a

Personal injury can result from being struck by
13. Tighten nuts and bolts (7) to a torque of 50 N·m parts propelled by a released spring force.
(35 lb ft).
Make sure to wear all necessary protective equip-
14. Install nuts and bolts (5). Tighten the nuts and ment.
Follow the recommended procedure and use all
End By: recommended tooling to release the spring force.
a. Install the fuel rail. Refer to Disassembly and

Assembly, “Fuel Manifold (Rail) - Remove and NOTICE
Install”. Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
b. Install the module for the exhaust temperature
sensors. Refer to Disassembly and Assembly,
“Engine Sensors - Remove and Install”.
KENR6924 47
Table 13
Required Tools
Part
A T6253/243 Valve Spring Compressor 1
NOTICE

component life.
g01453609
Illustration 113
1. Clean all components of the cylinder head

assembly. Ensure that all ports, and all passages
in the cylinder head are free from debris. Follow
Step 1.a through Step 1.e in order to inspect the
components of the cylinder head assembly.
a. Inspect the cylinder head for wear and for

damage. Refer to Systems Operation, Testing
and Adjusting, “Cylinder Head Inspect”.
b. Inspect the valve seats for wear and for

damage. Refer to Specifications, “Cylinder
Head Valves” for further information.
c. Inspect the valve guides for wear and for

damage. Refer to Specifications, “Cylinder
Head Valves” and Systems Operation, Testing
and Adjusting, “Valve Guide - Inspect” for
further information.
d. Inspect the valves for wear and for damage.

Refer to Specifications, “Cylinder Head Valves”.
Check the depth of the valve below the face of
the cylinder head. Refer to Systems Operation,
Testing and Adjusting, “Valve Depth - Inspect”
for more information.
Illustration 114
g01473533 e. Inspect the valve springs for the correct length.
Typical example Refer to Specifications, “Cylinder Head Valves”.
3. Use Tooling (A) in order to compress the

appropriate valve spring (3). Remove valve collets
(1).
4. Remove Tooling (A).
5. Remove cap (2). Remove valve spring (3).
6. Remove valve (4).

the remaining valves.
48 KENR6924
g01453609
Illustration 116
4. Use Tooling (A) in order to compress valve spring

(3). Install valve collets (1).
The valve spring keepers can be thrown from

the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
g01473533 of the valve spring keepers and valve springs
Illustration 115
during the installation of the valves.
Typical example
2. Lubricate the stem of valve (4) with clean engine 5. Remove Tooling (A).
oil. Install the valve in the appropriate position in
the cylinder head. 6. Repeat Step 2 through Step 5 in order to install
the remaining valves.
3. Install valve spring (3) to the cylinder head.
Position cap (2) on the valve spring. 7. Place the cylinder head on a suitable support.
Ensure that the heads of the valves are not
obstructed. Gently tap the top of the valves with
a soft hammer in order to ensure that the valve
collets are properly installed.
parts propelled by a released spring force. End By:
Make sure to wear all necessary protective equip- a. Install the cylinder head. Refer to Disassembly
ment. and Assembly, “Cylinder Head - Install”.
recommended tooling to release the spring force. i02855400
Inlet and Exhaust Valve Guides

NOTICE
Ensure that the valve spring is compressed squarely
- Remove and Install
or damage to the valve stem may occur.
Removal Procedure
Table 14
Required Tools
Part
A - Valve Guide Removal Drift 1
KENR6924 49
Start By:
NOTICE
a. Remove the inlet and exhaust valves. Refer to Keep all parts clean from contaminants.
Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”. Contaminants may cause rapid wear and shortened
component life.
NOTICE
Removal and installation of the valve guide and valve
1. Ensure that the bores in the cylinder head for the
seat must be carried out by personnel with the correct
valve guides are clean and free from burrs or
training. Also special machinery is required. For more
carbon.
information, refer to your authorized Perkins distribu-
tor.
NOTICE

component life.
g01475060
Illustration 118
2. Lubricate new valve guide (2) with clean engine

oil. Position the valve guide in the cylinder head.
Carefully tap the valve guide with a soft faced
hammer in order to locate the valve guides in
the cylinder head. Ensure that the valve guide is
located squarely in the cylinder head.
g01453852
Illustration 117 Note: Replacement valve guides are supplied,
finished to the correct size.
1. Use Tooling (A) and a suitable press in order to
push valve guides (1) out of the cylinder head. 3. Use Tooling (B) and a suitable press in order to
install the valve guide to the cylinder head. Press
Installation Procedure the valve guide until Tooling (B) bottoms out on
the cylinder head.
Table 15
Required Tools Note: The counterbore in Tooling (B) ensures that
the valve guide is installed to the correct height.
Valve Guide Installation 4. Repeat Step 2 and Step 3 in order to install the
B T85002/3 1 remaining valve guides.
Tool
NOTICE
Removal and installation of the valve guide and valve
seat must be carried out by personnel with the correct
training. Also special machinery is required. For more
information, refer to your authorized Perkins distribu-
tor.
50 KENR6924
NOTICE

component life.
NOTICE
g01475057
Illustration 119
5. Check the installed height of each valve guide. mandates.
Dimension (X) should be 9 mm (0.354 inch).
Note: After installing the valve guides, the valve seat

inserts must be refaced. This procedure ensures the
concentricity of the valve seat to the valve guide in
order to create a good seal. Refer to Specifications,
“Cylinder Head Valves” for more information. The
valves must not be lapped into the seats with
grinding paste. Abrasive particles are retained
in the faces of the valve and the valve seat. This
will cause rapid wear of the valves and the valve
seats.
6. Check the depths of the valves below the face

of the cylinder head. Refer to System Operation,
Testing and Adjusting, “Valve Depth - Inspect” for g01475073
Illustration 120
more information.
A Bank oil filter head
End By:
1. Remove drain plug (2) and allow the oil to drain
a. Install the inlet valves and the exhaust valves. from the oil filter head.
Refer to this Disassembly and Assembly Manual,
“Inlet and Exhaust Valves - Remove and Install”. 2. Use Tooling (A) to remove engine oil filters (1).
Refer to Operation and Maintenance Manual,
“Engine Oil and Filter Change” for the correct
i02855402 procedure.
Engine Oil Filter Base - 3. Remove engine oil cooler (4). Refer to
Remove Disassembly and Assembly, “Engine Oil Cooler -
Remove” for the correct procedure.
Removal Procedure
Table 16
Required Tools
A - Strap Wrench 1
KENR6924 51
i02855404
Engine Oil Filter Base -

Disassemble
Disassembly Procedure
Start By:
a. Remove the oil filter head. Refer to Disassembly

and Assembly, “Engine Oil Filter Base - Remove”.
g01449208
Illustration 121
NOTICE
A Bank oil filter head Keep all parts clean from contaminants.
4. Remove pipe (5). Contaminants may cause rapid wear and shortened
component life.
g01440099
Illustration 122
5. Remove bolts (8) and bolts (14). Remove pipe

(10).
6. Remove O-ring seal (6) (not shown) and O-ring

seal (12) (not shown) from pipe (10).
g01440587
Illustration 123
7. Remove bolts (9) and bolts (13). Remove pipe A Bank oil filter head
(11).
1. Remove nuts (22), oil filter head (23) and joint
8. Remove O-ring seal (7) (not shown) and O-ring (27).
seal (15) (not shown) from pipe (11).
2. Remove bolts (26), plate (25) and joint (24).
9. Remove bolts (17) and remove oil filter head (3).
3. Remove oil pipe (28) and joint (29).
4. Remove bolts (20), plate (19) and joint (18).
5. Remove connection (21).
52 KENR6924
i02855405 3. Position a new joint (18) and plate (19) on the oil
filter head. Install bolts (20). Tighten the bolts to a
Engine Oil Filter Base - torque of 40 N·m (30 lb ft).
Assemble
4. Position a new joint (24) and plate (25) on oil filter
head (23). Install bolts (26). Tighten the bolts to a
Assembly Procedure 5. Install a new joint (29) and oil pipe (28) over the
studs and onto the oil filter head.
Table 17
Required Tools 6. Install a new joint (27) and oil filter head (23) over
Part
the studs and onto the oil filter head. Install nuts
Tool Number Part Description Qty (22) hand tight.
POWERPART Note: Nuts (22) must only be tightened to the correct

B 21820121 1
Hydraulic Threadseal torque after the oil filter head has been installed to
the engine.
NOTICE
Keep all parts clean from contaminants. End By:
a. Install the oil filter head. Refer to Disassembly and

component life. Assembly, “Engine Oil Filter Base - Install”.
i02856142
1. Ensure that all components of the oil filter head
are clean. Ensure that all oil passages are free
from restriction.
Engine Oil Filter Base - Install
Table 18
Required Tools
- Guide Stud
C 2
(M10 by 75 mm)
NOTICE

component life.
1. Ensure that all components of the oil filter head

are clean and free from damage. Ensure that all
oil passages are free from restriction. Clean the
joint surface of the crankcase door.
g01440587
Illustration 124
2. Apply Tooling (B) to the threads of connection

(21). Install the connection to the oil filter head and
tighten the connection securely.
KENR6924 53
g01449236
Illustration 125
2. Install Tooling (C) to the crankcase door.
g01479390
Illustration 127
The bolt tightening sequence for the engine oil filter head
3. Use Tooling (C) to locate a new joint (16) (not

shown) and oil filter head (3) onto the crankcase
door. Install bolts (17) finger tight. Remove Tooling
(C) and install the remaining bolts.
4. Ensure that the nuts at Positions (X) are finger

tight.
Note: If the oil filter head was not previously

disassembled, the nuts should be loosened.
5. Install new O-ring seal (7) (not shown) and new

O-ring seal (15) (not shown) to pipe (11).
g01449224
Illustration 126 O-ring seal (12) (not shown) to pipe (10).
7. Place pipe (11) in position. Install bolts (9) and
bolts (13) finger tight.
8. Place pipe (10) in position. Install bolts (8) and

bolts (14) finger tight.
9. Tighten bolts (8), (9) and (17) to a torque of 50 N·m

(35 lb ft). Tighten bolts (13) and (14) to a torque
of 40 N·m (30 lb ft). Tighten the nuts at Positions
(X) securely. Tighten the nuts and the bolts in the
sequence that is shown in Illustration 127.
54 KENR6924
NOTICE

mandates.
g01449208
Illustration 128
10. Install pipe (5).
g01479573
Illustration 130
1. Drain the coolant from the cooling system into

a suitable container. Refer to Operation and
Maintenance Manual, “Cooling System Coolant -
Change” for the correct procedure. Open tap (2)
and drain the coolant from engine oil cooler (1).
g01475073
Illustration 129
2. If the engine oil cooler is equipped with an oil
pressure switch, disconnect the harness assembly
from the oil pressure switch.
11. Install drain plug (2) to oil filter head (3).
12. Install engine oil cooler (4). Refer to Disassembly

and Assembly, “Engine Oil Cooler - Intall”for the
correct procedure.
13. Install new engine oil filters (1). Refer to Operation

and Maintenance Manual, “Engine Oil and Filter
Change” for the correct procedure.
i02855417
Engine Oil Cooler - Remove
Removal Procedure
NOTICE
g01440977
Contaminants may cause rapid wear and shortened Illustration 131
component life. A Bank engine oil cooler
KENR6924 55
5. Remove bolts (13) and bolts (15). Remove elbow

(14). Remove joint (12) (not shown) and joint (16)
(not shown).
g01479632
Illustration 132
B Bank engine oil cooler
3. To remove A Bank engine oil cooler, disconnect g01480852

Illustration 134
hose assembly (3) and hose assembly (4) from Typical example
engine oil cooler (1).
6. Remove bolts (21) and (24). Remove pipe
To remove B Bank engine oil cooler, remove assembly (23). Remove O-ring seal (20) (not
nuts (9) and clamp (8). Remove bolts (6) and shown) and O-ring seal (25) (not shown).
(10). Remove pipe (5) from engine oil cooler (1).
Remove O-ring seal (7) (not shown) and O-ring
seal (11) (not shown).
g01440978
Illustration 135
Typical example

of engine oil cooler (1). The weight of the engine
oil cooler is approximately 45 kg (100 lb).
8. Remove bolts (26).
Illustration 133
g01480752 9. Carefully pry engine oil cooler (1) from the dowels
Typical example in the mounting bracket. Remove the engine oil
cooler.
4. Loosen hose clamps (17). Remove bolts (20).
Remove pipe and elbow assembly(18). Remove 10. Drain the oil from the engine oil cooler into a
joint (19) (not shown). suitable container.
56 KENR6924
i02855418
Engine Oil Cooler -

Disassemble
Start By:
a. Remove the engine oil cooler. Refer to

Disassembly and Assembly, “Engine Oil Cooler
- Remove”.
g01482114
Illustration 137
NOTICE
Keep all parts clean from contaminants. 2. Remove bolts (30) and bolts (34). Remove covers
(31) and (35).
component life. Note: If necessary, tap the covers with a soft faced
hammer in order to loosen the covers.
NOTICE 3. Remove O-ring seal (32). Remove joint (33) (not

Care must be taken to ensure that fluids are contained shown).

mandates.
g01482053
Illustration 138
g01453854
Illustration 136 4. Carefully tap the rear face of tubestack (37) with a
soft faced hammer in order to drive the tubestack
1. To remove the connection from A Bank engine oil from the housing of the engine oil cooler.
cooler, follow Step 1.a and Step 1.b.
Note: Use a block of wood in order to protect the
a. Remove bolts (27) and remove connection tubestack.
(28).
b. Remove joint (29).
KENR6924 57
i02855420
Engine Oil Cooler - Assemble
Assembly Procedure
NOTICE

component life.
g01482517
Illustration 140
1. Ensure that all parts of the engine oil cooler are
clean and free from damage. 5. Place a new O-ring seal (32) in position and install
cover (31).
Note: If the tubestack is still contaminated with
limescale or with sludge after cleaning, then 6. Install bolts (30). Tighten the bolts to a torque of
the tubestack must be replaced. Do not use a 40 N·m (30 lb ft).
contaminated tubestack. The use of a contaminated
tubestack could lead to engine failure. 7. Pressure test the engine oil cooler for leaks. Refer
to Systems Operation, Testing and Adjusting,
“General Information - Cooling System” for the
correct procedure.
g01453854
Illustration 141
8. To install the connection to B Bank engine oil

Illustration 139
g01482053 cooler, follow Step 8.a and Step 8.b .
2. Place a new joint (36) in position and push a. Place a new joint (29) in position and install
tubestack (37) into the housing of the engine oil connection (28).
cooler.
b. Install bolts (27). Tighten the bolts to a torque
3. Place a new joint (33) in position and install cover of 40 N·m (30 lb ft).
(35).
End By:
40 N·m (30 lb ft). a. Install the engine oil cooler. Refer to Disassembly
and Assembly, “Engine Oil Cooler - Install”.
58 KENR6924
i02855412
Engine Oil Cooler - Install
NOTICE

component life.
1. Ensure that the oil cooler and the pipes are clean
and free from damage or restrictions.
g01480852
Illustration 143
Typical example
4. Install a new O-ring seal (22) (not shown) and a

new O-ring seal (25) (not shown). Position pipe
assembly (23) and install bolts (21) and bolts (24).
5. Tighten bolts (21) and bolts (24) to a torque of

40 N·m (30 lb ft).
g01440978 Note: Ensure that the pipe assembly is not stressed

Illustration 142
as the bolts are tightened.
Typical example
2. Use a suitable lifting device to lift engine oil cooler

(1) into position. The weight of the engine oil
cooler is approximately 45 kg (100 lb). Align the
engine oil cooler with the dowels in the mounting
bracket and install the engine oil cooler to the
mounting bracket.

40 N·m (30 lb ft).
g01480752
Illustration 144
Typical example
KENR6924 59
6. Position a new joint (12) (not shown) and a new To install B Bank engine oil cooler, install new
joint (16) (not shown). Install elbow (14) and install O-ring seal (7) (not shown) and new O-ring seal
bolts (13) hand tight. Install nuts and bolts (15) (11) (not shown) to pipe (5). Position pipe (5) on
hand tight. Tighten bolts (13) to a torque of 40 N·m the engine oil cooler (1) and install bolts (6) and
(30 lb ft). Tighten nuts and bolts (15) to a torque of (10) hand tight. Position clamp (8) and install nuts
50 N·m (35 lb ft). (9) hand tight. Tighten bolts (6) to a torque of
40 N·m (30 lb ft). Tighten bolts (10) to a torque of
7. Position a new joint (19) (not shown). Install 50 N·m (35 lb ft). Tighten nuts (9) securely.
pipe and elbow assembly (18). Install bolts (20).
Tighten the bolts to a torque of 40 N·m (30 lb ft). 9. If the engine oil cooler is equipped with an oil
Tighten hose clamps (17) securely. pressure switch, connect the harness assembly to
the oil pressure switch.
10. Fill the cooling system with coolant to the correct

level. Refer to Operation and Maintenance
Manual, “Cooling System Coolant - Change” for
the correct procedure.
11. Ensure that the engine oil pan is filled to the

correct level. Refer to Operation and Maintenance
Manual, “Engine Oil Level - Check” for the correct
procedure.
i02855422
Engine Oil Relief Valve -

Remove and Install
(Engine Oil Pressure
Regulator)
g01440977
Illustration 145
A Bank engine oil cooler
Removal Procedure
NOTICE

component life.
NOTICE

mandates.
g01479632
Illustration 146
B Bank engine oil cooler
8. To install A Bank engine oil cooler, connect hose

assembly (3) and hose assembly (4) to engine oil
cooler (1).
60 KENR6924
NOTICE

component life.
1. Ensure that all components of the engine oil

pressure regulator are clean and free from
damage.
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.
g01453874
Illustration 147
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.
1. Carefully loosen bolts (7). Remove the bolts and

remove plate (6).
Note: The spring force will be released suddenly

when the bolts are removed.
2. Remove spring seat (2). Remove O-ring seal (5)

g01453874
from the spring seat. Illustration 148
3. Remove spring (4).
4. Remove plunger (1).
5. Remove joint (3).
Table 19
Required Tools
- Bolts
2 g01454169
A (M8 by 50 mm) Illustration 149
- Nuts (M8) 2 Using of temporary nuts and bolts to install the plate to the engine
oil pressure regulator
KENR6924 61
i02897055
Engine Oil Relief Valve -

Remove and Install
Removal Procedure
NOTICE

g01478067
component life.
Illustration 150
Initial position of adjustment screw
NOTICE
2. Install a new O-ring seal (5) to spring seat (2). Care must be taken to ensure that fluids are contained
3. Lubricate plunger (1) with clean engine oil. Install ing, adjusting and repair of the product. Be prepared to
the plunger and spring (4) into the bore for the collect the fluid with suitable containers before open-
relief valve in the engine oil pump. ing any compartment or disassembling any compo-
Note: The plunger must slide freely in the bore.
4. Position joint (3) on the engine oil pump. mandates.
5. If the position of adjustment screw (8) has been 1. If the engine is equipped with the early type
altered, set Dimension (X) to 17 mm (0.670 inch) of fuel priming pump, remove the fuel priming
and tighten locknut (9). Refer to Illustration 150. pump. Refer to Disassembly and Assembly, “Fuel
Priming Pump - Remove and Install”.
6. Place spring seat (2) and plate (6) in position. Use
Tooling (A) in order to temporarily hold the plate in
place. Refer to Illustration 149.
7. Tighten the nuts on Tooling (A) evenly in order to

compress spring (4).
8. Remove one nut and bolt from Tooling (A). Install

bolt (7) hand tight. Remove the remaining nut and
bolt from Tooling (A). Install the remaining bolt (7).
10. Run the engine in order to carry out final

adjustment of the engine oil pressure regulator.
Adjusting, “General Information - Lubrication
System” for the correct procedure.
g01453865
Illustration 151
Typical example
2. Disconnect hose assembly (1) from oil relief valve

(2).
3. Remove oil relief valve (2).
62 KENR6924
Note: Use a ring spanner on the end of the oil relief 2. Apply a bead of Tooling (A) to Threads (Y) on oil
valve that is nearest to the crankcase in order to relief valve (2).
loosen the oil relief valve.
3. Install oil relief valve (2) to the crankcase door.
Installation Procedure Ensure that Arrow (X) is to the crankcase.
Table 20 Note: Use a ring spanner on the end of the oil relief
valve that is nearest to the crankcase in order to
Required Tools tighten the oil relief valve securely.
4. Connect hose assembly (1) to oil relief valve (2).
POWERPART
A 21820117 1
Threadlock and Nutlock 5. If the engine is equipped with the early type of fuel
priming pump, install the fuel priming pump. Refer
NOTICE to Disassembly and Assembly, “Fuel Priming
Keep all parts clean from contaminants. Pump - Remove and Install”.
Contaminants may cause rapid wear and shortened i02855423

component life.
Engine Oil Pump - Remove
1. Ensure that the oil relief valve is clean and free
from damage. Ensure that the threads in the
crankcase door are clean.
Removal Procedure
NOTICE

component life.
NOTICE

mandates.

g01453865
Illustration 152
Typical example 2. Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and
Maintenance Manual, “Engine Oil and Filter
Change.” for the correct procedure.
3. Remove the drive for the alternator. Refer to

Disassembly and Assembly, “Alternator (Alternator
Drive) - Remove and Install”.
g01476652
Illustration 153
KENR6924 63
g01486074
Illustration 155
An engine oil pump that is equipped with the later type of fuel
priming pump
9. Remove bolts (13) and bolts (16). remove pipe

(15) and allow the oil to drain. Remove O-ring seal
(14) (not shown) and O-ring seal (17) (not shown).
Note: Cap all open ports.
10. If the engine is equipped with the early type of

fuel priming pump, remove fuel transfer pump
(11). Refer to Disassembly and Assembly, “Fuel
Illustration 154
g01454143 Transfer Pump - Remove and Install”
priming pump If the engine is equipped with the later type of fuel
priming pump, remove fuel transfer pump (11) and
4. Place a suitable container below the engine oil fuel priming pump (12). Refer to Disassembly and
pump. Disconnect hose assembly (1) from pipe Assembly, “Fuel Transfer Pump - Remove and
(3) and allow the oil to drain. Install”
5. Remove allen head screws (2) and remove pipe

(3). Remove O-ring seals (4) from the engine oil
pump.
Note: Cap all open ports and hose assemblies.
6. If the engine is equipped with the early type

of fuel priming pump, remove the fuel priming
pump. Refer to Disassembly and Assembly, “Fuel
Priming Pump - Remove and Install”
7. Remove oil relief valve (7). Refer to Disassembly

and Assembly, “Engine Oil Relief Valve (Oil Relief
Valve) - Remove and Install”. g01486142
Illustration 156
8. Remove bolts (5) and bolts (9). Remove pipe (8).
Remove joint (6) (not shown) and joint (10) (not 11. Remove nuts (20).
shown).
Note: Cap all open ports.
64 KENR6924
12. Support the weight of engine oil pump (18). The

weight of the engine oil pump is approximately
32 kg (71 lb). Carefully slide the engine oil pump
along the retaining studs and remove the engine
oil pump.
i02855428
Engine Oil Pump - Disassemble
Disassembly Procedure Illustration 157

g01454151
Table 21 1. Remove nut (24) and washer (23). The weight of

Required Tools the engine oil pump is approximately 32 kg (71 lb).
Tool Part Number Part Description Qty 2. Use Tooling (A) to pull gear (22) from the shaft of
A - Combination Puller 1 engine oil pump (18). Remove key (21).
Start By:
a. Remove the engine oil pump. Refer to

Disassembly and Assembly, “Engine Oil Pump -
Remove ”.
NOTICE

component life.
NOTICE
nent containing fluids. g01454156
Illustration 158
mandates. 3. Remove bolts (29) and separate cover (25) from
body (28).
Note: The overhaul of the engine oil pump is a 4. Remove seal (26) and joint (27).
specialist operation that should only be attempted
by trained personnel with the correct equipment. A 5. Remove the engine oil pressure regulator from
service exchange engine oil pump is available from cover (25). Refer to Disassembly and Assembly,
your authorized Perkins distributor. “Engine Oil Relief Valve (Engine Oil Pressure
Regulator) - Remove and Install” for the correct
procedure.
KENR6924 65
1. Ensure that all components of the engine oil

pump are clean and free from wear or damage.
Check the condition of the drive for the lift pump.
Check the clearance between the outer rotor of
the oil pump and the oil pump body. Check the
clearance between the outer rotor and the inner
rotor. Check the end play of the rotors. Refer to
the Specifications, “Engine Oil Pump” for more
information.
g01488173
Illustration 159
6. Slide the assembly of shaft (30) and inner rotor

(31) from body (29).
7. Remove outer rotor (31) from body (29).
i02855440
Engine Oil Pump - Assemble Illustration 160

g01488173
2. Lubricate the assembly of shaft (30) and inner

rotor (31) with clean engine oil. Lubricate the
inside body (29) with clean engine oil. Install the
Assembly Procedure assembly of shaft (30) and inner rotor (31) to body
(28).
Table 22
Required Tools 3. Install outer rotor (32) to body (28).
POWERPART
B 21820117 1
Threadlock and Nutlock
NOTICE

component life.
Note: The overhaul of the engine oil pump is a

specialist operation that should only be attempted
by trained personnel with the correct equipment. A
service exchange engine oil pump is available from
your authorized Perkins distributor.
g01454156
Illustration 161
66 KENR6924
i02855442
NOTICE
The end play of the engine oil pump is controlled
Engine Oil Pump - Install
by the joint. Always assemble a new POWERPART
joint to the engine oil pump. Failure to use a new
POWERPART joint may result in serious damage to
the engine. Installation Procedure
Table 23
4. Place a new joint (27) in position on body (28).
Required Tools
5. Install a new seal to cover (25). Part
6. Align cover (25) with body (28) and install the
POWERPART
cover to the body. B 21820117
1
7. Install bolts (29). Tighten the bolts evenly to a

torque of 50 N·m (35 lb ft). NOTICE
Note: Ensure that the shaft of the engine oil pump
is free to rotate. Contaminants may cause rapid wear and shortened
component life.
8. Install the engine oil pressure regulator. Refer to
Disassembly and Assembly, “Engine Oil Relief
Valve (Engine Oil Pressure Regulator) - Remove 1. Ensure that the engine oil pump is clean and free
and Install” for the correct procedure. from damage. Ensure that the pipes are clean and
free from restriction.
g01454151
Illustration 162 g01486142
Illustration 163
9. Install key (21) and gear (22) to the shaft of engine

oil pump (18).
10. Apply Tooling (B) to the threads of nut (24).
11. Install nut (24) and washer (23) to the shaft of

engine oil pump (18).
12. Prevent gear (22) from rotating. Tighten nut (24)

Note: Ensure that the gear is not damaged when the

nut is tightened.
End By:
a. Install the engine oil pump. Refer to Disassembly

and Assembly, “Engine Oil Pump - Install ”.
KENR6924 67
2. Install a new joint (19) (not shown).
3. Lubricate the gear of the engine oil pump with

clean engine oil.
4. Use a suitable lifting device to lift engine oil pump

(18) into position. The weight of the engine oil
pump is approximately 32 kg (71 lb). Carefully
slide the engine oil pump along the retaining studs
and install the engine oil pump.
5. Install nuts (20) hand tight.

O-ring seal (17) (not shown) to pipe (15).
7. Position pipe (15) and install bolts (13) hand tight.

Apply Tooling (B) to bolts (16). Install bolts (16)
hand tight.

g01486074
Illustration 164
priming pump Tighten bolts (16) to a torque of 40 N·m (30 lb ft).
10. If the engine is equipped with the early type

of fuel priming pump, install fuel transfer pump
(11). Refer to Disassembly and Assembly, “Fuel
Transfer Pump - Remove and Install”
If the engine is equipped with the later type of fuel

priming pump, install fuel transfer pump (11) and
fuel priming pump (12). Refer to Disassembly and
Assembly, “Fuel Transfer Pump - Remove and
Install”
11. Place a new joint (6) (not shown), pipe (8) and a
new joint (10) (not shown) in position. Install bolts
(5) and bolts (9) hand tight. Tighten bolts (5) to a
torque of 50 N·m (35 lb ft). Tighten bolts (9) to a
12. Install oil relief valve (7). Refer to Disassembly

and Assembly, “Engine Oil Relief Valve (Oil Relief
Valve) - Remove and Install”.
13. If the engine is equipped with the early type of fuel

priming pump, Install the fuel priming pump. Refer
to Disassembly and Assembly, “Fuel Priming
Pump - Remove and Install”
14. Install new O-ring seals (4) to the engine oil

pump. Position pipe (3) and install allen head
screws (2). Tighten the allen head screws to a
15. Connect hose assembly (1) to pipe (3).
16. Install the drive for the alternator. Refer

g01454143
Illustration 165 to Disassembly and Assembly, “Alternator
An engine oil pump that is equipped with the later type of fuel (Alternator Drive) - Remove and Install”.
priming pump
68 KENR6924
17. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
Level - Check” for the correct procedure.

Operation and Maintenance Manual, “Before
Starting the Engine ” for the correct procedure.
20. Prime the engine oil system. Refer to Operation

and Maintenance Manual, “Before Starting the
Engine ” for the correct procedure.
i02855444
Water Pump - Remove
Removal Procedure Illustration 166

g01441022
A Bank water pump

NOTICE

component life.
NOTICE
Dispose of all fluids according to local regulations and Illustration 167

g01525639
mandates.
A Bank water pipe
1. Drain the coolant from the cooling system into 2. Loosen the hose clamps and disconnect hose (3)
a suitable container. Refer to Operation and from connection (2). Remove bolts (1) and remove
Maintenance Manual, “Cooling System Coolant - connection (2). Remove joint (8) (not shown).
3. Loosen the hose clamps and release hose (10)
from water pipe (11). Loosen the hose clamps and
release hose (12) from water pipe (11).
4. Remove bolts (14) and remove water pipe (11).

Remove joint (15) (not shown).
5. To removeA Bank water pump, remove link

(7) from the alternator. Refer to Disassembly
and Assembly, “Alternator Remove and Install
(Alternator Drive)” for more information.
6. Remove bolts (5) and remove water pump (9).
KENR6924 69
i02855446 Note: If necessary, tap the body with a soft faced

hammer in order to separate the body from the
Water Pump - Disassemble bearing housing.
2. Remove O-ring seal (18).
Disassembly Procedure 3. Mount gear (22) in a suitable vice in order to

prevent the shaft from rotating.
Table 24
Required Tools Note: Ensure that the gear is protected by soft vice
jaws.
A - Circlip Pliers 1
4. Remove nut (24) and washer (23). Remove gear
(22) and remove the key from shaft (25).
Start By: 5. Use Tooling (A) in order to remove circlip (27) from
bearing housing (20).
a. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove”. 6. Position bearing housing (20) on a suitable support
with impeller (17) upward. Use a suitable mandrel
NOTICE and a press in order to press the assembly of
Keep all parts clean from contaminants. shaft (25) and bearings (28) from the impeller and
from the bearing housing.
component life. 7. Remove carbon seal (26) from impeller (17).
Remove counterface (19) from bearing housing
(20).
NOTICE
Care must be taken to ensure that fluids are contained 8. Remove seal (29) from bearing housing (20).
during performance of inspection, maintenance, test- Remove the snap rings from the bearing housing.
collect the fluid with suitable containers before open- Note: The snap rings retain the bearings in the
ing any compartment or disassembling any compo- bearing housing.
9. Position the assembly of shaft (25) and bearings
Dispose of all fluids according to local regulations and (28) on a suitable support. Use a suitable mandrel
mandates. and a press in order to press the bearings from
the shaft. Remove spacer (21).
Note: Shims may be installed between the bearings

and the spacer.
i02855447
Water Pump - Assemble
Assembly Procedure
Table 25
Required Tools
Part
A - Circlip Pliers 1
POWERPART
B 21820117 1
g01454166 Threadlock and Nutlock
Illustration 168
POWERPART
C 21820221 1
1. Separate body (16) from bearing housing (20). Rubber Grease
70 KENR6924
7. Mount gear (22) in a suitable vice in order to

NOTICE prevent the shaft from rotating. Tighten the nut to
Keep all parts clean from contaminants. a torque of 230 N·m (175 lb ft).
Contaminants may cause rapid wear and shortened Note: Ensure that the gear is protected by soft vice
component life. jaws.
8. Lubricate counterface (19) with a solution of

1. Ensure that the components of the water pump de-mineralised water and 4% Cylam lubricant. Use
are clean and free from damage. the tool that is supplied with the repair kit in order
to install the counterface to bearing housing (20).
Note: A repair kit for the water pump is available from
your authorized Perkins Distributor. All components Note: After the counterface has been installed, the
in the repair kit should be used when a water pump bearing housing should be left for ten minutes in
is overhauled. order to allow the Cylam lubricant to evaporate.
9. Lubricate the internal bore of carbon seal (26) with

a solution of de-mineralised water and 4% Cylam
lubricant. Position carbon seal (26) on shaft (25).
Use the tool that is supplied with the repair kit to
install the carbon seal to the shaft.
Note: After the carbon seal has been installed,

pressure should be maintained on the carbon seal
for ten minutes in order to hold the carbon seal in
position against the counterface until the Cylam
lubricant has evaporated.
10. Position bearing housing (20) on a suitable

support with gear (22) downward. Press impeller
(17) onto shaft (25). Press the impeller onto the
shaft until the face of the impeller is flush with the
end of the shaft.
Note: After the impeller has been installed, ensure

that the shaft is free to rotate and that the impeller is
g01454166 concentric to the bearing housing.
Illustration 169
2. Place shaft (25) on a suitable support and press 11. Lubricate a new O-ring seal (18) with Tooling (C).
on the inner race of bearing (28) until the bearing Install the O-ring seal to bearing housing (20).
is against the shoulder of the shaft. Install spacer
(21) to the shaft. Press on the inner race of the 12. Install body (16) to bearing housing (20).
second bearing (28) until the bearing is against
the spacer. Note: After the body has been installed, ensure that
the impeller is free to rotate without touching to the
Note: If shims were installed between the bearings, body.
install the shims before installing the second bearing.
End By:
3. Install a new seal (29) to bearing housing (20).
Install the seal with the spring toward the bearings. a. Install the water pump. Refer to Disassembly and
Lubricate the lip of the seal with clean engine oil. Assembly, “Water Pump - Install”.
4. Install new snap rings to bearing housing (20).

Install the assembly of shaft (25) and bearings
(28) to the bearing housing. Use Tooling (A) to
install circlip (27).
5. Position the key on the shaft and install gear (22).
6. Apply Tooling (B) to the threads on shaft (25).

Install washer (23) and nut (24) to the shaft.
KENR6924 71
i02855449
Water Pump - Install
Table 26
Required Tools
- Guide Stud
A 2
(M10 by 100 mm)
g01525639
Illustration 171
NOTICE A Bank water pipe
2. Install Tooling (A) to the timing case.
component life. Note: Install Tooling (A) to inner bolt holes for the
water pump.
1. Ensure that the water pump and the water pipe 3. Position a new joint (4) (not shown) on the timing
are clean and free from damage. Clean the joint case.
surface of the timing case.
4. Lubricate the gear on water pump (9) with clean
engine oil. Align the water pump with Tooling (A)
and install the water pump to the timing case.
Note: Ensure that the gear on the water pump is

aligned with the idler gear. Ensure that the water
pump is correctly seated on the timing case.
5. To install A Bank water pump, position link (7)

for the alternator. Install bolts (5) hand tight.
Remove Tooling (A) and install the remaining
bolts (5). Ensure that the link for the alternator
is in the correct position. Refer to Disassembly
and Assembly, “Alternator Remove and Install
(Alternator Drive)” for more information. Tighten
bolts (5) to a torque of 50 N·m (35 lb ft).
6. Place a new joint (15) (not shown) in position

and install water pipe (11). Ensure that hose (10)
and hose (12) are correctly positioned. Install
bolts (14). Tighten the bolts to a torque of 50 N·m
Illustration 170
g01441022 (35 lb ft). Tighten the hose clamps securely.
A Bank water pump
7. Position joint (8) (not shown) on the water pump
and install connection (2). Install bolts (1). Tighten
the bolts to a torque of 50 N·m (35 lb ft).
8. Connect hose (3) to connection (2). Tighten the

hose clamps securely.
9. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.
72 KENR6924
i02855456
Water Temperature Regulator

Housing - Remove and Install
(Thermostat Housing)
Removal Procedure
NOTICE

component life.
NOTICE

mandates. g01526461
Illustration 172
B Bank thermostat housing
2. Remove the heat shield from the thermostat

housings.
g01441033
Illustration 173
3. Remove crankcase breather (7). Refer to

Disassembly and Assembly, “Crankcase Breather
- Remove and Install” for more information.
Note: It is possible to remove the thermostat housing

without removing the crankcase breather. If the
crankcase breather is not removed, the upper
retaining bolts should be removed and the lower
retaining bolts should be loosened.
KENR6924 73
4. Loosen the hose clamp and disconnect hose (1)

from cover (13).
5. If necessary, follow Step 5.a through Step 5.d in

order to remove the thermostats.
a. Remove nuts (2) and remove bracket (4).
b. Remove cover (13) from thermostat housing

(11). Remove joint (14).
c. Remove bolts (15) and remove washers (16).
d. Remove thermostats (17).
6. Disconnect the harness assembly from coolant

temperature switch (3).
7. Remove nuts and bolts (6) and disconnect

thermostat housing (11) from water pipe (12).
Remove O-ring seal (5) (not shown).
8. Remove nuts (9) and remove thermostat housing

(11) from pipe (10). Remove O-ring seal (8) (not
shown).
g01526461
Illustration 174
NOTICE B Bank thermostat housing

component life.
1. Ensure that all components of the thermostat

housing are clean and free of wear or damage.
g01441033
Illustration 175
2. Install a new O-ring seal (8) (not shown) to pipe

(10). Install a new O-ring seal (5) (not shown) to
water pipe (12).
3. Position thermostat housing (11) on pipe (10).

Loosely install nuts (9). Install nuts and bolts (6)
hand tight.
74 KENR6924
4. Tighten nuts (9) to a torque of 50 N·m (35 lb ft). i03112843

Tighten nuts and bolts (6) to a torque of 50 N·m
(35 lb ft). Aftercooler - Remove
(Air Charge Cooler, TWG
5. Connect the harness assembly to coolant
temperature switch (3). Engines)
6. If necessary, follow Step 6.a through Step 6.e in
order to install the thermostats.
Removal Procedure
a. Check the thermostats for correct operation.
NOTICE
Adjusting, “Water Temperature Regulator -
Test” for the procedure to test the thermostats.
b. Install thermostats (17) to thermostat housing
component life.
(11).
c. Install bolts (15) and washers (16). Tighten the NOTICE

bolts to a torque of 50 N·m (35 lb ft). Care must be taken to ensure that fluids are contained
d. Position a new joint (14) on thermostat housing ing, adjusting and repair of the product. Be prepared to
(11). Install cover (13). collect the fluid with suitable containers before open-
e. Position bracket (4) and loosely install nuts (2). nent containing fluids.
7. Install crankcase breather (7). Refer to Dispose of all fluids according to local regulations and
Disassembly and Assembly, “Crankcase Breather mandates.
- Remove and Install” for more information.
Note: If the crankcase breather was not removed, 1. Drain the coolant from the cooling system into
the upper retaining bolts should be installed and a suitable container. Refer to Operation and
the lower retaining bolts should be tightened to the Maintenance Manual, “Cooling System Coolant -
correct torque. Change” for the correct procedure. Remove the
plug and drain the coolant from the air charge
8. Install the heat shield to the thermostat housings. cooler.
Tighten nuts (2) to a torque of 50 N·m (35 lb ft).
9. Connect hose (1) to cover (13). Tighten the hose

clamp securely.
10. Fill the cooling system to the correct level. Refer

to Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct filling
procedure.
g01527174
Illustration 176

from pipe (6). Remove bolts (7) and remove pipe
(6). Remove joint (8) (not shown).

from pipe (2). Remove bolts (3) and remove pipe
(2). Remove joint (4) (not shown).
KENR6924 75
8. Remove bolts (17). Use the lifting device to

carefully remove the assembly of air charge cooler
(21).
9. Remove gaskets (18) (not shown). Remove O-ring

NOTICE

component life.
NOTICE
g01455268 collect the fluid with suitable containers before open-
Illustration 177

mandates.
g01455267
Illustration 178

of the air charge cooler assembly. The weight of
the air charge cooler assembly is approximately
50 kg (110 lb).
5. Remove bolts (10) and remove tie bars (13).

Loosen hose clamps (11) and release hose (12)
from pipe (9).
6. Remove bolts (16) and remove the assembly of g01455269

Illustration 179
air pipe (14) and hose (12). Remove gasket (15)
(not shown).
1. Place the assembly of the air charge cooler on a
suitable stand. Remove allen head bolts (23) and
separate inlet manifold (22) from air charge cooler
(21). Remove gasket (24).
76 KENR6924
2. Remove nuts and allen head bolts (26). Separate

air pipe (27) from air charge cooler (21). Remove
gasket (25).
Note: Do not remove the end plates from the air

charge cooler.
i03112801
Aftercooler - Install
(Air Charge Cooler, TWG
Engines)
Assembly Procedure
NOTICE

component life.
1. Ensure that the air charge cooler is clean and free

from damage. Check the fins on the outside of g01455269
the water tubes. Remove any deposits of carbon Illustration 180
from the fins. Check the inside of the water tubes
for deposits of limescale. If necessary, use a 2. Place the air charge cooler on a suitable stand.
chemical solution in order to remove the deposits Position a new gasket (25) on air charge cooler
of limescale. Clean the gasket surfaces of the inlet (21) and install air pipe (27). Install nuts and allen
manifold and the air pipes. head bolts (26). Tighten the nuts and the allen
head bolts evenly to a torque of 19 N·m (14 lb ft).
Note: Ensure that any chemical solution that is used
to remove the deposits of limescale is suitable for 3. Place a new gasket (24) in position on air charge
use with aluminum components. cooler (21) and install inlet manifold (22). Install
allen head bolts (23). Tighten the allen head bolts
evenly to a torque of 19 N·m (14 lb ft).
NOTICE

component life.
KENR6924 77
4. Install nuts and bolts (20) finger tight.
6. Loosen bolts (28).
7. Connect the assembly of air pipe (14) and hose

(12) to pipe (9). Place a new gasket (15) (not
shown) in position and install nuts and bolts (16)
hand tight.
Note: Nuts and bolts (16) also secure bracket (29) to

the air charge cooler assembly.
8. Tighten nuts and bolts (17) and tighten bolts (16)

9. Tighten hose clamps (11) securely. Position tie

bars (13) and install bolts (10). Tighten the bolts
g01528951
Illustration 181
g01527174
Illustration 183
10. Connect pipe (2) to hose (1). Install a new joint

(4) (not shown) between the pipe and the air
charge cooler. Install bolts (3). Tighten the bolts
to a torque of 40 N·m (35 lb ft). Tighten the hose
clamps securely.
11. Connect pipe (2) to hose (1). Install a new joint

(4) (not shown) between the pipe and the air
charge cooler. Install bolts (3). Tighten the bolts
to a torque of 40 N·m (35 lb ft). Tighten the hose
clamps securely.
12. Fill the cooling system with coolant. Refer to

Illustration 182
g01455268 Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
1. Install new O-ring seal (19) (not shown). procedure. Remove the plug and drain the coolant
from the air charge cooler.
2. Use a suitable lifting device to lift the assembly of
the air charge cooler into position. The weight of
the air charge cooler assembly is approximately
50 kg (110 lb).
3. Position gaskets (18) (not shown) and air charge

cooler assembly (21) against the cylinder heads.
Install bolts (17) finger tight.
78 KENR6924
i02856090 4. Separate backplate (1) from the crankcase. Use

the lifting device in order to remove the backplate.
Engine Support (Front) -
Remove and Install 5. Remove joint (3) (not shown).
(Backplate) Installation Procedure

Table 27
Required Tools
Removal Procedure
Start By: Guide Studs
A - 2
(M10 by 100 mm)
a. Remove the fuel filter base. Refer to Disassembly
and Assembly, “Fuel Filter Base - Remove and
Install”. NOTICE
b. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump Contaminants may cause rapid wear and shortened
- Remove”. component life.
c. Remove the timing gears. Refer to Disassembly

and Assembly, “Gear Group (Front) - Remove”. 1. Ensure that the joint face of the crankcase and
the backplate are clean.
NOTICE

component life.
1. Ensure that the engine is adequately supported.
g01521779
Illustration 185
2. Install Tooling (A) to Positions (X) on the

crankcase.
3. Align joint (3) (not shown) with Tooling (A). Install

the joint to the crankcase.
Illustration 184
g01455336 4. Use a suitable lifting device to lift backplate (1)
into position. The backplate weighs approximately
2. Use a suitable lifting device to support the weight 45 kg (100 lb). Install the backplate to the
of backplate (1). The weight of the backplate is crankcase.
Note: Ensure that the backplate is seated on the
3. Remove bolts (2). dowels in the crankcase.
KENR6924 79
5. Install bolts (2) hand tight. Ensure that joint (3) (not
shown) protrudes below the base of the backplate.
Tighten bolts (2) to a torque of 50 N·m (35 lb ft).
6. Remove Tooling (A) and remove excess material

from joint (3) (not shown). The joint should be
flush with the base of the backplate.
End By:
a. Install the timing gears. Refer to Disassembly and

Assembly, “Gear Group (Front) - Install”.
b. Install the engine oil pump. Refer to Disassembly

and Assembly, “Engine Oil Pump - Install”. g01454176
Illustration 186
c. Install the fuel filter base. Refer to Disassembly
and Assembly, “Fuel Filter Base - Remove and
Install”.
i02856091
Flywheel - Remove
Removal Procedure
Table 28
Required Tools Illustration 187
g01454178
Part
Tool Number Part Description Qty 2. Follow Step 2.a and Step 2.b in order to prevent
the flywheel from rotating.
Support Studs
A T6253/157 2
Flywheel and Damper
a. Install a suitable bolt (1) to flywheel (4).
B - Bolt (M12 by 100mm) 2
b. Position a suitable piece of wood (3) between
Start By: bolt (1) and the floor.
a. Remove the engine speed sensor. Refer to 3. Loosen bolts (2). Remove two bolts (2) and install
Disassembly and Assembly, “Engine Speed Tooling (A) in place of the bolts. Remove the
Sensor - Remove and Install”. remaining bolts (2).
b. Remove the overspeed sensor. Refer to 4. Install Tooling (B) into the threaded holes in
Disassembly and Assembly, “Engine Speed flywheel (4). Tighten Tooling (B) evenly in order to
Sensor - Remove and Install (Overspeed Sensor)”. push the flywheel off the crankshaft.
c. Remove the electric starting motors. Refer to Note: Push the flywheel off the crankshaft until there
Disassembly and Assembly, “Electric Starting is sufficient clearance in order to install a suitable
Motor - Remove and Install”. sling to the flywheel.
NOTICE

component life.
1. Make a temporary mark in order to show the

position of the flywheel on the crankshaft.
80 KENR6924
g01454180 g01454184
Typical example
5. Pass a suitable sling through the center of flywheel
(4). Attach the sling to a suitable lifting device and b. Use a hammer and a chisel in order to split
support the weight of the flywheel. The weight of ring gear (5). Remove the ring gear from the
the flywheel is approximately 160 kg (350 lb). flywheel.
6. Continue to tighten Tooling (B) until the flywheel

has been pushed off the crankshaft. i02856093
7. Use the lifting device in order to remove flywheel Flywheel - Install

(4).
8. Inspect the starter ring gear for wear or damage. If

necessary, follow Step 8 through Step 8.a in order Installation Procedure
to remove the starter ring gear.
Table 29
Note: Identify the orientation of the teeth on the ring Required Tools
gear.
Part
Support Studs
A T6253/157 2
Flywheel and Damper
C CV60889 Anti-Seize Compound 1
NOTICE

component life.
g01454182
Illustration 189
Typical example Always wear protective gloves when handling
parts that have been heated.
a. Drill a hole through ring gear (5) between two
of the teeth.
1. If the starter ring gear required replacement, follow
Step 1.a through Step 1.d in order to install a new
ring gear.
KENR6924 81
4. Install Tooling (A) to the crankshaft.
5. Use the lifting device in order to position flywheel

(4) onto Tooling (A).
Note: Ensure the correct orientation of the flywheel.

Push the flywheel toward the crankshaft until there
is sufficient clearance in order to remove the sling
from the flywheel.
6. Remove the lifting device and the sling from

flywheel (4).
7. Apply Tooling (C) to the threads of bolts (2). Apply

g01454200
Tooling (C) to the underside of the heads of bolts
Illustration 191 (2). Install bolts (2) to flywheel (4). Tighten the
Typical example bolts evenly in order to pull the flywheel onto the
crankshaft.
a. Lay flywheel (4) on a horizontal surface.
8. Remove Tooling (A) and install the remaining bolts
b. Identify the orientation of the teeth on new ring (2) hand tight.
gear (5).
Note: The chamfered side of the ring gear teeth must

face toward the starting motor when the flywheel is
installed.
c. Heat ring gear (5) in an oven to a maximum

temperature of 250 °C (482 °F).
d. Ensure that the orientation of ring gear (5)

is correct and quickly install the ring gear to
flywheel (4).
Note: Ensure that the ring gear is seated on the

shoulder of the flywheel.
g01454201
Illustration 193
2. Inspect the crankshaft rear seal for leaks. If there
are any oil leaks, replace the crankshaft rear seal.
Refer to Disassembly and Assembly, “Crankshaft
Rear Seal - Remove and Install”.
g01577716
Illustration 192
3. Pass a suitable sling through the center of flywheel g01454202

Illustration 194
(4). Attach the sling to a suitable lifting device and
support the weight of the flywheel. The weight of The tightening sequence for the flywheel bolts
the flywheel is approximately 160 kg (350 lb).
9. Follow Step 9.a and Step 9.b in order to prevent
the flywheel from rotating.
82 KENR6924
a. Install a suitable bolt (1) to flywheel (4).

NOTICE
b. Position a suitable piece of wood (3) between Keep all parts clean from contaminants.
bolt (1) and the floor.
10. Use the following method in order to tighten the component life.
flywheel bolts to the correct torque.
a. Tighten bolts (2) hand tight, in the sequence NOTICE

that is shown in Illustration 194. Care must be taken to ensure that fluids are contained
b. Tighten bolts (2) to a torque of 135 N·m ing, adjusting and repair of the product. Be prepared to
(100 lb ft) in the sequence that is shown in collect the fluid with suitable containers before open-
Illustration 194. ing any compartment or disassembling any compo-
c. Tighten bolts (2) to a torque of 337 N·m
(250 lb ft) in the sequence that is shown in Dispose of all fluids according to local regulations and
Illustration 194. mandates.
11. Check the run out of the flywheel. Refer to

Specifications, “Flywheel” for further information.
End By:
a. Install the electric starting motors. Refer to

Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
b. Install the overspeed sensor. Refer to Disassembly

and Assembly, “Engine Speed Sensor - Remove
and Install (Overspeed Sensor)”.
c. Install the engine speed sensor. Refer to

Disassembly and Assembly, “Engine Speed
Sensor - Remove and Install”.
i03112867
Crankshaft Rear Seal - Remove

and Install Illustration 195
g01454205
1. Use a 4 mm (1/8 inch) drill in order to make three

equally spaced holes in crankshaft rear seal (1).
Removal Procedure Note: Ensure that debris does not enter the
crankcase.
Table 30
Required Tools 2. Screw Tooling (A) firmly into one of the holes. Use
Part Tooling (A) to dislodge crankshaft rear seal (1).
Tool Number Part Description Qty When the crankshaft rear seal begins to move,
unscrew Tooling (A). Install Tooling (A) in the next
A 27610311 Slide Hammer Puller 1 hole. Repeat the process using each hole, until
the crankshaft rear seal is removed.
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove”. Table 31
Required Tools
Part
B T6253/140 Rear Oil Seal Insertion Kit 1
KENR6924 83
End By:
NOTICE
Keep all parts clean from contaminants. a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install”.
component life.
i02856096
Note: Do not lubricate the crankshaft rear seal or the Flywheel Housing - Remove
crankshaft. The crankshaft seal should be installed and Install
dry.
1. Inspect the rear of the crankshaft for damage.

Ensure that the crankshaft is clean and dry.
Removal Procedure
Table 32
Required Tools
A - Lifting Eyebolt (M16) 2
- Guide Studs
B 2
(M10 by 100 mm)
Start By:
a. Remove the engine speed sensor. Refer to

Sensor - Remove and Install”.
b. Remove the overspeed sensor. Refer to

Sensor (Overspeed) - Remove and Install”.
g01454208
c. Remove the starting motors. Refer to Disassembly
Illustration 196 and Assembly, “Electric Starting Motor - Remove
and Install”.
2. Ensure that Tooling (B) is clean, dry and free from
damage. Install Tooling (B) (oil seal locator) to the d. Remove the flywheel. Refer to Disassembly and
rear of the crankshaft. Assembly, “Flywheel - Remove”.
3. Position a new crankshaft rear seal (1) on Tooling e. Remove the rear sections of the exhaust manifold.
(B) (oil seal locator). Refer to Disassembly and Assembly, “Exhaust
Manifold - Remove and Install”.
Note: A new crankshaft rear seal is supplied with a
plastic sleeve. The plastic sleeve should be aligned f. Remove the engine oil pan. Refer to Disassembly
with the chamfer on Tooling (B) (oil seal locator). and Assembly, “Engine Oil Pan - Remove”.
4. Push crankshaft rear seal (1) squarely over
Tooling (B) (oil seal locator). The plastic sleeve will NOTICE
be forced out of the crankshaft rear seal. Discard Keep all parts clean from contaminants.
the plastic sleeve. Push the crankshaft rear seal
up to the flywheel housing. Contaminants may cause rapid wear and shortened
component life.
5. Install Tooling (B) (outer sleeve). Lubricate the
face of the washer with clean engine oil and install
the nut.
6. Tighten the nut on Tooling (B) until the crankshaft

rear seal is pushed into the bore in the flywheel
housing.
7. Remove Tooling (B).
84 KENR6924
NOTICE

mandates.
1. Remove the brackets that support the

turbochargers from the flywheel housing. Remove
the brackets as an assembly.
Note: Mark the position of the brackets on the

flywheel housing so that the brackets can be installed
in the same position.
2. Remove the oil pipes for the turbochargers from g01454203

the connections on the flywheel housing. Illustration 198
5. Install Tooling (A) to flywheel housing (1). Use a

suitable lifting device to support the weight of the
flywheel housing. The flywheel housing weighs
Note: If Tooling (A) is not available, pass suitable

slings through the apertures for the starting motors.
6. Remove bolts (4) from Positions (X). Install Tooling

(B) to Positions (X).
7. Remove the remaining bolts (4).
8. Separate flywheel housing (1) from the crankcase.

g01621843
Illustration 197
9. Use the lifting device to remove the flywheel
3. Remove bolts (2) and bolts (3). housing.
4. Use a suitable hoist to lift the rear of the engine. 10. Use a suitable drift to remove the crankshaft rear
The weight of the engine is approximately 2040 kg seal from the flywheel housing.
(450 lb). Raise the rear of the engine so that there
is a distance of 10 mm (0.4 inch) between flywheel Installation Procedure
housing (1) and the base frame.
Table 33
Note: Ensure that the engine is supported. Required Tools
A - Lifting Eyebolt (M16) 2
- Guide Studs
B 2
(M10 by 100 mm)
C - LOCTITE 518 1
NOTICE

component life.
KENR6924 85
1. Ensure that the joint surfaces of the flywheel 4. Install Tooling (A) to flywheel housing (1). Use a
housing and the crankcase are clean and free suitable lifting device to lift the flywheel housing
from damage. Ensure that the oil galleries in into position. The flywheel housing weighs
the flywheel housing are free from debris or approximately 150 kg (330 lb).
restrictions.
Note: If Tooling (A) is not available, pass suitable
slings through the apertures for the starting motors.
5. Align flywheel housing (1) with Tooling (B) and

install the flywheel housing to the crankcase.
Note: Ensure that the flywheel housing is seated on

the dowels in the crankcase.
6. Install bolts (4) hand tight. Remove Tooling (B).

Install the remaining bolts.
7. Ensure that the bottom face of the flywheel

housing is aligned with the bottom face of the
crankcase. The bottom face of the flywheel
housing should be aligned with the bottom face of
the crankcase within 0.10 mm (0.004 inch).
g01523064
Illustration 199
Application of Tooling (C) to the rear of the crankcase
2. Apply a fine bead of Tooling (C) to the rear of the

crankcase. Refer to Illustration 199 for the correct
pattern of application. Ensure that camshaft Bore
(Y) and oil Holes (Z) are not contaminated with
Tooling (C).
Note: The flywheel housing should be installed within

ten minutes of applying Tooling (C).
g01621857
Illustration 201
9. Use a suitable hoist to lower the rear of the engine

onto the base frame. Install bolts (2) and bolts (3).
Tighten the bolts securely.
10. Install a new crankshaft rear seal. Refer to

Disassembly and Assembly, “Crankshaft Rear
Seal - Remove and nstall”.
11. Install the oil pipes for the turbochargers to the

connections on the flywheel housing.
12. Install the brackets that support the turbochargers

to the flywheel housing. Install the brackets as an
assembly. Ensure that the brackets are installed
in the original positions.
End By:
g01454203 a. Install the engine oil pan. Refer to Disassembly
Illustration 200
and Assembly, “Engine Oil Pan - Install”.
3. Install Tooling (B) to Positions (X) in the crankcase.
86 KENR6924
b. Install the rear sections of the exhaust manifold.

Refer to Disassembly and Assembly, “Exhaust
Manifold - Remove and Install”.
c. Install the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Install”.
d. Install the starting motors. Refer to Disassembly

and Assembly, “Electric Starting Motor - Remove
and Install”.
e. Install the overspeed sensor. Refer to

Sensor (Overspeed) - Remove and Install”.
g01454311
f. Install the engine speed sensor. Refer to Illustration 202
Sensor - Remove and Install”. 2. Remove allen head bolts (2) from pulley (1).
i02898380
Vibration Damper and Pulley -

Remove and Install
(Single Vibration Damper)
Removal Procedure
Table 34
Required Tools g01578094
Illustration 203
Tool Part Number Part Description Qty Using the jacking holes to release the pulley from the shaft
Support Studs
A T6253/157 2 3. Lubricate two allen head bolts (2) with clean
Flywheel and Damper
engine oil. Install the allen head bolts into the
B T6253/214 Damper Lifting Tool 1 jacking holes in pulley (1). Tighten the allen head
C T6253/209A Retaining Plate 1 bolts alternately until the center of the pulley is
released from shaft (3).
Crankshaft Adapter
D T6253/209 1
Extractor 4. Remove pulley (2) from shaft (3). If necessary,
remove the key from the shaft.
Start By:
a. Remove the V-belts from the fan drive. Refer to

Disassembly and Assembly, “V-Belts - Remove
and Install”.
b. Remove the mounting bracket for the governor

actuator. Refer to Disassembly and Assembly,
“Governor Actuator - Remove and Install”.
NOTICE

component life. g01454312
Illustration 204
1. Make a temporary mark in order to show the 5. Remove two bolts (4) from Positions (X). Install
position of the pulley on the shaft. Tooling (A) to Positions (X).
KENR6924 87
6. Remove the remaining bolts (4). If necessary, tap Note: The adapter will be released from the
the shaft with a soft faced hammer in order to crankshaft with considerable force.
separate the shaft from the adapter. Remove the
shaft. Remove Tooling (A). 11. Remove Tooling (D) and remove Tooling (C).
12. Use Tooling (B) in order to remove the assembly

of damper (5) and adapter (8). Lay the assembly
of the damper and the adapter on a flat surface
with the adapter downward.
g01579674
Illustration 205
7. Install Tooling (B) and a suitable lifting device

in order to support the weight of damper (5).
The weight of the damper and the adapter is
approximately 95 kg (210 lb). g01582314
Illustration 207
8. Remove bolts (6) and retaining plate (7). 13. Remove bolts (9) and separate damper (5) from
adapter (8).
Table 35
Required Tools
Support Studs
A T6253/157 2
Flywheel and Damper
B T6253/214 Damper Lifting Tool 1
POWERPART
E CV60889 1
Anti-Seize Compound
g01582313
Illustration 206
NOTICE
9. Install Tooling (C) to the nose of the crankshaft. Keep all parts clean from contaminants.

component life.
parts propelled by a released spring force. 1. Ensure that the nose of the crankshaft and the
bore of the adapter are clean, dry and free from
Make sure to wear all necessary protective equip- damage. Ensure that the casing of the damper is
ment. free from damage.
Follow the recommended procedure and use all Note: If a new damper is installed, the casing should
recommended tooling to release the spring force. be painted in order to prevent corrosion.
10. Install Tooling (D) to adapter (8). Lubricate the

threads of the forcing bolt with clean engine oil.
Tighten the forcing bolt in order to pull adapter (8)
off the crankshaft.
88 KENR6924
g01582314 g01579674
2. Position adapter (8) on rear damper (5) and install 5. Install Tooling (B) and a suitable lifting device to
bolts (9). damper (5). The weight of the damper and the
adapter is approximately 120 kg (265 lb).
6. Use the lifting device in order to position the

assembly of the adapter and damper onto the
crankshaft.
7. Install plate (7) and bolts (6). Remove Tooling (B).

Repeat this Step until a torque of 340 N·m
(250 lb ft) has been achieved.
g01580236
Illustration 209
The tightening sequence for the damper bolts
3. Use the following method in order to tighten the

damper bolts to the correct torque.
a. Tighten bolts (9) hand tight, in the sequence

that is shown in Illustration 209.
b. Tighten bolts (9) to a torque of 135 N·m

(100 lb ft) in the sequence that is shown in g01454312
Illustration 209. Illustration 211
c. Tighten bolts (9) to a torque of 337 N·m 9. Install Tooling (A) to Positions (X) on the adapter.
(250 lb ft) in the sequence that is shown in
Illustration 209. 10. Position shaft (3) onto Tooling (A). Slide the shaft
into position against the adapter.
4. Inspect the crankshaft front seal for leaks. If there
are any oil leaks, replace the crankshaft front seal. 11. Install bolts (4) hand tight.
Refer to Disassembly and Assembly, “Crankshaft
Front Seal - Remove and Install”. 12. Remove Tooling (A) and install the remaining
bolts (4).
13. Use the following method in order to tighten bolts

(4) to the correct torque.

KENR6924 89
b. Tighten bolts (4) to a torque of 135 N·m i02856097

Illustration 209. Vibration Damper and Pulley -
Remove and Install
(250 lb ft) in the sequence that is shown in (Twin Vibration Dampers)
Illustration 209.
Removal Procedure
Table 36
Required Tools
Support Studs
A T6253/157 2
Flywheel and Damper
C T6253/209A Retaining Plate 1
Crankshaft Adapter
Illustration 212
g01580454 D T6253/209 1
Extractor
14. Ensure that the mating surfaces of the two halves

of pulley (1) are clean, dry and free from damage. Start By:
Align the halves of the pulley. Lubricate the
threads of allen head bolts (2) with Tooling (E). a. Remove the V-belts from the fan drive. Refer to
Install the allen head bolts to the pulley finger Disassembly and Assembly, “V-Belts - Remove
tight. If necessary, install the key to the keyway and Install”.
on shaft (3).
15. Install pulley (1) to shaft (3). Align pulley (1) with actuator. Refer to Disassembly and Assembly,
the pulley on the fan drive. “Governor Actuator - Remove and Install”.
16. Tighten allen head bolts (2). Tighten the allen NOTICE
head bolts alternately and tighten the allen head Keep all parts clean from contaminants.
bolts evenly to a torque of 115 N·m (85 lb ft).
17. Tap the outer half of pulley (1) with a soft faced component life.
hammer in order to seat the two halves of the
pulley. 1. Make a temporary mark in order to show the
position of the pulley on the shaft.
18. Again, tighten allen head bolts (2) to a torque of
115 N·m (85 lb ft). Check the alignment of pulley
(1) with the pulley on the fan drive. Ensure that
the pulleys are aligned.
Note: After the engine has been run for the

appropriate length of time check the tightness of the
allen head bolts that secure the pulley.
End By:
a. Install the governor actuator and the mounting

bracket. Refer to Disassembly and Assembly,
b. Install the V-belts to the fan drive. Refer to Illustration 213

g01581894
and Install”. 2. Remove allen head bolts (2) from pulley (1).
90 KENR6924
g01581895 g01581897
Using the jacking holes to release the pulley from the shaft
7. Install Tooling (B) and a suitable lifting device in
3. Lubricate two allen head bolts (2) with clean order to support the weight of front damper (5).
engine oil. Install the allen head bolts into the The weight of the damper is approximately 95 kg
jacking holes in pulley (1). Tighten the allen head (210 lb).
bolts alternately until the center of the pulley is
released from shaft (3). 8. Use Tooling (B) in order to remove front damper
(5).
4. Remove pulley (2) from shaft (3). If necessary,
remove the key from the shaft. 9. Remove Tooling (A).
g01581896 g01582094
5. Remove two bolts (4) from Positions (X). Install 10. Remove bolts (6) and retaining plate (7).
Tooling (A) to Positions (X).
11. Install Tooling (B) and a suitable lifting device in
6. Remove the remaining bolts (4). If necessary, tap order to support the weight of rear damper (8).
the shaft with a soft faced hammer in order to The weight of the rear damper and the adapter is
separate the shaft from front damper (5). Remove approximately 120 kg (265 lb).
the shaft.
KENR6924 91
16. Remove bolts (10) and separate rear damper (8)

from adapter (9).
Table 37
Required Tools
Support Studs
A T6253/157 2
Flywheel and Damper
POWERPART
g01582017 E CV60889 1
Illustration 218 Anti-Seize Compound
12. Install Tooling (C) to the nose of the crankshaft.

NOTICE

Personal injury can result from being struck by component life.
parts propelled by a released spring force.
1. Ensure that the nose of the crankshaft and the
Make sure to wear all necessary protective equip-
bore of the adapter are clean, dry and free from
ment.
damage. Ensure that the casings of the dampers
are free from damage.
recommended tooling to release the spring force.
Note: If new dampers are installed, the casings
should be painted in order to prevent corrosion.
13. Install Tooling (D) to adapter (9). Lubricate the
threads of the forcing bolt with clean engine
oil. Tighten the forcing bolt in order to pull the
assembly of adapter (8) and rear damper (9) off
the crankshaft.
Note: The adapter will be released from the

crankshaft with considerable force.
14. Remove Tooling (D) and remove Tooling (C).
15. Use Tooling (B) in order to remove the assembly

of rear damper (8) and adapter (9). Lay the
assembly of the rear damper and the adapter on a
flat surface with the adapter downward.
g01581975
Illustration 220
2. Position adapter (9) on rear damper (8) and install

bolts (10).
g01581975
Illustration 219
92 KENR6924

Repeat this Step until a torque of 340 N·m
(250 lb ft) has been achieved.
g01580236
Illustration 221
The tightening sequence for the damper bolts
g01581958
3. Use the following method in order to tighten the Illustration 223
rear damper bolts to the correct torque.


Illustration 221.

Illustration 221.
4. Inspect the crankshaft front seal for leaks. If there

are any oil leaks, replace the crankshaft front seal. g01581957
Refer to Disassembly and Assembly, “Crankshaft Illustration 224
Front Seal - Remove and Install”.
9. Install Tooling (A) to the adapter.
5. Install Tooling (B) and a suitable lifting device to
rear damper (8). The weight of the damper and 10. Install Tooling (B) and a suitable lifting device to
the adapter is approximately 120 kg (265 lb). front damper (5). The weight of the damper is
6. Use the lifting device in order to position the
assembly of adapter (9) and rear damper (8) onto 11. Use the lifting device in order to position damper
the crankshaft. (5) onto Tooling (A). Slide the damper into position
against the adapter.
12. Position shaft (3) onto Tooling (A). Slide the shaft
into position against damper (5).
13. Install bolts (4) hand tight.
14. Remove Tooling (A) and install the remaining

bolts (4).

front damper bolts to the correct torque.

g01582094
Illustration 222
7. Install plate (7) and bolts (6). Remove Tooling (B). (100 lb ft) in the sequence that is shown in
Illustration 221.
KENR6924 93
c. Tighten bolts (4) to a torque of 337 N·m i03112860

Illustration 221. Crankshaft Front Seal -
Remove and Install
Removal Procedure
Table 38
Required Tools
Part
A 27610311 Slide Hammer Puller 1
Illustration 225
g01581955 Start By:
16. Ensure that the mating surfaces of the two halves a. Remove the damper from the crankshaft. Refer to
of pulley (1) are clean, dry and free from damage. Disassembly and Assembly, “Vibration Damper
Align the halves of the pulley. Lubricate the and Pulley - Remove and Install”.
threads of allen head bolts (2) with Tooling (E).
Install the allen head bolts to the pulley finger NOTICE
tight. If necessary, install the key to the keyway Keep all parts clean from contaminants.
on shaft (3).
17. Install pulley (1) to shaft (3). Align pulley (1) with component life.
the pulley on the fan drive.
18. Tighten allen head bolts (2). Tighten the allen NOTICE
head bolts alternately and tighten the allen head Care must be taken to ensure that fluids are contained
bolts evenly to a torque of 115 N·m (85 lb ft). during performance of inspection, maintenance, test-
19. Tap the outer half of pulley (1) with a soft faced collect the fluid with suitable containers before open-
hammer in order to seat the two halves of the ing any compartment or disassembling any compo-
pulley. nent containing fluids.
20. Again, tighten allen head bolts (2) to a torque of Dispose of all fluids according to local regulations and
115 N·m (85 lb ft). Check the alignment of pulley mandates.
(1) with the pulley on the fan drive. Ensure that
the pulleys are aligned.
Note: After the engine has been run for the

appropriate length of time check the tightness of the
allen head bolts that secure the pulley.
End By:
a. Install the governor actuator and the mounting

bracket. Refer to Disassembly and Assembly,
b. Install the V-belts to the fan drive. Refer to

and Install”.
g01454301
Illustration 226
94 KENR6924
1. Use a 4 mm (1/8 inch) drill in order to make three 3. Position a new crankshaft front seal (1) on Tooling
equally spaced holes in crankshaft front seal (1). (B) (oil seal locator).
Note: Ensure that debris does not enter the Note: A new crankshaft front seal is supplied with a
crankcase. plastic sleeve. The plastic sleeve should be seated
over the chamfer on Tooling (B) (oil seal locator).
2. Screw Tooling (A) firmly into one of the holes. Use
Tooling (A) to dislodge crankshaft front seal (1). 4. Push crankshaft front seal (1) squarely over
When the crankshaft front seal begins to move, Tooling (B) (oil seal locator). The plastic sleeve will
unscrew Tooling (A). Install Tooling (A) in the next be forced out of the crankshaft front seal. Push
hole. Repeat the process using each hole, until the crankshaft front seal up to the timing case.
the crankshaft front seal is removed. Discard the plastic sleeve.
Installation Procedure 5. Install Tooling (B) (outer sleeve). Lubricate the

face of the washer with clean engine oil and install
Table 39 the nut.
Required Tools 6. Tighten the nut on Tooling (B) until the crankshaft
Part front seal is pushed into the bore in the timing
Tool Number Part Description Qty case.
B T6253/141 Front Oil Seal Insertion Kit 1
7. Remove Tooling (B).
NOTICE End By:

a. Install the damper to the crankshaft. Refer to
Contaminants may cause rapid wear and shortened Disassembly and Assembly, “Vibration Damper
component life. and Pulley - Remove and Install”.
Note: Do not lubricate the crankshaft front seal or i02856100

the crankshaft. The crankshaft front seal should be
installed dry.
Gear Group (Front) - Remove
1. Inspect the nose of the crankshaft for damage.
Ensure that the crankshaft is clean and dry.
Removal Procedure
Start By:
a. Remove the rocker assemblies. Refer to

Shaft - Remove”.
b. Remove the timing case. Refer to Disassembly

and Assembly, “Housing (Front) - Remove”.
NOTICE

component life.
g01454310
Illustration 227
2. Ensure that Tooling (B) is clean, dry and free from

damage. Install Tooling (B) (oil seal locator) to the
nose of the crankshaft.
KENR6924 95
NOTICE

mandates.
g01522086
Illustration 230
4. Remove bolts (5) and remove plate (4).
5. Remove idler gear (3).
6. If necessary, remove allen head bolts (7) and

remove hub (6) from the backplate.
g01454282
Illustration 228
Alignment of the timing marks
1. Align the timing marks on the gears. Refer to

Illustration 228.
g01522092
Illustration 231
g01454286 7. Remove bolts (10) and remove plate (9).

Illustration 229
2. Remove bolts (1). 8. Remove idler gear (8).
3. Carefully remove camshaft gear (2) from the 9. If necessary, remove allen head bolts (12) and
camshaft. remove hub (11) from the backplate.
96 KENR6924
a. Ensure that nozzle (13) is clean and free from

restriction.
b. Place new joint (15) (not shown) and nozzle

(13) in position on the crankcase.
Note: Ensure the correct orientation of the oil holes

in the nozzle. Refer to Illustration 233.
c. Install bolts (14). Tighten the bolts to a torque

of 50 N·m (35 lb ft).
g01522097
Illustration 232
10. If necessary, remove bolts (13) and remove

nozzle (14). Remove joint (15) (not shown).
i02856101
Gear Group (Front) - Install
g01522171
Illustration 234
Installation Procedure Arrows show the position of the oil holes.
Table 40
2. Inspect hub (6) and hub (11) for wear or damage.
Required Tools Check the outside diameter of the hubs. Refer
Part to Specifications, “Gear Group (Front)” for more
Tool Number Part Description Qty information.
A 21825617 Dial Indicator Group 1
3. Position hub (11) on the backplate. Ensure
the correct orientation of the oil hole. Refer to
NOTICE Illustration 234. Install allen head bolts (12).
Keep all parts clean from contaminants. Tighten the allen head bolts to a torque of 50 N·m
(35 lb ft).
component life. Note: Ensure that allen head bolts of different lengths
are installed in the correct positions.
1. Follow Step 1.a through Step 1.c in order to install 4. Position hub (6) on the backplate. Ensure the
the lubricating nozzle for the gears. correct orientation of the oil hole. Refer to
Illustration 234. Install allen head bolts (7). Tighten
the allen head bolts to a torque of 50 N·m (35 lb ft).
Note: Ensure that allen head bolts of different lengths

are installed in the correct positions.
5. Inspect the idler gears for wear or damage.

Check the inside diameter of the bushes. Refer
to Specifications, “Gear Group (Front)” for more
information. If necessary, use a suitable mandrel
in order to press the old bush out of the idler gear.
Press a replacement bush into the gear.
Note: A replacement bush is supplied with the inside

g01522134
diameter that is finished to the correct size.
Illustration 233
Arrows show the correct positions of the oil holes. 6. Lubricate hub (6) and hub (11) with clean engine
oil.
KENR6924 97
g01522192 g01522195
7. Position idler gear (8) on the hub. 9. Align the timing marks on idler gear (3) with the
timing marks on the crankshaft gear and on the
Note: Ensure that the idler gear is correctly meshed camshaft gear. Refer to Illustration 236. Position
with the crankshaft gear and with the oil pump gear. the idler gear on the hub.
8. Lubricate plate (9) with clean engine oil. Position Note: Ensure that the idler gear is correctly meshed
the plate and install bolts (10). Tighten the bolts to with the crankshaft gear and with the camshaft gear.
a torque of 50 N·m (35 lb ft).
10. Lubricate plate (4) with clean engine oil. Position
the plate and install bolts (5). Tighten the bolts to
g01522620
Illustration 238
Checking the end play and the backlash of an idler gear
Illustration 236
g01454282 11. Use feeler gauges in order to check the end play
of the idler gears. Use Tooling (A) in order to
Alignment of the timing marks
check the backlash between the idler gears and
the crankshaft gear. Refer to Specifications, “Gear
Group (Front)” for more information.
98 KENR6924
i02856102
Housing (Front) - Remove

(Timing Case)
Removal Procedure
Table 41
Required Tools
g01454286
A T6253/236 Lifting Eye 1
Illustration 239
12. Align the timing marks on camshaft gear (2) with Start By:
the timing marks on the idler. Refer to Illustration
236. Align the hole in the camshaft gear with the a. Remove the water pumps. Refer to Disassembly
dowel in the nose of the camshaft. Position the and Assembly, “Water Pump - Remove”.
camshaft gear on the camshaft.
13. Install bolts (1). Tighten the bolts to a torque of actuator. Refer to Disassembly and Assembly,
150 N·m (110 lb ft). “Governor Actuator - Remove and Install”.
c. Remove the damper from the crankshaft. Refer to

Disassembly and Assembly, “Vibration Damper
and Pulley - Remove and Install”.
d. Remove the fuel injection control linkage from the

timing case. Refer to Disassembly and Assembly,
“Fuel Injection Control Linkage - Remove”.
e. Remove the drive pulley for the alternator. Refer to

Disassembly and Assembly, “Alternator - Remove
and Install (Drive Pulley)”.
NOTICE
g01522630
Illustration 240
Checking end play of the camshaft Contaminants may cause rapid wear and shortened
component life.
14. Use Tooling (A) in order to check the end play of
the camshaft. Use Tooling (A) in order to check
the backlash between the camshaft gear and the NOTICE
idler gear. Refer to Specifications, “Gear Group Care must be taken to ensure that fluids are contained
(Front)” for more information. during performance of inspection, maintenance, test-
15. Lubricate all gears with clean engine oil. collect the fluid with suitable containers before open-
End By: nent containing fluids.
a. Install the timing case. Refer to Disassembly and Dispose of all fluids according to local regulations and
Assembly, “Housing (Front) - Install”. mandates.
b. Install the rocker assemblies. Refer to

Shaft - Install”.
KENR6924 99
9. Use a suitable drift to remove the crankshaft front

seal from the timing case.
i02856103
Housing (Front) - Install

(Timing Case)
Table 42
Required Tools
A T6253/236 Lifting Eye 1
- Guide Studs
B 2
(M10 by 100 mm)
NOTICE

component life.
g01454211
Illustration 241
1. Ensure that the joint face of the timing case and

1. Remove bolts (1) and bolts (5).
the backplate are clean.
2. Use a suitable hoist to lift the front of the engine.
The weight of the engine is approximately 2040 kg
(450 lb). Raise the front of the engine so that there
is a distance of 10 mm (0.4 inch) between support
feet (4) and the base frame.
3. Remove nuts and bolts (3) and remove support

feet (4).
4. Remove the engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove”.
Note: It is possible to remove the timing case without

removing the engine oil pan. The bolts that secure the
engine oil pan to the timing case should be removed
so that the engine oil pan can be lowered. The joint
should then be separated from the timing case.
5. Install Tooling (A) to timing case (6). Use a suitable

lifting device to support the weight of the timing
case. The timing case weighs approximately 90 kg
g01521215
(200 lb). Illustration 242
6. Remove bolts (7). 2. Install Tooling (B) to Positions (X) on the backplate.
7. Separate timing case (6) from the crankcase. Use 3. Align joint (2) (not shown) with Tooling (B). Install
the lifting device in order to remove the timing the joint to the backplate.
case.
100 KENR6924
4. Install Tooling (A) to timing case (6). Use a suitable End By:
lifting device to lift the timing case into position.
The timing case weighs approximately 90 kg a. Install the drive pulley for the alternator. Refer to
(200 lb). Install the timing case. Disassembly and Assembly, “Alternator - Remove
and Install (Drive Pulley)”.
Note: Ensure that the timing case is seated on the
dowels in the backplate. b. Install the fuel injection control linkage to the
timing case. Refer to Disassembly and Assembly,
5. Install bolts (7) hand tight. Remove Tooling (B) “Fuel Injection Control Linkage - Install”.
and install the remaining bolts (7).
c. Install the damper to the crankshaft. Refer to
Note: Ensure that bolts of different lengths are Disassembly and Assembly, “Vibration Damper
installed in the correct positions. Ensure that joint (2) and Pulley - Remove and Install”.
(not shown) protrudes below the base of the timing
case. d. Install the mounting bracket for the governor
actuator. Refer to Disassembly and Assembly,
6. Tighten bolts (7) to a torque of 50 N·m (35 lb ft). “Governor Actuator - Remove and Install”.
Remove excess material from joint (2) (not
shown). The joint should be flush with the base e. Install the water pumps. Refer to Disassembly and
of the timing case. Assembly, “Water Pump - Install”.
7. Remove Tooling (A).

i02856104
8. Install the engine oil pan. Refer to Disassembly

Crankcase Breather - Remove
and Install
Removal Procedure
NOTICE

component life.
NOTICE
g01521245 Dispose of all fluids according to local regulations and
Illustration 243
mandates.
9. Position support feet (4) and install nuts and bolts
(3). Tighten the nuts and bolts to a torque of
95 N·m (70 lb ft).
10. Use a suitable hoist to lower the front of the

engine onto the base frame. Install bolts (1) and
bolts (5). Tighten the bolts securely.
11. Install a new crankshaft front oil seal. Refer to

Disassembly and Assembly, “Crankshaft Front Oil
Seal - Remove and Install”.
KENR6924 101
g01441057 g01441057
1. Loosen the hose clamp and disconnect hose (1) 2. Position crankcase breather (4) on the mounting
from crankcase breather (4). bracket. Loosely install the nuts and allen head
bolts (5).
2. Loosen the hose clamp and disconnect hose (6)
from crankcase breather (4). 3. Position spacers (3). Loosely install the nuts and
allen head bolts (2).
3. Remove the nuts and allen head bolts (5).
4. Tighten allen head bolts (5) and allen head bolts
4. Support crankcase breather (4). Remove the nuts (5) to a torque of 50 N·m (35 lb ft).
and allen head bolts (2). Remove spacers (3) and
crankcase breather (4). 5. Connect hose (6) to crankcase breather (4).
Tighten the hose clamp securely.
5. If necessary, disassemble the crankcase breather.
Refer to Operation and Maintenance Manual, 6. Connect hose (1) to crankcase breather (4).
“Engine Crankcase Breather - Clean” for the Tighten the hose clamp securely.
correct procedure.
i02856105
Valve Mechanism Cover -
NOTICE Remove and Install
(Rocker Box Cover)
component life.
1. If necessary, assemble the crankcase breather. Removal Procedure

“Engine Crankcase Breather - Clean” for the NOTICE
correct procedure. Keep all parts clean from contaminants.

component life.
102 KENR6924
NOTICE

mandates.
g01433348
Illustration 247
2. Remove the protective backing from joint (3) (not

shown) and install the joint to cover (1).
3. Position cover (1) on the rocker box and install

setscrews and washers (2). Tighten the setscrews
evenly to a torque of 4 N·m (35 lb in).
i02856106
Illustration 246
g01433348 Valve Mechanism Cover Base -
1. Remove setscrews and washers (2).
Remove and Install
(Rocker Box)
2. Remove cover (1).
Note: If necessary, carefully tap the cover with a soft

faced hammer in order to loosen the cover. Removal Procedure
3. Remove joint (3) (not shown) from cover (1). Start By:
Installation Procedure a. Remove the rocker assembly. Refer to

NOTICE Shaft - Remove”
NOTICE
Contaminants may cause rapid wear and shortened Keep all parts clean from contaminants.
component life.
component life.
1. Ensure that the cover is clean and dry. Ensure
that the joint face of the rocker box is clean and
free from damage.
KENR6924 103
5. Remove allen head screws and washers (5).

NOTICE
Care must be taken to ensure that fluids are contained 6. Remove rocker box (1).
ing, adjusting and repair of the product. Be prepared to Note: If necessary, carefully tap the rocker box with a
collect the fluid with suitable containers before open- soft faced hammer in order to loosen the rocker box.
nent containing fluids. 7. Remove joint (6) (not shown).

mandates.
g01434636
Illustration 250
8. Remove O-ring seal (7).
9. If necessary, remove stud (8) and stud (9) from

g01434485 the cylinder head.
Illustration 248
Note: In order to remove stud (9), first drain the
2. Loosen pipe (2) at both ends. Allow the fuel to coolant to a level that is below the cylinder head.
drain from the fuel rail. Remove the pipe. Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change” for the correct
3. Remove bolt (4). procedure.
4. Loosen pipe (3) at both ends. Allow the oil to drain
from the fuel rail. Disconnect the pipe from rocker Installation Procedure
box (1).
Table 43
Note: Cap the pipes and the connections on the rail. Required Tools
POWERPART
A 21820117 1
NOTICE

component life.
1. Ensure that the rocker box is clean and free from

damage. Ensure that the joint face of the cylinder
g01434466 head is clean.
Illustration 249
104 KENR6924
g01434466
Illustration 252
4. Position a new joint (6) (not shown) on the cylinder

head.
5. Align rocker box (1) with the dowels in the cylinder

g01434636 head and install the rocker box.
Illustration 251
6. Install allen head screws and washers (5). Tighten

2. If the studs for the rocker assembly were removed the allen head screws to a torque of 70 N·m
from the cylinder head, follow Step 2.a through (50 lb ft).
Step 2.c in order to install the studs.
a. Ensure that the threads of stud (8) and stud (9)

are clean and dry. Ensure that the holes for the
studs in the cylinder head are clean and dry.
b. Apply Tooling (A) to the threads of stud (8) and

stud (9).
Note: Apply the Tooling to the end of the studs that

have the short thread.
c. Install stud (8) and stud (9) to the cylinder

head. Tighten the studs to a torque of 50 N·m
(35 lb ft).
Note: Ensure that the coolant is filled to the correct

level. Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change” for the correct
procedure.
3. Position a new O-ring seal (7) in the recess in the

g01434485
cylinder head. Illustration 253
7. Connect pipe (3) to rocker box (1). Tighten the

nuts at both ends of the pipe securely.
8. Install bolt (4) to the pipe clip. Tighten the bolt to a

9. Install pipe (2). Tighten the nuts at both ends of

the pipe securely.

- Prime”.
KENR6924 105
End By:

and Assembly, “Rocker Arm and Shaft - Install”
i02856107
Rocker Arm and Shaft -

Remove
Removal Procedure
Start By:
a. Remove the cover from the rocker box. Refer to

Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
g01433435
Illustration 255
NOTICE
1. Remove nut (1) and nut (3).
component life. 2. Carefully remove rocker assembly (2) from the
rocker box.
Note: Make temporary identification marks on the Note: Take care not to misplace pad (5).
rocker assembly, on the bridge pieces and on the
pushrods in order to show the location. 3. Remove pad (5) from the fuel injector.
4. Remove bridge piece (4) and bridge piece (6)

from the rocker box.
5. Remove pushrod (7) (not shown), pushrod (8) and

pushrod (9).

the remaining rocker assemblies.
i02856109
Rocker Arm - Disassemble
Start By:
g01433401 a. Remove the rocker assembly. Refer to

Illustration 254
Shaft - Remove”.
NOTICE

component life.
106 KENR6924
Rocker Arm and Shaft Assembly Bridge Piece

1. Make a temporary identification mark on each
rocker arm and shaft assembly in order to show
the location.
Note: The components must be reinstalled in the

original location and orientation. Do not interchange
used components.
g01454320
Illustration 258
1. If necessary, remove nut (18) and adjuster (17)

from bridge piece (6).
2. Inspect pad (16) for wear or damage. If the pad is

worn or damaged, use a suitable press in order to
remove the pad from bridge piece (6).
i02856110
Rocker Arm - Assemble

g01454319
Illustration 256
Assembly Procedure
2. Remove rocker arm assembly (10) from rocker
shaft (13). Remove rocker arm assembly (11) from Table 44
rocker shaft (13). Remove rocker arm assembly
Required Tools
(12) from rocker shaft (13).
A - LOCTITE Activator 1
B - LOCTITE 603 1
NOTICE

component life.
Bridge Piece
Illustration 257
g01519113 1. Check the bridge piece for wear or damage.
Check the clearance between the bridge piece
3. If necessary, remove nuts (14) and adjusters (15) and the guide pillar in the cylinder head. Check
from the rocker arms. that the nut and the adjuster is free from damage.
Note: The components must be installed in the

used components.
KENR6924 107
Rocker Arm and Shaft Assembly

1. Check the rocker arms for wear or damage.
Check the rocker shaft for wear or damage. Refer
to Specifications, “Valve Mechanism” for more
information. Ensure that the oil holes in the rocker
shaft are free from restriction. Check that the nuts
and the adjusters are free from damage.
Note: The components must be installed in the

used components.
g01519114
Illustration 259
g01519113
Illustration 261
2. If necessary, install nuts (14) and adjusters (15)

g01454320 to the rocker arms.
Illustration 260
2. If the pad on the bridge piece required

replacement, follow Step 2.a through Step 2.d in
order to install a new pad.
a. Ensure that the new pad (16) and the bore in

bridge piece (6) are clean and dry.
b. Apply Tooling (A) to Stem (X) on the pad and

to Bore (Y) in the bridge piece.
c. Apply Tooling (B) to Bore (Y) in the bridge

piece.
Note: Ensure that the top face of the bridge piece is

not contaminated with Tooling (B).
d. Install pad (16) to bridge piece (6).
Note: Position the bridge piece with the pad upward.

Allow Tooling (B) to cure for 2 hours before installing g01454319
the bridge piece. Illustration 262
3. Install nut (18) and adjuster (17) to bridge piece 3. Lubricate rocker shaft (13) with clean engine
(6). oil. Install rocker arm assembly (10), rocker arm
assembly (11) and rocker arm assembly (12) to
rocker shaft (13).
End By:

and Assembly, “Rocker Arm and Shaft - Install”.
108 KENR6924
i02856108
Rocker Arm and Shaft - Install
Table 45
Required Tools
C 21825607 Angle Gauge 1
NOTICE

component life.
g01433401
Illustration 264
1. Ensure that all components are clean and free
from wear or damage. Replace any components
that are worn or damaged. 2. Apply clean engine oil to both ends of the
pushrods. Install pushrod (7) (not shown), pushrod
(8) and pushrod (9) to the engine with the cup
upward. Ensure that the ball end of each pushrod
is correctly seated in the cam follower.
3. Lubricate the posts for the bridge pieces and

lubricate the valves with clean engine oil.
4. Install bridge piece (4) and bridge piece (6).
5. Equalize the bridge pieces. Refer to Systems

Operation, Testing and Adjusting, “Engine Valve
Lash - Adjust”
6. Lubricate pad (5) with petroleum jelly and install

the pad to rocker assembly (2).
7. Position rocker assembly (2) onto the rocker box.

Take care not to misplace pad (5).
Note: Ensure that the rocker assembly is aligned

with the dowels in the rocker box. Ensure that the
g01591499
Illustration 263 adjustment screws are properly seated in the ends of
the pushrods.
8. Install nut (1) and nut (3). Evenly tighten the nuts
in order to pull the rocker assembly into position.
Tighten the nuts to a torque of 120 N·m (90 lb ft).
9. Use Tooling (C) to turn nut (1) and nut (3) through
an additional 90 degrees.
10. Adjust the engine valve lash. Refer to Systems

Operation, Testing and Adjusting, “Engine Valve
Lash - Adjust” for the correct procedure. Adjust the
fuel injector timing. Refer to Systems Operation,
Testing and Adjusting, “Fuel Injector Adjustment”
for the correct procedure..
KENR6924 109
End By:
a. Install the cover to the rocker box. Refer to

Cover - Remove and Install”.
i02856112
Cylinder Head - Remove
Removal Procedure
Table 46
Required Tools
Cylinder head Lifting
T6253/237 1
A Tool
g01509714
- Bolts (M10 by 25 mm) 2 Illustration 265
Typical example
Start By:
3. Follow Step 3.a through Step 3.c in order to
remove the appropriate sections of the coolant rail.
a. Remove the fuel rail. Refer to Disassembly and
Note: The coolant rail can be removed as an
Install”.
assembly or as individual sections. To remove the
front section, first loosen the thermostat housing.
b. Remove the appropriate sections of the exhaust
To remove the center section, first remove the rear
manifold. Refer to Disassembly and Assembly,
section.
“Exhaust Manifold - Remove and Install”.
a. Remove bolts (1). Remove nuts and bolts (2).
c. Remove the appropriate sections of the inlet
b. Remove coolant rail (4).
“Inlet Manifold - Remove”.
c. Remove O-ring seal (3). Remove joints (5).
NOTICE
Keep all parts clean from contaminants. 4. Remove the appropriate fuel injector. Refer to
Disassembly and Assembly, “Fuel Injector -
Contaminants may cause rapid wear and shortened Remove”.
component life.
5. Remove the appropriate rocker box. Refer to
NOTICE
Cover Base - Remove and Install”.
6. Remove the fuel injection control linkage from
the cylinder head. Refer to Disassembly and
Assembly, “Valve Mechanism Cover Base -
Remove and Install”.

mandates.

2. Remove the bolts that secure the heat shield to

the coolant rail and remove the heat shield.
110 KENR6924
9. Remove cylinder head bolts (6) and spacers (7)

from cylinder head (8).
g01622284
Illustration 266
Marking of the cylinder head bolts
(X) After the first removal, reuse the bolt.
(Y) After the second removal, reuse the bolt.
(Z) After the third removal, renew the bolt.
7. Before removing the cylinder head bolts, the

heads of the bolts should be marked with a dot
from a center punch. Any bolts that have two dots
before removal should not be reused.
g01454323
Illustration 269
10. Attach Tooling (A) to cylinder head (8). Carefully

lift the cylinder head off the cylinder block. The
weight of the cylinder head is approximately 40 kg
(88 lb).
g01454322
Illustration 267
g01454324
Illustration 270
11. Remove retainer (9) from cylinder head (8).

Remove O-ring seal (10) from the retainer.
g01511134
Illustration 268
The cylinder head tightening sequence
8. Gradually loosen cylinder head bolts (6) in reverse

numerical order to the sequence that is shown in
Illustration 268.
KENR6924 111
g01454325 g01454325
12. Remove O-ring seals (11), (12), (14), (15) and 2. Install flame ring (13).
(16). Remove flame ring (13).
3. Install new O-ring seals (11), (12), (14), (15) and
(16).
i02856113
Cylinder Head - Install Note: Use petroleum jelly in order to hold the O-ring
seals in position.
Table 47
Required Tools
Cylinder head Lifting
T6253/237 1
A Tool
- Bolts (M10 by 25 mm) 2
POWERPART
B CV60889 1
Anti-Seize Compound
C 21825607 Angle Gauge 1
NOTICE
Contaminants may cause rapid wear and shortened Illustration 273

g01454331
component life.
4. Install a new O-ring seal (10) to retainer (9).
1. Thoroughly clean the mating surfaces of the Install the retainer to cylinder head (8). Refer to
cylinder head and the crankcase. Ensure that Illustration 273 for the correct orientation of the
there is no debris in the cylinder bores, the coolant retainer.
passages or the lubricant passages.
Note: Use petroleum jelly in order to hold the retainer
in position.
112 KENR6924
g01454323 g01454322
5. Attach Tooling (A) to cylinder head (8). Carefully,

lift the cylinder head into position. The weight of
the cylinder head is approximately 40 kg (88 lb).
Note: Avoid damage to the rod for the fuel injection

control linkage when the cylinder head is lowered into
position. Ensure that the cylinder head is aligned with
the dowels in the crankcase. Ensure that the retainer
and the O-ring seal are not dislodged.
g01518548
Illustration 278
The cylinder head tightening sequence
Illustration 275
g01622284 7. Apply Tooling (B) to Threads (X) of cylinder head
bolts (6). Apply Tooling (B) to the faces of washers
Marking of the cylinder head bolts
(7).
(X) After the first removal, reuse the cylinder head bolt.
(Y) After the second removal, reuse the cylinder head bolt.
(Z) After the third removal, renew the cylinder head bolt.
8. Install cylinder head bolts (6) and spacers (7) to
cylinder head (8).
6. Inspect the cylinder head bolts for previous use.
Refer to Illustration 275. If necessary, replace the 9. Tighten cylinder head bolts (6) according to the
cylinder head bolts. following procedure:
a. Tighten the cylinder head bolts hand tight in the

b. Tighten the cylinder head bolts to a torque of

175 N·m (130 lb ft) in the sequence that is
shown in Illustration 278.
g01454332
c. Use Tooling (C) to turn the cylinder head
Illustration 276 bolts through 120 degrees. Turn the cylinder
head bolts in the sequence that is shown in
Illustration 278.
KENR6924 113
Note: In some cases, it may not be possible to 14. Follow Step 14.a through Step 14.d in order
follow the procedure that is described in Step 9. If to install the sections of the coolant rail to the
necessary, follow the alternative procedure that is cylinder head.
described in Step 10 in order to tighten the cylinder
head bolts. Note: The coolant rail can be installed as an
assembly or as individual sections. If a front section
10. The alternative procedure for tightening cylinder is installed, ensure that the thermostat housing
head bolts (6) is secured. Refer to Disassembly and Assembly,
“Water Temperature Regulator Housing - Remove
a. Tighten the cylinder head bolts hand tight in the and Install” for more information.
a. Install O-ring seal (3) to coolant rail (4). Install
b. Tighten the cylinder head bolts to a torque of joints (5) to the cylinder head.
shown in Illustration 278. b. Install coolant rail (4) to the cylinder head.
Position the heat shield on the coolant rail.
c. Tighten the cylinder head bolts to a torque of
270 N·m (200 lb ft) in the sequence that is c. Install bolts (1) finger tight. Install nuts and
shown in Illustration 278. bolts (2) finger tight.
d. Tighten the cylinder head bolts to a torque of d. Tighten bolts (1) to a torque of 50 N·m (35 lb ft).
540 N·m (400 lb ft) in the sequence that is Tighten nuts and bolts (2) to a torque of 50 N·m
shown in Illustration 278. (35 lb ft).
e. Tighten the cylinder head bolts to a torque of 15. Fill the cooling system with coolant to the correct
725 N·m (530 lb ft) in the sequence that is level Refer to Operation and Maintenance Manual,
shown in Illustration 278. “Cooling System Coolant - Change” for the correct
procedure.
11. Install the fuel injection control linkage to
the cylinder head. Refer to Disassembly and End By:
Assembly, “Valve Mechanism Cover Base -
Remove and Install”. a. Install the appropriate sections of the inlet
12. Install the rocker box to the cylinder head. Refer “Inlet Manifold - Install”.
to Disassembly and Assembly, “Valve Mechanism
Cover Base - Remove and Install”. b. Install the appropriate sections of the exhaust
13. Install the fuel injector to the cylinder head. Refer “Exhaust Manifold - Remove and Install”.
to Disassembly and Assembly, “Fuel Injector -
Install”. c. Install the fuel rail. Refer to Disassembly and
Install”.
i02856114
Lifter Group - Remove

(Cam Followers)
Removal Procedure
Table 48
Required Tools
A - Bolt (M8 by 50 mm) 2
B - Lifting Eye (M8) 2
g01509714
Illustration 279
Typical example
114 KENR6924
Start By: Note: Loosen the nuts on each connection by one

quarter of a turn at a time until the assembly of oil
a. Remove the front sections and the center sections pipe (4) is released from the cam followers.
of the exhaust manifolds. Refer to Disassembly
and Assembly, “Exaust Manifold - Remove and 4. Cap the open end of pipe (3) and the connections
Install”. on the cam followers. Make temporary marks on
the cam followers in order to show the location.
NOTICE

component life.
NOTICE
g01507981
Dispose of all fluids according to local regulations and Illustration 281
mandates.
5. Remove bolts (8). Remove allen head bolts (6)
and spacers (7).
g01507995
Illustration 282
6. Lubricate Tooling (A) with clean engine oil. Install

Tooling (A) into Holes (X). Tighten Tooling (A)
evenly until the cam follower is released from the
crankcase. Remove Tooling (A).
7. Install Tooling (B) into Holes (X). Use Tooling (B)

and a suitable lifting device in order to remove the
cam follower. The weight of the cam follower is
g01454345
Illustration 280 8. Remove joint (9) (not shown).
1. Remove bolts (1) and heat shields (2).
2. Disconnect oil pipe (3) from the tee connector on

oil pipe (4).
3. Gradually loosen nuts (5). Remove the assembly

of oil pipe (4) as a unit.
KENR6924 115
g01636741 g01509605
9. Remove dowels (10). 1. Remove jet (11). Remove O-ring seal (12) from
the jet.
Note: If the dowels remain in the crankcase, remove
the dowels from the crankcase.
i02856115
Lifter Group - Disassemble

(Cam Followers)
Table 49
Required Tools
Part
C - Circlip Pliers 1
Start By: g01454348

Illustration 285
a. Remove the cam followers. Refer to Disassembly

2. Make an identification mark on each component
of the cam follower in order to show the location.
NOTICE Note: The components must be reinstalled in the

Keep all parts clean from contaminants. original location and orientation. Do not interchange
used components.
component life. 3. Use Tooling (A) to remove circlip (13).
4. Withdraw shaft (15) from housing (16) and remove

cam followers (14).
116 KENR6924
i02856116
Lifter Group - Assemble

(Cam Followers)
Assembly Procedure
Table 50
Required Tools
Part
C - Circlip Pliers 1
NOTICE
Contaminants may cause rapid wear and shortened g01454348

component life. Illustration 287
3. Lubricate the bores in cam followers (14) and

1. Clean the components of the cam follower. housing (16) with clean engine oil.
4. Install shaft (15) and cam followers (14) to housing

(16). Use Tooling (A) to install circlip (13).
Note: The components must be reinstalled in the

used components.
g01508686
Illustration 286
2. Inspect cam followers (14). Check Bores (X),

Sockets (Y) and Rollers (Z) for excessive wear
or damage.
g01509639
Illustration 288
5. Ensure that jet (11) is clean and free from

restriction. Install new O-ring seal (12) to the jet.
6. Lubricate the threads of jet (11) with clean engine

oil. Install the jet to housing (16). Tighten the jet to
End By:
a. Install the cam followers. Refer to Disassembly

and Assembly, “Lifter Group - Install”.
KENR6924 117
i02856117
Lifter Group - Install

(Cam Followers)
Table 51
Required Tools
B - Lifting Eye (M8) 2 g01507995
Illustration 290
- POWERPART
D 1
Hydraulic Threadseal 4. Place a new joint (9) (not shown) in position.
NOTICE Note: Install the cam follower to the original location.

5. Install Tooling (B) into Holes (X) in the cam
Contaminants may cause rapid wear and shortened follower. Use Tooling (B) and a suitable lifting
component life. device in order to lift the cam follower into position.
The weight of the cam follower is approximately
16 kg (35 lb). Align the dowels in the cam follower
1. Ensure that the cam followers are clean and with the holes in the crankcase and install the
free from damage. Clean the joint surface of the cam follower. Ensure that the rollers of the cam
crankcase. followers are correctly positioned on the lobes of
the camshaft and that the cam follower is seated
Note: Ensure that debris does not enter the on the crankcase.
crankcase.
g01507981
Illustration 291
g01637130
Illustration 289
6. Remove Tooling (B). Apply Tooling (D) to the
2. Install dowels (10) to cam follower (16). threads of allen head bolts (6). Install allen head
bolts (6) and spacers (7). Tighten the allen head
Note: Ensure that there are no dowels in the bolts to a torque of 85 N·m (63 lb ft).
crankcase.
7. Install bolts (8). Tighten the bolts securely.
3. Lubricate the lobes of the camshaft and the rollers
of the cam followers with clean engine oil.
118 KENR6924
Start By:
a. Remove the flywheel housing. Refer to

Disassembly and Assembly, “Flywheel Housing
b. Remove the cam followers. Refer to Disassembly

c. Remove the camshaft gear. Refer to Disassembly

and Assembly, “Gear Group (Front) - Remove”.
NOTICE

component life.
g01454345
Illustration 292
8. Position the assembly of oil pipe (4). Gradually

tighten nuts (5). Tighten each nut by one quarter
of a turn at a time. Tighten the nuts to a torque of
g01519640
50 N·m (35 lb ft). Illustration 293
9. Connect oil pipe (3) to the assembly of oil pipe (4). 1. Remove allen head bolts (3) and remove thrust
Tighten the oil pipe to a torque of 33 N·m (25 lb ft). plate (1).
10. Place heat shields (2) in position and install 2. Ensure that Tooling (A) is clean and free from
bolts (1). Tighten the bolts to a torque of 25 N·m burrs. Install Tooling (A) to the nose of camshaft
(18 lb ft). (2).
End By:
a. Install the front sections and the center sections of

the exhaust manifolds. Refer to Disassembly and
Assembly, “Exaust Manifold - Remove and Install”.
i02856118
Camshaft - Remove
Removal Procedure
g01454355
Illustration 294
Table 52
Supporting the camshaft during the removal procedure
Required Tools
3. Use a long wooden drift in order to push on
Tooling (A). Carefully push camshaft (2) out of the
A T6253/142 Camshaft Guide Tool 1 engine. Use a suitable sling in order to support the
camshaft during the removal procedure.
KENR6924 119
4. Lift the camshaft from the engine. The weight 5. Align Tooling (A) with the rear camshaft bearing.
of the camshaft is approximately 70 kg (155 lb). Carefully push camshaft (2) into the engine. Use
Place the camshaft on a suitable support. If a suitable sling in order to support the camshaft
necessary, remove Tooling (A) from the camshaft. during the installation procedure.
6. When camshaft (2) is in the correct position,

i02856119
remove Tooling (A).
Camshaft - Install
Table 53
Required Tools
Tool Part Number Part Number Qty
A T6253/142 Camshaft Guide Tool 1
NOTICE
Keep all parts clean from contaminants. Illustration 296
g01519689
Contaminants may cause rapid wear and shortened 7. Position thrust plate (1) and install allen head bolts
component life. (3). Tighten the allen head bolts to a torque of
50 N·m (35 lb ft).
1. Ensure that the camshaft is clean and free
from wear or damage. Refer to Specifications, End By:
“Camshaft” for more information.
a. Install the camshaft gear. Refer to Disassembly
2. Inspect the camshaft bearings for wear or and Assembly, “Gear Group (Front) - Install”.
damage. If necessary, replace the camshaft
bearings. Refer to Disassembly and Assembly, b. Install the cam followers. Refer to Disassembly
“Camshaft Bearings - Remove ” and Disassembly and Assembly, “Lifter Group - Install”.
and Assembly, “Camshaft Bearings - Install ” for
the correct procedures. c. Install the flywheel housing. Refer to Disassembly
and Assembly, “Flywheel Housing - Remove and
Install”.
i02856121
Camshaft Bearings - Remove
Removal Procedure
Table 54
Required Tools
g01454389
Illustration 295
Camshaft Bearing
Supporting the camshaft during the installation procedure A T6253/199 1
Removal/Fitting Tool
3. Ensure that Tooling (A) is clean and free from
burrs. Install Tooling (A) to the nose of camshaft Start By:
(2).
a. Remove the camshaft. Refer to Disassembly and
4. Use a suitable lifting device in order to lift the Assembly, “Camshaft - Remove”.
camshaft into position. The weight of the camshaft
is approximately 70 kg (155 lb).
120 KENR6924
NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
1. Clean the bearing housing in the crankcase.

Ensure that the oil holes are free from debris.
Lubricate the bearing housing with clean engine
oil.
g01519735
Illustration 297
1. Lubricate the threads on Tooling (A) with clean

engine oil. Install Tooling (A) to the appropriate
camshaft bearing.
g01519735
Illustration 298
Note: Ensure that Tooling (A) is correctly aligned with
the camshaft bearing and with the crankcase.
2. Tighten the nut on Tooling (A) in order to pull

camshaft bearing (1) from the crankcase.
i02856122
Camshaft Bearings - Install
Table 55 g01520088
Illustration 299
Required Tools
2. Position new camshaft bearing (1) on Tooling (A).
Tool Part Number Part Description Qty Lubricate the threads on Tooling (A) with clean
Camshaft Bearing engine oil. Assemble Tooling (A).
A T6253/199 1
Removal/Fitting Tool
KENR6924 121
Note: The camshaft bearing should be installed with Engine Oil Pan
joint (X) in the twelve o’clock position. The locking
tabs should face toward A Bank. 1. Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and
Maintenance Manual, “Engine Oil and Filter
Change.” for the correct procedure.
g01637630
Illustration 300
Alignment of the oil groove
3. Tighten the nut on Tooling (A) in order to pull

camshaft bearing (1) into the crankcase. Install
the camshaft bearing so that bearing is central in
the bearing housing. Ensure that oil groove (Y) is
aligned with the oil hole in the crankcase.
End By: g01504026

Illustration 301
a. Install the camshaft. Refer to Disassembly and

Assembly, “Camshaft - Install”. 2. Remove bolts (1) and bolts (7). Remove pipe (3).
Remove joint (2) (not shown) and joint (5) (not
shown).
i02856123
3. Remove bolts (4) and bolts (10). Remove pipe (8).
Engine Oil Pan - Remove Remove O-ring seal (6) (not shown) and O-ring
Removal Procedure
NOTICE

component life.
NOTICE

mandates.
g01502614
Illustration 302
122 KENR6924
4. Loosen bolts (11) and nuts (12). Remove bolts 2. Remove O-ring seal (24) from plate (23). Remove
(13) and bolts (16). Remove block (15). Remove O-ring seal (25) from plate (26).
O-ring seal (14) (not shown) and O-ring seal (17)
(not shown). 3. Slide pipe (21) and withdraw the pipe from the
engine oil pan.
5. Support the weight of the engine oil pan. The
weight of the engine oil pan is approximately 60 kg
(130 lb).
g01502607
Illustration 303
Note: Before removal of the engine oil pan, note the

position of the mounting bracket for the start solenoid.
6. Remove bolts (20) and lower engine oil pan (19).

Remove the engine oil pan and remove joint (18)
(not shown).
7. If necessary, remove the dipstick and the tube.

g01502680
Illustration 305
Suction Pipe and Strainer
4. Remove bolts (34) and remove strainer (33) from
the engine oil pan.
5. Remove bolts (29) and bolts (31). Remove suction

pipe (30) and spacers (32) from the engine oil
pan. Remove O-ring seal (28).
g01454695
Illustration 304
1. Remove plate (23) and plate (26). Remove joint

(22) and joint (27).
KENR6924 123
i02856124
Engine Oil Pan - Install
Table 56
Required Tools
Part
POWERPART
A 21820221 1
Rubber Grease
POWERPART
B 21820518 Gasket and Flange 1
Sealant
- Guide Studs
C 2
(M10 by 50 mm)
POWERPART
D 21820117 1
POWERPART
E 21820121 1
Hydralic Threadseal
NOTICE Illustration 306

g01502680
2. Install a new O-ring seal (28) to suction pipe (30).
Contaminants may cause rapid wear and shortened Position the suction pipe and spacers (32) in the
component life. engine oil pan. Loosely install bolts (29) and bolts
(31).
Suction Pipe and Strainer 3. Tighten bolts (29) finger tight. Tighten bolts (31) to
a torque of 40 N·m (30 lb ft). Tighten bolts (29) to
1. Ensure that the components of the engine oil pan
and suction pipe are clean and free from damage.
4. Position strainer (33) in the engine oil pan and
install bolts (34). Tighten bolts (34) to a torque of
40 N·m (30 lb ft).
124 KENR6924
g01502607
Illustration 309
3. Position a new joint (18) (not shown) on oil pan

(19).
Note: Ensure the correct orientation of the joint.

g01454695
Illustration 307
4. Use a suitable lifting device to lift engine oil pan
(19) into position. The weight of the engine oil pan
5. Install new O-ring seal (24) to plate (23). Install is approximately 60 kg (130 lb). Align the engine
O-ring seal (25) to plate (26). Lubricate the O-ring oil pan with Tooling (C). Carefully install the engine
seals with Tooling (A). oil pan. Place the bracket for the start solenoid in
position and install bolts (20).
6. Slide pipe (21) into the engine oil pan.
7. Position new joint (22) and new joint (27) on the
ends of pipe (21). Carefully slide plate (23) and
plate (26) over the ends of the pipe.
Engine Oil Pan

1. Ensure that the joint faces of the engine oil pan
and the crankcase are clean.
g01502614
Illustration 310
g01505982
Illustration 308
Note: If a new joint has been installed to the timing O-ring seal (17) (not shown) to block (15).
case, to the back plate or to the flywheel housing,
ensure that the joint is flush with the crankcase. 7. Position block (15). Install bolts (13) and bolts (16)
hand tight.
2. Apply Tooling (B) to the joint face of the crankcase
at Positions (X) and Positions (Y). Install Tooling 8. Tighten bolts (11) to a torque of 40 N·m (30 lb ft).
(C) to each end of the crankcase. Tighten bolts (16) to a torque of 40 N·m (30 lb ft).
Tighten bolts (13) to a torque of 50 N·m (35 lb ft).
KENR6924 125
9. Tighten nuts (12) securely. i02856125
Cylinder Liner - Remove
Removal Procedure
Table 57
Required Tools
A SE253 Engine Turning Tool 1
B T6253/152 Liner Extractor 1
Start By:
a. Remove the pistons and connecting rods. Refer

to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.
g01504026
Illustration 311 NOTICE
O-ring seal (9) (not shown) to pipe (8). Contaminants may cause rapid wear and shortened
component life.
11. Position pipe (8) and install bolts (4) hand tight.
Apply Tooling (D) to bolts (10). Install bolts (10)
hand tight. NOTICE
12. Tighten bolts (4) to a torque of 50 N·m (35 lb ft). during performance of inspection, maintenance, test-
Tighten bolts (10) to a torque of 40 N·m (30 lb ft). ing, adjusting and repair of the product. Be prepared to
13. Place a new joint (2) (not shown), pipe (3) and a ing any compartment or disassembling any compo-
new joint (5) (not shown) in position. Install bolts nent containing fluids.
(1) and bolts (7) hand tight. Tighten bolts (1) to a
torque of 50 N·m (35 lb ft). Tighten bolts (7) to a Dispose of all fluids according to local regulations and
torque of 40 N·m (30 lb ft). mandates.
14. If necessary, follow Step 14.a and Step 14.b in

1. Use Tooling (A) in order to rotate the crankshaft.
order to install the dipstick and the tube.
Rotate the crankshaft until there is sufficient
clearance in order to install Tooling (B).
a. Apply Tooling (E) to the threads of the dipstick
tube.
b. Install the dipstick and the dipstick tube to

the engine oil pan. Tighten the dipstick tube
securely.
15. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter- Change” for the correct procedure.
16. Prime the engine oil system. Refer to Operation

and Maintenance Manual, “Before Starting the
Engine ” for the correct procedure.
126 KENR6924
g01454704
Illustration 313
5. Remove O-ring seals (2) from cylinder liner (1).
i02856126
Illustration 312
g01454703 Cylinder Liner - Install
2. Follow Step 2.a through Step 2.c in order to
assemble Tooling (B) to the cylinder liner.
a. Position the lower clamping plate in the
bottom of the cylinder liner. Position the upper Table 58
clamping plate in the top of the cylinder liner.
Required Tools
b. Install the bolts to the clamping plates. Tighten Tool Part Number Part Description Qty
the bolts securely.
POWERPART
C 21820221 1
Rubber Grease
c. Locate the frame in the cylinder head bolt
holes. Lubricate the threads with clean engine D - LOCTITE 638 1
oil. T6253/200 Liner Clamp Kit 1
3. Tighten the forcing bolt on Tooling (B) in order to E - Cylinder Head Bolts 2
pull cylinder liner (1) from the crankcase. - Spacers 2
Note: A small quantity of coolant and accumulated
debris will be released when the liner is removed NOTICE
from the crankcase. Ensure that the crankshaft is Keep all parts clean from contaminants.
protected from the debris.
4. Lift Tooling (B) and the cylinder liner from the component life.
crankcase. The weight of Tooling (B) and the
cylinder liner is approximately 45 kg (100 lb).
Remove the cylinder liner from Tooling (B). 1. Clean the interior of the crankcase. Ensure that
the seat for the cylinder liner is clean, dry and
free from rust or sealant. Ensure that the cylinder
liner is clean and dry. If a used cylinder liner is
installed, ensure that the cylinder liner is free from
rust or sealant.
KENR6924 127
g01454704
Illustration 314
2. Install new O-ring seals (2) to cylinder liner (1).
g01454329
Illustration 316
6. Install Tooling (E).
Note: Install Tooling (E) so that the Tooling does not

foul the dowels in the crankcase.
7. Use Tooling (E) to push cylinder liner (1) into the

crankcase. When the cylinder liner is correctly
seated, tighten the bolts to a torque of 5 N·m
(45 lb in). Allow Tooling (D) to cure for three hours
before removing Tooling (E).
Note: When the cylinder liner is correctly seated, the

top of the cylinder liner will sit below the face of the
crankcase.
8. Check Dimension (X).

g01454706
Illustration 315
Dimension (X) ............................ 2.07 to 2.20 mm
3. Apply Tooling (C) to Bore (Z) in the crankcase. (0.082 to 0.087 inch)
4. Apply Tooling (D) to Face (Y) on the crankcase. End By:
5. Carefully install liner (1) to the crankcase. Push a. Install the pistons and connecting rods. Refer
the liner into the crankcase by hand until the to Disassembly and Assembly, “Pistons and
O-ring seals make contact with the bottom of the Connecting Rods - Install”.
crankcase.
Note: When the O-ring seals make contact with the

bottom of the crankcase, resistance will be felt.
128 KENR6924
i02856127
Piston Cooling Jets - Remove

and Install
Removal Procedure
Table 59
Required Tools
Start By:
a. Remove the starting motors. Refer to Disassembly

and Install”.
g01454710
Illustration 317
b. Remove the engine oil coolers. Refer to Typical example
Disassembly and Assembly, “Engine Oil Cooler
- Remove”. 1. Remove bolts (3) and crankcase door (4) from the
crankcase. Remove joint (5) (not shown).
NOTICE
Keep all parts clean from contaminants. 2. Use Tooling (A) in order to rotate the crankshaft
so that the piston of the appropriate cylinder is at
Contaminants may cause rapid wear and shortened the top center position.
component life.
3. Remove bolt (2). Rotate cooling jet (1) clockwise
through 90 degrees. Withdraw the cooling jet from
NOTICE the crankcase.

mandates.
g01454712
Illustration 318
Typical example
4. Remove O-ring seal (6) and O-ring seal (7) from

cooling jet (1).
KENR6924 129
Installation Procedure e. Use a torch and a mirror to check that the

nozzle of cooling jet (1) is centrally located in
Table 60 oil gallery (X) in the piston.
Required Tools
f. Use Tooling (A) in order to rotate the crankshaft
Tool Part Number Part Description Qty so that the piston of the appropriate cylinder is
A SE253 Engine Turning Tool 1 at the top center position.
g. Remove bolt (2) and cooling jet (1).

NOTICE

component life.
g01454712
Illustration 320
2. Lubricate the body of cooling jet (1) with clean

engine oil. Install a new O-ring seal (7) and a new
O-ring seal (6) to the cooling jet. Lubricate the
O-ring seals with clean engine oil.
g01454711
Illustration 319
Checking the alignment of a cooling jet
1. Follow Step 1.a through Step 1.g in order to check

the alignment of the cooling jet.
a. Ensure that the cooling jet is clean and free

from damage or restriction.
b. Ensure that the piston of the appropriate

cylinder is at the top center position.
c. Temporarily install cooling jet (1) and bolt (2).
Note: Install the cooling jet without O-ring seals.

g01507806
Illustration 321
d. Use Tooling (A) in order to rotate the crankshaft
so that the piston of the appropriate cylinder is 3. Ensure that the piston of the appropriate cylinder
at the bottom center position. is at the top center position.
130 KENR6924
4. Install cooling jet (1) to the crankcase with Hole Note: The removal procedure can be performed
(Y) in the 3 o’clock position. Rotate the cooling jet from the B Bank side of the engine without removing
counterclockwise through 90 degrees and push the starting motors, the oil cooler or the engine oil
the cooling jet into position. filter head from the A Bank side of the engine. If it is
necessary to perform the removal procedure from
Note: Ensure that the flange of the cooling jet is the A Bank side of the engine, remove the starting
seated against the crankcase. motors, the oil cooler and the engine oil filter head
from the A Bank side of the engine.
5. Install bolt (1). Tighten the bolt to a torque of
50 N·m (35 lb ft). NOTICE
6. Place a new joint (5) (not shown) and crankcase
door (4) in position. Install bolts (3). Tighten the Contaminants may cause rapid wear and shortened
bolts to a torque of 50 N·m (35 lb ft). component life.
End By:
1. Use Tooling (A) to rotate the crankshaft to a
a. Install the engine oil coolers. Refer to Disassembly convenient position and remove the carbon ridge
and Assembly, “Engine Oil Cooler - Install”. from the top of the cylinder liner bore.
b. Install the starting motors. Refer to Disassembly

and Install”.
i02856128
Pistons and Connecting Rods

- Remove
Removal Procedure
g01584314
Table 61 Illustration 322
Required Tools
B T6253/212 Piston Crown Handle 1
Start By:
a. Remove the cylinder heads. Refer to Disassembly

and Assembly, “Cylinder Head - Remove”.
b. Remove the engine oil cooler from B Bank. Refer

to Disassembly and Assembly, “Engine Oil Cooler
- Remove”. Illustration 323
g01454730
c. Remove the engine oil filter head from B Bank. 2. The connecting rod and connecting rod cap
Refer to Disassembly and Assembly, “Engine Oil have an etched Number (X) on the side. The
Filter Base - Remove”. number on connecting rod (1) and the number on
connecting rod cap (2) must match. Ensure that
d. Remove the crankcase doors and remove the the connecting rod and the connecting rod cap
piston cooling jets. Refer to Disassembly and are marked for the correct location. If necessary,
Assembly, “Piston Cooling Jets - Remove and make a temporary mark on the connecting rod
Install”. and the connecting rod cap in order to identify the
cylinder number.
KENR6924 131
3. Remove connecting rod bolts (3) and connecting 1. Make a temporary mark on the components of
rod cap (2) from connecting rod (1). the piston and connecting rod assembly in order
to show the location and the orientation. This
4. Use Tooling (A) to carefully rotate the crankshaft. will ensure that the components of each piston
Rotate the crankshaft until the appropriate piston and connecting rod assembly can be reinstalled
on A Bank is just past the top center position, or in the original cylinder. Do not interchange used
the appropriate piston on B Bank is just before components.
the top center position.
Note: Take care not to displace the big end bearing

as the crankshaft is rotated.
5. Position Tooling (B) onto the crown of piston (4).

Carefully expand Tooling (B) into the valve recess
of the piston.
Note: Ensure that Tooling (B) is installed to the piston

securely.
6. Use Tooling (B) in order to pull the piston and the

connecting rod out of the cylinder liner bore.
Note: Be careful not to damage the cylinder liner

or the crankshaft journal during the removal of the
piston and the connecting rod.
7. Temporarily install connecting rod cap (2) and

connecting rod bolts (3) to connecting rod (1) in
order to keep the big end bearings in position. g01584454
Illustration 324
Typical example
i02856129
2. Remove connecting rod bolts (3) and connecting
Pistons and Connecting Rods rod cap (2) from connecting rod (1).
- Disassemble
3. Remove lower big end bearing (6) from connecting
rod cap (2). Remove upper big end bearing (5)
from connecting rod (1).
Table 62
Required Tools
Part
C T6253/258 Circlip Pliers 1
D T6253/256 Piston Ring Pliers 1
E T6253/159 Small End Bush Tool 1
Start By:
a. Remove the pistons and the connecting rods.

Refer to Disassembly and Assembly, “Pistons and
NOTICE
Keep all parts clean from contaminants. g01584456
Illustration 325
component life. 4. Use Tooling (C) to remove circlips (11) from piston
(4).
132 KENR6924
5. Remove gudgeon pin (10) and connecting rod (1)

from piston (4). NOTICE
Note: If the gudgeon pin cannot be removed by
hand, heat the piston to a temperature of 45 ± 5 °C Contaminants may cause rapid wear and shortened
(113 ± 9 °F). Note the orientation of the connecting component life.
rod to the piston.
6. Place the piston on a suitable surface with the 1. Follow Step 1.a through Step 1.e in order to
crown upward. Use Tooling (D) in order to remove inspect the pistons and the connecting rods.
compression rings (7) and (8), and oil control ring
(9) from piston (4). a. Carefully remove the carbon deposits from the
piston. Visually check the piston for cracks,
Note: Identify the position and the orientation of the signs of seizure or other damage.
compression rings and the oil control ring.
b. Inspect piston ring grooves for wear. Refer to
Specifications, “Pistons and Rings” for more
information.
c. Carefully remove the carbon deposits from

the piston rings. Inspect the piston rings for
wear or damage. Install the piston rings into
the cylinder liner bore and check the clearance
between the ends of the piston rings. Refer to
Specifications, “Pistons and Rings” for more
information.
d. Check that the gudgeon pin is free from wear

or damage. Refer to Specifications, “Pistons
and Rings” for more information.
g01584533
Illustration 326
e. Check that the connecting rod is free from
7. Inspect small end bush (12) for wear or for cracks. Inspect the connecting rod for wear
damage. Refer to Specifications, “Pistons and and for distortion. Refer to Specifications,
Rings” for more information. If the small end bush “Connecting Rod” for more information. If the
is damaged or worn beyond the specified limits, connecting rod requires replacement, ensure
use Tooling (E) in order to remove the small end that the weight of the new connecting rod is the
bush from connecting rod (1). same weight as the original connecting rod.
i02856130

- Assemble
Assembly Procedure
Table 63
Required Tools
Part g01584533
Tool Number Part Description Qty Illustration 327
C T6253/258 Circlip Pliers 1 2. If the small end bush required replacement, use
D T6253/256 Piston Ring Pliers 1 Tooling (E) in order to install small end bush (12)
to connecting rod (1).
E T6253/159 Small End Bush Tool 1
Note: A replacement small end bush is supplied,
finished to the correct size.
KENR6924 133
g01454802
Illustration 330
The location and orientation of the piston rings
3. Lubricate the small end bush and the bores for the
gudgeon in the piston with clean engine oil.
Illustration 328
g01584456 4. Ensure the correct orientation of the connecting
rod and install connecting rod (1) to piston (4).
Lubricate gudgeon pin (10) with clean engine oil.
Slide the gudgeon pin into position.
Note: If the gudgeon pin cannot be installed by

hand, heat the piston to a temperature of 45 ± 5 °C
(113 ± 9 °F).
5. Use Tooling (C) to install new circlips (11). Ensure

that the circlips are seated into the grooves.
6. Follow Steps 6.a through 6.e in order to install the

piston rings to the piston.
a. Position the spring for oil control ring (9) into

the oil ring groove in piston (4). The central wire
must be located inside the end of the spring.
b. Use Tooling (D) to install oil control ring (9)

over the spring.
g01622252
Note: Ensure that the central wire is 180 degrees
Illustration 329 from the ring gap.
The correct orientation of the piston and connecting rod
(Y) Cut out for the piston cooling jet. c. Use Tooling (D) to install intermediate
(Z) Flat thrust face of connecting rod compression ring (8) into the second groove
in piston (4). The identification “TOP” must be
upward.
d. Use Tooling (D) to install top compression

ring (7) into the top groove in piston (4). The
identification “TOP” must be upward.
e. Position the piston ring gaps at 120 degrees

away from each other.
134 KENR6924
i02856131

- Install
Table 64
Required Tools
Part
B T6253/212 Piston Crown Handle 1
Piston Ring Compression
F T6253/139 1
Tool
30 Degree Indicator Socket
g01584454 G SE671K 1
Illustration 331 Tool
NOTICE

component life.
g01622255
Illustration 332
Location of the bearing tab
7. Install upper big end bearing (5) to connecting rod

(1). Install lower big end bearing (6) to connecting
rod cap (2). Ensure that the bearings are correctly
seated and that the tabs are located in the slots.
g01454763
Illustration 333
8. Temporarily install connecting rod cap (2) to
connecting rod (1) in order to keep the bearings in 1. Position Tooling (B) onto the crown of piston (4).
position. Loosely install new connecting rod bolts Carefully expand Tooling (B) into the valve recess
(3). of the piston. Remove the connecting rod bolts
and the connecting rod cap from the connecting
End By: rod.
a. Install the pistons and the connecting rods. Refer Note: Ensure that Tooling (B) is installed to the piston
to Disassembly and Assembly, “Pistons and securely.
Connecting Rods - Install”.
2. Use Tooling (A) to carefully rotate the crankshaft.
Rotate the crankshaft until the appropriate piston
on A Bank is just past the top center position, or
the appropriate piston on B Bank is just before
the top center position.
KENR6924 135
3. Apply clean engine oil to the cylinder liner bore, 9. Install the new connecting rod bolts (3) to
to the piston rings and to the outer surface of the connecting rod cap (2) hand tight.
piston.
4. Lubricate the big end bearings, and the crankshaft

pin with clean engine oil. Lubricate the threads and
the underside of the heads of the new connecting
rod bolts with clean engine oil.
Note: Install the big end bearings dry when clearance

checks are performed. Refer to Disassembly and
Assembly, “Bearing Clearance - Check” for the
correct procedure. Apply clean engine oil on the big
end bearings for final assembly.
5. Ensure that the gaps for the piston rings are at

120 degrees away from each other. Position
Tooling (F) onto the piston in order to compress
the piston rings. Carefully position the piston and
the connecting rod into the cylinder liner bore.
Note: Ensure that Tooling (F) is installed correctly

and that the piston can easily slide from the tool.
Ensure that the piston and the connecting rod are g01454762
Illustration 335
installed in the correct cylinder.
6. Carefully push the piston and the connecting rod
connecting rod bolts to the correct torque.
into the cylinder liner bore. At the same time, guide
the connecting rod onto the pin of the crankshaft.
a. Tighten connecting rod bolts (3) to a torque of
Take care not to displace the big end bearing.
110 N·m (82 lb ft).
Note: Be careful not to damage the cylinder liner, the
b. Install Tooling (G) to connecting rod bolt (3).
big end bearings or the crankshaft during installation
Apply light pressure to the wrench. Set the
of the piston and the connecting rod.
leading edge of Tooling (G) in line with the
center of the connecting rod. Turn connecting
7. Remove Tooling (F).
rod bolt (3) through 30 degrees. The trailing
edge of Tooling (G) is now in line with the
center of the connecting rod.
c. Reposition Tooling (G) so that the leading edge

of Tooling (G) is in line with the center of the
connecting rod. Turn connecting rod bolt (3)
through an additional 30 degrees. The trailing
edge of Tooling (G) is now in line with the
center of the connecting rod.
g01584314
Illustration 334
8. The connecting rod and connecting rod cap have

an etched Number (X) on the side. The number on
connecting rod (1) and the number on connecting
rod cap (2) must match. Position connecting rod
cap (2) on the connecting rod.
NOTICE
Discard all used connecting rod bolts. g01587153
Illustration 336
Using feeler gauges to check the side float of the connecting rods
136 KENR6924
11. Check the side float of the connecting rods.
Connecting rod side float ........... 0.36 to 0.69 mm

(0.014 to 0.027 inches)
Note: The installation procedure can be performed

from the B Bank only. If it is necessary to perform
the installation procedure from the A Bank side of
the engine, install the starting motors, the oil cooler
and the engine oil filter head to the A Bank side of
the engine.
End By:
a. Install the piston cooling jets and the crankcase g01329038

doors. Refer to Disassembly and Assembly, Illustration 337
“Piston Cooling Jets - Remove and Install”.
1. Remove upper main bearings (1) from the
b. Install the cylinder heads. Refer to Disassembly crankcase.
and Assembly, “Cylinder Head - Install”.
Note: The upper main bearings have a groove and
c. Install the engine oil filter head to B Bank . Refer two oil holes.
to Disassembly and Assembly, “Engine Oil Filter
Base - Install”.
d. Install the engine oil cooler to B Bank . Refer to

Disassembly and Assembly, “Engine Oil Cooler -
Install”.
i02875443
Crankshaft Main Bearings -

Remove and Install
g01329039
Illustration 338
Removal Procedure
2. Remove lower main bearings (2) from the main
Start By: bearing caps.
a. Remove the crankshaft and the thrust washers. Note: The lower main bearings are plain bearings
Refer to Disassembly and Assembly, “Crankshaft that have no oil holes.
- Remove”.
NOTICE
NOTICE
component life.
component life.
1. Inspect the main bearings for wear or for damage.

Refer to Specifications, “Crankshaft” for more
information. If necessary, replace the main
bearings.
Note: If the engine is undergoing a major overhaul,

the main bearings and the main bearing bolts should
be replaced.
KENR6924 137
i02633925
Crankshaft - Remove
Removal Procedure
Start By:
a. Remove the crankcase doors and remove the

piston cooling jets. Refer to Disassembly and
Assembly, “Piston Cooling Jets - Remove and
Install”.
g01329039
Illustration 339
b. Remove the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
2. Install lower main bearings (2) to the main bearing
caps.
c. Remove the fuel injection control linkage. Refer to
Note: The lower main bearings are plain bearings
Disassembly and Assembly, “Fuel Injector Control
that have no oil holes.
Linkage - Remove”.
d. Remove the engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove”.
e. Remove the back plate. Refer to Disassembly and

Assembly, “Engine Support (Front) - Remove and
Install”.
f. Remove the flywheel housing. Refer to

Disassembly and Assembly, “Flywheel Housing
NOTICE
g01329038
Illustration 340
3. Install upper main bearings (1) to the crankcase. component life.
Note: The upper main bearings have a groove and

two oil holes. 1. The engine should be placed in the inverted
position. The weight of the engine is approximately
End By: 2040 kg (4500 lb).
a. Install the crankshaft and the thrust washers. Note: Place the engine on a suitable surface in
Refer to Disassembly and Assembly, “Crankshaft order to avoid damage to the machined faces of the
- Install”. crankcase.
138 KENR6924
g01587233
Illustration 343
7. Attach a suitable sling and a lifting device to

crankshaft (5). Attach the sling around the center
balance weights of the crankshaft. The weight of
the crankshaft is approximately 390 kg (860 lb).
g01328986
Illustration 341
8. Carefully lift crankshaft (5) out of the crankcase.
Place the crankshaft on a suitable support.
2. Rotate the crankshaft so that the center balance
weights are in the horizontal position. 9. Remove the crankshaft main bearings. Refer to
Disassembly and Assembly, “Crankshaft Main
3. Remove allen head bolts (3). Bearings - Remove and Install”.
4. Remove main bearing bolts (1).
i02648185
5. Remove main bearing caps (2).
Crankshaft - Install
Table 65
Required Tools
Part
A 21825617 Dial Indicator 1
NOTICE
g01431403
Illustration 342 Keep all parts clean from contaminants.
6. Remove thrust washers (4) from the crankcase. Contaminants may cause rapid wear and shortened
component life.
Note: The crankshaft has two thrust washers. The
thrust washers are located on each side of the rear
main bearing. 1. Inspect the crankshaft for wear and for damage.
Refer to Specifications, “Crankshaft” for more
information.
2. Install the main bearings to the crankcase and to

the main bearing caps. Refer to Disassembly and
Assembly, “Crankshaft Main Bearings - Remove
and Install”.
KENR6924 139
Note: Install the main bearings dry when clearance

checks are performed. Refer to Disassembly and
Assembly, “Bearing Clearance - Check” for the
correct procedure. Apply clean engine oil on the face
of the main bearings for final assembly.
g01587233
Illustration 344
g01328986
Illustration 346
3. Attach a suitable sling and a lifting device to
crankshaft (5). Attach the sling around the center
balance weights of the crankshaft. The weight of
the crankshaft is approximately 390 kg (860 lb).
4. Carefully lift crankshaft (5) into the crankcase.
Note: The crankshaft should be installed with the

center balance weights in the horizontal position.
g01331451
Illustration 347
Identification of the main bearing caps
g01431403
Illustration 345
6. The crankcase and main bearing cap have a
5. Lubricate thrust washers (4) with clean engine oil. Number (X) on the bottom. The number on main
Install the thrust washers to the crankcase. bearing cap (2) must match the corresponding
number on the crankcase. Install the main bearing
Note: The crankshaft has two thrust plates. The caps to the crankcase.
thrust washers are located on each side of the rear
main bearing. Install the thrust washers with the 7. Lubricate the underside of the head and the
grooves toward the crankshaft. threads of main bearing bolts (1) with clean engine
oil. Install the main bearing bolts finger tight.
8. Lubricate the underside of the head and the

threads of allen head bolts (3) with clean engine
oil. Install the allen head bolts finger tight.
140 KENR6924
g01333139
Illustration 348
Sequence for tightening main bearing bolts (1)

main bearing bolts to the correct torque.
a. Tighten main bearing bolts (1) to a torque of Illustration 350

g01331447
Checking the end play of the crankshaft
shown in Illustration 348.
b. Tighten main bearing bolts (1) to a torque of 10. Use Tooling (A) to check the crankshaft end play.
shown in Illustration 348. Crankshaft end play (new thrust
washers) .. 0.13 to 0.51 mm (0.005 to 0.020 inch)
c. Tighten main bearing bolts (1) to a torque of
540 N·m (400 lb ft) in the sequence that is Maximum crankshaft end play (service
shown in Illustration 348. limit) ................................... 0.55 mm (0.025 inch)
d. Tighten main bearing bolts (1) to a torque of End By:

shown in Illustration 348. a. Install the flywheel housing. Refer to Disassembly
and Assembly, “Flywheel Housing - Remove and
Install”.
b. Install the back plate. Refer to Disassembly and

Assembly, “Engine Support (Front) - Remove and
Install”.
c. Install the engine oil pan. Refer to Disassembly

d. Install the fuel injection control linkage. Refer to

Disassembly and Assembly, “Fuel Injector Control
Linkage - Install”.
e. Install the pistons and connecting rods. Refer

Illustration 349
g01331450 to Disassembly and Assembly, “Pistons and
Sequence for tightening allen head bolts (6) Connecting Rods - Install”.
e. Tighten allen head bolts (3) to a torque of f. Install the piston cooling jets and the crankcase
168 N·m (124 lb ft) in the sequence that is doors. Refer to Disassembly and Assembly,
shown in Illustration 349. “Piston Cooling Jets - Remove and Install”.
f. Ensure that the crankshaft rotates freely.
KENR6924 141
i02920989
Crankshaft Gear - Remove and

Install
Removal Procedure
Table 66
Required Tools
Part
g01454833
A - Puller 1 Illustration 352
1. Heat crankshaft gear (1) in an oven to 250 °C

Start By: (480 °F).
a. Remove the timing gears. Refer to Disassembly
and Assembly, “Gear Group (Front) - Remove”.
NOTICE Always wear protective gloves when handling

Keep all parts clean from contaminants. parts that have been heated.
Contaminants may cause rapid wear and shortened 2. Align Timing Mark (X) on crankshaft gear (2) with
component life. Timing Mark (X) on crankshaft (1). Install the
crankshaft gear to the crankshaft.
Note: Ensure that the crankshaft gear is seated

against the shoulder on the crankshaft.
End By:
a. Install the timing gears. Refer to Disassembly and

Assembly, “Gear Group (Front) - Install”.
g01454825
Illustration 351
1. Ensure that Timing Mark (X) is upward.
2. Use Tooling (A) in order to pull crankshaft gear

(2) from crankshaft (1).
NOTICE

component life.
142 KENR6924
i02748526 • Ensure that the bearing locking tabs are properly

seated in the tab grooves.
Bearing Clearance - Check
• The crankshaft must be free of oil at the contact
points of Tooling (A).
Measurement Procedure 1. Put a piece of Tooling (A) on the crown of the

bearing that is in the cap.
Table 67
Required Tools Note: Do not allow Tooling (A) to extend over the
edge of the bearing.
Part
Tool Number Part Description Qty 2. Use the correct torque-turn specifications in order
Plastic Gauge (Green) to install the bearing cap. Do not use an impact
- 0.025 to 0.076 mm 1 wrench. Be careful not to dislodge the bearing
(0.001 to 0.003 inch) when the cap is installed.
Plastic Gauge (Red) Note: Do not turn the crankshaft when Tooling (A)
- 0.051 to 0.152 mm 1
is installed.
(0.002 to 0.006 inch)
A
Plastic Gauge (Blue) 3. Carefully remove the cap, but do not remove
- 0.102 to 0.229 mm 1 Tooling (A). Measure the width of Tooling (A)
(0.004 to 0.009 inch) while Tooling (A) is in the bearing cap or on the
Plastic Gauge (Yellow) crankshaft journal. Refer to Illustration 353.
- 0.230 to 0.510 mm 1
(0.009 to 0.020 inch)
NOTICE

component life.
Note: Perkins does not recommend the checking of

the actual clearances of the bearing shells particularly
on small engines. This is because of the possibility
of obtaining inaccurate results and of damaging the
bearing shell or the journal surfaces. Each Perkins
bearing shell is quality checked for specific wall
thickness.
Note: The measurements should be within

specifications and the correct bearings should Illustration 353
g01152855
be used. If the crankshaft journals and the bores Typical Example

for the block and the rods were measured during
disassembly, no further checks are necessary. 4. Remove all of Tooling (A) before you install the
However, if the technician still wants to measure the bearing cap.
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with Note: When Tooling (A) is used, the readings can
small diameters if clearances are less than 0.10 mm sometimes be unclear. For example, all parts of
(0.004 inch). Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
NOTICE within the specification range. Refer to Specifications
Lead wire, shim stock or a dial bore gauge can dam- Manual, “Connecting Rod Bearing Journal” and
age the bearing surfaces. Specifications Manual, “Main Bearing Journal” for the
correct clearances.
The technician must be very careful to use Tooling (A)
correctly. The following points must be remembered:
• Ensure that the backs of the bearings and the

bores are clean and dry.
KENR6924 143
i02887613 4. Remove nuts and bolts (3) and remove module (1)
and the mounting bracket as an assembly.
Engine Sensors - Remove and
Install Installation Procedure
(Exhaust Temperature)
NOTICE

component life.
Removal Procedure
NOTICE

component life.
g01455706
Illustration 356
g01455706
Illustration 354
g01605418
Illustration 357
1. Position the assembly of module (1) and the

mounting bracket on the inlet manifold and install
nuts and bolts (3). Tighten the nuts and bolts to a
2. Connect thermocouples (2) to module (1).

g01605418
Illustration 355
3. Position thermocouples (2) on the fuel rail.
1. Disconnect thermocouples (2) from module (1). Connect the thermocouples to the exhaust
manifolds.
2. Disconnect thermocouples (2) from the exhaust
manifolds. 4. Secure thermocouples (2) to the fuel rail and to the
rocker boxes with clips and with new cable straps.
3. Loosen the clips that secure thermocouples (2)
to the fuel rail and to rocker boxes. Cut the cable
straps that secure the thermocouples and remove
the thermocouples.
144 KENR6924
i02856133 4. Remove sealing washer (2) (not shown) from

coolant temperature switch (1).
Coolant Temperature Switch -
Remove and Install Installation Procedure
NOTICE
Removal Procedure
NOTICE component life.

component life.
NOTICE

mandates.
1. Drain the coolant from the cooling system to a

level that is below the coolant temperature switch.
Use a suitable container for storage or disposal.
“Cooling System Coolant - Change”. Illustration 359
g01431021
1. Install a new sealing washer (2) (not shown) to

coolant temperature switch (1).
2. Install coolant temperature switch (1) into

the thermostat housing. Tighten the coolant
temperature switch to a torque of 30 N·m (22 lb ft).
3. Connect the harness assembly to coolant

4. Fill the cooling system to the correct level. Refer

to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
g01431021
Illustration 358
2. Disconnect the harness assembly from coolant

3. Remove coolant temperature switch (1) from the

thermostat housing.
KENR6924 145
i02887612 Installation Procedure

Engine Oil Pressure Switch - NOTICE
Remove and Install Keep all parts clean from contaminants.
(Alternator Warning Lamp) Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
NOTICE

component life.
NOTICE

mandates.
g01431027
Illustration 361
1. Install engine oil pressure switch (1) to adapter

(2). Tighten the engine oil pressure switch to a
torque of 9.5 N·m (84 lb in).
2. Connect the harness assembly to engine oil

pressure switch (1).
i02856134
Engine Oil Pressure Switch -

Remove and Install
Removal Procedure
NOTICE
Illustration 360
1. Disconnect the harness assembly from engine oil Contaminants may cause rapid wear and shortened
pressure switch (1). component life.
2. Remove engine oil pressure switch (1) from

adapter (2).
146 KENR6924
2. Connect the harness assembly to engine oil

NOTICE pressure switch (1).
i02856135
collect the fluid with suitable containers before open- Engine Speed Sensor -
nent containing fluids. Remove and Install
(Overspeed Sensor)
mandates.
Removal Procedure
NOTICE

component life.
g01455414
Illustration 362
1. Disconnect the harness assembly from engine oil

pressure switch (1).
2. Remove engine oil pressure switch (1) from

adapter (2).
NOTICE

component life.
g01431041
Illustration 364
1. Disconnect the harness assembly from overspeed

sensor (1).
2. Loosen locknut (2) and remove overspeed sensor

(1) from the flywheel housing.
NOTICE

g01455414 component life.
Illustration 363
1. Install engine oil pressure switch (1) to adapter 1. Refer to Operation and Maintenance Manual,
(2). Tighten the engine oil pressure switch to a “Speed Sensor - Clean/Inspect” for the correct
torque of 9.5 N·m (84 lb in). procedure that should be used to install the
overspeed sensor.
KENR6924 147
i02875268 i02856136
Engine Speed Sensor - Boost Pressure Sensor -

Remove and Install Remove and Install
Removal Procedure Removal Procedure

NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
g01431058 g01455703
1. Disconnect the harness assembly from engine 1. Slide the locking tab on the plug into the unlocked
speed sensor (1). position and disconnect the harness assembly
from boost pressure sensor (1).
2. Loosen locknut (2) and remove engine speed
sensor (1) from the flywheel housing. 2. Use a deep socket in order to remove boost
pressure sensor (1).
Installation Procedure 3. Remove O-ring seal (2) from boost pressure
sensor (1).
NOTICE
Table 68
component life.
Required Tools
1. Refer to Operation and Maintenance Manual, Tool Part Number Part Description Qty
“Speed Sensor - Clean/Inspect” for the correct POWERPART
procedure that should be used to install the engine A 21820221 1
Rubber Grease
speed sensor.
148 KENR6924
NOTICE

component life.
g01609813
Illustration 368
Typical example
2. Remove pulley guard (1). Remove the cover from

aperture (2).
g01455703
Illustration 367
1. Lubricate a new O-ring seal (2) with Tooling (A).

Install the O-ring seal to boost pressure sensor (1).
2. Use a deep socket to install boost pressure sensor

(1). Tighten the boost pressure sensor to a torque
of 10 N·m (89 lb in).
3. Connect the harness assembly to boost pressure

sensor (1) and slide the locking tab on the plug
into the locked position.
i02856210
V-Belts - Remove and Install

(Fan Drive Belts)
g01455720
Illustration 369
Removal Procedure The guards are not shown for clarity.
3. Loosen nuts (3).

NOTICE
Keep all parts clean from contaminants. 4. Loosen locknut (5).
Contaminants may cause rapid wear and shortened 5. Rotate nut (4) in an counterclockwise direction in
component life. order to release the tension on the V-belts.
1. Turn the battery disconnect switch to the “OFF”

position.
KENR6924 149
g01609010 g01609010
The guards are not shown for clarity. The guards are not shown for clarity.
6. Remove the V-belts from pulleys (6), (7) and (8).

Lay the V-belts on shaft (9). Lift the V-belts over
pulley (8) and withdraw the V-belts through the
aperture in the guard.
NOTICE

component life.
1. Inspect the V-belts for cracks or contamination. If

necessary, replace the V-belts.
Note: V-belts must be replaced as a set. Do not

replace individual V-belts.
g01609813
Illustration 372
Typical example
2. Ensure that pulleys (6), (7) and (8) are aligned.

If necessary, adjust the position of pulley (8) on
shaft (9). Refer to Disassembly and Assembly,
“Vibration Damper and Pulley - Remove and
Install” for more information.
3. Pass the V-belts through aperture (2). Position the

V-belts on pulleys (6), (7) and (8).
150 KENR6924
V-belt tension ........... 24 to 36 N (5.4 to 8.1 lb)
Note: The tension of the V-belts can be checked

through the aperture in the fan guard.
5. Tighten locknut (5) securely.
7. Install pulley guard (1). Install the cover to aperture

(2). Refer to Illustration 368.
8. Turn the battery disconnect switch to the “ON”

position.
i02856138
Alternator - Remove and Install

(Battery Charging Alternator)
g01455720
Illustration 373
The guards are not shown for clarity.
Removal Procedure



being worked on.
NOTICE
g01609013
Illustration 374
Checking Deflection (X) with a spring balance and a straight edge
component life.
4. Follow Step 4.a and Step 4.b in order to adjust the
tension of the V-belts. 1. Disconnect the batteries.
a. Rotate nut (4) in a clockwise direction in order 2. Make temporary identification marks on the
to increase the tension on the V-belts. harness assemblies that are connected to the
alternator. Disconnect the harness assemblies
b. Use a spring balance and a straight edge in from the alternator.
order to apply a force of 31 to 49 N (7 to 11 lb)
to each V-belt separately. Apply the force to the
longest free length of the V-belt. Deflection (X)
should be 8 mm (0.315 inch).
c. Use a suitable belt tension gauge to check the

tension of the V-belts.
KENR6924 151
g01431433
Illustration 377
Releasing the pulley from the drive shaft
b. Lubricate one screw (10) with clean engine

oil. Install the grub screw into the jacking hole
in pulley (9). Tighten the grub screw until the
Illustration 375
g01431424 center of the pulley is released from the shaft
of the alternator.
3. Remove bolts (5) and guard (8).
c. Remove the pulley from the shaft of the
4. Loosen nut (6). alternator. Remove grub screw (10) from pulley
(9) and separate the two halves of the pulley.
5. Remove nut (3) and bolt (2).
6. Push alternator (4) toward the engine. Slide belt
(1) from the pulley of the alternator. NOTICE
7. Remove nut (6) and bolt (7). Remove alternator
(4) from the mounting bracket. Contaminants may cause rapid wear and shortened
component life.
8. If necessary, follow Step 8.a through Step 8.c in
order to remove the pulley from the alternator.
1. If necessary, follow Step 1.b through Step 1.d in
order to install the pulley for the alternator.
g01431432
Illustration 376
g01431432
a. Remove grub screws (10) from pulley (9). Illustration 378
a. Ensure that the mating surface of the two

halves of pulley (9) are clean, dry and free from
damage. Align the halves of the pulley. Lightly
lubricate grub screws (10) with clean engine oil.
Install the grub screws to the pulley finger tight.
b. Install pulley (9) to the alternator.
152 KENR6924
c. Tighten grub screws (10). Tighten the grub Note: After the engine has been run for the
screws alternately and tighten the grub screws appropriate length of time check the tightness of the
evenly to a torque of 22 N·m (15 lb ft). grub screws that secure the alternator pulley. Refer
to Operation and Maintenance Manual, “Alternator
d. Tap the outer half of pulley (9) with a soft faced Pulley - Check.” for more information.
pulley.
i02897056
Note: Use a block of wood in order to prevent

damage to the pulley.
Alternator - Remove and Install
(Alternator Drive)
e. Again, tighten grub screws (10) to a torque of
22 N·m (15 lb ft).
Note: Ensure that the pulley is seated against the Removal Procedure
shoulder on the shaft of the alternator.
NOTICE

component life.
NOTICE

mandates.
1. Remove the alternator. Refer to Disassembly

and Assembly, “Alternator (Battery Charging
g01431424 Alternator) - Remove and Install” for the correct
Illustration 379
procedure.
2. Position alternator (4) on the mounting bracket
and push the alternator toward the engine. Slide
belt (1) over the pulley of the alternator. Ensure
that the belt is correctly aligned. Install bolt (7) and
nut (6) hand tight.
3. Install bolt (2) and install nut (3) hand tight.

Ensure that the belt tension is correct. Refer
to Operation and Maintenance Manual, “Belts
- Inspect/Adjust/Replace”. Tighten the nut to a
4. Tighten nut (6) to a torque of 66 N·m (50 lb ft).
5. Position guard (8) and install bolts (5). Tighten the

6. Connect the harness assemblies to the alternator.
7. Connect the batteries.

g01455696
Illustration 380
2. Remove bolt (3) and link (1).
KENR6924 153
3. Remove nuts (4), guard (2) and bracket (5). Installation Procedure
4. Remove the drive belt. NOTICE

component life.
g01455697
Illustration 381
g01455697
Illustration 383
1. If necessary, follow Step 1.a through Step 1.c in

order to install the seal for the drive shaft.
a. Press a new seal (8) into housing (7) so that

the seal is flush with the outer face of the
housing. Ensure that the seal spring is inward.
b. Lubricate seal (8) with clean engine oil. Position

a new joint (10) (not shown) and install housing
g01494314
Illustration 382 (7).
Releasing the pulley from the drive shaft
Note: Ensure that the lip of the seal is not damaged
5. Remove grub screws (11) from pulley (12). as the seal is installed.
6. Lubricate one grub screw (11) with clean engine c. Install bolts (9). Tighten the bolts to a torque of
oil. Install the grub screw into the jacking hole in 25 N·m (18 lb ft).
pulley (12). Tighten the grub screw until the center
of the pulley is released from the shaft. 2. Install key (6) to the drive shaft.
7. Remove pulley (12) and key (6) from the shaft. 3. Ensure that the mating surface of the two halves
Remove grub screw (11) from the pulley and of pulley (12) are clean, dry and free from damage.
separate the two halves of the pulley. Align the halves of the pulley. Lightly lubricate
grub screws (11) with clean engine oil. Install the
8. If necessary, follow Step 1.a through Step 1.c in grub screws to the pulley finger tight.
order to remove the seal for the drive shaft.
4. Install pulley (12) to the shaft of the engine oil
a. Remove bolts (9). pump.
b. Remove housing (7) and joint (10) (not shown). 5. Tighten grub screws (11). Tighten the grub screws
alternately and tighten the grub screws evenly to
c. Remove seal (8) from housing (7). a torque of 22 N·m (15 lb ft).
Note: Use a block of wood in order to prevent

damage to the pulley.
6. Tap the outer half of pulley (12) with a soft faced

pulley.
154 KENR6924
7. Again, tighten grub screws (11) to a torque of i02856139

22 N·m (15 lb ft).
Electric Starting Motor -
8. Position the drive belt on pulley (12). Remove and Install
Removal Procedure



being worked on.
g01455696
Illustration 384
NOTICE
9. Position bracket (6) and guard (2) on the studs Keep all parts clean from contaminants.
and install nuts (4). Tighten the nuts to a torque of
47 N·m (35 lb ft). Contaminants may cause rapid wear and shortened
component life.
10. Position link (1) and install bolt (3) hand tight.
11. Install the alternator. Refer to , “Alternator (Battery 1. Disconnect the batteries.
Charging Alternator) - Remove and Install” for the
correct procedure. 2. Place identification marks on all of the harness
assemblies that are connected to the solenoids
Note: After the engine has been run for the and to the electric starting motors. Disconnect the
appropriate length of time check the tightness of harness assemblies from solenoids and electric
the grub screws that secure the pulley. Refer to starting motors.
Operation and Maintenance Manual, “Alternator
Pulley - Check.” for more information.
g01455429
Illustration 385
KENR6924 155
3. Attach a suitable sling and a lifting device to the 4. Use the lifting device to install electric starting
upper electric starting motor (2). The weight of motor (4) to the flywheel housing. Install nuts (3).
the electric starting motor is approximately 26 kg Tighten the nuts to a torque of 85 N·m (60 lb ft).
(57 lb).
5. Connect the harness assemblies to the solenoids
4. Remove nuts (1). Use the lifting device to remove and to the starting motors.
electric starting motor (2) from the flywheel
housing. 6. Connect the batteries.
5. Attach a suitable sling and a lifting device to the

lower electric starting motor (4). The weight of
the electric starting motor is approximately 26 kg
(57 lb).
6. Remove nuts (3). Use the lifting device to remove

electric starting motor (4) from the flywheel
housing.
NOTICE

component life.
g01455429
Illustration 386

(57 lb).
2. Use the lifting device to install electric starting

motor (4) to the flywheel housing. Install nuts (3).
Tighten the nuts to a torque of 85 N·m (60 lb ft).

(57 lb).
156 KENR6924
Index Section
Index
A Crankshaft - Remove........................................... 137
Removal Procedure ......................................... 137
Aftercooler - Install (Air Charge Cooler, TWG Crankshaft Front Seal - Remove and Install.......... 93
Engines)............................................................... 76 Installation Procedure ........................................ 94
Assembly Procedure.......................................... 76 Removal Procedure ........................................... 93
Installation Procedure ........................................ 76 Crankshaft Gear - Remove and Install ................ 141
Aftercooler - Remove (Air Charge Cooler, TWG Installation Procedure ...................................... 141
Engines)............................................................... 74 Removal Procedure ......................................... 141
Disassembly Procedure ..................................... 75 Crankshaft Main Bearings - Remove and Install.. 136
Removal Procedure ........................................... 74 Installation Procedure ...................................... 136
Air Cleaner - Remove and Install........................... 30 Removal Procedure ......................................... 136
Installation Procedure ........................................ 31 Crankshaft Rear Seal - Remove and Install .......... 82
Removal Procedure ........................................... 30 Installation Procedure ........................................ 82
Air Lines - Remove and Install (Air Pipes, TAG Removal Procedure ........................................... 82
engines) ............................................................... 37 Cylinder Head - Install .......................................... 111
Installation Procedure ........................................ 38 Installation Procedure ....................................... 111
Removal Procedure ........................................... 37 Cylinder Head - Remove ..................................... 109
Air Shutoff - Install ................................................. 36 Removal Procedure ......................................... 109
Installation Procedure ........................................ 36 Cylinder Liner - Install.......................................... 126
Air Shutoff - Remove ............................................. 35 Installation Procedure ...................................... 126
Removal Procedure ........................................... 35 Cylinder Liner - Remove...................................... 125
Alternator - Remove and Install (Alternator Removal Procedure ......................................... 125
Drive) ................................................................. 152
Installation Procedure ...................................... 153
Removal Procedure ......................................... 152 D
Alternator - Remove and Install (Battery Charging
Alternator) .......................................................... 150 Disassembly and Assembly Section........................ 5
E
B Electric Starting Motor - Remove and Install ....... 154

Bearing Clearance - Check ................................. 142 Removal Procedure ......................................... 154
Measurement Procedure ................................. 142 Engine Oil Cooler - Assemble ............................... 57
Boost Pressure Sensor - Remove and Install...... 147 Assembly Procedure.......................................... 57
Installation Procedure ...................................... 147 Engine Oil Cooler - Disassemble........................... 56
Removal Procedure ......................................... 147 Disassembly Procedure ..................................... 56
Engine Oil Cooler - Install...................................... 58
Installation Procedure ........................................ 58
C Engine Oil Cooler - Remove.................................. 54
Removal Procedure ........................................... 54
Camshaft - Install.................................................. 119 Engine Oil Filter Base - Assemble......................... 52
Installation Procedure ....................................... 119 Assembly Procedure.......................................... 52
Camshaft - Remove.............................................. 118 Engine Oil Filter Base - Disassemble .................... 51
Removal Procedure .......................................... 118 Disassembly Procedure ..................................... 51
Camshaft Bearings - Install ................................. 120 Engine Oil Filter Base - Install ............................... 52
Installation Procedure ...................................... 120 Installation Procedure ........................................ 52
Camshaft Bearings - Remove .............................. 119 Engine Oil Filter Base - Remove ........................... 50
Removal Procedure .......................................... 119 Removal Procedure ........................................... 50
Coolant Temperature Switch - Remove and Engine Oil Pan - Install ........................................ 123
Install ................................................................. 144 Installation Procedure ...................................... 123
Installation Procedure ...................................... 144 Engine Oil Pan - Remove .................................... 121
Removal Procedure ......................................... 144 Removal Procedure ......................................... 121
Crankcase Breather - Remove and Install........... 100 Engine Oil Pressure Switch - Remove and
Installation Procedure ...................................... 101 Install ................................................................. 145
Removal Procedure ......................................... 100 Installation Procedure ...................................... 146
Crankshaft - Install............................................... 138 Removal Procedure ......................................... 145
KENR6924 157
Index Section
Engine Oil Pressure Switch - Remove and Install Fuel Injector - Install .............................................. 26
(Alternator Warning Lamp) ................................ 145 Installation Procedure ........................................ 26
Installation Procedure ...................................... 145 Fuel Injector - Remove .......................................... 20
Removal Procedure ......................................... 145 Removal Procedure ........................................... 20
Engine Oil Pump - Assemble................................. 65 Fuel Injector Sleeve - Install .................................. 28
Assembly Procedure.......................................... 65 Installation Procedure ........................................ 28
Engine Oil Pump - Disassemble............................ 64 Fuel Injector Sleeve - Remove .............................. 27
Disassembly Procedure ..................................... 64 Removal Procedure ........................................... 27
Engine Oil Pump - Install ....................................... 66 Fuel Manifold (Rail) - Remove and Install ............... 9
Installation Procedure ........................................ 66 Installation Procedure ......................................... 11
Engine Oil Pump - Remove ................................... 62 Removal Procedure ............................................. 9
Removal Procedure ........................................... 62 Fuel Priming Pump - Remove and Install (Early
Engine Oil Relief Valve - Remove and Install ........ 61 Type)...................................................................... 5
Installation Procedure ........................................ 62 Installation Procedure .......................................... 5
Removal Procedure ........................................... 61 Removal Procedure ............................................. 5
Engine Oil Relief Valve - Remove and Install (Engine Fuel Priming Pump - Remove and Install (Late
Oil Pressure Regulator) ....................................... 59 Type)...................................................................... 6
Installation Procedure ........................................ 60 Installation Procedure .......................................... 7
Removal Procedure ........................................... 59 Removal Procedure ............................................. 6
Engine Sensors - Remove and Install (Exhaust Fuel Transfer Pump - Remove and Install (Lift
Temperature) ..................................................... 143 Pump) .................................................................... 8
Installation Procedure ...................................... 143 Installation Procedure .......................................... 9
Removal Procedure ......................................... 143 Removal Procedure ............................................. 8
Engine Speed Sensor - Remove and Install........ 147
Removal Procedure ......................................... 147 G
Engine Speed Sensor - Remove and Install
(Overspeed Sensor) .......................................... 146 Gear Group (Front) - Install ................................... 96
Removal Procedure ......................................... 146 Gear Group (Front) - Remove ............................... 94
Engine Support (Front) - Remove and Install Removal Procedure ........................................... 94
(Backplate)........................................................... 78 Governor - Install (Electronic Control Unit)............ 12
Installation Procedure ........................................ 78 Installation Procedure ........................................ 12
Removal Procedure ........................................... 78 Governor - Remove (Electronic Control Unit)........ 12
Exhaust Elbow - Remove and Install..................... 42 Removal Procedure ........................................... 12
Installation Procedure ........................................ 42 Governor Actuator - Remove and Install ............... 13
Removal Procedure ........................................... 42 Installation Procedure ........................................ 14
Exhaust Manifold - Remove and Install ................. 39 Removal Procedure ........................................... 13
H
F Housing (Front) - Install (Timing Case) ................. 99

Flywheel - Install.................................................... 80 Housing (Front) - Remove (Timing Case) ............. 98
Installation Procedure ........................................ 80 Removal Procedure ........................................... 98
Flywheel - Remove................................................ 79
Flywheel Housing - Remove and Install ................ 83 I
Removal Procedure ........................................... 83 Important Safety Information ................................... 2
Fuel Filter Base - Remove and Install ..................... 7 Inlet and Exhaust Valve Guides - Remove and
Installation Procedure .......................................... 8 Install ................................................................... 48
Removal Procedure ............................................. 7 Installation Procedure ........................................ 49
Fuel Injection Control Linkage - Install .................. 18 Removal Procedure ........................................... 48
Installation Procedure ........................................ 18 Inlet and Exhaust Valves - Remove and Install ..... 46
Fuel Injection Control Linkage - Remove .............. 16 Installation Procedure ........................................ 47
Removal Procedure ........................................... 16 Removal Procedure ........................................... 46
Fuel Injector - Assemble........................................ 24 Inlet Manifold - Install............................................. 45
Assembly Procedure.......................................... 24 Installation Procedure ........................................ 45
Fuel Injector - Disassemble ................................... 22 Inlet Manifold - Remove......................................... 43
Disassembly Procedure ..................................... 22 Removal Procedure ........................................... 43
158 KENR6924
Index Section
L Vibration Damper and Pulley - Remove and Install

(Single Vibration Damper) ................................... 86
Lifter Group - Assemble (Cam Followers) ............ 116 Installation Procedure ........................................ 87
Assembly Procedure......................................... 116 Removal Procedure ........................................... 86
Lifter Group - Disassemble (Cam Followers) ....... 115 Vibration Damper and Pulley - Remove and Install
Disassembly Procedure .................................... 115 (Twin Vibration Dampers) .................................... 89
Lifter Group - Install (Cam Followers)................... 117 Installation Procedure ........................................ 91
Installation Procedure ....................................... 117 Removal Procedure ........................................... 89
Lifter Group - Remove (Cam Followers)............... 113
Removal Procedure .......................................... 113
W
P Water Pump - Assemble........................................ 69

Assembly Procedure.......................................... 69
Piston Cooling Jets - Remove and Install............ 128 Water Pump - Disassemble................................... 69
Installation Procedure ...................................... 129 Disassembly Procedure ..................................... 69
Removal Procedure ......................................... 128 Water Pump - Install .............................................. 71
Pistons and Connecting Rods - Assemble .......... 132 Installation Procedure ........................................ 71
Assembly Procedure........................................ 132 Water Pump - Remove .......................................... 68
Pistons and Connecting Rods - Disassemble ..... 131 Removal Procedure ........................................... 68
Disassembly Procedure ................................... 131 Water Temperature Regulator Housing - Remove and
Pistons and Connecting Rods - Install................. 134 Install (Thermostat Housing)................................ 72
Pistons and Connecting Rods - Remove............. 130 Removal Procedure ........................................... 72
Rocker Arm - Assemble....................................... 106

Assembly Procedure........................................ 106
Rocker Arm - Disassemble.................................. 105
Disassembly Procedure ................................... 105
Rocker Arm and Shaft - Install............................. 108
Rocker Arm and Shaft - Remove......................... 105
Table of Contents..................................................... 3
Turbocharger - Install ............................................ 33
Turbocharger - Remove ........................................ 32
V-Belts - Remove and Install (Fan Drive Belts) ... 148

Valve Mechanism Cover - Remove and Install
(Rocker Box Cover) ........................................... 101
Valve Mechanism Cover Base - Remove and Install
(Rocker Box)...................................................... 102
KENR6924 159
Index Section
©2008 Perkins Engines Company Limited Printed in U.K.
All Rights Reserved

Disassembly and Assembly: 4012-46A Industrial Engine

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Disassembly and Assembly: 4012-46A Industrial Engine

Uploaded by

Copyright:

Available Formats

KENR6924

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Aftercooler - Install (Air Charge Cooler, TWG

V-Belts - Remove and Install (Fan Drive Belts) .. 148

and Install 3. Disconnect hose assembly (1) from fuel priming

Removal Procedure 5. If necessary, follow Step 5.a through Step 5.c in

Contaminants may cause rapid wear and shortened

Fuel Priming Pump - Remove

Contaminants may cause rapid wear and shortened

c. Position fuel priming pump assembly (4) and

Note: Ensure the correct orientation of the fuel

2. Place the assembly of fuel priming pump (4) and

Note: Use two spanners to connect the hose

3. Connect hose assembly (1) to fuel priming pump

Installation Procedure i03112890

Contaminants may cause rapid wear and shortened

Dispose of all fluids according to local regulations and

1. Turn the fuel supply to the “OFF” position.

2. Position a new joint (2) (not shown) on fuel lift

Note: Ensure correct orientation of the joint.

3. Position fuel priming pump (4) on fuel lift pump

4. Turn the fuel supply to the “ON” position.

5. Remove the air from the fuel system. Refer to

2. Drain and remove fuel filter (5). Refer to Operation

3. Disconnect pipe (2) from filter head (4).

4. Loosen pipe (3) at the lift pump. Disconnect the

Dispose of all fluids according to local regulations and

1. Turn the fuel supply to the “OFF” position.

2. Position filter head (4) on the mounting bracket.

3. Install nuts and bolts (1). Tighten the nuts and

4. Connect pipe (2) to filter head (4) and tighten the

5. Install a new fuel filter (5) to filter head (4). Refer

If the fuel lift pump is equipped with the early type

Fuel Manifold (Rail) - Remove

a. Remove the electronic governor control unit.

2. If the fuel lift pump is equipped with the late type

Dispose of all fluids according to local regulations and

1. Turn the fuel supply to the “OFF” position.

2. Cut the cable straps that secure the thermocouples

5. Remove pipe (6) and remove pipe (8).

6. Remove bolt (4) and remove pipe (7).

7. Repeat Step 5 and Step 6 in order to remove the

Note: Cap the pipes and cap the connections on the

8. Remove bolts (9). Remove fuel rail (1) from the

Installation Procedure 4. Install pipe (8) and install pipe (6).

NOTICE 5. Repeat Step 3 and Step 4 in order to install the

9. Turn the fuel supply to the “ON” position.

10. Remove the air from the fuel system. Refer to

a. Install the electronic governor control unit. Refer to

3. Install pipe (7). Install bolt (4) to the tube clip.

i02855349 3. Cut the cable straps that secure harness assembly

4. Loosen nuts (6) and (10). Remove electronic

Contaminants may cause rapid wear and shortened

Accidental engine starting can cause injury or

To avoid accidental engine starting, disconnect

Place a Do Not Operate tag at the Start/Stop switch

Contaminants may cause rapid wear and shortened

1. If necessary, follow Step 1.a and Step 1.b in

1. Disconnect electrical connectors (7) from

2. Disconnect harness assembly (9) from solenoids

5. Position harness assembly (9) on plate (3). Secure

Governor Actuator - Remove